CH153 Phase1 19CHUOG008

A
Project Report
On
MAHCL (METHOXYLAMINE
HYDROCHLORIDE)
Submitted in partial fulfilment towards the bachelor’s
degree in the field of Chemical Engineering
Shubham Atulbhai Trambadia
CH-153 (I.D NO. 19CHUOG008)
Under The Guidance Of

Prof. Hitesh Panchal Sir
Department of Chemical Engineering Faculty of Technology,

Dharmsinh Desai University
College Road, Nadiad – 387001
Feb - 2023
I
Copy of Company Training Certificate
II
CERTIFICATE
This is to certify that Shubham A. Trambadia (CH-153,

I.D. NO.19CHUOG008) has duly submitted his Project Report on MAHCL
(METHOXYLAMINE HYDROCHLORIDE) as a partial fulfilment towards
bachelor’s degree in chemical engineering at Dharmsinh Desai University, Nadiad
in the year 2023.
Prof. Hitesh N. Panchal Date:01/02/2023

Associate Professor, Dr. M. S. Rao
Dept. of Chemical Engineering Prof. & Head of Department,
DDU, Nadiad. DDU, Nadiad.
Date:01/02/2023 Date:01/02/2023
III
DECLARATION
I Shubham A. Trambadia declare that the project report on MAHCL

comprises my original work towards the degree of Bachelor of
Technology in Chemical Engineering at Dharmsinh Desai University
and is not copied from any published or proprietary source. I further
declare that this work is not submitted elsewhere towards degree or
diploma in any university or college. The whole content of this project
work is genuine and distinctive.
Shubham A. Trambadia
CH153 (19CHUOG008)
Dept. of
Chemical
Engineering
DDU, Nadiad
Date:01/02/2023
IV
Acknowledgement
Upon successfully completing my internship at Deepak Nitrite Ltd., I would like

to express my sincere gratitude to all the individuals who have offered their
valuable support and guidance throughout this journey. I am also grateful for
having a chance to meet so many wonderful people and professionals who led me
through this internship period.
I would like to extend my heartfelt thanks to Mr. Tarun Soni and Mr. Keyur
Shah, my internship project guides at Deepak, for their persistent support which
helped me in the completion of the internship. I am also thankful to HR Huzefa
M. Patel and Mr. Sarang Trambadiya at Deepak Nitrite for their kind support
at various stages of the internship program.
My sincere appreciation also goes to my internship project guide, Prof. Hitesh

N. Panchal at DDU, whose constant guidance and support were instrumental in
my successful completion of the internship. Additionally, I am thankful to Dr.
M.S. Rao, the Head of Department at the Department of Chemical Engineering,
for granting me permission to pursue my training in these esteemed companies.
Thank you all for your unwavering support and guidance.
Sincerely,
V
Preface
As a part of my curriculum in Chemical Engineering, I underwent an industry

training to gain practical knowledge. Along with the training, I was required to
prepare a report documenting my experiences. My Phase I training was
completed at Deepak Nitrite Ltd. The main purpose of this project report is to
gain knowledge of real-life situations in the work field and learn from them.
This report covers various concepts related to material balance, energy balance,
equipment, cost estimation, as well as health, safety, and environment.
CH153 (19CHUOG008)
Dept. of
Chemical
Engineering
DDU, Nadiad
Date:01/02/2023
VI
Phase I
MAHCL
(Methoxylamine Hydrochloride)
VII
Contents
Chapter 1 : Introduction ........................................................................................................ 1
1.1 History of Methoxyamine Hydrochloride(MAHCL) :.............................................. 2
1.2 Total Capacity of Plant:........................................................................................... 2
1.3 Market Value: ......................................................................................................... 2
1.4 Competitors ............................................................................................................ 2
1.5 Technology Providers ............................................................................................. 2
1.6 Application ............................................................................................................. 3
1.7 Physical and Chemical Properties ............................................................................ 3
1.8 Conclusions: ........................................................................................................... 3
Chapter 2 : Selection Of Process ........................................................................................... 4
2.1 Different Methods for MAHCL production ............................................................. 5
2.1.1 By Cascade One-Pot Method ........................................................................... 5
2.1.2 By cleavage of acetone oxime methyl ether by means of hydrogen chloride and
water 5
2.2 Process Selected ...................................................................................................... 6
2.3 Raw Material Specification ..................................................................................... 6
2.3.1 Availability and Transportation of Raw Materials ............................................ 7
2.3.2 Cost of Raw Materials ...................................................................................... 7
2.3.3 Properties of Raw Materials ............................................................................. 7
2.4 Detailed Process Description ................................................................................. 10
2.4.1 Process Block Diagram .................................................................................. 10
2.4.2 Process Description ........................................................................................ 13
2.4.3 Process Flow Diagram ................................................................................... 17
2.4.4 Conclusions ................................................................................................... 18
Chapter 3 : Material Balance ............................................................................................... 19
3.1 Introduction .......................................................................................................... 20
VIII
3.1.1 Material Balance Over HADS Reactor (RT-001/RT-003) .............................. 21
3.1.2 Material Balance Over Alkaline HADS Reactor (XRT-3002)......................... 23
3.1.3 Material Balance Over MADS Reactor .......................................................... 25
3.1.4 Material Balance Over XRT-001.................................................................... 26
3.1.5 Material Balance Over MABase Reactor (XRT-011) ..................................... 27
3.1.6 Material Balance Over MAHCL Reactor........................................................ 29
3.2 Overall Material Balance....................................................................................... 31
3.3 Conclusions: ......................................................................................................... 33
Chapter 4 : Energy Balance ................................................................................................. 34
4.1 Introduction: ......................................................................................................... 35
4.2 Standard Heat Of Formation and Heat Capacity Of Components: .......................... 35
4.2.1 Energy Balance Over HADS Reactor (RT-001/RT-003) ................................ 39
4.2.2 Energy Balance Over Alkaline HADS Reactor (XRT-3002) .......................... 41
4.2.3 Energy Balance Over MADS Reactor ............................................................ 43
4.2.4 Energy Balance Over XRT-001...................................................................... 45
4.2.5 Energy Balance Over MAB Reactor (XRT-011) ............................................ 47
4.3 Summary Diagram Of Energy Balance:................................................................. 51
4.4 Conclusions: ......................................................................................................... 52
Chapter 5 : Plant Utilities .................................................................................................... 53
5.1 Utilities used in plants ........................................................................................... 54
5.2 Steam .................................................................................................................... 54
5.3 Electricity ............................................................................................................. 55
5.4 Cooling Water ....................................................................................................... 55
5.5 Chilling Brine ....................................................................................................... 56
5.6 Compressed air ..................................................................................................... 56
5.7 DM Water or RO water ......................................................................................... 57
5.8 Conclusions: ......................................................................................................... 58
IX
Chapter 6 : Detailed Description Of Equipment ................................................................... 59
6.1 Caustic Storage Tank ............................................................................................ 60
6.2 RO Water Tank ..................................................................................................... 60
6.3 HADS Reactor ...................................................................................................... 61
6.4 SO2 Vaporizer ...................................................................................................... 61
6.5 Alkaline HADS Reactor ........................................................................................ 62
Type ............................................................................................................................ 62
CSTR ........................................................................................................................... 62
6.6 MADS Reactor ..................................................................................................... 62
6.7 DMS Storage Tank ............................................................................................... 63
6.8 MADS Storage Tank ............................................................................................. 63
6.9 Hydrolysis Reactor................................................................................................ 64
6.10 MABase Reactor ................................................................................................... 64
6.11 MAHCL Reactor................................................................................................... 65
6.12 HCl Storage Tank ................................................................................................. 65
6.13 MAHCL Storage Tank .......................................................................................... 66
6.14 Conclusions: ......................................................................................................... 66
Chapter 7 : Designing Of Equipment ................................................................................... 67
7.1 Introduction .......................................................................................................... 68
7.2 Major Equipment Design ...................................................................................... 68
7.2.1 Process Design Of Reactor ............................................................................. 68
7.2.2 Mechanical Design of Reactor ....................................................................... 71
7.3 Minor Equipment Design ...................................................................................... 80
7.3.1 Pressure Vessel .............................................................................................. 80
7.3.2 Centrifugal Pump ........................................................................................... 82
7.3.3 Shell and Tube Heat Exchanger ..................................................................... 85
7.4 Conclusions: ......................................................................................................... 91
X
Chapter 8 : Pumps, piping, fittings, and Control Valves....................................................... 92
8.1 Pumps ................................................................................................................... 93
8.1.1 Types of Pumps: ............................................................................................ 93
8.2 Control Valves ...................................................................................................... 98
8.3 Conclusions: ....................................................................................................... 106
Chapter 9 : Safety, Health and Environment ...................................................................... 107
9.1 Safety Measures .................................................................................................. 108
9.2 Work Permit ....................................................................................................... 109
9.3 Personal Protective Equipments .......................................................................... 109
9.3.1 Selection Criteria for PPE ............................................................................ 110
9.3.2 Different PPEs ............................................................................................. 110
9.4 Safety Related Equipment and Their Locations ................................................... 111
9.5 Fire Fighting Equipments .................................................................................... 112
9.6 Pollution ............................................................................................................. 113
9.7 Water Pollution Control ...................................................................................... 113
9.8 HAZOP Study Over HADS Reactor.................................................................... 114
9.9 Conclusions: ....................................................................................................... 117
Chapter 10 : Plant Location and Layout ............................................................................. 118
10.1 Justification of Plant Location: ............................................................................ 119
10.1.1 Plant Location: ............................................................................................. 119
10.1.2 Factors Affecting Plant Location: ................................................................. 119
10.2 Plant Layout........................................................................................................ 121
10.2.1 Objectives of Plant Layout: .......................................................................... 123
10.3 Conclusions: ....................................................................................................... 125
Chapter 11 : Cost Estimation ............................................................................................. 126
11.1 Introduction: ....................................................................................................... 127
11.1.1 Cost based on a fixed capacity ..................................................................... 127
XI
11.2 Cost of equipments at plants................................................................................ 128
11.3 Direct Cost .......................................................................................................... 129
11.4 Indirect Cost: ...................................................................................................... 129
11.5 Fixed Charges ..................................................................................................... 130
11.6 Raw Material Cost .............................................................................................. 130
11.7 General expense .................................................................................................. 131
11.8 Profitability: ........................................................................................................ 132
11.8.1 Break-even Analysis: ................................................................................... 132
11.9 Conclusion: ......................................................................................................... 133
Chapter 12 : Conclusion .................................................................................................... 134
Chapter 13 : References .................................................................................................... 136
XII
List of Tables:
Table 3-1 M.B over HADS Reactor..................................................................................... 21
Table 3-2 Summary of M.B over HADS Reactor ................................................................ 21
Table 3-3 M.B Over Alkaline HADS Reactor...................................................................... 23
Table 3-4 summary table of M.B Over Alkaline HADS Reactor .......................................... 24
Table 3-5 Summary of M.B. Over MADS Reactor .............................................................. 25
Table 3-6 Summary of Material Balance Over XRT-001 ..................................................... 27
Table 3-7 Material Balance Over MABase Reactor ............................................................. 28
Table 3-8 Summary of Material Balance Over MABase Reactor ........................................ 28
Table 3-9 Material Balance Over MAHCL Reactor ............................................................. 29
Table 3-10 Summary of Material Balance Over MAHCL Reactor ....................................... 30
Table 3-11 Overall Material Balance ................................................................................... 31
Table 4-1 Standard Heat Of Formation ................................................................................ 35
Table 4-2 Heat Capacity Of Components ............................................................................ 36
Table 4-3 Energy Balance Over HADS Reactor .................................................................. 39
Table 4-4 Energy Balance Over Alkaline HADS Reactor .................................................... 41
Table 4-5 Energy Balance Over MADS Reactor.................................................................. 43
Table 4-6 Energy Balance Over XRT-001 ........................................................................... 45
Table 4-7 Energy Balance Over MAB Reactor .................................................................... 47
Table 4-8 Energy Balance Over MAHCL Reactor ............................................................... 49
Table 6-1 Details about Caustic Storage Tank ..................................................................... 60
Table 6-2 Details About RO Water Tank ............................................................................. 60
Table 6-3 Details about HADS Reactor ............................................................................... 61
Table 6-4 Details about SO2 Vaporizer ............................................................................... 61
Table 6-5 Alkaline HADS Reactor ...................................................................................... 62
Table 6-6 Details about MADS Reactor .............................................................................. 62
Table 6-7 Details about DMS Storage tank .......................................................................... 63
Table 6-8 Details about MADS Storage Tank ...................................................................... 63
Table 6-9 Details About Hydrolysis Reactor ....................................................................... 64
Table 6-10 Details about MABase Reactor .......................................................................... 64
Table 6-11 Details about MAHCL Reactor.......................................................................... 65
Table 6-12 Details about HCl storage tank .......................................................................... 65
Table 6-13 Details of MAHCL Storage Tank .................................................................... 66
XIII
Table 7-1 Data for Process Design Of Reactor .................................................................... 68
Table 7-2 Courses Calculation Data .................................................................................... 70
Table 7-3 Data for Agitator ................................................................................................. 74
Table 7-4 Data for Bracket support...................................................................................... 77
Table 7-5 Data for Pressure vessel ....................................................................................... 80
Table 7-6 Data for Centrifugal pump ................................................................................... 82
Table 7-7 Data for Head loss and Fittings ............................................................................ 84
Table 7-8 Data for Shell & Tube Heat exchanger ................................................................ 85
Table 8-1 Control Valve Types & Application .................................................................. 104
Table 9-1 Hazop study ...................................................................................................... 114
Table 11-1 Cost based on a fixed capacity ......................................................................... 127
Table 11-2 Cost of equipments at plants ............................................................................ 128
Table 11-3 Direct Cost ...................................................................................................... 129
Table 11-4 Indirect Cost .................................................................................................... 129
Table 11-5 Fixed Charges ................................................................................................. 130
Table 11-6 Direct Production Cost .................................................................................... 130
Table 11-7 General expense .............................................................................................. 131
Table 11-8 Cost and Selling Capacity ............................................................................... 132
List Of Figures:
Figure 2-1 PBD HAS Plant ................................................................................................. 10
Figure 2-2 PBD MPP-2 Plant .............................................................................................. 11
Figure 2-3 PBD MPP-1 Plant .............................................................................................. 12
Figure 2-4 PBD MAHCL Solid Plant .................................................................................. 13
Figure 2-5 Process Flow Diagram ....................................................................................... 17
Figure 3-1 Block diagram of M.B Over HADS Reactor....................................................... 21
Figure 3-2 Block Diagram of M.B over MADS Reactor ...................................................... 25
Figure 3-3 Material Balance Over XRT-001 ....................................................................... 26
Figure 3-4 Material Balance Over MABase Reactor ............................................................ 28
Figure 3-5 Material Balance Over MAHCL Reactor............................................................ 29
Figure 3-6 Overall Material Balance.................................................................................... 32
Figure 4-1 Energy Balance Over HADS Reactor ................................................................. 39
Figure 4-2 Energy Balance Over Alkaline HADS Reacto .................................................... 41
XIV
Figure 4-3 Energy Balance Over MADS Reactor ................................................................ 43
Figure 4-4 Energy Balance Over XRT-001.......................................................................... 45
Figure 4-5 Energy Balance Over MAB Reactor................................................................... 47
Figure 4-6 Energy Balance Over MAHCL Reactor.............................................................. 49
Figure 4-7 Summary Diagram Of Energy Balance............................................................... 51
Figure 5-1 Block diagram of Boiler Section ........................................................................ 55
Figure 5-2 Cooling Tower ................................................................................................... 56
Figure 5-3 DM RO Water Plant ........................................................................................... 57
Figure 8-1 Volute Casing or Spiral Casing .......................................................................... 95
Figure 8-2 Vortex Casing .................................................................................................... 95
Figure 8-3 Foot Valve ......................................................................................................... 96
Figure 8-4 Centrifugal Pump ............................................................................................... 97
Figure 8-5 Control Valve .................................................................................................. 100
Figure 8-6 Pneumatic Actuator .......................................................................................... 101
Figure 8-7 Electrical Actuators .......................................................................................... 102
Figure 8-8 Hydraulic Actuators ......................................................................................... 102
Figure 8-9 Control Valve .................................................................................................. 103
Figure 10-1 Plant Layout ................................................................................................... 122
XV
ABBREVIATION
MAHCL = Methoxylamine Hydrochloride
HADS = Hydroxylamine Desulphonate Disodium
MADS = Methoxylamine Desulphonate Disodium
MAS = Methoxylamine Sulphate
MABASE = Methoxylamine Base
DMS = Dimethyl Sulphate
PPE = Personal Protection Equipment
NIOSH = National Institute for Occupational Safety and Health
TLV = Threshold Limit Value
IDLH = Immediately Dangerous to Life or Health
OSHA = Occupational Safety and Health Association
STEL = Short Time Exposure Limit
PLC = Programmable Logic Control
DCS = Distributed Control System
SS = Stainless Steel
HDPE = High Density Polyethylene
FRP = Fibre Reinforcement Plastic
PPGL = Polypropylene Glass line
MSGLR = Mild Steel Glass Line Reactor
CSTR = Continuous Stir Tank Reactor
MOC = Material of Construction
BD = Blank Diameter
RPM = Rotation Per Minute
MS = Mild Steel
CS = Carbon Steel
PE = Polyethylene
PP = Polypropylene
SHE = Safety Health and Environment
ETP = Effluent Treatment Plant
TDS = Total Dissolved Solids
ISI = Indian Standard Institution
BIS = Bureau of Indian Standard
XVI
PVC = Poly Vinyl Chloride
NPSH = Net Positive Suction Head
STHE = Shell and Tube Heat Exchanger
NOMENCLATURE
ρ = Density of Fluid, kg/m3
μ = Viscosity of Fluid, g/cm.s
m = Mass Rate, kg/hr
M = Mass of Solid, kg
V = Volume of Liquid, lit or m3
v = Velocity of Fluid, m/s
C = Molar Concentration of Fluid, mole/lit
Cp = Specific Heat Capacity of Fluid, KJ/kg.K
Q = Amount of Heat, J
T = Actual Temperature, 0C or K
ΔH = Heat of Formation, KJ/mol
ΔHr = Heat of Reaction, KJ/mol
ΔT = Temperature Difference
K = Reaction Constant, (concentration)1-n time-1
X = Conversion
-rA = Rate of Reaction
P = Pressure, KPa
D = Diameter, m
H = Height, m
f = Allowable Stress, kg/cm2
XVII
J = Joint Efficiency Factor
Rc = Crown Radius, m
Rk = Knuckle Radius, m
W = Weight, kg
trs = Actual Thickness, mm
td = Thickness with Corrosion, mm
tf = Design Thickness, mm
tn = Nozzle Thickness, mm
Dc = Diameter of Coil, mm
Dj = Diameter of Jacket, mm
bw = Width of Blade, mm
N = Speed of impeller, rpm
σ= Stress, kgf/cm2
E = Modulus of Elasticity, kgf/cm2
Nre = Reynolds Number
Np = Power Number
P = Power, hp
Tc = Torque, kgf.m
Zp = Section Modulus, cm3
Rb = Radius of Blade, m
M = Bending Moment, kgf.m
I = Moment of Inertia, cm4
δ = Maximum Deflection, c
XVIII
Chapter 1 : Introduction
1
1.1 History of Methoxyamine Hydrochloride(MAHCL) :
Methoxyamine Hydrochloride is the hydrochloride salt form of methoxyamine.
It is a derivative of Hydroxylamine with hydroxyl hydrogen replaced by a methyl
group. Alternatively, it can be viewed as a derivative of methanol with the hydroxyl
hydrogen replaced by amino group.
O-methylhydroxylamine is a useful intermediate to produce pharmaceuticals

and agrochemicals. It is used in the stereo selective reduction of ketones. It is used as a
reagent for the protection and derivatization of keto-groups of steroids particularly. It
is used to detect sugars and amino sugars in glycoproteins. It is used as a powerful
reducing agent in organic synthesis.
1.2 Total Capacity of Plant:
Total Capacity of Plant: 2800 metric tonnes per annum
1.3 Market Value:
Market Value of MAHCL: ₹1500 per kg
1.4 Competitors
1. Organo Fine Chemicals, India
2. Leap Chem Co., Ltd., China
3. Beijing Colory Chemical Co., Ltd., China
4. Gansu Hairuida Chemical Technology Co., Ltd., China
5. Hangzhou Molcore Biopharmatech Co., Ltd., China
6. Hebei Sight Chemicals & Pharmaceuticals Co., Ltd., China
7. Anvia Chemicals, LLC, USA
8. Cayman Chemical Company, USA
1.5 Technology Providers

1. SCADA by Siemens
2
2. GLASS FIBRE by O.K. Glass Fibre Ltd.
3. Other by Deepak Nitrite Ltd.
1.6 Application
 Methoxyamine hydrochloride is an important intermediate in the preparation of drugs
and crop protection agents.
 It is used as a powerful reducing agent in organic synthesis.
 It is used for the developing and printing of colour photography and film, and is widely
used in the synthesis of medicine, functional dye, low-toxin farm chemicals and new
herbicides.
 It is used as a reagent for the protection and derivatization of keto-groups of steroids
particularly.
1.7 Physical and Chemical Properties

 Molecular Formula: CH3ONH2.HCl
 Molecular Weight: 83.51 g/mol
 Appearance: liquid and solid
 Color: Colorless
 Odor: Pungent
 Boiling range: 105 to 110 0C
 Crystallization point: -10 0C
 Vapor Pressure: 15 mmHg at 28 0C
 Density: 1.14 g/cm3 at 20 0C
 Soluble in water
 When in aqueous phase, acidic in nature.
1.8 Conclusions:
This chapter introduces the MAHCL product and covers various aspects related to it, such as
its competitors in the market, the overall production capacity and value of the product, and the
physical and chemical properties of MAHCL.
3
Chapter 2 : Selection Of Process
4
2.1 Different Methods for MAHCL production
2.1.1 By Cascade One-Pot Method

According to the method, sulfur dioxide gas, sodium nitrite, sodium hydroxide and dimethyl
sulfate have a cascade one-pot reaction in a water phase, and methoxyamine hydrochloride is
prepared. Compared with the prior art, the preparation method has the advantages as follows:
methoxyamine hydrochloride is prepared with a cascade one-pot method, a novel synthetic
route is provided, and the preparation method is simple and convenient to operate,
environment-friendly and suitable for industrial production on a certain scale and is a green
and clean production process; sulfur dioxide waste gas produced by enterprises can be used as
a raw material, the cost is further saved, and sustainable development of the enterprises is
facilitated.
 Advantages: The process is environment-friendly, simple and easy to operate

and the basic raw material like Sodium Nitrite used is manufactured by
company itself (i.e. low cost to company).
2.1.2 By cleavage of acetone oxime methyl ether by means of hydrogen chloride and
water
 The starting compound acetone oxime methyl ether is prepared by methods

known from the literature.
 The hydrogen chloride introduced in the form of hydrochloric acid or gaseous
hydrogen chloride is generally used in an excess over the acetone oxime methyl
ether, but is used in at least the stoichiometric amount. The reaction is preferably
carried out at a molar ratio of hydrogen chloride to acetone oxime methyl ether
of 2:1.
 . Bubble cap tray columns are particularly useful since the residence times on
the trays can be readily set in them. Packed columns are also possible. The
number of theoretical plates is restricted to 19 for economic reasons.
 A reflux ratio of from 2 to 15 is preferably set, the minimum number of
theoretical plates in the reaction column is 8. On the other hand, if a reflux ratio
5
of 16 or more is chosen, acetone oxime methyl ether can be cleaved completely
even in reaction columns having less than 8 theoretical plates.
 The reaction temperature is generally in the range from 40 to 110° and
preferably from 65 to 95° C. and is determined, in particular, by the amount
taken off at the top and the pressure which is set. The process is preferably
carried out at a pressure of from 100 mbar to 3 bar.
 Methoxyamine hydrochloride is preferably obtained at he bottom of the column
in the form of an aqueous suspension or solution which is continuously
discharged, and the methoxyamine hydrochloride can be obtained in pure form.
 Disadvantage: The cleavage of acetone oxime methyl ether by means of
hydrogen chloride to form methoxyamine hydrochloride has the great
disadvantage that a reaction column having many theoretical plates is necessary
to achieve high yields. Such an apparatus is costly and its operation consumes
a large amount of energy.
2.2 Process Selected
 Cascade One-pot method is selected by the company because of the above mentioned
advantages.
2.3 Raw Material Specification
1. Sodium Nitrite
2. Caustic Soda Lye (48% w/v)
3. Sulphur Dioxide
4. RO Water
5. Dimethyl Sulphate
6. Hydrochloric Acid (31% w/v)
6
2.3.1 Availability and Transportation of Raw Materials
1. Sodium Nitrite: Manufactured by Deepak Nitrite itself.

2. Caustic Soda Lye (48% w/v): From GACL transported in trucks by road.
3. Sulpfur Dioxide: From Shree Sulphuric Pvt. Ltd. by trucks in liquid SO 2 tonner.
4. Dimethyl Sulphate: From Aarti Industries Pvt. Ltd. transported in trucks by road.
5. Hydrochloric Acid (31% w/v): From GACL transported in trucks by road.
2.3.2 Cost of Raw Materials
1. Caustic Soda Lye (48% w/v): 30 Rs/Lt

2. Sodium Nitrite : 48 Rs/Kg
3. Sulfur Dioxide : 40 Rs/Kg
4. RO Water : 0.5 Rs/kg
5. Hydrochloric Acid (31% w/v) : 45 Rs/Lt
2.3.3 Properties of Raw Materials
1. Sodium Nitrite
 Chemical Formula: NaNO2
 Molar Mass: 68.9953 g/mol
 Melting point: 271 0C
 Density: 2.168 g/cm3
 Melting Point: 280 0C
7
 Boiling Point: 320 0C
 Autoignition Temperature: 530 0C
 Solubility: 82 g/100ml at 20 0C
 Odour: Odourless
 Colour: Yellowish White Crystals
2. Caustic Soda Lye

 Chemical formula: NaOH
 Molecular weight: 40 g/mol
 Melting point: 318.4 0C
 Boiling point: 1390 0C
 Specific gravity: 2.12 gm/cm3
 Solubility: Soluble in alcohol, methanol and glycerol
 Flammability: Non-explosive
 Explosivity: Non-explosive
 Appearance: White flakes/pellets
 Odour: Odourless
 TLV: 2 mg/m3
3. Sulphur Dioxide
 Chemical Formula: SO2
 Molecular Weight: 64.06 g/mol
 Boiling Point: -10 0C
 Melting Point: -71 0C
 Specific Gravity to air: 2.263 at 0 0C
 Appearance: Colourless
 Odour: Irritating and pungent
 Flamability: Combustible in solid
 Solubility (at 20 0C): 110 g/l
 Molar Volume: 21.9 l/mol at 0 0C
 Specific heat, Cp at 0 0C : 586 J/kg K
8
4. Dimethyl Sulphate
 Chemical Formula: C2H6O4S
 Molar mass: 126.13 g/mol
 Appearance: colourless, oily liquid
 Odour: Faint onion like
 Density: 1.33 g/ml
 Melting point: -32 0C
 Boiling point: 188 0C
 Vapor pressure: 0.1 mmHg (20 0C)
 Flash point: 83 0C
5. Hydrochloric Acid
 Chemical Formula: HCl
 Molecular weight: 36.46 g/mol
 Appearance: Colourless or slightly yellow
 Odour: Pungent
 Boiling Point: 90 0C
 Melting Point: -52 0C
 Specific Gravity: 1.149
 Viscosity: 1.7 mPa.s
 Specific heat: 2.6 kJ/kg. K
 Vapor pressure: 2.13 kPa
9
2.4 Detailed Process Description
2.4.1 Process Block Diagram
Figure 2-1 PBD HAS Plant
10
Figure 2-2 PBD MPP-2 Plant
11
Figure 2-3 PBD MPP-1 Plant
12
Figure 2-4 PBD MAHCL Solid Plant
2.4.2 Process Description
The pre-mix tanks are initially charged with 7200 lit. of RO water by means of RO water pump,
then manually charged with 1.8MT of SNI, and 1450 lit. of caustic by way of pump from the
storage tank of caustic.
13
The pre-mixture is then agitated for approximately 1 to 2 hours. After that, a sample of the
same is checked for the percentage of CSL (11.2 to 12% w/v) and SNI (18.5 to 19.5% w/v).
The pre-mix is then pumped into a storage tank. Gravity then drives this pre-mix into HADS
reactor.
HADS intermediate formation requires sulphur dioxide, for which SO2 is first vaporized in a
vaporizer from a tonner storing SO2.
Vapor SO2 is received by receiver from vaporizer. In the HADS reactor, SO2 is sent and
inserted from the bottom by means of a sparger.
3.5 pH is maintained in HADS reactor by means of SO2. Also 10 - 12 0C is also maintained in

the reactor oy shell and tube heat exchanger where on one side brine is circulated and on other
side process fluid is passed.
Continuous overflow of acidic HADS is removed from the reactor containing 17 – 18% of
HADS. This is then passed further to another continuous reactor for alkylation of acidic HADS
to get alkaline HADS.
In this reactor 10 – 30 0C temperature is maintained, there is continuous addition of caustic

and RO water according to ratio of 1.15 caustic and 0.7 RO water of incoming overflow from
HADS reactor.
Alkaline HADS is then sent to storage tanks and then to dosing tank from which alkaline HADS
is sent to batch reactors according to batch requirements. Initial temp is 60 0C, at this time
DMS and CSL is added slowly in the reactor as the reaction is highly exothermic. Therefore,
cooling water is also passed. Here, MADS is formed and stored in the storage tank.
After this, MADS liquor is sent for alkaline recovery. For this temperature in reactor mass is
raised above 100 0C, then vapor is removed from top is then condensed and stored in tanks and
then sent to ETP latter.
After the alkaline recovery is done, temperature is lower down to 40 to 45 0C. Now for acidic
recovery, sulphuric acid is added and pH upto 2 is achieved. Then temperature of reaction is
increased to 100 0C. So vapours from top of reactor is removed, condensed and stored in tanks
for ETP treatment.
14
The reaction mass is further cooled down to 45 0C, then reaction mixture is transferred in
another batch reactor where MABASE is formed by addition of CSL. Temperature is
maintained around 60 0C by means of cooling water and pH is maintained around 8.3 to 8.5.
At the same instance in another batch reactor corresponding to previous one, HCl is received
and circulated through eductor to create vacuum in previous reactor.
Vacuum is produced in the reactor having MABASE after applying steam. MABASE is
vaporized leaving sodium sulphate and other impurities in reactor itself. Now this MABASE
vapor is condensed and sent to MSGLR reactor containing HCl.
Here, crude MAHCL is formed which is then sent for further increase concentration up to 25%
in another reactor and after that it is stored in tanks.
Reaction 1: At 10-12 degree Celsius (Exothermic Reaction)
2NaOH + 2NaNO + 4SO2 → 2HON(SO3Na

2
)2
Sodium hydroxide Sodium Nitrite Sulphur dioxide HADS
Reaction 2: At 10-25 degree Celsius
2HON(SO3Na)2 + 2NaOH → 2NaON (SO3Na)2 + 2H2O
HADS Sodium hydroxide Alk HADS Water
Reaction 3: At 70-72 degree Celsius
2NaON (SO3Na)2 + 2(CH3)2SO4→ 2CH3ON(SO3Na)2 + 2CH3NaSO4
Alk. HADS DMS MADS SMS
15
Reaction 4: 100-110 degree Celsius
2CH3ON(SO3Na + H2O → (CH3ONH2)2H2S+ H2SO4 + 2Na2SO4

)2 O4
Sulphuric Sodium
Acid Sulphate
MADS Water MAS
Reaction 5: 40-65 degree Celsius
1(CH3ONH2)2H2SO + 2NaOH → 2CH3ONH + Na2SO4 + 2H2O

4 2
Sodium Sodium
hydroxide Sulphate
MAS MAB Water
Reaction 6: 15 -25 degree Celsius
2CH3ONH2 + 2HCl → 2CH3ONH2.HCl
MAB Hydrochloric Acid MAHCl
16
2.4.3 Process Flow Diagram
Figure 2-5 Process Flow Diagram
17
2.4.4 Conclusions
Based on this chapter, we can conclude that there are various methods available for
manufacturing Methoxylamine Hydrochloride, and we have selected the optimal one.
Additionally, we have examined the process description in detail.
In the next chapter, we will discuss the raw materials required for this process using a mass
balance approach.
18
Chapter 3 : Material Balance
19
3.1 Introduction
Material balance calculations are a fundamental tool for process design. They provide
information about the materials that are entering, leaving, accumulating, or being depleted
during unit processes or operations. The performance of equipment and the feasibility of a
process can be determined based on these calculations. The foundation of material balance
calculations is the Law of Conservation of Mass, which states that the total mass of the various
components involved remains constant during any unit process or operation.
Plant Capacity = 2800 tonnes per annum
No. of batches per day = 10
2800000
Plant production per hour = = 767.12 kg/batch
365×10
Plant production per hour (as per roll no.) = (767.12 ÷ 153) × 10 + 767.12 = 817.25 kg/batch
Basis = 817.25 kg/batch of MAHCL
Component Properties:
20
3.1.1 Material Balance Over HADS Reactor (RT-001/RT-003)
Figure 3-1 Block diagram of M.B Over HADS Reactor
Table 3-1 M.B over HADS Reactor
Reaction 1: Reaction 2NaOH + 2NaNO2 + 4SO2 → 2HON(SO3Na)2

HAS Plant Compound Name Sodium Sodium Sulphur HADS
hydroxide Nitrite dioxide
Conversion Stoichiometry 2 2 4 2
0.7 Molecular 40 69 64 237
Weight(kg/kmole)
Weight(kg) 2426.43 4185.58 7764.56 10063.60
Moles(kmole) 60.66 60.66 121.32 42.46
Table 3-2 Summary of M.B over HADS Reactor
Compound Input Output

Sodium hydroxide 2426.42 727.92
Sodium Nitrite 4185.58 1255.67
Sulphur dioxide 7764.56 2329.36
HADS 0 10063.60
Total 14376.57 14376.57
Unreacted Reactants weight

Sodium hydroxide 727.92
Sodium Nitrite 1255.67
21
Sulphur dioxide 2329.36
Total 1983.60
 Calculations
NOTE: Here, we have taken the basis as per above and the calculation starts from the
last reaction. Here, is the sample for the calculation.
 From Back Calculation we get, weight of HADS = 10063.60 kg
𝑊𝑡 𝑜𝑓 𝐻𝐴𝐷𝑆 10063.60
Moles of HADS produced = 𝑀𝑜𝑙. = = 42.46 moles
𝑤𝑡 𝑜𝑓 𝐻𝐴𝐷𝑆 237
 As per material balance,
Input – Output + Generation – Consumption = Accumulation
 For NaOH,
Input = Output + Consumption
2 moles of HADS = 2 moles of NaOH
42.46 moles of HADS = (?) of NaOH
Therefore, moles of NaOH = 42.46 × 2 ÷ 2 = 42.46 moles
Here, conversion = 70%
42.46
Therefore, Actual moles of NaOH = = 60.66 moles
0.7
 For NaNO2,
2 moles of HADS = 2 moles of NaNO2
42.46 moles of HADS = (?) of NaNO2
Therefore, moles of NaNO2 = 42.46 × 2 ÷ 2 = 42.46 moles
22
42.46
Therefore, Actual moles of NaNO2 = = 60.66 moles
0.7
 For SO2,
2 moles of HADS = 4 moles of SO2
42.46 moles of HADS = (?) of SO2
Therefore, moles of SO2 = 42.46 × 4 ÷ 2 = 84.92 moles
84.92
Therefore, Actual moles of SO2 = = 121.32 moles
0.7
The calculations for following reactions are done similarly.
3.1.2 Material Balance Over Alkaline HADS Reactor (XRT-3002)
Figure 3-2:Material Balance Over Alk. HADS Reactor
Table 3-3 M.B Over Alkaline HADS Reactor
Reaction 2: Reaction 2HON(SO3Na)2 + 2NaOH → 2NaON(SO3Na)2 +

2H2O
23
HAS Plant Compound Name HADS Sodium Alk Water
hydroxide HADS
0.7 Molecular 237 40 259 18
Weight(kg/kmole)
Weight(kg) 10063.60 1698.50 7698.44 535.03
Moles(kmole) 42.46 42.46 29.72 29.72
Table 3-4 summary table of M.B Over Alkaline HADS Reactor

HADS 10063.60 3019.08
Alk HADS 0 7698.44
Water 0 535.02
Total 11762.09 11762.09

HADS 3019.08
Total 3528.62
24
3.1.3 Material Balance Over MADS Reactor
Figure 3-2 Block Diagram of M.B over MADS Reactor
Reaction 3: Reaction NaON(SO3Na)2 + (CH3)2SO4 → CH3ON(SO3Na)2 +

CH3NaSO4
MPP:2 Compound Name Alk. DMS MADS SMS
Plant HADS
0.7 Molecular 259 126 251 134
Weight(kg/kmole)
Weight(kg) 7698.44 3745.19 5222.46 2788.08
Moles(kmole) 29.72 29.72 20.81 20.81
Table 3-5 Summary of M.B. Over MADS Reactor
25
Alk. HADS 7698.44 2309.53
DMS 3745.18 1123.55
MADS 0 5222.45
SMS 0 2788.08
Total 11443.63 11443.63

Alk. HADS 2309.53
DMS 1123.55
Total 3433.08
3.1.4 Material Balance Over XRT-001
Figure 3-3 Material Balance Over XRT-001
Reaction 4: Reaction 2CH3ON(SO3Na)2 + 4H2O → (CH3ONH2)2H2SO4 + H2SO4 +

2Na2SO4
26
MPP:1 Compound Name MADS Water MAS Sulphuric Sodium
Plant Acid Sulphate
Conversion Stoichiometry 2 4 1 1 2
0.7 Molecular 251 18 192 98 142

Weight(kg/kmole)
Weight(kg) 5222.46 749.04 1398.20 713.67 2068.18
Moles(kmole) 20.81 41.61 7.28 7.28 14.56
Table 3-6 Summary of Material Balance Over XRT-001

MADS 5222.45 1566.73
Water 749.03 224.71
MAS 0 1398.20
Sulphuric Acid 0 713.66
Sodium Sulphate 0 2068.17
Total 5971.49 5971.49

MADS 1566.73
Water 224.71
Total 1791.44
3.1.5 Material Balance Over MABase Reactor (XRT-011)
27
Figure 3-4 Material Balance Over MABase Reactor
Table 3-7 Material Balance Over MABase Reactor
Reaction 5: Reaction (CH3ONH2)2H2SO4 +2NaOH → 2CH3ONH2 + Na2SO4 +

2H2O
MPP:1 Compound MAS Sodium MAB Sodium Water
Plant Name hydroxide Sulphate
Conversion Stoichiometry 1 2 2 1 2
0.7 Molecular 192 40 47 142 18

Wt.(kg/kmole)
Weight(kg) 1398.20 582.58 479.18 723.86 183.51
Moles(kmole) 7.28 14.56 10.20 5.10 10.20
Table 3-8 Summary of Material Balance Over MABase Reactor

MAS 1398.20 419.46
MAB 0 479.17
28
Water 0 183.51
Total 1980.78 1980.78

MAS 419.46
MAB 143.75
Total 737.98
3.1.6 Material Balance Over MAHCL Reactor
Figure 3-5 Material Balance Over MAHCL Reactor
Table 3-9 Material Balance Over MAHCL Reactor
Reaction Reaction CH3ONH2 + HCl → CH3ONH2.HC

6: l
MPP:1 Compound Name MAB Hydrochlori MAHCl
Plant c Acid
Coversio Stoichiometry 2 2 2
n
29
0.96 Molecular 47 36.5 83.5
Weight(kg/kmole)
Weight(kg) 479.18 372.13 817.25
Moles(kmole) 10.20 10.20 9.79
Table 3-10 Summary of Material Balance Over MAHCL Reactor

MAB 479.17 19.16
Hydrochloric Acid 372.12 14.88
MAHCl 0 817.25
Total 851.30 851.30

MAB 19.16
Hydrochloric Acid 14.88
Total 34.05
30
3.2 Overall Material Balance
Table 3-11 Overall Material Balance
Compound Input (kg) Output (kg)

Sodium Nitrite 4185.58 1255.67
Sulphur dioxide 7764.56 2329.36
HADS 10063.60 13082.68
Alk. HADS 7698.44 10007.97
DMS 3745.18 1123.55
Water 749.03 943.25
MADS 5222.45 6789.19
MAB 479.17 498.34
Hydrochloric Acid 372.12 14.88
SMS 0 2788.08
Sulphuric Acid 0 713.66
MAS 1398.20 1817.66
MAHCl 0 817.25
Total 46385.88 46385.88
31
Figure 3-6 Overall Material Balance
32
3.3 Conclusions:
In this chapter, we have computed the quantities of raw materials, intermediates, and solvents
needed to produce MAHCL. Material balance also offers advantages in terms of optimizing
storage space for both raw materials and the final product.
However, the production process cannot be considered complete without the addition or
removal of energy in certain steps. This is where the Energy Balance of Process comes into
play, which will be discussed in the next chapter.
33
Chapter 4 : Energy Balance
34
4.1 Introduction:
Energy Balance involves calculating the demand placed on utilities by a system. Its purpose is
to determine the amount of utilities necessary for the system to reach optimal conditions. For
instance, the calculation of the load on the cooling water is used to determine the cooling
tower's total water requirement, the size of the fans, and other relevant factors. Similarly, the
calculation of the load on steam is used to determine the boiler's capacity.
The process of Energy Balance requires an understanding of thermodynamics. The heat duty
on both the process side and the utility side is matched to calculate the utilities' load. To perform
the calculation, accurate values for heat capacities, latent heat of vaporization, latent heat of
condensation, and so on, at their respective temperatures, must be considered.
Conservation of Energy states that:
rate of energy accumulation = rate of energy entering system by inflow – rate of energy
leaving system by outflow + rate of heat added to system + rate of work done on system
Sensible Heat: Heat related to changes in temperature. It is calculated by M*Cp*ΔT.
Latent Heat: Heat required for changing the physical state from solid to liquid, liquid to gas, or
solid to gas. It is calculated by (M*λ).
Heat of Reaction: Heat involved during a reaction, which may be released to or absorbed from
the surroundings. It is calculated as, [ΔH0 (Products) - ΔH0(reactants)]
4.2 Standard Heat Of Formation and Heat Capacity Of Components:
Table 4-1 Standard Heat Of Formation
Compounds Heat of Formations KJ/mol J/mol
35
NaOH -425.8 -425800
NaNO2 -359 -359000
SO2 -296.81 -296810
HADS -1542.19 -1542190
MADS -1767.31 -1767310
WATER -285.82 -285820
Alk HADS -1829.34 -1829340
DMS -735.25 -735250
MAS -3874.51 -3874510
MAB -74.6 -74600
HCl -92.3 -92300
H2SO4 -814 -814000
Na2SO4 -2013.25 -2013250
SMS -965.65 -965650
MAHCL -198.56 -198560
Table 4-2 Heat Capacity Of Components
Compounds Temperature( Celsius) Temperature Heat capacity J/mol

(kelvin)
MAHCl 25 298 82.8
MAB 60 333 69
MAB 25 298 65.2
HCL 25 298 42.83
Na2SO4 60 333 131.86
Na2SO4 45 318 131.06
WATER 60 333 75.3
36
MAS 60 333 200.14
MAS 45 318 193.66
NaOH 25 298 41.83
NaOH 45 318 41.85
NaOH 60 333 43.13
NaOH 70 343 44
NaOH 100 373 46.57
H2SO4 45 318 81.4
H2SO4 100 373 87.2
Na2SO4 100 373 133.86
MAS 100 373 216.34
Water 100 373 75.9
WATER 70 343 75.5
WATER 45 318 75.3
WATER 10 283 75.6
WATER 25 298 75.6
MADS 100 373 249.36
MADS 70 343 219.16
SMS 100 373 137.76
SMS 70 343 134.73
SMS 60 333 133.4
SMS 45 318 131.03
MADS 60 333 209.16
MADS 45 318 194.16
ALK HADS 70 343 220.19
DMS 70 343 343
DMS 25 298 129.2
ALK HADS 25 298 188.24
ALK HADS 10 283 233
HADS 25 298 195.66
HADS 10 283 193.06
NaOH 10 283 41.13
37
NaNO2 100 373 73.55
NaNO2 70 343 69.78
NaNO2 60 333 68.46
NaNO2 45 318 66.56
NaNO2 25 298 64.03
NaNO2 10 283 62.13
SO2 45 318 44.5
SO2 10 283 41.5
38
4.2.1 Energy Balance Over HADS Reactor (RT-001/RT-003)
Figure 4-1 Energy Balance Over HADS Reactor
Reaction 1: 2NaOH + 2NaNO2 + 4SO2 → 2HON(SO3Na)2
Table 4-3 Energy Balance Over HADS Reactor
Reaction1 kg/hr kmol/hr Temperature

Compound Input Output Input Output In Out
Sodium 2426.43 727.93 60.66 18.20 298 283
hydroxide
Sodium 4185.58 1255.68 60.66 18.20 298 283
Nitrite
Sulphur 7764.56 2329.37 121.32 36.40 318 283
dioxide
HADS 0.00 10063.60 0.00 42.46 - 283
water 16742.34 16742.34 930.13 930.13 298 283
Total 31118.91 31118.91
Heat of Reaction,
39
ΔHrxn = (n×ΔHf) HADS - (n×ΔHf) NaOH - (n×ΔHf) NaNO2 - (n×ΔHf) SO2
ΔHrxn = (1 × (-1542190)) – (1× (-425800)) – (1× (-359000)) – (1×(-296810))
ΔHrxn = -163770 J/mol
Heat Input,
Hin = (n × Cp × ∆T) NaNO2 + (n × Cp × ∆T) NaOH + (n × Cp × ∆T) SO2 + (n × Cp × ∆T) Water
Hin = (60.66 × 64.03 × 298) + (60.66 × 41.83 × 298) + (121.32 × 44.5 × 318) + (930.13 × 75.6
× 298)
Hin = 24585145.35 J/hr
Heat Output,
Hout = (n × Cp × ∆T) HADS+(n × Cp × ∆T) NaNO2 +(n × Cp × ∆T) NaOH +(n × Cp × ∆T) SO2 + (n ×
Cp × ∆T) Water
Hout = (42.46 × 193.06 × 283) + ( 18.20 × 62.13 × 283) + (18.20 × 41.13 × 283) + (36.40 × 41.5
× 283) + (930.13 × 75.6 × 283)
Hout = 23179175.99 J/hr
Heat absorbed by brine,
Heat absorbed by brine = Hin - Hout - (n × ΔHrxn)
Heat absorbed by brine = 24585145.35 - 23179175.99 – (42.46 × (-163770))
Heat absorbed by brine = 8360045 J/hr
Mass flowrate of brine,
Mass flowrate of brine = (m × Cp × ∆T) brine = 8360045 J/hr
8360045
mbrine = 3.11×10×1000 = 268.81 kg/hr
40
4.2.2 Energy Balance Over Alkaline HADS Reactor (XRT-3002)
Figure 4-2 Energy Balance Over Alkaline HADS Reacto
Reaction 2: 2HON(SO3Na)2 + 2NaOH → 2NaON(SO3Na)2 + 2H2O
Table 4-4 Energy Balance Over Alkaline HADS Reactor

HADS 10063.60 3019.08 42.46 12.74 283 298
Sodium 1698.50 509.55 42.46 12.74 283 298
hydroxide
Alk. HADS 0.00 7698.44 0.00 29.72 - 298
Water 16742.34 17277.36 930.13 959.85 283 298
Total 28504.44 28504.44
ΔHrxn = (n × ΔHf) H2O + (n × ΔHf) Alk. HADS - (n × ΔHf) HADS - (n × ΔHf) NaOH
41
Hin = (n × Cp × ∆T) HADS + (n × Cp × ∆T) NaOH + (n × Cp × ∆T) Water
Hin = 22714174.47 J/batch
Hout = (n × Cp × ∆T) HADS + (n × Cp × ∆T) NaOH + (n × Cp × ∆T) Water + (n × Cp × ∆T) Alk. HADS
Hout = 24193263.09 J/batch
Heat absorbed by brine = Hin - Hout - (n × ΔHrxn)
Heat absorbed by brine = 11019309.27 J/batch
Flowrate of brine
(m × Cp × ∆T) Brine = 11019309.27 J/hr
m = 354.31 kg/batch
42
4.2.3 Energy Balance Over MADS Reactor
Figure 4-3 Energy Balance Over MADS Reactor
Reaction 3: 2NaON(SO3Na)2 + 2(CH3)2SO4 → 2CH3ON(SO3Na)2 + 2CH3NaSO4
Table 4-5 Energy Balance Over MADS Reactor

Alk. HADS 7698.44 2309.53 29.72 8.92 298 343
DMS 3745.19 1123.56 29.72 8.92 298 343
MADS 0.00 5222.46 0.00 20.81 - 343
SMS 0.00 2788.08 0.00 20.81 - 343
Water 17277.36 17277.36 959.85 959.85 298 343
Total 28721.00 28721.00
ΔHrxn = (n × ΔHf) MADS + (n × ΔHf) SMS - (n × ΔHf) DMS - (n × ΔHf) Alk. HADS
Hin = (n × Cp × ∆T) DMS + (n × Cp × ∆T) Alk. HADS + (n × Cp × ∆T) Water
43
Hin = 24436127.68 J/batch
Hout = (n × Cp × ∆T) DMS + (n × Cp × ∆T) Alk. HADS + (n × Cp × ∆T) Water + (n × Cp × ∆T) MADS
+ (n × Cp × ∆T) SMS
Hout = 29104999.05 J/batch
Heat absorbed by cool water = Hin - Hout - (n × ΔHrxn)
Heat absorbed by cool water = 2337543.473 J/batch
Flowrate of cool water
(m × Cp × ∆T) cool water = 2337543.473 J/batch
m (cool water) = 27.93 kg/batch
Heat supplied by steam = (n × Cp × ∆T) DMS + (n × Cp × ∆T) Alk. HADS + (n × Cp × ∆T) Water
Heat supplied by steam = 3690019.28 J/batch
Flowrate of steam,
m(Cpw × ∆Tw + λ + Cps × ∆Ts) = 3690019.28 J/batch
m (steam) = 1.605 kg/batch
44
4.2.4 Energy Balance Over XRT-001
Figure 4-4 Energy Balance Over XRT-001
Reaction 4: 2CH3ON(SO3Na)2 + 4H2O → (CH3ONH2)2H2SO4 + H2SO4 + 2Na2SO4
Table 4-6 Energy Balance Over XRT-001

MADS 5222.46 1566.74 20.81 6.24 343 318
Water 18026.40 17502.08 1001.47 972.34 343 318
MAS 0.00 1398.20 0.00 7.28 - 318
Sulphuric 0.00 713.67 0.00 7.28 - 318
Acid
Sodium 0.00 2068.18 0.00 14.56 - 318
Sulphate
Total 23248.86 23248.86
ΔHrxn = (n × ΔHf) MAS + (n × ΔHf) H2SO4 + (n × ΔHf) Na2SO4 - (n × ΔHf) MADS - (n × ΔHf) H2O
Hin = (n × Cp × ∆T) MADS + (n × Cp × ∆T) Water
45
Hin = 27498556.34 J/batch
Hout = (n × Cp × ∆T) MADS + (n × Cp × ∆T) Water + (n × Cp × ∆T) MAS + (n × Cp × ∆T) H2SO4 +

(n × Cp × ∆T) Na2SO4
Hout = 24347063.71 J/batch
Heat supplied by steam = (n × Cp × ∆T) MADS+ (n × Cp × ∆T) Water
Flowrate of steam
Heat absorbed by cool water =32550980.68 J/batch
Flowrate of cool water,
46
4.2.5 Energy Balance Over MAB Reactor (XRT-011)
Figure 4-5 Energy Balance Over MAB Reactor
Reaction 5: (CH3ONH2)2H2SO4 + 2NaOH → 2CH3ONH2 + Na2SO4 + 2H2O
Table 4-7 Energy Balance Over MAB Reactor

MAS 1398.20 419.46 7.28 2.18 318 333
Sodium 582.58 174.78 14.56 4.37 298 333
hydroxide
MAB 0.00 479.18 0.00 10.20 - 333
Sodium 0.00 723.86 0.00 5.10 - 333
Sulphate
Water 17502.08 17685.59 972.34 982.53 318 333
Total 19482.86 19482.86
ΔHrxn = (n × ΔHf) MAB + (n × ΔHf) NA2SO4 + (n × ΔHf) H2O - (n × ΔHf) MAS - (n × ΔHf) NaOH
ΔHrxn = 1992020 J/mol
Hin = (n × Cp × ∆T) MAS + (n × Cp × ∆T) NaOH + (n × Cp × ∆T) Water
47
Hin = 23913037.68 J/batch
Hout = (n × Cp × ∆T) MAB + (n × Cp × ∆T) Na2SO4 + (n × Cp × ∆T) Water + (n × Cp × ∆T) MAS
Hout = 25303357.48 J/batch
Heat supplied by steam = (n × Cp × ∆T) MAS + (n × Cp × ∆T) NaOH + (n × Cp × ∆T) Water
Flowrate of steam,
4.3.6 Energy Balance Over MAHCL Reactor
48
Figure 4-6 Energy Balance Over MAHCL Reactor
Reaction 6: 2CH3ONH2 + 2HCl → 2CH3ONH2.HCl
Table 4-8 Energy Balance Over MAHCL Reactor

MAB 479.18 19.17 10.20 0.41 298 298
Hydrochloric 372.13 14.89 10.20 0.41 298 298
Acid
MAHCl 0.00 817.25 0.00 9.79 - 298
Water 17685.59 17685.59 982.53 982.53 298 298
Total 18536.89 18536.89
ΔHrxn = (n × ΔHf) MAHCL - (n × ΔHf) HCl - (n × ΔHf) MAB
Hin = (n × Cp × ∆T) MAB + (n × Cp × ∆T) HCl + (n × Cp × ∆T) Water
Hin = 22463499.39 J/batch
Hout = (n × Cp × ∆T) MAHCl+ (n × Cp × ∆T) MAB + (n × Cp × ∆T) HCl + (n × Cp × ∆T) Water
Hout = 22389912.24 J/batch
49
50
4.3 Summary Diagram Of Energy Balance:
Figure 4-7 Summary Diagram Of Energy Balance
51
4.4 Conclusions:
In this chapter, we have computed the amounts of steam, cooling water, and brine solution
needed for the process. This calculation will aid in determining the boiler duty for steam
production and the cooling tower duty for cooling water production. Steam and cooling water
are referred to as utilities, which are necessary to maintain the process parameters. The
production of utilities will be discussed in detail in the next chapter.
52
Chapter 5 : Plant Utilities
53
5.1 Utilities used in plants
1. Steam
2. Electricity
3. Cooling water
4. Chilling Brine
5. Compressed Air
6. DM Water or RO water
5.2 Steam
The company has a Boiler section that supplies steam to all plants where it is needed. The
company has three boilers, which were supplied and commissioned by M/S Foster Wheeler
Power Products UK Ltd. The turbine generators for the boilers were made by M/S BHEL Ltd.
Each boiler is designed to generate steam at a rate of 275 tons per hour, at a pressure of 105
kilograms per square centimetre (absolute) and at a temperature of 5100 degrees Celsius at the
outlet of the boiler. All three boilers are connected to a single common header to supply high-
pressure steam to various consuming points. Typically, two boilers are kept in service, which
are sufficient to meet the steam requirements of the company, while the third boiler is kept as
a standby and is either under wet preservation or maintenance and inspection. The normal
steam generation capacity of each boiler is approximately 220 tons per hour.
The water used as feed for the boiler is either raw water or a combination of raw water and
water that has been used in the plants, but it must have a specific pH and alkalinity.
54
Figure 5-1 Block diagram of Boiler Section
5.3 Electricity
The plant mainly has three sources for electricity:
1. A coal-based power plant
2. A captive power plant
3. MGVCL power supply, and there is also a 66 KV substation in the company.
 The electricity is mainly used for lighting in the plant, for pump motors, and in some
equipment such as centrifuges, vibrators of VFBD, blower motors, for power in
PLCs and DCSs, for air conditioning systems, fans, and tube lights.
5.4 Cooling Water

 Cooling water is used as a cooling medium in condensers and to lower the air
temperature in heat exchangers for the cold zone of VFBD. Cooling towers are used to
provide cooling water wherever it is needed in the plant.
 A cooling tower is a structure in which water is circulated to remove heat generated
from various industrial operations. The hot water returns to the cooling tower, where it
is cooled and collected in a sump before being recirculated. This process continues in a
cyclical manner. There are three types of cooling towers: natural draft, in which natural
air circulation cools the hot water; forced draft, in which a fan is used to force air into
the tower; and induced draft, in which a fan is used to draw air through a water shower.
In the case of Deepak Nitrite Limited, an induced draft cooling tower is utilized, in
which fans are used to draw air through a water shower.
55
Figure 5-2 Cooling Tower
5.5 Chilling Brine

 The existing facility has a total capacity of 674 TR for chilled brine plants used in
various pesticide manufacturing processes. With the proposed expansion, an additional
674 TR capacity for chilled brine plants, with a temperature drop of almost -15°C, will
be required. As a result, the total capacity for chilling brine plants will be 1348 TR after
the expansion.
 Brine is produced by dissolving 30% urea in water, which can then generate ammonia
and be used as a brine solution.
5.6 Compressed air

 Control valves are generally operated using compressed air. Compressed air is also used
for cleaning dust and small debris in tight spaces. Air compressors are used to compress
and store this air.
56
5.7 DM Water or RO water
 A reverse osmosis plant is a facility where the process of reverse osmosis takes place.
This process involves purifying or desalinating contaminated water by forcing it
through a membrane. The water produced by reverse osmosis can be used for a variety
of purposes, such as desalination, wastewater treatment, and the removal of
contaminants and dissolved minerals.
 In order to perform reverse osmosis, the water must go through several pre-treatment
processes like softening, dechlorination, and anti-scalent treatment. After pre-
treatment, high levels of pressure are applied to force the water through a semi-
permeable membrane, which retains all contaminants while allowing pure water to pass
through. The energy required for the process depends on the concentration of salts and
contaminants in the influent water. The higher the concentration, the more energy is
required to treat the water. The reverse osmosis water mainly used in providing water
as a medium in a reaction and for cleaning purposes.
Figure 5-3 DM RO Water Plant
57
5.8 Conclusions:
To ensure the highest possible output at each stage of the process, it is crucial to maintain
optimal operating conditions. This is accomplished by utilizing various utilities that are
carefully selected based on the specific requirements of the process. These utilities include
heating and cooling mediums such as steam and cooling water, and their capacity is determined
by performing energy balance calculations.
Once the utilities are established, the process can be carried out efficiently and effectively using
well-maintained equipment. The raw materials are transformed into finished products through
a sequence of steps that are executed in specialized equipment. The specifics of this equipment
and its function in the process will be examined in the upcoming chapter.
58
Chapter 6 : Detailed Description Of Equipment
59
6.1 Caustic Storage Tank
Table 6-1 Details about Caustic Storage Tank
Parameter Value
Nos. 3
MOC SS316
Type Cylindrical storage with fixed roof
Orientation Vertical
Capacity 42 KL each
Diameter 3.782 m
Height 3.870 m
Safe Storage 3m
Operating pressure Atmospheric
6.2 RO Water Tank
Table 6-2 Details About RO Water Tank
Parameter Value
Nos. 1
MOC HDPE
Capacity 50 KL
Diameter 4m
Height 3.98 m
Safe Storage 3.4 m
60
6.3 HADS Reactor
Table 6-3 Details about HADS Reactor
Parameter Value
Nos. 2
MOC SS316
Type CSTR
Capacity 2.5 KL each
Diameter 1.290 m
Height 1.91378 m
Operating Temperature 10-12 0C
Operating Pressure Atmospheric
Jacket Type Half Coil
6.4 SO2 Vaporizer
Table 6-4 Details about SO2 Vaporizer
Parameter Value
Nos. 2
MOC SS316
Capacity 3 KL each
Diameter 1.29 m
Height 1.91378 m
Operating Pressure 1-1.5 kg/cm2
61
6.5 Alkaline HADS Reactor
Table 6-5 Alkaline HADS Reactor
Parameter Value
Nos. 1
MOC SS316
Type CSTR
Capacity 3.5 KL
Diameter 1.9 m
Height 1.23 m
6.6 MADS Reactor

Table 6-6 Details about MADS Reactor
Parameter Value
Nos. 7
MOC SS316
Type CSTR (Batch reactors)
Capacity 7 KL
Diameter 1.5 m
Height 3.96 m
62
6.7 DMS Storage Tank
Table 6-7 Details about DMS Storage tank
Parameter Value
Nos. 2
MOC SS316
Capacity 35 KL each
Diameter 3m
Height 4.95 m
Safe Storage 2.5 m
6.8 MADS Storage Tank

Table 6-8 Details about MADS Storage Tank
Parameter Value
Nos. 2
MOC SS316
Capacity 40 KL each
Diameter 3.5 m
Height 4.15 m
Safe Storage 3m
63
6.9 Hydrolysis Reactor
Table 6-9 Details About Hydrolysis Reactor
Parameter Value
Nos. 10
MOC SS316
Capacity 7 KL
Diameter 1.5 m
Height 3.96 m
Operating Temperature 100 – 110 0C
6.10 MABase Reactor

Table 6-10 Details about MABase Reactor
Parameter Value
Nos. 7
MOC SS316
Capacity 7 KL
Diameter 1.5 m
Height 3.96 m
64
6.11 MAHCL Reactor
Table 6-11 Details about MAHCL Reactor
Parameter Value
Nos. 7
Equipment no. XRT- 021/009/005/012/008, V-30A/31A
MOC MSGLR
Capacity 7 KL
Diameter 1.5 m
Height 3.96 m
Operating Pressure Under Vacuum of 680 mmHg approx. (80 mmHg abs.)
pH 8.3 to 8.5
6.12 HCl Storage Tank

Table 6-12 Details about HCl storage tank
Parameter Value
Nos. 2
MOC HDPE
Capacity 20 KL each
Diameter 2m
65
Height 6.36 m
Safe Storage 5.8 m
6.13 MAHCL Storage Tank
Table 6-13 Details of MAHCL Storage Tank
Parameter Value
Nos. 1
MOC FRP + PPGL

Capacity 30 KL
Diameter 2.5 m
Height 6.11 m
Safe Storage 5.6 m
6.14 Conclusions:
In this chapter, we have provided a detailed description of the equipment available at Deepak
Nitrite Ltd. Proper design of this equipment is crucial for achieving better production and cost
optimization, which will be discussed in the next chapter.
66
Chapter 7 : Designing Of Equipment
67
7.1 Introduction
 The proper handling, storage, and transportation of any raw material, product, or utility
requires specialized equipment. These tools are designed to maximize yield by
considering optimal conditions and the duration of the process.
 The design process is divided into two parts: process design and mechanical design.
 In chemical engineering, process design involves selecting and arranging units to
achieve the desired physical and/or chemical transformation of materials. It is the
pinnacle of the field, as it incorporates all its various components.
 Mechanical design, on the other hand, is more intricate and complex. It involves
calculations for factors such as height, diameter, thickness of shell, head, nozzles,
flanges, bolts, and supports.
7.2 Major Equipment Design
7.2.1 Process Design of Reactor
Table 7-1 Data for Process Design Of Reactor
Quantity Value Unit

Flowrate of NaOH 2426.42 kg/hr
Flowrate of NaNO2 4185.58 kg/hr
Conversion X 0.7
Rate constant K 2.5 1/hr
Total Flowrate 6612.01 kg/hr
Residence time 2.761 hr
Density 1072 kg/m3
Volume 8.515 m3
L/D Ratio 2
Operating Pressure 0.0980665 N/mm^2
68
Temperature 10 0C
Allowable Stress (SS 316) 252 N/mm^2
Joint Efficiency, J 0.85

Corrosion Allowance 2 mm
Density of Material 7990 kg/m3
Pressure Inside Jacket (Pj) 0.1962 N/mm^2
Modulus of elasticity 1.64E+11 N/m^2
Poison's Ratio 0.28
 Performance Equation,
𝜏 𝑋𝐴
𝐶𝐴0
= −𝑟𝐴
Reaction is of First Order. Therefore, -rA = k × CA
– rA = K ∗ CA0 ∗ (1 – XA)
Where K = Rate Constant = 2.5 hr-1
XA = Conversion of SO2 = 70 %
τ = Residence time
𝑋𝐴
τ = CA0 × −𝑟𝐴
𝑋𝐴
τ = CA0 * 𝑘∗𝐶𝐴0∗(1−𝑋𝐴)
0.7
τ= 2.5∗(1−0.7)
τ = 0.933 hr
𝑉𝑜𝑙𝑢𝑚𝑒
τ = 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒
Volume = τ * Volumetric Flowrate
69
6612.01
V = 0.933 * 1072
V = 2.88 m3
L/D ratio = 2
𝜋
V = * D2 * L
4
𝜋
2.88 = 4 * D2 * 2D
D = 1223.88 mm
L = 2D = 2447.77 mm
Table 7-2 Courses Calculation Data
Courses Calculation:
length of plate 2 m
height of length 1 m
Circumference of shell 4 m
Plates in horizontal direction 2
Plates in vertical direction 4
Total plates 8
height of shell 4 m
4000 mm
diameter of shell 2 m
2000 mm
Thickness of plate 5 mm
Volume of one plate 10000000 mm3
0.01 m3
Weight of one plate 79.9 kg
New Volume 12566370614 mm3
12.57 m3
70
7.2.2 Mechanical Design of Reactor
1. Thickness of Shell
Operating Pressure (Pi) = 0.098 N/mm2
Design Pressure inside reactor = 0.10 N/mm^2
Design Temperature (Td) = 10 0C
Outer Diameter (Do) = 1370 mm
Corrosion Allowance (CA) = 2 mm
Vessel Class = Class I
Welded Joint Efficiency (J) = 0.9
Allowable Stress (SS316) (f) = 252 N/mm2
Density of Material (SS316) = 7990 Kg/m3
Pressure Inside Jacket (Pj) = 0.1962 N/mm2
 Corroded thickness:
tsc = (P * Do) / (2 * f * J + P)
tsc = 0.48 mm
Design Thickness
tsd = tsc + CA
tsd = 2.48 mm
 Fabrication thickness
tsf = Standard Fabrication thickness
= 5 mm
 Design shell with respect to External Pressure:
Model Brown Equation:
71
Critical Pressure,
Pcr = 2.26 N/mm^2
Allowable Pressure,
Pall = Pcr/4
Pall = 0.565 N/mm^2
Pall > Pcr (Condition Satisfied)
Therefore, tsf = 5 mm.
2. Torispherical Head Design for Top and Bottom
 Crown Radius (Rc)
Rc = Di = 2000 mm
 Knuckle Radius (Rk)
Rk = 0.06 * Rc
Rk = 120 mm
 Stress Concentration Factor (Cs)
Cs = 0.25*(3+ p (Rc/Rk))
Cs = 1.77
 Thickness of head
th = Pi*Di*Cs/(2*J*f-Pi*(Cs-0.2))
th = 0.85 mm
 Design Thickness
td = 0.85 + CA
72
td = 2.85 mm
Fabricated thickness
tf = 5 mm
Blank Diameter = 2626.59 mm
3. Jacket Design
Pressure Inside Jacket = 0.1962 N/mm2
Internal Design Pressure of Jacket (Pj) = 0.21582 N/mm2
Jacket Inside Diameter (Dij) = 1450.00 mm
Shell Corroded Thickness (ts’) = 9 mm
Shell inside diameter (Di) = 1348.00 mm
Pressure Inside shell (P) = 0.1078 N/mm2
Maximum allowable stress for Jacket (f) = 252 N/mm2
Welded Joint Efficiency (J) = 0.9
CA = 2 mm
 Corroded Thickness
tsc = (P * Do) / (2 * f * J + P)
tsc = 0.56 mm
 Design Thickness = tsc + CA = 2.56 mm

 Fabrication Thickness = 5 mm
4. Agitator Design
73
Table 7-3 Data for Agitator
Speed Of Agitator n 150 RPM

2.5 RPS
Ultimate Stress El 567 N/mm^2
Yield Stress f 252 N/mm^2
Shear Stress Tau 400 N/mm^2
Width Of Blade Wa 150 mm
Material Of Construction MoC SS 316
Length Of Agitator Shaft L 2600 mm
Tank Diameter Dt 2000 mm
Agitator Diameter Da 611.9414202 mm
Thickness of Blade tb 10 mm
Modulus of Elasticity E 1.64E+11 N/m^2
Viscosity Meu 0.003 kg/m*s
Gravitational Acceleration g 9.81 m/s^2
gc 1
Density Ro 1072 kg/m3
 Reynold's No. NRe = (ρ * n * Da2)/μ = 334528.5895
Turbine Type Six Blades

A 1
B 40
M -0.113110831
𝑃∗𝑔𝑐
 Power number (Np) = 𝑛 3∗(𝐷𝑎)5 ∗ 𝜌
Np = 1
𝑛 2 ∗𝐷𝑎
 Froude's Number, NFr = 𝑔
NFr = 0.389870935
74
 Corrected Power Number, Npc = Np * (NFr)m
Npc= 1.112426386
 Power = 1598.95 W
P = 2.13 hp
Design Power = 1.1 * 1.2 * 1598.95
Pa = 2110.61 W
Pa = 2.81 hp
 Torque,
Tau c = P/(2πN)
Tau c = 134.43 N m
 Maximum Torque,
Tau m = 1.5 *Tau c = 201.65 N m
 Bending Force acting On Shaft with Blades
Fm = (Tau m)/(0.75*Rb) = 878.73 N
Bending Moment on Shaft Due to Agitator
M = Fm * L = 2284.72 N m
 Estimation Of Shaft Diameter
Shaft Diameter as per MOC
D = 15.97 mm
D = 0.0159 m
 Equivalent Bending Moment
2
Me = 0.5*(M + √(𝑇𝑎𝑢 𝑚)2 + 𝑀2 ) = 2289.16 N m
Now we'll use Section Modulus
Checking if Allowable Stress exceeds Elastic Limit
75
Section Modulus = (π*D^3)/4 = 4.00305E-07 m^3
 Allowable Stress as per calculated Shaft Diameter = 5718549262 N/m^2
= 5718.54 N/mm^2
Changing Shaft Diameter to = 55 mm
Actual Stress Acting on Shaft = 140.14 N/mm^2
𝜋𝐷4
 Moment Of Inertia (I) = = 4.4918E-07 m^4
64
𝐹𝑚∗𝐿3
 Shaft Deflection (δ) = = 6.98 cm
3∗𝐸∗𝐼
N (in RPM) = 150
4.987∗60
Nc (in RPM) = = 113.18623
√𝛿
N/Nc * 100 = 32.52 %
Stress Condition = Satisfied
N/Nc Range: > 130% (propeller type agitator) = Satisfied
New Diameter = 55 mm
N/Nc * 100 = 132.52 %
 Moment for Blade:
Mb = Fm * (0.75 * Rb – Wb) = 69840.42 N mm
F = Mb/zb =1.86N/mm2
5. Bracket Support
76
Table 7-4 Data for Bracket support
Data Given:
Outer Diameter 2010 mm
Thickness of Shell 5 mm
Height of Vessel (H-F) 4000 mm
Clearance from Vessel bottom to foundation 1500 mm
Weight of Vessel Content(W) 3085.605 kg
Wind Pressure(P1) 0.0001 N/mm2
Size of the base plate

A (larger) 150 mm
B (smaller) 150 mm
Height of C Channel from Foundation 1750 mm
Bolt Circle Diameter (Db) 2335 mm
Size of C Channel
B 75 mm
D 150 mm
Cross Section Area of C Channel (A) 2458.06 mm2
Section Modulus (Z) 283496.2 mm3
Tensile Stress 567 N/mm2
Compressive stress 567 N/mm2
Bending Stress 400 N/mm2
No. of Brackets 4
K 0.7
A 0.000133
Radius of gyration (r) 22.1 mm
 Bracket And Gusset Plate Design
Total Wind Load (pw) = 562.8 N
77
Max. compressive load per lug (P) = 1735.51 N
Assume thickness of gusset plate (t2) = 5.5 mm
Assume height of gusset plate = 150 mm
Distance between two gusset plate (a) = 139 mm
Avg. Compressive load (Pav) = 0.083 N/mm2
Thickness of base plate (t1) = 1.55 mm
Fabricated thickness of base plate (t1) = 5 mm
Θ = 45 ᵒ
C = 162.5 mm
Recalculated thickness of gusset plate (t2) = 0.093 mm
fabricated thickness of base plate (t2) = 5 mm
 CHANNEL DESIGN
Max. compressive stress due to dead (fcmax) = 0.853N/mm2
fc max < fc allowable
Eccentricity (e) = 165 mm
Stress created by Eccentricity (fec) = 0.448 N/mm2
Max. compressive stress due to wind (fw) = 0.434 N/mm2
Condition is Satisfied
 BEARING PLATE DESIGN
Take l1= l2 = 20mm
B = 0.8 * 75 + 2 * 20 = 100 mm
C = 0.95 * 150 + 2 * 20 = 182.5 mm
Bearing Pressure (Pb) = 0.01584943 N/mm2
78
Max. Bending Moment in plate (Mmax) = 3.16 N
Thickness of Bearing Plate (t) = 0.218mm
Fabricated Thickness of Bearing Plate (th) = 5mm
 Weight of equipment
Shell = 8 * 79.9 = 639.2 kg
Top Head = π * (ds+2 * tsf)2 * th * 7990/(4 * 109) = 126.76 kg
Bottom Head = 126.76 kg
Total Weight = 892.729 kg
 Cost of Reactor Vessel:

 MOC cost = 300 Rs/kg
 Cost of equipment by weight = 892.729 * 300 = 267818.89 Rs
 Cost of Agitator = 25000 Rs
 Cost of fabrication = 175 * 892.729 = 156227.69 Rs
 Total Cost without taxation = 267818.89 + 25000 + 156227.69 = 449046.58 Rs
 GST = 18%
 GST Amount = 0.18 * 449046.58 = 80828.38 Rs
 Total Cost with taxation = 449046.58 + 80828.38 = 529874.97 Rs
79
7.3 Minor Equipment Design
7.3.1 Pressure Vessel
 Design of caustic soda lye storage tank
CSL weight = 2426.43 kg
Capacity for 15 days = 2426.43 * 15 = 36396.39kg
Density of CSL = 1537.6kg/m3
Volume of CSL = 47.342 m3
Density of Material = 7990 kg/m3
L/D = 1
L = ∛(V*4/π) = 3.9210 m
D = L = 3.9210m
J = 0.85
CA = 2 mm
F = 252000000 Pa
Pressure(P) = ρg(L-0.3) = 54618.95 N/m2
Table 7-5 Data for Pressure vessel
Courses Calculation:
length of plate 2 m
height of length 1 m
Circumference of shell 14 m
Plates in horizontal 7
direction
Plates in vertical direction 4
Total plates 28
80
height of shell 4 m
4000 mm
diameter of shell 14 m
14000 mm
Volume of one plate 10000000 mm3
0.01 m3
Weight of one plate 79.9 kg
Thickness(tsc) = (P * Do) / (2 * f * J) = 0.0005m
tsd = tsc + CA = 2.50 mm
tsf = 5 mm
 Cost of SS-316 storage tank
Weight of storage tank = 79.9 * 28 =2237.2 kg
Cost of SS 316 = 300 Rs/kg
Cost of storage tank = 2237.2 * 300 = 671160 Rs
Fabrication Cost = 175 * 2237.2 = 391510 Rs
Cost Prior Taxation = 671160 + 391510 = 1062670 Rs
GST = 18%
GST Amount = 0.18 * 1062670 = 191280.6 Rs
Cost of Storage tank = 1062670 + 191280.6 = 1253950.6 Rs
 Cost of MAHCL storage tank
Density of Material = 8110 kg/m3
Cost of FRP+PPGL = 364 Rs/kg
Weight of storage tank = 81.1 * 28 = 2270.8 kg
81
Cost of storage tank = 2270.8 * 364 = 826571.2 Rs
Fabrication Cost = 200 * 2270.8 = 454160 Rs
Cost Prior Taxation = 826571.2 + 454160 = 1280731.2 Rs
GST = 18%
GST Amount = 0.18 * 1280731.2 = 230531.616 Rs
Cost of Storage tank = 1280731.2 + 230531.616 = 1511262.816 Rs
7.3.2 Centrifugal Pump
Table 7-6 Data for Centrifugal pump
Data Given:
Parameter Value Units
Demineralized Water Required 749.04 kg/hr
Water Density (𝛒) 1000 kg/m3
Water supplied 0.75 m3/hr
Water Flowrate (Q) 0.75 m3/hr
Inlet pipe Diameter (Di) 25.4 mm
Outlet pipe Diameter (Do) 25.4 mm
Pipe Length (L) 20 m
Suction Pressure (Ps) 101325 N/m2
Discharge Pressure (Pd) 147100 N/m2
Elevation Head 5 m
Viscosity of water (𝛍) 0.00089 kg/m*s
Vapour Pressure of Water at 25 Celsius 3171.47 N/m2
(Pv)
NPSH Required 5 m
 Calculation:
 Cross Section Area of Pipe,
82
A = π/4 * (Do)2
A = 0.000507 m2
 Water Velocity,
u = Q/A
u = 1478.245 m/hr
u = 0.41 m/s
 Reynolds Number
NRe = ρ * u * Di/μ = 11718.92
 Absolute Roughness of Pipe = 46 mm

 Relative Roughness = 46/25.4 = 1.81
 Friction Factor from Chart
Friction Factor (f) = 0.03
83
 Head Loss = f * L * u2/ (2 * 9.81 * Do * 0.001) * 4 = 0.81 m
Table 7-7 Data for Head loss and Fittings
Head loss due to Bendings and Fittings:

No. ev L/Rh
90 Degree bends 4 0.6 20
Globe Valve 1 8 266.667
 Head loss due to Bendings and Fittings = (f * u2) * ((4 * 100) + (1 * 1333.33))/(2 *
9.81) = 0.09 m
 Pressure Head = (Pd-Ps)/(ρ * g) = 4.67 m
Head Loss ev L/Rh

Due to expansion 1 33.33
Due to contraction 0.45 15
 Head loss due to expansion and contraction = (f*u^2) * (1+0.45) / (2*9.81) = 0.01 m
 Total Head Loss (h) = 0.09 + 4.67 + 0.01 + 0.81 + 5 = 10.58 m
 Actual Head Required (Hact) = 1.2 * 10.58 = 12.70 m
 Power Of Pump
Required Power Preq = Q * ρ * 9.81 * Hact / 3600 = 25.91 W
Let, Efficiency of pump (%) = 75
Actual Power Required (Pact) = Preq / (75 * 0.01) = 34.55 W
Pact = 0.03 kW
Pact = 0.05 hp
NPSH Available = (Ps/(ρ*9.81)) - (Pv/(ρ*9.81)) - (u^2/(2*9.81)) = 10 m
Condition Satisfied = NPSH Available > NPSH Required
84
Pump available at Industry = 0.5 hp
7.3.3 Shell and Tube Heat Exchanger
Table 7-8 Data for Shell & Tube Heat exchanger
Process Fluid
Data
Mass flowrate 10063.6 kg/hr
Temp. in 14 0C
Temp. out 4 0C
Fluid HADS
Avg. Temp 9 0C
Cp 4 kJ/kg*0C
Heat Duty 100.636 kW
Thermal 0.00015 kW/m*0C
Conductivity
Viscosity 0.00038 kg/ms
Density 866 kg/m3
Service Fluid
Data
Mass flowrate 20127.2 kg/hr
Temp. in -4 0C
Temp. out ?
Fluid Brine
Cp 3.11 kJ/kg*0C
Thermal 0.0007 kW/m*0C
Conductivity
Viscosity 0.00102 kg/ms
Density 1007 kg/m3
85
 Calculations
 Equating Heat Duties,
Temp. out = 1.787 ℃
T avg (brine) = (-4 + 1.787)/2
T avg (brine) = -1.106 ℃
 Assume 1-4 pass.
No. of passes = 4
((14−1.787) − (4 − (−4)))
 LMTD =𝐿𝑁((14 − 1.787)/(4 − (−4)))
LMTD = 9.958 ℃
R = 1.727
S = 0.321
Ft = 0.8925 > 0.75
Checking = Assumptions are true
Tm = Ft * LMTD = 8.888
Heat Transfer Area = Duty/(Uo * Tm) = 22.644 m2
 Assume U = 500 W/m2*℃
Take tube OD (d0) = 19.06 mm
86
d0 = 0.01906 m
Tube ID (di) = 0.606 inch
di = 0.0153 m
BWG = 15
Length (Assumed) = 12 ft = 3.658 m
Area of the tube = π * d0 * L = 0.216 m2
No. of the tubes = 104.798
Total tubes (Nt) = 100
For 4 passes(tubes/pass) = 25
 Consideration of Arrangement = Triangular Pitch
K1 =0.175
n1 = 2.285
Bundle Diameter Db = 306.66 mm = 0.3066 m
Clearance = 12 mm
Shell Diameter Ds = 306.66 + 12 = 318.66 mm = 0.318669649 m
Checking
Total Length/Ds = 11.4806559(Satisfied)___________range [5,15] because fixed tube

sheet
87
 Cooling Brine:
Fouling Factor Coefficient Average = 2000
Resistance = 0.0005
 HADS:
Fouling Factor Coefficient Average = 5000
Resistance = 0.0002
 Fluid allocation = Service fluid on shell side
 Side Cross sectional Area = π/4 * di2 = 0.0002 m2

 Area per pass = 25 * 0.0002 = 0.0047 m2
 Volumetric Flow = 0.0056 m3/s
 Tube side Velocity (ut) = Vol. flowrate/Area per pass = 1.1935 m/s
 Reynolds No. NRe = ρvd/μ = 18136.125

 Prandtl No. Pr = Cp * μ/k = 4.532
 C = 0.027

 Heat transfer coefficient hi = 5158.91 W/m2*0C
 Baffle Spacing (Lb) = 0.3 * Ds = 95.601 mm

 Pt = 1.25 * do = 23.825 mm

 Cross Flow Area (As) = 0.006 m2
 us = 0.530 m/s
88

Shell Side Equivalent Diameter(de) = 0.013534 m = 13.534 mm
 Reynolds No. Re = 16339.8

 Prandtl No. Pr = 10.1
 Baffle Cut assumption = 25%
 jh = 0.004
hs = 1567.48 W/m2 * ℃
 di = 0.015 mm
1/Uo = 0.002
 Overall Heat transfer Conductivity Uo = 574.471 W/m2*0C

 %Error = 12.963 < 30%
 Pressure Drop:
 Tube side:
m = 0.5 Re<2100
m = 0.14 Re>2100
Reynolds No. NRe = 18136.12______Turbulent
89
jf = 0.004
Δ Pt = 26262.953 Pa = 0.259 bar <1 bar
 Shell Side:
jf = 0.045
Δ Pt = 10776.011 Pa = 0.106 bar <1 bar
90
7.4 Conclusions:
In this chapter, we have focused on the crucial aspect of designing the equipment as per their
required capacity to ensure optimal production output. To achieve this, we have considered
several factors, including the type of equipment, the manufacturing process, and the production
goals.
In the next chapter, we will delve deeper into the specifics of regulating flow using pumps and
valves. We will explore the various types of pumps and valves and their unique characteristics,
as well as their applications in specific equipment types.
91
Chapter 8 : Pumps, piping, fittings, and Control Valves
92
8.1 Pumps
A pump is a device that moves fluids or sometimes slurries, by mechanical action, typically
converted from electrical energy into hydraulic energy.
8.1.1 Types of Pumps:
Pumps are classified into:
1. Positive Displacement Pumps

2. Centrifugal Pumps
Centrifugal Pumps are mainly used in the plants.
 About Centrifugal Pumps:
• The hydraulics machine that converts the mechanical energy into pressure energy by
means of centrifugal force acting on the fluid is known as centrifugal pump.
• These are the most popular and commonly used type of pumps for the transfer of fluids
from low level to high level. When a certain mass of liquid is made to rotate by an
external source, it is thrown away from the centrifugal axis of rotation and a head is
impressed which enables it to rise to a higher level. Centrifugal Pumps can be used for
viscous and non-viscous liquids and has higher efficiency.
• Every centrifugal pump is made up of mechanical components that make the operation
of the pump possible.
• This mechanical assembly involves the pump’s shaft mounted on bearings, the sealing
mechanism that prevents the pump from leaking uncontrollably, structural components
that are designed to handle the loads and stresses imposed on the pump during use, and
also wear surfaces that permit the pump to be returned and returned to its original
specifications.
93
 Components of Centrifugal Pump
 Shaft:
 It is the central part of the pump which rotates together with the impeller when
connected. The shaft is linked to the prime mover in order to get the power. The shaft
fits perfectly with the ball bearing.
 Impeller:
 It comprises an arrangement of backward curved vanes. It is mounted to an electric

motor’s shaft. This is known as the rotating part of the centrifugal pump enclosed in a
casing that is watertight. The impeller rotates and imparts velocity to a liquid.
 Casing:
 This is a passage surrounding the impeller, which will be airtight. It is made in such a
way that the water’s kinetic energy discharged at the outlet is changed to pressure
energy before the water leaves the casing and is delivered into the delivery pipe. It
works as a cover so that it protects the system. The casing transforms the velocity
developed by the impeller into a stable flow.
 Types of casing:
1. Volute Casing
2. Vortex Casing
3. Casing with guided blades
 Volute Casing or Spiral Casing
 The impeller surrounds this type of casing. Such a casing provides a successive increase
in the area of flow and hence decreases the velocity of water and increases the pressure.
94
Figure 8-1 Volute Casing or Spiral Casing
 Vortex Casing
 This casing is a circular chamber that is introduced between the casing and impeller.
The fluid from the impeller has to pass through the vortex chamber first and then
through the volute casing. Velocity energy has been changed to pressure and has good
efficiency compared to the volute casing.
Figure 8-2 Vortex Casing
95
 Casing with Guide Blades
 In this type of casing, there are blades surrounding the impeller. These blades are
arranged and designed in such a way that the water from the impeller passes through
the guide vanes without shock and forms a passage of increasing area, through which
the water passes through and reaches the delivery to leave with pressure.
 Suction Pipe with a Strainer and Foot Valve:
 The suction pipe has two ends. The first end is connected to the pump’s inlet and one
end is dipped into the water in a sump. At the suction pipe’s lower end, a foot valve is
fitted. The valve only opens in an upward direction as it will be a one-way type. To
prevent the entry of unknown and unwanted bodies into the suction pipe, a strainer is
fitted at the end of the pipe.
Figure 8-3 Foot Valve
 Delivery Valve:
 The delivery valve also has two ends. One end is connected to the pump’s outlet and
the other end delivers the water at a required height.
96
Figure 8-4 Centrifugal Pump
 Working of Centrifugal Pump
• In the operation of a centrifugal pump before the pump is started, priming of the pump
is done.
• In the priming operation the suction pipe pump casing and portion of the delivery pipe
are completely filled with liquid to be pump so that all the air, gas or vapor from this
portion of pump is removed and no air pocket is left. In presence of even very small air
pocket in any of this portion pump will not discharged the liquid.
• After the pump is prime properly the delivery valve is kept a close and power from an
outside source (electric motor) is applied to this shaft. The delivery valve is kept close
in order to reduce this starting torque for the motor.
• The impeller then rotates within the stationary casing. The rotation of the impeller
produces a force vertex which imparts a centrifugal head to the liquid and thus result in
an increase of pressure throughout the liquid mass.
• When the delivery valve is open the liquid is made to flow in an outward radial direction
thereby leaving the vanes of the impeller at the outer circumference with high velocity
and pressure.
97
• Due to centrifugal action, a partial vacuum is created at the eye of the impeller. This
cause the liquid from the sump or reserves to rush through the suction pipe to the eye
of the impeller thereby replacing the liquid which is being discharged from the entire
circumference of the impeller.
• The high pressure of the liquid leaving the impeller is utilized in lifting the liquid to the
required height to the delivery pipe.
• During the operation liquid receive energy from the vanes which result in an increase
in pressure. So that a large portion of the kinetic energy is converted into useful pressure
energy, this is usually achieved by shaping the casing such that the leaving liquid flows
through a passage of gradually increased area.
 Supplier of Centrifugal Pumps
• Investa Pumps Pvt. Ltd.
• Antico Pumps
8.2 Control Valves
 The control valve is used for controlling fluid flow by changing the size of the flow
passage according to the controller and enabling direct control over the flow rate. This
results in controlling process quantities such as liquid level, temperature, and pressure.
 In process systems of production wells, oil and gas plants, chemical and petrochemical
industries, refineries, and power plants, control valves are frequently used to control or
manage any of the process parameters.
 What is a Control Valve?
 The control valve is an automated valve that can make precise adjustments to
regulate and monitor any commodity flowing through a piping system. The
function of a control valve is to provide throttling control in response to signals
from a control system, using an actuator and a positioner.
98
 Components of Control Valve
 Body:
 It is a type of pressure vessel containing an orifice or an opening. The controlled liquid

is allowed to flow through the body of the valve. It helps to monitor the flow regulation
behavior.
 Trim:
 Besides the body, trim is one such part of the valve that comes directly in contact with
the fluid. It consists of the seat, disc, plug, and stem.
 Actuator:
 It consists of electric or pneumatic mediums to provide the force required to operate

the control valve.
 Bonnet:
 It provides a mounting for the guide and actuator and a medium for the stem to pass
through. It is made of the centerpiece, packing, packing nut and guide. The packing acts
as a fastener between the bonnet and stem. It helps to avoid any leakage.
99
Figure 8-5 Control Valve
 Control Valve Actuators
 Pneumatic Actuators:
 Pneumatic Actuators are the most basic and widely used control valve actuators
that use an air or gas signal from an external source to produce a modulating
control action. The top port sends the pneumatic signal to the actuator that exerts
100
pressure on the diaphragm plate to move the valve stem. On loss of driver
power, pneumatic actuators provide a fail-safe response.
Figure 8-6 Pneumatic Actuator
 Electric Actuators:
 Electric Actuators of a control valve are motor-driven devices. A motor rotates

when an electrical signal is received. A gear reduction drive converts this
rotating motion into a linear motion to drive the control valve stem for flow
modulation. They are used for On-OFF applications in isolation services and for
continuous positioning control.
101
Figure 8-7 Electrical Actuators
 Hydraulic Actuators:
 Control Valve Hydraulic actuators use a hydraulic oil as the signal fluid. When
the force required to move the valve stem is high, hydraulic actuators are used.
Due to non-compressibility of the liquid they exhibit stable positioning.
Figure 8-8 Hydraulic Actuators
102
 Types of Control Valve Characteristics
1. Linear
2. Equal Percentage
3. Quick Opening
Note:
Control Valves used in the plant are manufactured by Mascot.
Figure 8-9 Control Valve
103
 Selection of Control Valve
 Ability to control the flow rate.
 Lack of turbulence or resistance to flow when fully open – turbulence reduces head
pressure.
 Quick opening and closing mechanism – rapid response is many times needed in an
emergency or for safety.
 Tight shut-off – prevents leaks against high pressure.
 Ability to allow flow in one direction only – prevents return.
 Opening at a pre-set pressure – procedure control to prevent equipment damage.
 Ability to handle abrasive fluids – hardened material prevents rapid wear.
 Control Valve Types & Application
Table 8-1 Control Valve Types & Application
Service and Function

Valve type
IoS TH PR DC
Gate YES NO NO NO
Globe YES YES NO YES (note 1)
Check (note 2) NO NO NO
Stop check YES NO NO NO
104
Butterfly YES YES NO NO
Ball YES (note 3) NO YES (note 4)
Plug YES (note 3) NO YES (note 4)
Diaphragm YES NO NO NO
Safety Relief NO NO YES NO
 Notes:
1. Only angle-globe valves can be used for a 90-degree change in direction of flow.
2. Check valves (other than the stop-check valves) stop flow only in one (reverse)
direction. Stop check valves can be and are used as stop, block, or isolation valves, in
addition to being used as a check valve.
3. Some designs of ball-and-plug valves (contact the valve manufacturer) are suitable for
throttling service.
4. Multiport ball-and-plug valves are used for changing the direction of flow and mixing
flows.
DC = Directional Change
IoS = Isolation or Stop
PR = Pressure Relief
TH = Throttling
 Operation of Control Valve
 The process control industry includes control valves as the final control element.
Control valves manipulate fluids, such as water, gas, steam, or chemical compounds, to
compensate for load disturbances, keeping the regulated process variable as close to the
desired set point as possible.
105
 Typically, automatic control valves are opened or closed by electrical, hydraulic, or
pneumatic actuators. When a modulating valve can be set anywhere between fully
closed and fully open, valve positioners are normally used to ensure that the valve
achieves the desired degree of opening.
 The simplicity of air-actuated valves makes them popular, as they are only powered by
compressed air, as opposed to electrically-operated valves, which require additional
cabling and switch gear, and hydraulically-actuated valves, which require high-pressure
fluid supply and return lines.
 Control signals for pneumatic systems are typically based on a pressure range of 3 to
15 psi (0.2 to 1.0 bar) or, typically, on a 4-20mA electrical signal for industry or a 0-
10V signal for HVAC systems. Nowadays, electrical control often includes a smart
communication signal that can be superimposed over the 4-20mA control signal,
allowing the controller to monitor and signal valve health and position back to the
controller.
 Cost of Control Valves
 Festo Control Valves:₹ 5,060
 Cs Globe Type Control Valve: ₹ 3,405
 Aira Globe Type Pneumatic Diaphragm Low Temperature Control Valve: ₹ 16,380
 Microflow Control Valve: ₹ 15,000
 Yuken Feed Control Valve: ₹ 7,000
 Mascot Globe Valve; ₹ 1.2 lakh
8.3 Conclusions:
During batch operation, some process parameters are controlled manually while others are
controlled by a PLC system. Valves and pumps are adjusted manually to regulate the process.
Centrifugal pumps are commonly used for material handling, while ball valves are preferred
for their smooth operation.
106
Chapter 9 : Safety, Health and Environment
107
9.1 Safety Measures
 To ensure a safe, healthy, and clean environment, various health and safety policies
have been developed, including SHE policies, quality policy, energy management
policy, and training and development policy.
 The safety team at the plant regularly participates in safety meetings, which are held
every three months. The decisions made in these meetings are then passed on to the
safety inspector. This safety committee is made up of employees from various parts of
the plant. They also organize safety programs for workers.
 Any accidents or incidents are investigated and recorded, and employees are informed
about the cause of the accident. Regular internal safety inspections are conducted by
safety officers.
 An occupational health centre with 24-hour service under the guidance of a doctor is
available on the premises, and ambulance services are available for emergencies.
 To ensure the proper functioning of the fire alarm, mock drills are conducted in the
plant. Water lines are installed throughout the entire plant to deal with fires, and fire
extinguishers are also provided at various locations within the plant for additional safety
measures.
 To prevent fires caused by static electricity, all equipment is grounded. Fire alarms are
also installed at various locations throughout the plant. To ensure the safety of the
equipment, safety interlocks such as safety valves, rupture discs, and pressure safety
valves are installed.
108
 The safety department provides training to all operators and trainees to promote safety
in the workplace. Adequate safe assembly points are designated at specific locations
within the plant where workers can gather in case of an emergency.
9.2 Work Permit
1. Hot work
2. Cold work
3. Confined space entry
4. Excavations
5. Work at heights
6. Handling of hazardous chemicals
7. Electrical work
8. High pressure and vacuum system
9. Loading and unloading material
9.3 Personal Protective Equipments
 Personal protective equipment, often abbreviated as "PPE", is worn to minimize

exposure to workplace hazards that can result in serious injuries and illnesses. Such
injuries and illnesses may arise from contact with chemical, radiological, physical,
electrical, mechanical, or other workplace hazards.
 Personal protective equipment can include a variety of items, such as gloves, safety
glasses, safety shoes, earplugs or earmuffs, hard hats, respirators, coveralls, vests, and
full-body suits.
109
9.3.1 Selection Criteria for PPE
 It should give adequate protection against the nature, severity & type of hazard.
 The equipment should not pose any additional hazards due to its material, design,
defects, use, or failure.
 The attachment of the equipment to the body should be flexible yet effective, and the
equipment itself should be of minimal weight and provide minimal discomfort while
maintaining its protective efficiency. The equipment should not restrict the wearer's
movement.
 It is essential that the equipment meets the ISI (BIS) standards and passes the required
tests. Additionally, the equipment should be easy to clean, repair, and maintain, with
readily available parts, pieces, and services.
9.3.2 Different PPEs
 Helmets made of PVC, fiberglass, laminated plastics, and vulcanized rubber are used
to protect the head from falling objects and other potential hazards.
 Various types of safety goggles, such as safety spectacles, mono goggles, impact
goggles, and welding goggles, are used to protect the eyes from workplace hazards.
 Safety shoes and boots are used to protect the feet and legs in environments where
heavy materials, corrosive liquids, wet, and molten conditions are present.
 Gas masks are worn by workers to protect their bodies against hazardous gas leaks.
These masks prevent workers from inhaling dangerous gases that could negatively
impact their respiratory systems and breathing.
110
 To protect hands and arms from sharp ends and edges, hot and molten materials, and
corrosive materials, workers use safety equipment such as gauntlet gloves, wrist gloves,
and thumb and finger guards. These gloves are typically made of PVC, rubber, cotton,
or asbestos.
 When exposed to noise levels above 90 decibels for more than 8 hours per day or 48
hours per week, workers may experience permanent deafness, irritation, temporary
deafness, and hearing loss. To protect the ears, earplugs or earmuffs made of plastics
and rubbers are used.
 To protect the body from potential harm, body protectors such as aprons, jackets, spark
arrestors, asbestos suits, and asbestos blankets are used.
 Dust, airborne particles, and radiation can cause injury to the eyes and face. Workers
can prevent such damage by using a face shield.
9.4 Safety Related Equipment and Their Locations
 SO2 Sensors:
 Multiple sensors are located in the SO2 tonner storage area to measure the
concentration of SO2 gas. The short-term exposure limit (STEL) is 5 parts per
million (ppm). If a leakage is detected, the affected tonner will be isolated with a
cover and connected to an elephant hose pipe through which leaked SO2 gas is
transferred to the SO2 scrubber.
 SO2 Scrubber:
111
 If the sensor detects a concentration of SO2 gas above 2 ppm, the scrubber will
automatically start. Caustic is used to scrub the SO2 gas.
 A Breathing Apparatus Box is also provided near the storage tanks of SO2 tonner,
DMS, and HCl to ensure the safety of workers. Additionally, a Silica Gel vessel is
located near the storage and dosing tanks of DMS as DMS is highly toxic and
hazardous to human health. Silica Gel will absorb any DMS vapor that may form.
 Additionally, there are fire hydrants provided on each floor, and a hose reel box
located nearby which contains a water hose for firefighting purposes.
 Furthermore, throughout the plant on all floors, there are DCP (Dry Chemical
Powder) and CO2 extinguisher cylinders available. DCP can be used to fight fires
in class A, B, C, and D, while CO2 can be used for fires in class B and C.
9.5 Fire Fighting Equipments
1. Fire extinguisher
2. Fire Alarm
3. Fire and Safety Department
4. Smoke detector
5. Water Hydrant System
6. Fire Tender
7. Foam System
8. Foam tank
9. Fire lines
112
9.6 Pollution
Four types of pollution is caused by the industry:
1. Air
2. Water
3. Land
4. Noise
9.7 Water Pollution Control
 Sources and Uses of Water in Industry
 Water used in industry is obtained from GIDC and recycled treated water from ETP.
It serves two main purposes:
 Plant utilities: for boilers, cooling towers, and processes
 Domestic: for gardening, canteen use, housekeeping, washrooms,
toiletries, and drinking
 Wastewater is generated from various sources, including residue discharge, washing,
domestic use, and utilities. To ensure proper treatment and purification, the wastewater
goes through several stages of processing.
 Water Segregation
 The water coming from various sources in the plant may contain varying levels of COD,
BOD, and TDS content. To reduce the load on the Effluent Treatment Plant, the water
is pre-segregated based on its content and stored in different tanks.
113
Table 9-1 Hazop study
9.8 HAZOP Study Over HADS Reactor
114
115
116
9.9 Conclusions:
This chapter focuses on the safety precautions implemented by the industry, the safety
equipment utilized in the industry, and the HAZOP study conducted on the reactor. These
measures are taken to prevent accidents and injuries, ensuring the safety of the workers.
Additionally, the chapter discusses the pollution control measures adopted by the industry to
protect the environment.
117
Chapter 10 : Plant Location and Layout
118
10.1 Justification of Plant Location:
10.1.1 Plant Location:

Plant location refers to the process of selecting a suitable site for setting up a manufacturing
plant or facility. This is a crucial decision that can greatly impact the success of a business. The
location of a plant can affect its production cost, transportation costs, labor availability, and
access to raw materials and markets. Hence, it is important to carefully evaluate various factors
before deciding on the plant location. These factors may include economic, geographic,
political, and environmental conditions. A well-planned plant location can enhance the
efficiency, productivity, and profitability of a business.
As per the statement of Dr. Vishweshwarya, "A plant should be located at a place where
inhabitants are interested in its success, the product can be sold profitably, and production cost
is minimum."
The Deepak Nitrite LTD plant is located at Nandesari GIDC, which is situated near National
Highway no 8, making it easy to transport raw materials and finished products. Nandesari's
location is also near Vadodara and Anand, which makes it convenient to find workers. Other
factors affecting plant location are mentioned below:
10.1.2 Factors Affecting Plant Location:

• Past records
• Availability of housing and other amenities
• Availability of Raw Material
• Near to source of operating requirements
• Easy start up
• Supply of labour
• Transportation Facility
• Safety requirements
119
• Personal factors
• Nearness to potential market
• Suitability of land and climate
• Integration with other companies
• Local rules and regulation or Government policies
1) Operating requirements:
 The power required to operate the plant is supplied by Gujarat industrial power
corporation limited at a subsidized rate in Nandesari.
2) Community factor:
 Public utilities such as electricity, gas supply, water supply, hospitals, schools, temples,
theaters, and libraries are available in Baroda. This ensures the workability of
employees.
3) Land and Climate:

 The characteristics of the location, such as soil type, elevation, groundwater level,
weather conditions including wind velocity and rainfall, are important considerations
when choosing a plant location. Nandesari has all the ideal characteristics required for
a plant location. Extreme temperatures and high humidity can affect the productivity of
workers. Fortunately, Nandesari has a pleasant climate, making it a suitable place for
increased productivity.
4) Transportation Facility:
 Transportation of raw materials, products, and labor is available through the railway
and highway, making it easy to transport the product at a low cost.
5) Availability of Raw Material:
120
 When producing Sodium Nitrite, plant location is a crucial aspect to consider. Raw
materials like Ammonia, Caustic, and Air are needed for its production. Caustic can be
sourced from GACL Nandesari and BLEACH CHEM, Vadodara. Ammonia, on the
other hand, can be obtained from SURAT AMMONIA & CHEMICAL COMPANY,
Ankleshwar, Ahmedabad, IFFCO, Kalol, and GSFC, Baroda. To transport these raw
materials, trucks and trains can be utilized for convenience.
6) Supply of Labour:
 The supply of skilled labor is an important factor. Labor is easily available for the plant
from Nandesari, Vasad, and Baroda. Moreover, housing facilities are also available in
Nandesari for the workers.
7) Water Supply:
 Water is the most important raw material and process utility for any chemical plant.
There is an abundant supply of water to the company due to the help of the municipal
corporation of the GSFC estate, and because of the large river Mahi Sagar flowing near
Vasad very near to Nandesari. So, there is no problem regarding the water supply in the
future for plants.
8) Nearness to Potential Market:

 The product has a big market in Nandesari and Vadodara. Nandesari has good
connections to the state through national highways and railways, making it easy to
transport the product at a low cost. The market for the product is expected to grow in
the future.
10.2 Plant Layout
121
Figure 10-1 Plant Layout
122
10.2.1 Objectives of Plant Layout:
• Overall integration of all space
• Effective utilization of all space
• Flexible arrangement
• Material moving at minimum distance
• Satisfactory and safety for workers
• There must be protection against fire fumes and comfortable and pleasant working
environment.
 During preparation of plant layout below mention things should be kept in mind,
• Layout planning
• Unit area concept
• Scale Model
• Storage layout
123
• Equipment layout
• Roads
124
10.3 Conclusions:
It can be inferred from the location of the plant that the chosen site meets all the essential
criteria for an ideal plant, such as the availability of raw materials, energy requirements,
transportation, waste disposal, etc. Therefore, the location is well-suited for setting up a
production facility for manufacturing MAHCL. However, before establishing the plant, the
estimated cost must be calculated. This will be discussed in the next chapter, which is dedicated
to the cost estimation of the plant.
125
Chapter 11 : Cost Estimation
126
11.1 Introduction:
Cost estimation involves calculating the total cost of the plant, which includes fixed costs,
direct costs, production costs, raw material costs, labor costs, maintenance costs, utility costs,
as well as costs associated with plant and administrative overheads, distribution of final
products, and other miscellaneous expenses.
Once the final process design stage is complete and detailed equipment specifications and plant
facility information are available, accurate cost estimation becomes possible. Direct price
quotations based on these specifications can be obtained from various manufacturers. However,
it is essential to consider costs before proceeding to the final stages of any design project, and
cost estimates should be made throughout all the early stages of design when complete
specifications are not available.
Cost estimation also provides insight into direct and indirect charges, fixed capital investments,
working capital, plant overhead expenses, and other related expenses.
11.1.1 Cost based on a fixed capacity
Table 11-1 Cost based on a fixed capacity
Equipment Capacity unit No. of Price per

units unit
CSTR (MSGLR) 8000 L 1 1500000
Jacketed Reactor 8000 L 1 529874.9749
Storage Tanks (SS-316) 45000 L 1 1253950.6
Storage Tanks (HDPE) 1000 L 1 20000
Storage Tanks (FRP + PPGL) 45000 L 1 1511262.816
Dosing Tanks 45000 L 1 1253950.6
127
11.2 Cost of equipments at plants
Table 11-2 Cost of equipments at plants
Equipment Capacity unit No. of Price per unit Total price

units
Premixing Tank 3000 L 2 250000 500000
SO2 Receiver 500 L 2 240000 480000
SO2 Vaporizer 3000 Kgs 2 600000 1200000
SO2 Scrubber 4000 m3/hr 1 500000 500000
Heat Exchanger - - 20 480000 9600000
MSGLR Reactor 7000 L 10 1384509.981 13845100
Rotary Vacuum 1200 kg 3 1000000 3000000
Dryer
Centrifuge Dryer 3 6000000 18000000
Jacketed Reactor 2500 L 2 263683.7838 527367.57
3500 L 1 322671.2292 322671.23
7000 L 20 489078.1276 9781562.6
Centrifugal Pump - - 30 60000 1800000
Dosing Tanks 5000 L 10 335532.7543 3355327.5
Storage Tanks (SS- 42000 L 3 1203102.124 3609306.4
316)
35000 L 2 1078434.433 2156868.9
40000 L 2 1168392.913 2336785.8
20000 L 2 770851.8459 1541703.7
16000 L 2 674256.1384 1348512.3
37000 L 1 1114997.654 1114997.7
Storage Tanks 50000 L 1 209127.9105 209127.91
(HDPE)
20000 L 2 120683.5267 241367.05
Storage Tanks (FRP 30000 L 1 1511262.816 1511262.8
+ PPGL)
128
Total Equipment Cost 76981961
11.3 Direct Cost
Table 11-3 Direct Cost
Direct Cost
Components % Of TEC Cost
Onsite Purchase Equipment Installation 39 30022964.86
Instrumentation & Control 28 21554949.13
Insulation 8 6158556.893
Piping 80 61585568.93
Electrical 22 16936031.46
Offsite Building 22 16936031.46
Yard Improvement 10 7698196.117
Service Facility 55 42340078.64
Land 6 4618917.67
Total Direct Cost(D) = 207851295.2
11.4 Indirect Cost:
Table 11-4 Indirect Cost
Indirect Cost
Components % % Of Cost
Engineering and Supervision 30 TEC 23094588.4
Construction Expense 34 TEC 26173866.8
Sum of above indirect costs(I) 49268455.1
Contractor's Fees 5 (D+I) 2463422.76

Contingency 10 (D+I) 4926845.51
129
Total Indirect Cost 56658723.4
Fixed Capital Investment = Total Direct Cost + Total Indirect Cost
FCI = Rs. 264510018.6
Working Capital Investment = 20% of FCI
WCI = Rs. 52902003.71
Total Capital Investment (TCI) = Rs. 317412022.3
11.5 Fixed Charges
Table 11-5 Fixed Charges
Components % of FCI Cost

Depreciation 10 26451001.86
Local Taxes 3 7935300.557
Insurance 1 2645100.186
Total Fixed Charges = Rs. 37031402.6
Direct Production Cost
11.6 Raw Material Cost
Table 11-6 Direct Production Cost
Compound Cost per kg or kg or lit used Total Cost

lit
CSL (48%) 21 1718240.661 36083053.9
130
RO Water 0.5 273398.7382 136699.369
SNI 45 1527738.333 68748225
DMS 45 1366993.691 61514716.1
SO2 40 2834065.314 113362613
HCl (31%) 3.5 135826.012 475391.042
Total Raw Material Cost = Rs. 280320697.9
Let, Total Production Cost = X
Components % % of Cost
Operating Labour Cost 15 TPC 0.15*X
Utilities 15 TPC 0.15*X
Direct Supervision 15 Operating Labour 0.15*0.15*
Cost X
Laboratory Charges 15 Operating Labour 0.15*0.15*
Cost X
Maintenance and repair 8 FCI 21160801.5
Direct Production Cost = 0.345*X + 338512902
11.7 General expense
Table 11-7 General expense
Components % of TPC Total Cost

Administrative Cost 20 0.2*X
Distributive and Marketing Cost 14 0.14*X
Research and Development Cost 10 0.1*X
Total Production Cost = Direct Production Cost + General expense
131
Total Production Cost = Rs. 1574478614
11.8 Profitability:
Table 11-8 Cost and Selling Capacity
Product Production/Year Rate per Kg Total rate

MAHCL 1193185 1500 1789777500
Na2SO4 4076375.187 11 44840127.1
Total 1834617627
Gross Profit = Total Annual Sales - Total production Cost
Gross Profit =Rs. 183335178.1
Assume the local Tax = 30 %
Income tax = Taxable income*0.30
Income Tax = Rs. 55000553.44
Net Profit = Rs. 128334624.7
Rate of return = (Net Profit / TCI) * 100
Rate of Return = 40.43155763
Payout Period (With depreciation) = 2.050655667 Years
11.8.1 Break-even Analysis:
132
Direct Production Cost = Rs. 908205346.9
Fixed Charges = Rs. 37031402.6
Overhead cost = Rs. 7406280.52
General expense = Rs. 726564277.5
Total Annual Sales = Rs. 1834617627
kg sold = 1223078.418 kg
Cost to company = Rs. 742.5569232
BEP = 1017900.862 kg
11.9 Conclusion:
This chapter includes the calculation of various financial metrics related to the project, such as
the cost of equipment based on the material of construction (MOC), total production cost, total
capital investment, gross profit, net profit, rate of return, and breakeven point
133
Chapter 12 : Conclusion
134
Upon completion of Phase-I training in Deepak Nitrite Ltd, I embarked on studying the
practical aspects of Chemical Engineering, which proved to be a valuable learning experience
for me, both technically and socially. During this training, I had the opportunity to gain hands-
on knowledge of various equipment, including their basic design and application, as well as
observing the running processes. I also gained insights into important aspects of industrial
management, discipline, and safety precautions.
I gained insights into important topics such as product and process description, mass and energy
balances, safety rules, utilities, ETP, and cost estimation of the plant. PBD and PFD are useful
for understanding the process and flow of processes, while P&ID is helpful for maintenance,
troubleshooting, and process changes. Material and energy balances are essential for selecting
processes and operating plants, identifying material loss, and finding opportunities for energy
savings. Utilities are also crucial, and engineers must be familiar with their standard operation
procedures and troubleshooting.
Knowing the specific codes for equipment labeling is important for communication and smooth
operation. Designing equipment is a significant responsibility for chemical engineers. Overall,
the training provided me with valuable knowledge and skills that I can apply to my future
career.
135
Chapter 13 : References
136
1. Smith, J., Van Ness, H. C., Abbott, M. (2005). Introduction to chemical engineering
thermodynamics. Boston: McGraw-Hill Education.
2. McCabe, W. L., Smith, J. C. (1967). Unit Operations of Chemical
Engineering. Japan: McGraw-Hill.
3. Green, D. W., Southard, M. Z. (2018). Perry's Chemical Engineers' Handbook, 9th
Edition. United States: McGraw Hill LLC.
4. Treybal, R. E. (1980). Mass-transfer Operations. Colombia: McGraw-Hill.
5. DUTTA, B. K. (2007). PRINCIPLES OF MASS TRANSFER AND SEPERATION
PROCESSES. India: PHI Learning.
6. CHEMICAL REACTION ENGINEERING, 3RD ED. (2006). India: Wiley India Pvt.
Limited.
7. Fogler, H. S. (1999). Elements of chemical reaction engineering. United
Kingdom: Prentice Hall PTR.
8. Bhattacharyya, B. C. (2008). Introduction to Chemical Equipment Design: Mechanical
Aspects. India: CBS Publishers & Distributors.
9. Crowl, D. A., Louvar, J. F. (2011). Chemical Process Safety: Fundamentals with
Applications. United Kingdom: Pearson education international.
10. Introduction to Process Engineering and Design. (2007). India: McGraw-Hill
Education (India) Pvt Limited.
137

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A

Under The Guidance Of

Department of Chemical Engineering Faculty of Technology,

This is to certify that Shubham A. Trambadia (CH-153,

Prof. Hitesh N. Panchal Date:01/02/2023

I Shubham A. Trambadia declare that the project report on MAHCL

Upon successfully completing my internship at Deepak Nitrite Ltd., I would like

My sincere appreciation also goes to my internship project guide, Prof. Hitesh

Thank you all for your unwavering support and guidance.

As a part of my curriculum in Chemical Engineering, I underwent an industry

1.1 History of Methoxyamine Hydrochloride(MAHCL) :.............................................. 2

1.2 Total Capacity of Plant:........................................................................................... 2

1.3 Market Value: ......................................................................................................... 2

1.4 Competitors ............................................................................................................ 2

1.5 Technology Providers ............................................................................................. 2

1.6 Application ............................................................................................................. 3

1.7 Physical and Chemical Properties ............................................................................ 3

1.8 Conclusions: ........................................................................................................... 3

Chapter 2 : Selection Of Process ........................................................................................... 4

2.1 Different Methods for MAHCL production ............................................................. 5

2.1.1 By Cascade One-Pot Method ........................................................................... 5

2.2 Process Selected ...................................................................................................... 6

2.3 Raw Material Specification ..................................................................................... 6

2.3.1 Availability and Transportation of Raw Materials ............................................ 7

2.3.2 Cost of Raw Materials ...................................................................................... 7

2.3.3 Properties of Raw Materials ............................................................................. 7

2.4 Detailed Process Description ................................................................................. 10

2.4.1 Process Block Diagram .................................................................................. 10

2.4.2 Process Description ........................................................................................ 13

2.4.3 Process Flow Diagram ................................................................................... 17

2.4.4 Conclusions ................................................................................................... 18

Chapter 3 : Material Balance ............................................................................................... 19

3.1 Introduction .......................................................................................................... 20

3.1.2 Material Balance Over Alkaline HADS Reactor (XRT-3002)......................... 23

3.1.3 Material Balance Over MADS Reactor .......................................................... 25

3.1.4 Material Balance Over XRT-001.................................................................... 26

3.1.5 Material Balance Over MABase Reactor (XRT-011) ..................................... 27

3.1.6 Material Balance Over MAHCL Reactor........................................................ 29

3.2 Overall Material Balance....................................................................................... 31

3.3 Conclusions: ......................................................................................................... 33

Chapter 4 : Energy Balance ................................................................................................. 34

4.1 Introduction: ......................................................................................................... 35

4.2 Standard Heat Of Formation and Heat Capacity Of Components: .......................... 35

4.2.1 Energy Balance Over HADS Reactor (RT-001/RT-003) ................................ 39

4.2.2 Energy Balance Over Alkaline HADS Reactor (XRT-3002) .......................... 41

4.2.3 Energy Balance Over MADS Reactor ............................................................ 43

4.2.4 Energy Balance Over XRT-001...................................................................... 45

4.2.5 Energy Balance Over MAB Reactor (XRT-011) ............................................ 47

4.3 Summary Diagram Of Energy Balance:................................................................. 51

4.4 Conclusions: ......................................................................................................... 52

Chapter 5 : Plant Utilities .................................................................................................... 53

5.1 Utilities used in plants ........................................................................................... 54

5.2 Steam .................................................................................................................... 54

5.3 Electricity ............................................................................................................. 55

5.4 Cooling Water ....................................................................................................... 55

5.5 Chilling Brine ....................................................................................................... 56

5.6 Compressed air ..................................................................................................... 56

5.7 DM Water or RO water ......................................................................................... 57

5.8 Conclusions: ......................................................................................................... 58

6.1 Caustic Storage Tank ............................................................................................ 60

6.2 RO Water Tank ..................................................................................................... 60

6.3 HADS Reactor ...................................................................................................... 61

6.4 SO2 Vaporizer ...................................................................................................... 61