Atul

222352
IN PLANT TRAINING AT ATUL LIMITED
A PROJECT REPORT
Submitted by
PATEL DEEP JAYESH
180470105039
In partial fulfilment for the award of the degree of
BECHELOR OF ENGINEERING
in
Chemical Engineering Department
V.V.P. Engineering College, Rajkot
Gujarat Technological University, Ahmadabad
April ,2022
Gujarat Technological University V.V.P Engineering College

222352
V.V.P ENGINEERING COLLEGE, RAJKOT

Opp Motel The village, Kalawad Road, Virda-vajdi
Rajkot-5
CERTIFICATE
This is certify that the project report submitted along with the project entitled Internship
at ATUL Ltd. has been carried out by Patel Deep Under my guidance in partial fulfilment
for the degree of Bachelor of Engineering in chemical , 8th Semester of Gujarat
Technological University Ahmadabad during the academic year 2021-2022.
MR. JILESH PANDYA DR. PIYUSH VANZARA

(Internal Guide) ( Head of the department)

222352

222352
V.V.P ENGINEERING COLLEGE, RAJKOT

Opp Motel The village, Kalawad Road, Virda-vajdi
Rajkot-5
DECLARATION
We hereby declare that the Internship report submitted along with the Internship entitled at
ATUL Ltd. submitted in partial fulfilment for the degree of Bachelor of Engineering in
chemical to Gujarat Technological University, Ahmedabad, is a Bonafede record of original
project work carried out by me at ATUL Ltd. under the supervision of Mr. Jayesh Prajapati
and that no part of this report has been directly copied from any students’ reports or taken from
any other source, without providing due reference.
Name of the student Sign of Student
(Patel Deep)

222352
ACKNOLEDGEMENT
I would like to take this opportunity to express my gratitude and sincere thanks to my mentor
Mr. Jayesh Prajapati Who offered me the chance to explore each and every aspect in the
industry. He helped me in co-ordinating and getting information about my quarries.
I would also thanks to plant charge Mr. Heril Desai for helping me throughout the course of
internship, guiding me and being a constant source of information.
I am greatly thankful to all my well-wishers, Mr. Jayesh Prajapati and production engineer
for their inspiration and help.
We sincerely thank to Dr. Piyush Vanjara [Head, Department of Chemical Engineering

V.V.P.E.C] for giving us this great opportunity for industrial training.
We would like to thanks to Mr. Jilesh Pandya [lecturer, Department of Chemical Engineering
V.V.P.E.C] who guided us during this industrial training and also help for prepare industrial
training report.
i
222352
ABSTRACT
This report contains detailed information about each and every single process, equipment, plant
investigated by me during the internship.
In this report all the types of equipment are mentioned and all the process which used in
industry. All the operating parameters are specified. A brief study on manufacturing process of
methyl bromide and also study about the different solvents and chilling agents.
In second phase of internship contains different process is off to maintaining the temperature
and pressure of solvents and chilling agents and in last containing packaging department which
name is teen plant used in industry.
ii
222352
LIST OF TABLES
Table No. Content Page No.
2.1 Properties of Dimethyl Sulphate 4
2.2 Properties of Monochloro Benzene 6
2.3 Properties of Sulphur Trioxide 7
2.4 Properties of Sulphuric Acid 8
2.5 Properties of Methanol 9
2.6 Properties of DCDPS 10
2.7 Properties of Trimethyl Boret 11
7.1 Pipelines Identification Colour code 51
11.1 Denotations of fig 11.1 73
iii
222352
LIST OF FIGURES
Fig No. Content Page No.

2.1 Structure of Dimethyl Sulphate 4
2.2 Structure of Monochloro Benzene 5
2.3 Structure of DCDPS 10
2.4 Structure of Trimethyl Boret 11
3.1 Block Diagram 14
3.2 Process Flow Diagram 16
3.3 Methanol Recovery 20
3.4 MCB Recovery 22
5.1 Diagram of Batch Reactor 31
5.2 Diagram of ANF and S shaped Agitator 34
5.3 Diagram of Rotary Vacuum Paddle Dryer 37
6.1 Air Drying System 47
6.2 Nitrogen Plant 48
6.3 Natural Draft Cooling Tower 49
6.4 Thermic Fluid Heater 50
7.1 Rockwool 53
7.2 Thermocol 54
9.1 Two stage water ring vacuum pump 58
9.2 Diaphragm pump 59
9.3 Magnetic pump 60
9.4 Centrifugal Pump Assembly 61
9.5 Types of impellers 62
10.1 PPE Kit 67
10.2 Types of fire extinguisher 69
11.1 Plant Layout of Ground Floor 72
11.2 Plant Layout of First Floor 73
11.3 Plant Layout of Second Floor 74
11.4 Plant Layout of Third Floor 75
11.5 Plant Layout of Fourth Floor 76
iv
222352
LIST OF CONTENTS
Acknowledgemet………………………………………………………………………..Ⅰ
Abstract…………………………………………………………………………………Ⅱ
List of Tables……………………………………………………………………………Ⅲ
List of Figures…………………………………………………………………………..Ⅳ
Chapter 1: - Introduction ................................................................................................................... 1
1.1 History of company................................................................................................................... 1
1.2 Major Products ......................................................................................................................... 1
1.3 Other Company Details ............................................................................................................ 2
1.4 Social Activities ......................................................................................................................... 2
1.5 Our Plant and our product ...................................................................................................... 3

1.6 Raw materials and Catalyst ..................................................................................................... 3
1.7 Applications of DCDPS ............................................................................................................ 3

Chapter 2: - Properties of Raw Materials and Products................................................................. 4
2.1 Dimethyl Sulphate (DMS) ........................................................................................................ 4
2.2 Monochloro Benzene (MCB) ................................................................................................... 5
2.3 Sulphur Trioxide (SO3) ............................................................................................................ 6
2.4 Sulphuric Acid (70%) ............................................................................................................... 7
2.5 Methanol .................................................................................................................................... 8

2.6 Dichloro Diphenyl Sulfone (DCDPS) ...................................................................................... 9
2.7 Trimethyl Boret (TMB) .......................................................................................................... 10
Chapter 3: - Process Details ............................................................................................................. 11

3.1 Overview of the Plant ............................................................................................................. 11
3.2 DCDPS Production Process ................................................................................................... 11
3.2.1 Block Diagram of DCDPS Production Process ................................................................ 11
3.2.2 Process Flow Diagram of DCDPS Production Process .................................................... 14
3.3 Methanol Recovery ..................................................................................................................18

3.4 MCB (Mono chloro Benzene) Recovery ................................................................................19
Chapter 4:- Material and Energy Balance ..................................................................................... 21
4.1 Material Balance ..................................................................................................................... 21
4.1.1 Material Balance of Pyro Complex Forming Reactor ...................................................... 21
v
222352
4.1.2 Material Balance of Condensation and Cracking Reactor .............................................. 22

4.1.3 Material Balance of Drowning and Quenching Reactor .................................................. 22
4.1.4 Material Balance of Agitated Nutsche Filter ................................................................... 24
4.1.5 Material Balance on Digestor, ANF, Dryer ...................................................................... 25

4.2 Energy Balance ........................................................................................................................26
4.2.1 Energy Balance of Complex Forming Reactor .................................................................25

4.2.2 Energy Balance of Condensation & Cracking Reactor.....................................................25
4.2.3 Energy Balance of Quenching & Drowning Reactor ...................................................... 26
4.2.4 Energy Balance of Digestor 2 ............................................................................................. 26
4.2.5 Energy Balance of Rotary vacuum Dryer ........................................................................ 27

Chapter 5 :- Major Equipments and Instrumentation .................................................................. 28
5.1 Batch Reactor .......................................................................................................................... 28

5.2 Agitated Nutsche Filter .......................................................................................................... 31
5.3 Rotary Vacuum Paddle dryer .................................................................................................34
5.4 Process Equipment Design of Heat exchanger (Condenser) ............................................... 37
Chapter 6: Utilities ........................................................................................................................... 43
6.1 Compressed Air: .................................................................................................................... 43
6.2 Instrument Air: ....................................................................................................................... 44
6.3 Nitrogen ................................................................................................................................... 46

6.4 Cooling Water : .......................................................................................................................47
6.5 Brine ......................................................................................................................................... 48
6.6 Oil ............................................................................................................................................. 48
Chapter 7: Piping Systems ............................................................................................................... 50

7.1 PIPELINES IDENTIFICATION COLOUR CODE ........................................................ 50
7.2 Pipe Insulations .......................................................................................................................52
Chapter 8: Maintenance Work ........................................................................................................ 54

8.1 Agitated Nutsche filter: ........................................................................................................ 54
8.2 MSRL reactor: ....................................................................................................................... 54

8.3 Pump: ...................................................................................................................................... 54
8.4 Reactor: .................................................................................................................................. 55

8.5 Rupture disc: .......................................................................................................................... 55
8.6 Thermic fluid heater: ............................................................................................................ 55
vi
222352
Chapter 9: - PUMP & CONTROL VALVE .................................................................................. 56
9.1 Pump: ...................................................................................................................................... 56
9.1.1 Vacuum Pump ...................................................................................................................... 56

9.1.2 Diaphragm pump ................................................................................................................. 57
9.1.3 Magnetic Pump ..................................................................................................................... 58

9.1.4 Centrifugal pump: ............................................................................................................... 59
9.2 Instrumentation: ...................................................................................................................... 63
9.3 Valves: ...................................................................................................................................... 63

Chapter 10:- SAFETY MANAGEMENT....................................................................................... 66
10.1 Introduction: ......................................................................................................................... 66
10.2 Personal Protective Equipment (PPEs): ............................................................................. 66
10.3 Safety Talk: ........................................................................................................................... 67

10.4 Fire Safety and Fire Alarm: ................................................................................................. 68
10.5 SCBA Set (Self Contain Breathing Apparatus): ................................................................ 69
10.6 Type of Permits: .................................................................................................................... 69

Chapter 11: - Plant Layout .............................................................................................................. 71
11.1 Plant Layout of Ground Floor ............................................................................................. 71
11.2 Plant Layout of First Floor .................................................................................................. 72

11.3 Plant Layout of Second Floor .............................................................................................. 73
11.4 Plant Layout of Third Floor ..................................................................................................74
11.5 Plant Layout of Fourth Floor .............................................................................................. 75
Chapter 12:- Learning and Conclusion……………………………………………………………76
vii
222352 Introduction
Chapter 1: - Introduction
In this chapter the introduction of the plant is provided where we will cover the history of
the company, major products, other company details, our plant product, applications of our
plant product.
1.1 History of company

Atul is an integrated chemical company founded by Kasturbhai Lalbhai on
September 5, 1947 in India which inaugurated by Pandit jwaharlal Nehru.
Sunil Siddharth Lalbhai is the Chairman and Managing Director of the company.
The first manufacturing site of the company in Atul, Gujarat is spread over 1250
acres. The company has its registered office in Ahmedabad and head office at Atul.
1.2 Major Products

The company manufactures 900 products and 400 formulations and owns 140
retail brands. It serves 4000 customers belonging to 30 diverse companies in the US, the UK,
the UAE, china and Brazil to serve its customers.
The prominent products manufactured by Atul include:
• Para-cresol, para-anisic aldehyde, para cresidine

• Resorcinol formaldehyde resins, 1,3 Cyclohexanedione
• Vat Green 1, Vat Red 10, Vat Brown 1, Sulphur black,
Pigment Yellow 139
• 2,4-Dichloro phenoxy acid and its derivatives,
Chlorimuron ethyl, Isoprothiolane, Indoxacarb
• API intermediates- Phenyl chloroformate
• 3,3’ and 4,4’ Diaminodiphenyl sulphone
• Multi-functional resins, epoxy systems for infusion,
adhesives for wind turbine blades, epoxy phenol novolac
resins
1
222352 Introduction
1.3 Other Company Details
• Joint venture companies(past)

Cynamid India
ATIC
Citabul
• Joint venture companies(current)

Atul Rajasthan Date palms
Rudolf Atul
Anaven
• Subsidiary companies
Atul Bio-Science
DPD Figure 1
• Associate Company
Amal
1.4 Social Activities

Education
Kalyani School, Atul Vidyalaya, Atul
Vidyamandir
Women Empowerment
Urmi stree sansthsa, Atul adhyapikas
Youth Empowerment
Atul institute of vocational excellence
Health Camps  Relief and

Infrastructures Figure 2
2
222352 Introduction
1.5 Our Plant and our product

The name of our plant is SPIC-II. In our plant 4,4’ Dichloro Diphenyl
Sulphone (DCDPS) is produced which is our main product.
Produced DCDPS is sent to other plant in atul for further application.
1.6 Raw materials and Catalyst
 Raw Material
Dimethyl Sulphate, Sulfur Trioxide, Monochloro Benzene
 Sub Raw Material
Soda Ash , Methanol
 Catalyst
Trimethyl Borate
 By-Product
Spent Sulphuric Acid , Methanol
1.7 Applications of DCDPS
• Our Product 4,4’ DCDPS (Dichlorodiphenyl sulfone) is a monomer used for

polymerization into the production of polysulphones.
• Sulphones are used as replacements for metals and glass in a wide range of medical,
automotive, aerospace and consumer products.
• 4,4’ DCDPS is the main monomer for polysulphones that are used in composites in
aerospace to help reduce weight & improve thermo stability.
3
222352 Properties of Raw Material and Products
Chapter 2: - Properties of Raw Materials and

Products
2.1 Dimethyl Sulphate (DMS)

Dimethyl sulphate is the reactant which is used in pyro complex formation.
Its Structure, properties are mentioned below
Figure 3
Structure: -
Fig 2.1 Structure of Dimethyl Sulphate
Physical and Chemical

Properties: -
Sr Property Data
No.
1 Chemical Formula (CH3O)2SO2
2 Form Liquid
3 Colour Colourless
4 Odour Sweet
5 Melting Point -31.8 0C
6 Boiling Temp 188.5 0C at 1 atm

7 Flash point 83 0C
8 Density 1.33 g/cm3 at 20 0C
9 Water Solubility 29 g/l at 18 0C
10 Decomposition Temp > 180 0C
11 Molecular Weight 126 g/mol
1
Table 2.1 Properties of Dimethyl Sulphate
NFPA DIAMOND
Red indicates Flammability
2 indicates it will ignite if

2 moderately heated or exposed to high
ambient Temp
4 1
Blue indicates Health
4 indicates Extremely
hazardous inhalation, skin contact, eye
Figure 4
contact can be lethal
Yellow indicates Instability
1 Normally stable even under fire conditions
White indicates Special information
No
2.2 Monochloro Benzene (MCB)

Monochloro Benzene is the key reactant which is reacted with Pyro complex.
Structure: -
Figure 5
Fig 2.2 Structure of Monochloro Benzene
2
Physical and Chemical Properties: -

Sr No. Property Data
1 Chemical Formula C6H5Cl

2 Molecular Weight 112.5 g/mol
3 Form Colourless clear liquid
4 Odour Faint, almond like odour
5 Melting Point -45 0C
6 Boiling Point 132 0C at 1 atm
7 Flash point 28 0C
8 Density 1100 kg/m3
9 Water Solubility Insoluble
Table 2.2 Properties of Monochloro Benzene
2.3 Sulphur Trioxide (SO3)

Sulphur Trioxide is generally in the vapor phase because it boils
at 44 0C. So it is stored in hot room where temp kept below 44 0C and above 40 0C. It is stored
above 40 0C because its melting point is 16.8 0C. SO3 is main component is forming of pyro
complex.

1 Chemical Formula SO3
2 Molecular weight 80 g/mol
3 Form Liquid at room temp
4 Melting Point 16.8 0C

5 Boiling Point 44.7 0C
6 Vapour density 2.76(Air=1)
7 Relative density 1.97 g/ml at 25 0C
Table 2.3 Properties of Sulphur Trioxide
3
0
3 2
w
NFPA DIAMOND
Figure 6
Health 3 Can cause serious injury, Require immediate medical attention.
Flammability 0 Will not burn
Instability 2 Can explode if heated under confinement.
Special W Material is reactive to water & should be kept dry
2.4 Sulphuric Acid (70%)

Spent acid which contains mainly sulphuric acid which is
recovered in Monochloro benzene recovery. It also forms in the production of DCDPS.

Sr Property Data
No.
1 Chemical Formula H2SO4
3 Form Clear liquid
4 Melting Point 3 0C
5 Boiling Point 290 0C
6 Vapour Density 3.39 (Air=1)
7 Relative Density 1.84 g/cm3
Table 2.4 Properties of Sulphuric Acid
4
Gujarat Technological University V.V.P Engineering
College
0
3 2
w
Figure 7
Health 3 Corrosive or toxic, Avoid skin contact or inhalation
Flammability 0 Not combustible
Instability 2 Will react violently if mixed with water

Special W Material is reactive to water and should be kept dry
2.5 Methanol
Methanol is the byproduct of our process. It is also used as solvent to
make slurry in our process.

1 Chemical Formula CH3OH
3 Form Colourless liquid
4 Melting Point -98 0C
5 Boiling Point 64.7 0C
6 Odour Pungent
7 Vapour Density 1.11
8 Relative Density 0.791 g/ml at 25 0C
9 Water Solubility Completely Miscible with

water
Table 2.5 Properties of Methanol
5
College
3
1 0
Figure 8
Health 1 Can Cause Significant irritation
Flammability 3 Can be ignited under almost all ambient temp conditions
Instability 0 Normally stable, even underfire
Special - -
2.6 Dichloro Diphenyl Sulfone (DCDPS)
DCDPS is the final product of our plant. Structure and its
properties are mentioned below.
Structure: -

1 Chemical Formula (ClC6H4)2SO2
2 Molecular weight 287 g/mol
3 Form Crystalline Powder
4 Colour White powder
6
College
6 Melting Point 148 0C
7 Solubility Soluble in Alcohols
8 Flash point 233 0C
Table 2.6 Properties of DCDPS
2.7 Trimethyl Boret (TMB)

Trimethyl boret is the catalyst of our process in which pyro
complex formation takes place. It is not recovered from Product. Structure and its properties
are mentioned below. Structure: -
Fig 2.7 Structure of Trimethyl Boret

1 Chemical Formula (CH3O)3B
3 Form Colourless liquid
5 Melting Point - 34 0C
6 Specific gravity 0.915
7 Vapour Density 3.59
8 Solubility Alcohol, ether,

Organic solvents
Table 2.7 Properties of Trimethyl Bote
7
222352 Process Details
Chapter 3: - Process Details

In this chapter the overview of the plant is explained with the block
diagram and flow diagram along with reactions.
3.1 Overview of the Plant

 In this part overview of the plant is given. The plant is divided in 3 main sections listed
as below.
1. DCDPS production process
2. Methanol Recovery
3. Monochloro Benzene Recovery
 In first section our product DCDPS is produced and after separate it from other
impurities it packed in jumbo bags.
 In second section methanol which is used as a solvent is recovered from mixture of
mainly methanol, water & other impurities.
 In third section monochloro benzene which unreacted is recovered from mixture of
many components.
3.2 DCDPS Production Process
3.2.1 Block Diagram of DCDPS Production Process

The Block Diagram of the process is shown in fig and description is
also given after the figure.
8
Pyro Complex
Forming
Reaction
Condensation
And Cracking
Reaction
Drowning
and
Quenching
Filteration
Digestor
Filteration
Dryer
Figure 9
Product
Fig 3.2.1 Block Diagram
9
Description of Block Diagram
 Here each process and operation are presented in the form of blocks. First process is Pyro
complex forming Reaction in which Dimethyl sulphate and Sulfur trioxide Reacts. After
that in Condensation and cracking reactor Pyro complex and Monochloro benzene reacts.
In Quenching Reaction mass temp is controlled. Afterwards in Filteration unreacted
components and impurities is removed and DCDPS slurry is made. In digestor PH is
maintained and product crystals are made. In filteration Methanol is removed and product
is sent to dryer. After drying product is filled in jumbo bags.
10
3.2.2 Process Flow Diagram of DCDPS Production Process

The process Flow diagram is shown in fig and description is also given after
figure.
Figure 10
11
Description of Process Flow Diagram
1. Pyro Complex Forming
 First of all, in Pyro complex forming reactor, we added Fixed amount of DMS and
heated up to 60 0C. After that we starts SO3 addition and then reaction proceeds. We
add SO3 at fixed flow rate. Reaction is exothermic so if reaction mass temp goes above
65 0C during addition, then we reduce SO3 flow rate by some amount. At the end of
addition temp of reaction mass should reach 75 0C. If not then heat up to 750C. At the
end pyro complex is formed which is mixture of Dimethyl pyro sulphate and SO3.
Here Material of Construction of Reactor is SS-304 used because there is no any
chloride present. So, it is economical to use SS-304
2. Condensation and Cracking Reaction
 Pyro Complex and Monochloro Benzene Reacts To form Crude DCDPS. Fist we add
MCB in Reactor and after that we starts the addition of Pyro complex which is at 40
0
C. The Reaction is very exo-thermic. We maintain temp about 50 0C during pyro
addition with the help of cooling water. We stop the cooling water supply when some
amount of pyro addition remaining. At the end of reaction temp is reached up to 90
0
C. Here MOC of reactor is SS-316 used because MCB is more corrosive and
SS-316 provides extra resistance because of molybdenum content in comparison of
SS-304
3. Quenching
 Quenching is a process of Heat treating in which after heating , rapid cooling is done
by dumping mass in Water. In Quenching reaction mass is dumped into large Quantity
of water. Temp of whole mixture is maintained up to 50-60 0C.
Advantages of Quenching
• Obtain required material properties by altering molecular structure.
12
• Preventing undesired low temp process like phase transformation from occurring.
4. Filteration in Agitated Nutsch Filter
• In agitated nutsch filter slurry is compressed with air so unreacted reactants and other
impurities are separate out. This liquid is called Mother liquor . After that 2 washes of
water is given so more liquor is separated and it is sent to MCB recovery section.
• After those 2 washes 1 wash of soda ash solution and 1 wash of water is given. Last
wash liquor is sent to wash liquor tanks.
• Soda ash wash is used to remove salts which are sticked on DCDPS which cause
chocking problem further.
• After all washes in ANF our DCDPS wet cake with some impurities are present. After
that we make slurry of methanol and wet cake of DCDPS. We use methanol as solvent
because our DCDPS is soluble in alcohols and methanol is also formed during
quenching.
5. Digestor
• After filteration we add methanol in ANF to make slurry according to weight of wet
cake and Compressing it with Nitrogen because methanol can burn with contact of air.
• We dumped this slurry in digestor and adjusting its PH with addition of Some Soda
Ash.
• After that we heat the mass to 65 to 70 0C and maintain for 15 min.
• Further we heat the mass to 110 0C with the help of steam.
• With the help of methanol vapour condensation, we allow mixture to cool down up to
70-75 0C
13
• Further we cooled mixture up to 45 0C with the help of cooling water and up to 25 0C

with the help of chilled water.
6. Filteration
• In Agitated Nutsch Filter Our slurry is compressed with nitrogen and Mother liquor
contains mainly as Methnol and water and Mix isomers is seperate out. This Mother
liquor sent to methanol recovery section.
7. Rotary vacuum Paddle Dryer
• A rotary vaccum filter drum consists of a cylindrical filter membrane that is partially
sub merged in a slurry to be filtered.
• Firstly, the agitation of RVDF is started. We Dumped the cake from ANF in RVDF.
• A vaccum system lowers the pressure inside a large drying vessel, as the pressure
within the vessel lowers to the vapour pressure of liquid, the methanol and water
vapours evaporated leaving a dry product.
• Also, Heaters inside the vaccum dryer are installed. They are generally used for heat
sensitive material
• Start heating up to 50-60 0C and maintain for 4-6 hour after start cooling up to 40 0C
and maintain for 2 hours.
• Take the sample and sent to QC Lab if moisture content is > 0.5 wt. % then continue
drying for 2-3 hours and if moisture content is < 0.5 wt. % then open discharge valve
of RVDF and dumped dry DCDPS in SILO and start the filling Dry DCDPS in jumbo
bags.
14
Methanol Recovery
• In methanol Recovery section Methanol recovered from ML from last ANF and From
RVDF . Afterwards Methanol is Recovered from this ML by Distillation of water and
methanol.
• Here our ML consists of methanol and water and mix isomers. By the heating vapours
of methanol and water generated and by distillation we can separate out them .
Remaining non - volatile solution consists of mix isomers which is sent to pit to cool
down and precipitate as by product.
• Flow Diagram of Methanol recovery is shown in Fig.
• Here V-162 is used for collecting methanol and water from condenser . Tank 126 is
used for collecting Mother liquor which constitutes mainly methanol . Reactor is used
for generating methanol and water vapour . HE 105A & HE 105B are the overhead &
vent condensers Respectively.
Figure 11
Fig 3.3 Methanol Recovery
15
MCB (Mono chloro Benzene) Recovery
• Our Mother liquor is consists of following Compounds : Methanol , water , PCBS

Acid,
MCB, H2SO4.
• Here PCBS acid , H2SO4 , MCB are relatively very less volatile so first we sent our ML
to series of evaporators where vapours of methanol and water are generated . With the
help of distillation we can separate out methanol & water.
• So, Now our buffer solution contains PCBS acid, H2SO4 , MCB & some amount of
water.
• Here water obtained from distillation is sent to T 507 (liquid discharge tank).
• Now Buffer Solution is sent to Cracking Reactor where PCBS acid is Converted to
MCB
& H2SO4.
• In Cracking Reactor MCB & H2O is in vapour form. After condensation of this vapours
MCB & H2O is separate out in 2 different phases and remaining solution in the
cracking reactor is Spent Acid (PCBS acid + H2SO4)
• MCB & H2O are insoluble so they separate out as a different phases by gravity
Seperators and stored in Recovered MCB tank & Liquid discharge tank respectively.
• Flow Diagram of MCB recovery is shown in fig.
16
Figure 12
Fig 3.4 MCB Recovery
17
222352 Material and Energy Balance
Chapter 4:- Material and Energy Balance

In this chapter material and energy balance of whole plant has been
carried out and whole procedure of doing so is shown in details.
4.1 Material Balance

In this topic material balance of plant is covered. Where operations wise
material balance is provided as below:
4.1.1 Material Balance of Pyro Complex Forming Reactor
Basis: - 100 Kg DMS (Dimethyl Sulphate)
Reaction (CH3)2SO4 + 2SO3 (CH3OSO2)2 O + SO3

Dimethyl pyro
Sulphate
M.W 126 80 206 80
Kmol 0.79365 1.5873 0.79365 0.79365 Kg
100 126.9841 163.4919 63.492
This entire mixture is called Pyro Complex
100 KG DMS 126.98 KG SO3

Complex Forming
Reactor
226.98 KG Pyro Complex
18
4.1.2 Material Balance of Condensation and Cracking Reactor
Reaction
(CH3OSO2 )2O + SO3 + 2C6H5Cl ( ClC6H4)2SO2 + 2CH3HSO4
Pyro complex MCB DCDPS
Crude
M.W 206 80 112.5 287 112
Kmol 0.79365 0.79365 1.5873 0.79365 1.5873
Kg 163.4919 63.492 178.57125 227.77755 177.7776
226.9839 Kg pyro Condensation 178.57125 Kg MCB

And Cracking
Reactor
227.77755 Kg DCDPS Crude
177.7776 KG CH3HSO4
19
4.1.3 Material Balance of Drowning and Quenching Reactor
Reaction
CH3HSO4 + H2 O CH3OH + H2SO4
M.W 112 18 32 98
Kmoles 1.5873 1.5873 1.5873 1.5873
Kg 177.7776 28.5714 50.7936 155.554
227.77755 KG DCDPS Crude
177.7776 KG CH3HSO4
357 KG Water
Drowning and quenching

Reactor
227.77755 KG DCDPS Crude

50.7936 KG CH3OH
155.554 KG H2SO4
328.4286 KG H2O
20
4.1.4 Material Balance of Agitated Nutsche Filter
762.55375 Kg Crude
769 Kg Water Agitated 511.55 Kg ML

5 Kg Soda Ash
Nutsche Filter 800 Kg Wash Liquor
220 Kg Crude DCDPS wet Cake
Here DCDPS wet cake have 12% impurities.

220 * 0.12 = 26.4 Kg Impurities
220 * 0.88 = 193.6 Kg Dry DCDPS
Methanol required to make slurry = 193.6 * 2.35 = 455 Kg
21
4.1.5 Material Balance on Digestor, ANF, Dryer
Figure 13
190 Kg Dry DCDPS
22
4.2.3 Energy Balance of Quenching & Drowning Reactor
First, we heat 357 Kg water up to 50 0C
Q = m Cp ΔT = 357 Kg × 4.184 KJ/Kg 0C × (50-25) 0C
= 37342.2 KJ
After addition of mass from Condensation & Cracking Reactor Maintain mixture of
reaction mass and water at 90 0C which is initially at around 65-70 0C=
Q = m Cp ΔT = (226.9841 + 178.57125 + 357) × (0.5318 × 1.9933 + 0.4682 ×4.184) ×
(90-68)
= 50645.7 KJ
After that cool mixture upto 40 0C
Q = m Cp ΔT = 762.555 × 3.0189 × (90-40)
= 115103.8645 KJ
4.2.4 Energy Balance of Digestor 2
In digestor 2 around 676 Kg slurry of DCDPS is added.
Q = m Cp ΔT = 676 × 2.69066 × (67-30) = 67298.787 KJ
Q = m Cp ΔT = 676 × 2.69066 × (110-67) = 78212.104 KJ
Q = m Cp ΔT = 676 × 2.69066 × (110-75) = 63661.0156 KJ
Q = m Cp ΔT = 676 × 2.69066 × (75-45) = 54566.58 KJ
Q = m Cp ΔT = 676 × 2.69066 × (45-28) = 30921.064 KJ
23
4.2.5 Energy Balance of Rotary vacuum Dryer
Cp of DCDPS = 0.9383 KJ/Kg 0C
Q = m Cp ΔT = 202 × (0.9405 × 0.9383 + 0.0495 × 2.69066 + 0.0099 × 4.184 )
× (65-28) = 7900 KJ
Q = m Cp ΔT = 202 × 1.057 × (65-45) = 4270.28 KJ
24
222352 Major Equipment’s and Instrumentation
Chapter 5 :- Major Equipments and Instrumentation

In this chapter all the major equipments which are used in our plant are illustrated below.
Construction, working, advantages, disadvantages and applications of all these equipments are
covered in this chapter. Equipments are as listed below.
 Batch Reactor
 Agitated Nutsche Filter
 Rotary Vacuum Paddle Dryer
5.1 Batch Reactor

There are mainly two types of reactors named as batch reactor and
continuous reactor. Where in continuous reactor there are two reactors named as Plug Flow
Reactor (PFR) and Continuous Stirred Tank Reactor (CSTR). Where these continuous reactors
are steady state and batch reactor is unsteady state means the concentration in this reactor will
change with respect to time.
• Construction:
The batch reactor is a cylindrical vessel with 2 heads which could be torispherical,
hemispherical or elliptical as per condition of pressure inside the vessel. In Our Plant tori
spherical heads are used for reactors. Batch reactor is unsteady state reactor as mentioned in
introduction part of it.
An agitator is also provided at there for agitation of the content in the reactor to increase
the rate of reaction and to maintain same concentration in every place in the reactor. Selection
of agitator is done on the basis of the content which is used in the reaction i.e. on the basis of
reactants phase that weather they are highly viscous or less viscous.
For high viscous liquid paddle type agitators are used which has less rotational speed but
has more strength so that will not break when it will deal with highly viscous fluid. For less
25
viscous fluid propeller is used which has very high rotational speed so used for rapid mixing
and at last turbine type agitator is there for intermediate purpose.
In our plant pitched blade type impeller is used because in Condensation and Cracking
Reactor reaction mixture is of intermediate viscosity. Figure of Batch Reactor is shown
below.
Figure 14
Fig.5.1 Diagram of Batch reactor
• Working:
All the reactants are added in the reactor in the starting of the process then agitation of
them with help of agitator is done so that concentration inside the reactor will be same at every
place at a time. As the time will pass reactants will get converted into product and with time
the concentration inside the reactor will change that is why it is known as unsteady state
reactor. Rate equation of the batch reactor is shown below.
XA
t = CA0 ʃdX A / (-rA)

26
0
CA0 = Initial concentration of A
XA = Conversion of A
(-rA) = Rate of disappearance of A (Rate of reaction with respect to A)
With help of above equation we can find out the concentration of reactant A at a particular
time.
• Advantages:
Advantages of batch reactors are as shown below:  It
is simple in construction.
 It is simple to operate.
 It has flexibility of operation.
 Its cost is relatively low.
 It requires small instrumentation and less supporting equipment.
 It can give high conversion that can be obtained by leaving the reactant in the reactant
for long period of time.
• Disadvantages:
Disadvantages of batch reactor are as shown below:
 High labour costs per unit volume of production.
 Requires considerable time to empty, clean out and refill.
 Poorer quality control of product. It is difficult to maintain the same quality in different
batches.
 Large scale production is difficult.
• Applications:
Batch reactors are often used for liquid phase reaction when the required production rates
are low i.e. a batch reactor is used for small scale production, to produce many different
products from the same piece of equipments, to carry out reactions having long reaction times,
for testing new processes that have not been fully developed, for kinetic study, and for
manufacture of expensive products such as pharmaceuticals, dyes, dye intermediates etc.
27
5.2 Agitated Nutsche Filter

This is multi-utility equipment which is a combination of filter and dryer Unit
in single equipment to achieve economy in process, space, energy, Labour and Cost, thereby
improving Profitability. It is suitable for filtration of liquids with high solid content. ANF is a
closed vessel designed to separate solid and liquid by filtration under pressure or vacuum. The
closed operation ensures odourless, contamination free and non-polluting working conditions
maintaining product quality and hygiene. The advanced technology of agitation and hydraulics
used in the equipment makes it versatile and user friendly. The resulting wet cake can be
reslurried and washed thoroughly with water or solvents unlike in centrifuges. Wash liquid
quantity can be controlled and monitored, reducing effluent load.
The discharge of wet cake is automatic.
Construction
The Agitated Nutsche Filter consists of a cylindrical shell with top dished
and welded flat bottom made as per pressure vessel codes. The base plate is stiffened by
supports welded under the plate. The base plate is having arrangement of bolting bar to hold
filter cloth. Suitable support mesh is provided under filter cloth to facilitate the flow of filtrate.
Suitable nozzles are provided including Manhole and side discharge valve. The Specially
designed Agitator assembly is mounted on top of the vessel and the design adopted is advanced
and unique to this system which improvides the degree of filtration. The ‘S’ shaped stirrer
blades are mounted on the shaft, capable of performing various function such as cake
smoothening, vigorous agitation and cake discharge. These ‘S’ curved blades are self centering
made from heavy sections to take high torque generated during solid discharge and re-slurring
operation. Figure of ANF and S shaped agitator is shown in fig.
28
Figure 15
Fig.5.2 Diagram of ANF and S shaped Agitator
Working:
The first step involves the transferring of the product to be filtered, usually
aqueous or solvent based solid/liquid slurry which is into filter preferably by gravity flow
from Reactor installed above the filter or by slurry pump.
The second step involves the filter is charged with slurry, filtrate will start
passing through filter cloth by gravity. To enhance filtration pressure or vacuum is applied
to displace the filtrate leaving the cake retained over filter medium. The Process is stopped
when solids are visible, or can be continued until all the liquid is pushed out. In
29
the washing Stage a spray ring or connections on top of the cover introduce the wash liquid
over the cake, taking care not to disturb the surface of the cake.
The liquid is forced through with pressure or vacuum. Displacement washing serves
several purposes – it removes the liquid and its impurities while keeping the cake intact
and it replaces the previous liquid with fresh liquid.
At the closing stage, the stirrer blades are lowered on the cake surface. The
specially designed hydraulic system, takes over to perform a systematic, efficient and
productive smoothing of the cracks which appear in the cake, leaving behind low residual
moisture 10 to 20 % less as compared to other conventional filters.
The stirrer blades are rotated and lowered to cut away the upper surface off
the filter cake. As the blades descend into the cake mass, the discharge valve is opened
and a controlled discharge of the cake is achieved.
Salient Features
 Method of operation is totally enclosed, neat and hygienic. These conditions are
excellent for solvent recovery, handling of sterile compounds or toxic and hazardous
materials without human intervention.
 Enables easy non-manual and automatic cake/solid discharge.
 Scraper blades is provided to scrap the material which may stay on shell.
 The equipment is functionally safe and easy to operate.
 Minimum hold up of filtrate in the equipment.
 Agitator moves clockwise, anticlock wise, up and down. This ensures through washing
and re-slurring of the cake.
 Blending of Product possible before discharging
 Product can be washed thoroughly and economically with solvents.
 Reduce capital and operating costs.
 Large Quantities can be processed faster than the conventional systems.
 The number of conventional machines is employed for filtration process is also

reduced.
30
Rotary Vacuum Paddle dryer

Rotary Vacuum Paddle Dryer (RVPD) offers a versatile, clean, simple and effective process
solution for vacuum drying at low Temperatures. Extraction of Useful liquids, solvent
recovery, Reaction, Process commencing with either slurries or pastes or wet cake, in Batch
Operation carried out by indirect heating and often under vacuum.
It is possible to dry heat sensitive materials at well below boiling

points of solvents.
Construction
The Horizontal shell with end closers forms the inner process
chamber, which is made in process compatible material of construction.
The Standard MOC are SS304/SS304L or SS316/SS316L. The Main shell and
optionally end covers forming chamber are provided with Limpet jacket/coil, for
indirect heating of process mass.
The heating media could be steam/hot thermic fluid/hot water
depending upon application.
Agitator is made of heavy central hollow pipe shaft, sturdy arms
provided with doctors’ Knife type Scrapper Blades, arranged and sized to sweep entire
internal surface and agitate process mass for efficient heat transfer for drying.
A Dust Catcher/filter is provided to prevent carry over of dried product particles to
Distillate collection system.
A Condenser of adequate heat transfer area is required wherein the
evaporated vapours of solvents are condensed for recovery. It is designed and
manufactured in accordance to TEMA standard, Counter current , with the process vapours
through tubes and cooling water through shell.
31
Figure 16
Fig.5.3 Diagram of Rotary Vacuum Paddle Dryer
Working
Slurry / Wet cake is charged through the charging door while keeping a
rotation of the agitator on. The vacuum is then applied to the Dryer along with Dust
Catcher (mounted on the Dryer) Condenser and Receiver. The heating medium is
passed through the jacket and Agitator. Vigorous evaporation of moisture takes place
under a vacuum.
The vapor passes through the Bag Filters of the Dust Catcher, goes into
the Condenser and the Condensate is collected in the receiver. Evaporation under
high vacuum and low-temperature results in faster recovery of maximum solvents.
Adequate provision has been provided to cater for fluctuations in steam
pressure/temperature, in Condenser cooling water temperature, moisture content of
the feed, etc.
32
The dry product is discharged via the discharge valve by reversing the
Agitator rotational direction to the “Discharge” direction.
Advantages
 These Dryers gives optimum performance with very high heat transfer rates.
 These Dryers have been successfully used for reaction, Crystallization and extraction
Operations in addition to the primary function of drying.
 Low Temp drying for heat sensitive product is possible.
 Complete solvent recovery is possible with this rotary vacuum paddle dryer.
Disadvantages
 In vacuum dryer, heat transfer coefficients are low.

 It has a limited capacity and used for batch process.
 It is more Expensive than dryer. Labour and running costs are also high.
 Sometimes, there is a danger of overheating as the material in contact with steam heated
surface for longer period.
33
5.4 Process Equipment Design of Heat exchanger

(Condenser)
Cooling Water Return at 32 0C
Methanol Saturated vapour at Methanol at 31 0C Heat
67 0C at 111.569 KPa Exchanger
Cooling Water Supply at 26 0C
For Methanol at 67 0C Latent Heat λv = 1133. 694784 KJ/Kg

Average Temp = 67 + 31 / 2 = 49 0C
At 49 0C Cp of Methanol = 2.69066 KJ/Kg K
1) Heat Duty
Фt = m λv + m Cp ΔT
= 670 Kg/hr × 1133.694784 KJ/Kg + 670 Kg/hr × 2.69066 KJ/Kg K × (67-31) 0C
= 759575.5033 KJ/hr + 64898.7192 KJ/hr
= 210.993 KW + 18.0274 KW
= 229.0204 KW
229.0204 KJ/s = mw Cp ΔT
Water flow rate mw = 229.0204 / ( 4.18478 × 6 ) = 9.1211 Kg/s

= 32835.96 Kg/hr
= 32.8359 m3/hr
For Condensation Assume Uc = 500 W/ m2 0C
Usubcooling = 300 W/ m2 0C
Assume that entire flow of cooling water is first utilized for subcooling & then for
condensation.
34
Фsub = 18.0274 KW = 9.1211 Kg/s × 4.18478 KJ/Kg K × (t’ – 26) t’ = 26.4722 0

C
2) LMTD Calculation
LMTD for Condensation LMTD for Subcooling
67 0C 67 0C 67 0C
32 0C
31 0C
26.4722 0C 26.4722 0C
26 0C ΔT1 = 35 0C
ΔT1 = 40.5278 0C
ΔT2 = 40.5278 0C ΔT2 = 5 0C
ΔTLM = 40.5278 – 35/ ln(40.5278/35) ΔTLM = 40.5278 – 5 /ln(40.5278/5)

= 37.6963 0C = 16.9782 0C
Area for condensation = Фc / Uc ΔTLM
= 210.993 KJ/s / (500 W/m2 0C × 37.6963 0C)
= 11.1943 m2
Area for subcooling = Фsub / Usub ΔTLM

= 18.0274 KJ/s / (300 W/m2 0C × 16.9782 0C)
= 3.5393 m2
Total Area = 11.1943 + 3.5393 = 14.7336 m2
Tube O.D = 3/4 in = 19.05 mm BWG = 14 L = 6 ft = 1.83 m

Tube I.D = 0.584 in = 14.8336 mm
14.7336 m2 = Nt (Number of tubes ) × п × 0.01905 × 1.83

Nt = 135 tubes
Pitch Pt = 1.25 × Do = 23.8125 mm
35
3) Tube Bundle Diameter
Db = d0 (Nt / K1)^(1/n^1) = 19.05 (135/0.319)^(1/2.142)
= 320.7048 mm
Di = Db + C = 320.7048 + 12 = 332.7048 mm
Single Tube Cross sectional Area = п/4 × di^2
= п/4 × (0.0148336^2)
= 1.7281 × 10^-4 m2
For 135 Tubes = 135 × 1.7281 × 10^-4 m2
= 0.02332 m2
Tube side water velocity = m/(ρ× A) = 9.1211 / (1000 × 0.02332) = 0.3911 m/s
L/Di = 1.83/0.3327048 = 5.50 ԑ (5,10)
4) Tube side Heat transfer co-efficient

hi = 4200 (1.35 × 0.02 T) ut^0.8 / di^0.2
= 4200 (1.35 × 0.02 × 29 ) 0.3911^0.8 / 14.8336^0.2
= 2230.4245 W/m^2 0C
= 2231 W/m^2 0C
5) Shell side Heat Transfer Co-efficient

For shell side co efficient
Tw = Tube Wall Temp hco = 1500 W/m^2 0C hco
Ac (Tc – Tw) = Uc Ac (Tc - Tav)
1500 (67-Tw) = 800 (67 – (32+26.4722)/2)
Tw = 46.8592 0C
Mean Temp of Film = (67 + 46.8592)/2 = 56.9296 0C
36
At 56.9296 0C for methanol (liquid)

ρl = 755.6 Kg/m^3 , Kl = 0.19094 W/m K, µl = 3.716 ×10 ^-4 Pa .s methanol vapor
density ρv = PMav/RT = 111.569 KPa × 32 Kg/kmol / 8.314 × 340.15 K
= 1.2624 Kg/m3
Γ
h = mc / L × Nt = (670/3600)/ (1.83 × 135) = 7.5333 × 10 ^-4 Kg/m s
Nr = 2/3 (Nr’) = 2/3 (Db /Pt) = 2/3 (320.7048/23.8125) = 8.9786 = 9 hco =
0.95 Kl ( ρl(ρl- ρv)g/ µl × Γh )^(1/3) × Nr^(-1/6)
= 3412.468779 = 3413 hod = 10000
W/m^2 0C , hid = 4000 W/m^2 0C
1/Uoc = 1/ho + 1/hod + Do/2 Kw ln(Do/Di) + 1/hid (Do/Di) + 1/hi (Do/Di)
1/Uoc = 1/3413 + 1/10000 + 0.01905/(2×16.3) ln(0.01905/0.0148336) +
1/4000 (0.01905/0.0148336) + 1/2231 (0.01905/0.0148336)
= 14.3586 × 10^-4 W/m^2 0C
Uoc = 696.4467 W/m^2 0C
Acr = 210993/(696.4467×37.6963) = 8.03676 m2
1/Uosub = 1/500 + 1/10000 + 0.01905/ 2 × 16.3 ln(19.05/14.8336) +
1/4000 × (19.05/14.8336) + 1/2231 × (19.05/14.8336)
= 31.4287 × 10^-4
Uosub = 318.1805 W/m^2 0C
Asubr = 18.0274 × 10^3 / (318.1805 × 16.9782) = 3.3370 m2
Atr = 8.03676 + 3.3370 = 11.37376 m2
At provided/Atr = (14.7336/11.37376) = 1.2954
37
Excess Area = 29.54 %

Assume equal percentage of excess H.T Area in both zones are provided then.
Ac provided = 8.03676 × 1.2954 = 10.4108 m2
Asub provided = 3.3370 × 1.2954 = 4.3227 m2
Asub / Atpro = 4.3227/(10.4108 + 4.3227) = 0.2933 = 29.33 % Area provided for
Subcooling
6) Shell side pressure drop

Assuming that tube will be uniformly distributed in the cross section of
the shell.
Shell side flow area (cross section) As = (Pt-do)Bs D/ Pt
= (1.25 do - do ) 0.5 Di × Di / 1.25 do
= 0.25 do × 0.5 Di^2 / 1.25 do
= 0.25 × 0.5 × 0.33270482 / 1.25
= 0.01106 m2
Shell side velocity u = m/(ρ×A) = 670 /(3600 × 1.2624 × 0.01106 ) = 13.3296 m/s
For Triangular Pitch de = 1.1/do (Pt2 – 0.907 do2) = 0.01373 m µmethanol of vapour
at 67 0C = 0.01089 × 10^-3 Pa.s
Reynold Number Nre = ρ v Deq / µ = 1.2624 × 13.3296 × 0.01373 / 0.01089 × 10^-3
= 21215.67044
Shell side pressure drop ΔPs’ = 8 Jf (Ds/de) (L/Bs) (ρs us^2/2)
Jf = 4.5 × 10^-2 (25 % baffle cut)
ΔPs’ = 10762.52748 Pa
= 10.762 KPa
For condensation = 0.5 × ΔPs’ = 0.5 × 10.762 = 5.381 KPa < 10.244 KPa g
38
7) Tube side Pressure Drop

Tube side pressure drop ΔPt = Np (8 Jf (L/di) + 2.5 ) ρ ut2/2
Reynolds number Nre = ρ V D/µ = 1000 × 0.3911 × 0.0148336 / 0.8141 × 10 -

3
= 7126.177
Jf = 5.3 × 10-3
ΔPt = (8× 5.3 × 10-3 (1.83/0.0148336) + 2.5) × 1000 × 0.3911^2 / 2

= 591.250 KPa
= 0.591250 KPa <<<< 35 Kpa
Resulting Heat Exchanger Specifications
• 1,1 Fixed Tube Shell and Tube Heat exchanger

• Shell I.D = 332.7048 mm
• Baffles = 25 % Cut Segmental
• Baffle Spacing = 0.5 × 332.7048 = 166.3524 mm
• Tube OD = 19.05 mm BWG = 14
• Tube Length = 1.83 m = 1830 mm
• Triangular Pitch Arrangement Pt = 1.25 do
• Number of Tubes Nt = 135
• Heat Exchanger Area = 15 m2
39
222352 Utilities
Chapter 6: Utilities
1. Compressed air. (4.8 kg/cm2)
2. Instrument air. (4.7 kg/cm2)
3. Nitrogen. (2.6 kg/cm2)
4. Cooling water. (4.8 kg/cm2) (22 0C)
5. Brine. (-170C)
6. Oil. (230 0C)
7. Chilling water. (3.9 kg/cm2) (100C)
8. Steam : LPS (2.5 kg/cm2), MPS (7.5 kg/cm2), HPS (19.5 kg/cm2)
6.1 Compressed Air:

Compressed air is obtained by using air compressors. The work of compressors is to increase
the pressure of the air from atmospheric pressure to the required set pressure.
Applications of compressed air are as follows:
• Process air — used in direct contact with product for such usages as cleaning, aeration
and product moving
• Control valves & cylinders — equipment used in the manufacturing process is
controlled by compressed air
• Material handling — air operated fluid pumping systems are used in volatile
environments without the risk of explosion
• Nitrogen generation — air is filtered via a membrane to produce nitrogen used in a
variety of chemical applications
• Air curtains — to create a safe and clean area
• Product drying — air is mixed with product to accelerate drying processes
• Compressed air is used as process air, to make instrument air for instrument valve
operations and to make nitrogen.
6.2 Instrument Air:

The term “Instrument Air” refers to an extremely clean supply of compressed air that is free
from contaminates such as moisture & particulates. A system may utilize instrument air for
40
222352 Utilities
various types of pneumatic equipment, valves & electrical controls. Air dryer is used for proper
drying of compressed air so that it can be used as an instrument air for operations .
Air dryer:
Ambient air typically has a relative humidity of around 30 to 50%. Compressing air packs
higher quantities of moisture in a small volume. This increases the relative humidity to 100%
while the excess moisture that cannot be held condenses. Air with high moisture content is
detrimental to plant operation and reliability downstream equipment as it can cause process
stream contamination, premature failure and wearing of instrument parts, equipment
corrosion, and so on. The basic function of the air dryer is to remove moisture from the air by
cooling it with a refrigerant. Thus, the water vapor is condensed, and the air can be
compressed. The result is dry compressed air, which can be used as an instrument air in
equipment without causing any damage.
Figure 17
Figure: Air drying system

It works on a Vapour compression refrigeration system with R-22 as a refrigerant. Main
components of VCRs include evaporator, expansion device- capillary tube, compressor,
receiver and a condenser. Condensor uses cooling water to cool the refrigerant
41
222352 Utilities
6.3 Nitrogen
Nitrogen utility is obtained from compressed air by adsorption process.
Pressure swing adsorption process (PSA) is based on the phenomenon that under high
pressure, gases tend to be trapped onto solid surfaces, i.e., to be "adsorbed". The higher the
pressure, the more gas is adsorbed. When the pressure is dropped, the gas is released, or
desorbed. PSA can be used to separate gases in a mixture because different gases are adsorbed
onto a given solid surface more or less strongly. If a gas mixture such as air is passed under
pressure through a vessel containing an adsorbent bed of Carbon molecular sieves that attracts
oxygen more strongly than nitrogen , a fraction of oxygen will stay in the bed, and the gas
exiting the vessel will be richer in nitrogen than the mixture entering. When the bed reaches
the limit of its capacity to adsorb oxygen, it can be regenerated by decreasing the pressure,
thus releasing the adsorbed oxygen. It is then ready for another cycle of producing
nitrogenenriched air.
Figure 18
Figure: Nitrogen Plant

.
42
222352 Utilities
Cooling Water :
Cooling water flows through a closed piping system that circulates water through various
pieces of equipment. Exchangers and condensers require chilled water to reduce the
temperature of the process commodity.
Natural draft cooling tower
In this type of cooling towers the air circulating through the natural draft. The
atmospheric natural draft type cooling towers are consists of box shaped MS MDG
supporting structure with FRP louvers. The louvers allow the atmospheric air to pass
through the tower. in this type of cooling tower water from system is pumped to a Gl
spray header provided at the top of a tower. it is sprayed down into the tower through
the nozzles, since the heat transfer from water to air is dependent upon the surface of
water exposed to the air stream, therefore, these cooling towers are supplied with a
special type spray nozzles having finer spray pattern for good performance of the cooling
tower. These cooling towers should be located in the open space or on the building where
the air can blow freely through them.
Figure 19
Figure: Natural draft cooling tower
43
222352 Utilities
6.5 Brine
Cooling brine, also known as heat transfer fluid, is an aqueous salt solution whose
solidification temperatures are far below the freezing point of water. Cooling brines are
generally used as refrigerants. The start of solidification of the cooling brine is the decisive
application criterion. The start of solidification depends on the concentration and type of
dissolved salts. Depending on the requirements, the concentration required is set or determined
in advance. This is done by increasing or reducing the corresponding water content.
6.6 Oil
A Thermic fluid heater is industrial heating equipment, used where only heat transfers are
desired instead of pressure. In this equipment, a thermic fluid is circulated in the entire system
for heat transfers to the desired processes. Combustion process heats up the thermic fluid and
this fluid carries and rejects this heat to the desired fluid for concluding the processes. After
rejecting it, this fluid comes back again to the thermic fluid heater and this cycle goes on.
The maximum temperature of 350℃ of thermal fluid can be achieved in a Fluidtherm although
the higher temperature of the thermal fluid can be achieved provided the temperature of fluid
does not exceed the auto-ignition temperature.
Figure 20
Figure: Thermic Fluid Heater
44
222352 Utilities
The properties of a typical thermal oil are:-
• Density at 200 ˚C 760 kg/m3

• Specific Thermal Capacity 2.4 kJ/kgK
• Flash Point 180 ˚C
• Ignition Point 370 ˚C
• Boiling Point 330 ˚C
• Pour Point -18 ˚C
Coefficient of Thermal Expansion 0.00076 / ˚C
45
222352 Piping Systems
Chapter 7: Piping Systems

7.1 PIPELINES IDENTIFICATION COLOUR CODE
46
47
IS 2379: 1990 (Reaffirmed 2006), Amendment 1(May 2007) Pipelines:

Identification – Color Code
2 Pipe Insulations
• Hot insulation:
 Removable insulation is specifically designed to insulate piping systems
transporting gas and substances at high temperatures. The materials used to
construct the insulation work to prevent your pipes from overheating, while
keeping the warmth inside the pipe.
 Specifications of Rockwool:
 Thickness : 40mm, 65mm
 Density : 100kg/m3
48
Figure 21
Rockwool
• Cold insulation:
 Just like hot insulation materials, some of the materials used to produce cold insulation
vary dependent upon the system of pipes they are insulating. Therefore, the materials
used in either hot or cold insulation are dependent on the customization of the
particular piping system.
Figure 22
Thermocol
49
222352 Maintenance Work
Chapter 8: Maintenance Work
8.1 Agitated Nutsche filter:
Problem: damaged rubber lining due to solid material getting filtered and altered the rubber
Observations:
 Removal of rubber lining.

 Replacing the rubber lining with the new one.
 Curing process of rubber.
 Spark test.
 Arc welding on MS shell.
 Hydraulic test.
 Pressure test.
8.2 MSRL reactor:
Problem: Corrosion on the glass lined surface.
Observations:
 Gas Cutting of MS Shell.

 Arc welding.
 Fitting PFA material disk on the corroded part.
8.3 Pump:
Problem: Broken Mechanical seal
Observation:
 All parts of pump.

 Fitting the mechanical seal.
50
222352 Maintenance Work
8.4 Reactor:
Problem: Stirrer key got displaced.
Observations:
 Clamping of stirrer on both sides.

 Use of Ultrasonic thickness tester.
8.5 Rupture disc:
 Installation of rupture disc.
8.6 Thermic fluid heater:
Problem: Carbon deposited on the surface of spark plug.
Observations:
 Cleaning of spark plug.

 Maintaining the gap of the spark plug.
 Flow control of PNG and compressed air.
51
222352 Pump and Control Value
Chapter 9: - PUMP & CONTROL VALVE

Any chemical plant is impossible to operate without the use of various pumps and instruments.
Pumps are used to transfer fluid material from one place to another place. There are many
types of instruments which are used to measure physical quantities.
 Pumps used in plants are as follows:

1. Centrifugal pump
2. Diaphragm pump
3. Magnetic pump
4. Vacuum pump
 Instruments used in plants are as follows:
1. Pressure gauge
2. Temperature sensor
3. Level sensor
Valves used are manual, XV (ON/OFF) and control valves. Pressure relief valve (PRV),
Rupture disc followed by Safety relief valve (SRV) located on autoclave.
9.1 Pump:
Types of pumps:
1) Vacuum pump
2) Diaphragm pump
3) Magnetic pump
4) Centrifugal pump
9.1.1 Vacuum Pump

Liquid ring vacuum pumps normally operate with water as the operating medium. An
eccentrically installed impeller rotates in the casing partly filled with liquid. By the rotational
movement of the impeller and the resulting centrifugal force the liquid within the cylinder
forms the so-called liquid ring.
Gas is conveyed in the spaces between the single vanes and the liquid ring. Due to the eccentric
installation of the impeller the spaces enlarge and the process gas is sucked in through the
suction slot.
52
As the impeller further rotates, the spaces are reduced, so that the gas is compressed and
discharged through the discharge slot. The vacuum pump can be operated with water
recirculation, open or closed loop circuit.
Figure 23
Figure: Two stage water ring vacuum pump
9.1.2 Diaphragm pump
A diaphragm pump is a PD or positive displacement pump. It is also called as a membrane

pump. This pump works with using a blend of the reciprocating action of a rubber, Teflon
diaphragm otherwise thermoplastic & appropriate valves on any face of the diaphragm to push
a liquid.
These pumps are widely used to handle a wide range of fluids in many industries. These pumps
can push fluids with high, low, or medium viscosities. These can also be used to handle
numerous violent chemicals like acids as they are assembled with an extensive range of
diaphragms and body materials.
A double diaphragm pump uses two bendable diaphragms that respond back & forward to
make a temporary hall, where both receives and ejects liquid through this pump. The working
53
principle of the pump is on an air displacement principle which is like a separation partition
among the air as well as the fluid.
Figure 24
Figure: Diaphragm Pump
9.1.3 Magnetic Pump

Magnetic drive pumps are typically used where leakage of the pumped liquid poses a great
risk such as with aggressive or risky liquids, exotic materials, acids, alkalis, corrosives,
pollutants and toxics. They are also used for ultra-pure liquids and hard-to-seal liquids. Sealed
pumps applied to these types of services may leak over time or require complex, expensive
double seals to prevent hazardous/challenging liquids from escaping to the atmosphere, which
can lead to safety hazards, downtime and increased maintenance requirements.
Another important application for magnetic drive pumps is for difficult liquids; for example,
some liquids can crystallize on seal faces, which then can cause seal failures. To avoid this, a
permanent flush system should be run to the seal. This, however, can increase the cost of
maintenance, seal flushing liquids and energy consumption. A better solution for these
difficult services is to use a magnetic drive pump.
54
Figure 25
Figure: Magnetic Pump
Magnetic drive pumps have no direct connection between the electric motor shaft and the
impeller; therefore, no seal is needed. There is no risk of leakage unless the pump casing is
broken. Seals are known as a major cause of pump trips and unscheduled shutdowns.
Obviously, the elimination of seals is a great improvement for performance, reliability and
availability of pumps. The risk of leakage is completely eliminated; this means that liquids
can be pumped without spillages. Eliminating the seals also gets rid of associated friction loss,
wear, costs and noise. This provides complete separation of liquid from the pump drive and
better transfer of motor power to the pump. There is practically no heat transfer from the
electric motor because the pump chamber is completely separated from the electric motor by
a large air gap; this provides an effective barrier between the two. The magnetic coupling will
soften any shock or spike torques. Even in extreme situations, it will act as a fuse. Magnetic
couplings can be broken temporarily if the load of the pump is too great. In practice, it means
the pump does not overload and get damaged.
55
9.1.4 Centrifugal pump:

A centrifugal pump is a mechanical device designed to move a fluid by means of the transfer
of rotational energy from one or more driven rotors, called impellers. Fluid enters the rapidly
rotating impeller along its axis and is cast out by centrifugal force along its circumference
through the impeller’s vane tips. The action of the impeller increases the fluid’s velocity and
pressure and also directs it towards the pump outlet. The pump casing is specially designed
to constrict the fluid from the pump inlet, direct it into the impeller and then slow and control
the fluid before discharge.
Components of centrifugal pump assembly:
1) Casing
2) Impeller
3) Backplate
4) Mechanical seal/ Gland
5) Adaptor/ Stuffing box
6) Bearing housing
7) Oil seals
8) Bearings
Figure 26
Figure: Centrifugal pump assembly
1) Casing
56
It is a pipe which is connected at the upper end to the inlet of the pump to the center of impeller
which is commonly known as eye. The double end reaction pump consists of two suction pipe
connected to the eye from both sides. The lower end dips into liquid in to lift. The lower end
is fitted in to foot valve and strainer. Commonly three types of casing are used in centrifugal
pump, Volute Casing, Vortex Casing, Casing with Guide Blades
2) Impellers
The impeller is the key component of a centrifugal pump. It consists of a series of curved
vanes. These are normally sandwiched between two discs (an enclosed impeller). For fluids
with entrained solids, an open or semi-open impeller (backed by a single disc) is preferred.
Figure 27
Open type impeller Semi open type impeller Closed type impeller
• Open impeller. Open impellers have the vanes free on both sides. Open impellers are
structurally weak. They are typically used in small-diameter, inexpensive pumps and
pumps handling suspended solids.
• Semi-open impeller. The vanes are free on one side and enclosed on the other. The
shroud adds mechanical strength. They also offer higher efficiencies than open
impellers. They can be used in medium-diameter pumps and with liquids containing
small amounts of suspended solids. Because of the minimization of recirculation and
other losses, it is very important that a small clearance exists between the impeller
vanes and the casing.
• Closed impeller. The vanes are located between the two discs, all in a single casting.
They are used in large pumps with high efficiencies and low required Net Positive
Suction Head. The centrifugal pumps with closed impellers are the most widely used
pumps handling clear liquids. They rely on close-clearance wear rings on the impeller
and the pump casing. The closed impeller is a more complicated and expensive design
because of the impeller, but additional wear rings are needed.
57
3) Back plate:
The back plate consists of a gland ring facing the bearing side where the
mechanical seal or gland packings are arranged in such a way that the pumped fluid cannot
leak.
4) Mechanical seal:
A mechanical seal is a very effective device. Every centrifugal pump must accommodate a
spinning shaft while mechanically maintaining fluid or gas contained in the “wet end” of the
pump. Mechanical seals consists primarily of a rotary seal face with a driving mechanism
which rotates at the same speed as the pump shaft, a stationary seal face which mates with the
rotary and is retained using a gland or in some pump models an integral stuffing box cover, a
tension assembly (utillizing springs or a metal bellows) keeps the rotary face firmly positioned
against the stationary face preventing, excluding, and containing contamination and leakage,
both when the pump is not in operation and when the pump shaft is rotating.
Gland:
Gland packing is used extensively for the sealing and restriction of leakage of the working
fluid along the stem in valves and along the shaft in the case of pumps and also for stationary
duties like manhole cover sealing.
5) Adaptor:
It is used to connect the bearing housing with the pump.
Stuffing Box:
A stuffing box of a pump houses a gland that compresses the packing used to seal the pumped
fluid. It prevents leakage along the shaft that passes through a hole in the pump. Stuffing box
reliability is critical to the condition and performance of the whole fluid sealing program.
6) Bearing housing:
Bearing housings are modular assemblies designed to make it easy to install bearings and
shafts, while protecting bearings, extending their operating life and simplifying maintenance.
7) Bearings:
Bearings are "parts that assist objects' rotation". They support the shaft that rotates inside the
machinery.
58
Centrifugal pump uses double row ball bearing and single row ball bearings.
8) Oil seals:
Oil seals close off the space between stationary and moving components in the mechanical
equipment. It saves the lubricant from escaping through the equipment and ensures smooth
operation of the machine. Oil seals are called rotary shaft seal or radial lip also
9.2 Instrumentation:
9.2.1 Pressure gauge
 It is used to measure gauge pressure. It is required to check the pressure of steam line,
cooling water line and vacuum unit.
 Pressure gauge located at autoclaves, packed column’s bottom and top, ANF, Dissolver,
RVD, Candle Filter etc.
9.2.2 Temperature sensor

 It is used to measure temperature. It is required to check the temperatures of cooling water,
reactor and steam lines.
 Resistance temperature detector (RTD) is located at batch reactor, autoclave, packed
columns, CWS and CWR line in Shell and Tube Heat Exchanger, etc.
9.2.3 Level sensor

 It is used to measure level in the vessel in percentage.
 It is located in storage tanks, measure vessels, autoclaves, Holding Vessel, Dissolver, etc.
9.3 Valves:
Various types of valves used in anisole plant are as follows
 Ball valve
 Globe valve
 Plug valve
 Needle valve
 Gate valve
 Butterfly valve
59
9.3.1 Gate valve

FUNCTION ADVANTAGES
Linear motion valve Simple design & cheap
On/Off Less pressure drop
Wide application
Low torque required to open & close
9.3.2 Globe valve

FUNCTION Application ADVANTAGES
The all-control valve is globe Control valve and its Very good for flow regulation
valve. bypass
It can be used for both on/off Shutdown valve Shorter stroke compared to gate
and flow regulation purpose valve so can be used as
emergency shutdown valve
Flow regulation Tight shutoff
9.3.3 Needle valve

Location Application ADVANTAGES
Mostly found in compressed Used in instrumentation Precise regulation-turns directly

air lines proportional to flow, used as
metering of flow
Small size
60
9.3.4 Ball valve

FUNCTION ADVANTAGES
90% are ball valves in plant On/off
Precise control not possible Fast acting/quarter turn
Cost effective and most processes don’t Very low pressure drop when fully open
require precise accuracy of flow rates
Tight shutoff
Smaller in size & lighter in weight than gate

valve
Multi-port design available
9.3.5 Plug valve

 On/off
 Fast acting-used when frequent operation required
 Very low pressure drop when fully open
 Not suitable for flow regulation
 Multi-port valve
9.3.6 Butterfly valve

 On/off
 Flow regulation
 Wafer shape of body so less space required and used in large line size
 Light weight
 Fast acting
 Pressure drop very low when fully open
61
222352 Plant Layout
Chapter 10:- SAFETY MANAGEMENT

10.1 Introduction:
Safety denotes continuing and healthful living without injury. The word safety also refers to
the precaution people take to prevent from accident, harms, damage and from air/ water/
environment pollution. Safety is important and necessary to everywhere and at all times in
home, in office, in public, place, on roads, in working in industries etc.
Now a days, “Safety Management is essential and important part of industrial management, it
is one type of management function which connected with the caring of an enterprise that
relate with safety of the personal in an Enterprise.”
10.2 Personal Protective Equipment (PPEs):

“Figure 9.1”
Figure 28
 Some PPEs used in plant during operation, during loading and unloading of raw materials
tanker. They are used to protect person from mild or severe injuries during process.
These PPEs are as Safety Helmet, Safety Goggles, Safety Shoes, Dust Mask and Body
Suit.
62
222352 Plant Layout
10.3 Safety Talk:
There is various type of Safety Talk for awareness of workers:
 Fire Triangle
 Types of Fire
 Types of Fire Extinguisher
 How to Operate Extinguisher – PASS (Pull-Aim-Squeeze-Spray)
 Awareness of SCBA (Self Contain Breathing Apparatus)
 Assembly Point
 Wind Sock
 Types of Emergency Siren
 First Aid
 Work at Height
 Electrical Safety
 Important of Dyke Wall
 Types of Utilities
 Safety Attitude
 Awareness of control on leakage
 Hot work Permit
 Safety and Scaffolds
 Life changing Injury
 Near miss
 Unsafe Act and Unsafe Condition
 Awareness of 5s
 Critical Parameter in Plant
 Permit System
 Flammable Chemical Storage
 Important of Housekeeping
63
222352 Plant Layout
10.4 Fire Safety and Fire Alarm:
For fire safety various equipment is used such as fire extinguisher of the type ABC which
contain Dry Chemical Powder and second is the CO2 gas type. There is also given fire hydrant
line on all the floors and also the hose pipe to fight with the fire.
“Figure 10.4”
Figure 29
There is also alarm system which is as follow:
“TABLE-5”
1 minute wailing Local Emergency
4 minute wailing On Site Emergency
10 minute wailing Off Site Emergency
1 minute wailing All Clear
64
222352 Plant Layout
10.5 SCBA Set (Self Contain Breathing Apparatus):
Every plant contains SCBA set. Whenever there is leakage of any poisonous gas in the plant,
due to this emergency arises, and at such situation SCBA set has to be worn by plant in charge
or plant operator.
This apparatus contains pure air which is pressurized at 300 bar in a cylinder with a pressure
gauge indicator and it is worn on backside. Generally, when this apparatus is fully filled,
pressure indicator shows the reading of 300 bar and it work for total 45 minutes. When pressure
gauge indicates 50 bar whistles will blow which indicate only 10 minutes are left after which
cylinder will be emptied and we have to stop using it and send it for refilling.
Once it is used partially or fully, we need to inform this to safety officer. So that SCBA can
be replaced with the new one and is again operable. Also, entry is made when installed and
expiry is checked every year.
10.6 Type of Permits:
10.6.1 General Work Permit

 The General Permit to Work allows you and your contractor to consider and record all
of the hazards connected with the work they are going to conduct along with the
necessary precautions that must be taken. By considering these hazards, the opportunity
for accidents is greatly reduced and, therefore, the permit will help to protect the health
& safety of employees and contractors.
10.6.2 Hot Work Permit

 The Hot work permit is given when work activity is capable of supplying an ignition
source to flammable gases. Examples are welding, riveting, burning, cutting, grinding,
hammering, etc. If a permit is not given then certain problems may create like
flammable gas inserts in a working environment from any leakage, flammable gas may
be heated up and an explosion takes place. To reduce these kinds of problems we need
to give a hot work permit which ensures safety.
65
222352 Plant Layout
10.6.3 Confined Space Work Permit

 The Confined space permit is given when a person needs to enter inside equipment for
cleaning, maintenance, or any other purpose. Different types of confined spaces are
there in process plant like a storage tank, reaction vessel, pressure vessel, boiler, silos,
pipes, sumps, pits, etc. The confined space may contain hazardous gases, toxic gases,
or oxygen deficiency. We need to isolate the equipment so that no process stream
material enters the equipment.
 The person is allowed to enter the vessel only if the oxygen percentage is between 19.5
and 21 and 0 % LEL inside the vessel.
10.6.4 Permit to Work at Height/Fragile Roof

 Working at a height permit is required when a person is going to work on height (>2m).
All fall accidents happen while working at height. 10-20% of the total accident is fatal.
Two types of fall accidents are there: 1) Falling of person(s) 2) Falling of object(s).
10.6.5 Excavation/Digging/Floor Breaking Work Permit

 It is required for excavation beyond 1 foot. It is necessary to check if there are any
underground and embedded cables including power, LAN, instrument, or fire alarm
present
66
222352 Plant Layout
Chapter 11: - Plant Layout
In this chapter, the layout of whole plant is shown with help of figure, which shows
floor wise top views of the plant.
11.1 Plant Layout of Ground Floor
Figure 30
Fig 11.1 Plant layout of ground floor
The names of each denotation used in the figure 10.1 are written in table below:
Sr Denotation Name Sr Denotation Name

No. No.
1 T1 Spent Acid Tank 8 T8 SO3 storage tank
9 Pyro complex storage
2 T2 ML storage tank 1 T9
tank
3 T3 ML storage tank 2 10 R1 Complex forming Reactor
Liquid discharge 11
4 T4 R2 Digestor 1
tank
5 T5 ML storage tank 12 R3 Digestor 2
Methanol storage
6 T6
tank
7 T7 ML storage tank
67
222352 Plant Layout
11.2 Plant Layout of First Floor

Lift
ANF ANF
1 2
Walking Passage
9
R4
RVPD
Stairs
Figure 31
Fig 11.2 Plant layout of firstfloor
Sr Denotation Name
No.
1 ANF 1 Agitated Nutsche Filter 1
3 RVPD Rotary Vacuum Paddle Dryer
4 R4 Methanol water vapour generator
68
222352 Plant Layout
11.3 Plant Layout of Second Floor
Lift
R5
Walking Passage
Stairs
ANF
3
DC
T9
HE 1
Fig 11.3 Plant layout of second floor
Figure 32
Sr No. Denotation Name
1 R5 Quenching Reactor
3 DC Dust collector for RVPD
4 HE 1 Heat Exchanger for Dryer
5 T9 Methanol condensate receiver
69
222352 Plant Layout
11.4 Plant Layout of Third Floor
Walking Passage L
i
f
t
R6
Walking Passage
DCDPS Storage
Figure 33
Area
Stairs
C1
Chapter-11 1
Fig 11.4 Plant layout of third floor
Sr Denotation Name
No.
1 R6 Condensation & Cracking Reactor
2 C1 Methanol-water Distillation Column
3 HE 2 Overhead Condenser of column
4 HE 3 Vent condenser
70
222352 Plant Layout
11.5 Plant Layout of Fourth Floor
Figure 34
Sr No. Denotation Name
1 T10 MCB Measure vessel
2 T11 Pyro Measure vessel
3 T12 Raw water storage tank
71
222352 Reference
References
• “Unit Operations of Chemical Engineering”, McCabe W L, smith J C, Harriott P,

Mc Graw Hill publication, 7th edition 2005.
• R. E. Treybal, mass transfer operations, 3rd edition, Mc Graw hill international.
• Perry’s chemical Engineer’s handbook 9th edition
• Introduction to Process Engineering and Design by S. B. Thakore and B I Bhatt,
Mc Graw Hill, 3rd edition.
• Binay k. Dutta, “Heat Transfer Principles and applications” prentice hall of India.
• Octave Levenspiel, Chemical Reaction Engineering, 3rd edition, wiley-India Pvt.
Ltd.
https://www.atul.co.in/
https://www.safeopedia.com/definition/1052/industrial-safety
https://www.nfpa.org/assets/files/aboutthecodes/704/704_faqs.pdf
72
222352 Learning and Conclusions
Chapter – 12: Learning Outcomes and Conclusion
12.1 Learning Outcomes
➢ Practical Experience
➢ Economical use of Material and Energy
➢ Different types of safety aspects
➢ Material handling and recovery of unreacted reactants
12.2 Conclusion
➢ This internship gives us overall idea about how industry works, how to connect theoretical knowledge to
practical applications. It is very beneficial for us to work in industry in future. We have also learned about how
process runs in industry, how materials handled, maintenance of equipment and different types of safety aspects.
In Nutshell our in-plant training is very productive and useful for gaining practical knowledge.
73
222352
Appendix
Weekly Report 1……………………………………………………………………78

Weekly Report 2……………………………………………………………………82
Weekly Report 3……………………………………………………………………85
Weekly Report 4……………………………………………………………………87
Weekly Report 5……………………………………………………………………90
Weekly Report 6……………………………………………………………………94
Weekly Report 7……………………………………………………………………97
Weekly Report 8……………………………………………………………………102
Weekly Report 9…………………………………………………………………...105
Weekly Report 10…………………………………………………………………108
Weekly Report 11………………………………………………………………….111
Weekly Report 12………………………………………………………………….114
Feedback Form…………………………………………………………………………..118
74
222352
Weekly Report 1:-
75
222352
76
222352
77
222352
78
222352
79
222352
Weekly Report 2:-
80
222352
81
222352
82
222352
Weekly Report 3: -
83
222352
84
222352
Weekly Report 4:-
85
222352
86
222352
87
222352
Weekly Report 5:-
88
222352
89
222352
90
222352
91
222352
Weekly Report 6:-
92
222352
93
222352
94
222352
Weekly Report 7: -
95
222352
96
222352
97
222352
98
222352
99
222352
Weekly Report 8:-
100
222352
101
222352
102
222352
103
222352
Weekly Report 9: -
104
222352
105
222352
106
222352
Weekly Report 10:-
107
222352
108
222352
109
222352
Weekly Report 11: -
110
222352
111
222352
112
222352
Weekly Report 12:-
113
222352
114
222352
115
222352
116
222352
Feedback Form: -
117

Atul

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Atul

Uploaded by

Copyright:

Available Formats

222352

IN PLANT TRAINING AT ATUL LIMITED

PATEL DEEP JAYESH

In partial fulfilment for the award of the degree of

Chemical Engineering Department

V.V.P. Engineering College, Rajkot

Gujarat Technological University, Ahmadabad

Gujarat Technological University V.V.P Engineering College

V.V.P ENGINEERING COLLEGE, RAJKOT

MR. JILESH PANDYA DR. PIYUSH VANZARA

Gujarat Technological University V.V.P Engineering College

Gujarat Technological University V.V.P Engineering College

V.V.P ENGINEERING COLLEGE, RAJKOT

Name of the student Sign of Student

Gujarat Technological University V.V.P Engineering College

We sincerely thank to Dr. Piyush Vanjara [Head, Department of Chemical Engineering

Table No. Content Page No.

2.1 Properties of Dimethyl Sulphate 4

2.2 Properties of Monochloro Benzene 6

2.3 Properties of Sulphur Trioxide 7

2.4 Properties of Sulphuric Acid 8

2.5 Properties of Methanol 9

2.6 Properties of DCDPS 10

2.7 Properties of Trimethyl Boret 11

7.1 Pipelines Identification Colour code 51

11.1 Denotations of fig 11.1 73

11.2 Denotations of fig 11.2 74

11.3 Denotations of fig 11.3 74

11.4 Denotations of fig 11.4 75

11.5 Denotations of fig 11.5 76

Fig No. Content Page No.

1.1 History of company................................................................................................................... 1

1.2 Major Products ......................................................................................................................... 1

1.3 Other Company Details ............................................................................................................ 2

1.4 Social Activities ......................................................................................................................... 2

1.5 Our Plant and our product ...................................................................................................... 3

1.7 Applications of DCDPS ............................................................................................................ 3

2.3 Sulphur Trioxide (SO3) ............................................................................................................ 6

2.4 Sulphuric Acid (70%) ............................................................................................................... 7

2.5 Methanol .................................................................................................................................... 8

Chapter 3: - Process Details ............................................................................................................. 11

3.2 DCDPS Production Process ................................................................................................... 11

3.2.1 Block Diagram of DCDPS Production Process ................................................................ 11

3.2.2 Process Flow Diagram of DCDPS Production Process .................................................... 14

3.3 Methanol Recovery ..................................................................................................................18

4.1.2 Material Balance of Condensation and Cracking Reactor .............................................. 22

4.1.5 Material Balance on Digestor, ANF, Dryer ...................................................................... 25

4.2.1 Energy Balance of Complex Forming Reactor .................................................................25

4.2.4 Energy Balance of Digestor 2 ............................................................................................. 26

4.2.5 Energy Balance of Rotary vacuum Dryer ........................................................................ 27

5.1 Batch Reactor .......................................................................................................................... 28

6.2 Instrument Air: ....................................................................................................................... 44

6.3 Nitrogen ................................................................................................................................... 46

6.6 Oil ............................................................................................................................................. 48

Chapter 7: Piping Systems ............................................................................................................... 50

Chapter 8: Maintenance Work ........................................................................................................ 54

8.2 MSRL reactor: ....................................................................................................................... 54

8.4 Reactor: .................................................................................................................................. 55

Chapter 9: - PUMP & CONTROL VALVE .................................................................................. 56

9.1 Pump: ...................................................................................................................................... 56

9.1.1 Vacuum Pump ...................................................................................................................... 56

9.1.3 Magnetic Pump ..................................................................................................................... 58