A

Internship Report

to be submitted to

INDRASHIL UNIVERSITY
in partial fulfillment for the requirements of the degree of

Bachelor of Technology
in Chemical and Biochemical Engineering By

Vasudiya Himanshu
Enrollment No.
200110102008
Supervisor
Dr. Paritosh Agnihotri

DEPARTMENT OF CHEMICAL AND BIOCHEMICAL ENGINEERING SCHOOLOF

ENGINEERING, INDRASHIL UNIVERSITY At. & Po. RAJPUR, Ta. KADI, Dist:
MEHSANA-382715, GUJARAT, INDIA Academic Year: 2023-24
 DEPARTMENT OF CHEMICAL AND BIOCHEMICAL ENGINEERING SCHOOLOF
ENGINEERING, INDRASHIL UNIVERSITY
At. & Po. RAJPUR, Ta. KADI, Dist: MEHSANA-382715, GUJARAT, INDIA

CERTIFICATE

This is to certify that the internship report entitled “Summer Internship Report 2024”

submitted by Vasudiya Himanshu (200110102008.) in partial fulfillment for the award of the

degree of “Bachelor of Technology in Chemical and Biochemical Engineering” of Indrashil

University-Kadi Gujarat, India is a record of his own work carried out under my supervision and

guidance.

Supervisor

Dr Paritosh Agnihotri

II
III
 DEPARTMENT OF CHEMICAL AND BIOCHEMICAL ENGINEERING SCHOOL OF
ENGINEERING,
INDRASHIL UNIVERSITY
At. & Po. RAJPUR, Ta. KADI, Dist: MEHSANA-382715, GUJARAT, INDIA

INTERNSHIP REPORT APPROVAL CERTIFICATE

This is to certify that the internship report entitled “summer internship 2024” submitted

Vasudiya Himanshu (200110102008) in partial fulfillment for the award of the degree of

“Bachelor of Technology in Chemical and Biochemical Engineering” of Indrashil University-Kadi

Gujarat, is hereby approved.

Members of Committee

1. ……………………………(External Examiner)

2. ……………………………(Internal Examiner)

3. …………………………….(Head of Department)

Date:

Place: School of Engineering, Indrashil University- Kadi, Mehsana

IV
 ACKNOWLEDGEMENTS

I would like to express my deepest gratitude to my internship advisor, professor Dr. Paritosh
Agnihotri, for providing me guidance and support throughout my internship. Thank you to take on
new challenge and for the valuable advice that helped me navigate my internship experience.

I am extremely thank full to my internship supervisor bhusan Shinde sir for giving me the opportunity
to join silox Indian pvt lmt as an intern, thank you for believing in me and entrusting me with
important project and
responsibilities. Under your mentorship I have developed. Under your mentorship. I have developed
both profession and personally.

My sincere thank to the team at silox india pvt lmt for warmly welcoming me and making my time
here so enjoyable. In particular , I would like to recognize my colleagues for patiently training me
and always being available to answer question . I have learned so much from all of you.

V
 DECLARATION

I Vasudiya Himanshu Jagdishbhai, Roll Number-200110102008 declare that, the project

report on (sodium hydrosulphite) and (Product name for phase II) comprises my original
work towards the degree of Bachelor in Chemical Engineering at Indrashil 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.

VI
 PREFACE

Industrial training fill gaps between theoretical knowledge from academics and the practical
knowledge. Practical give chance to learn new thing. In other words Practical experience is one of the
best type of experience that one can remember throughout the life. During semesters we have enough
learning of all chemical engineering aspect so vocational training in industry give good learning chance
and how to approach in corporate world. The man objective of vocational training is to develop
industrial knowledge and prepare self about industrial environment and HR practices in the student. It
increases the skill, ability and attitude of a student and boost confidence.

The main objective of the training report to get details of plant processes, unit operations,
general practice carried by every industry, technical aspects of equipment and instruments used in
chemical industry. So, every technical person have to gain some kind of training in related filed to
enhance knowledge.
 INDEX
DECLARATION……………………………………………………………………..

PREFACE…………………………………………………………………………….

CONTENTS PAGE NO.

1. Introduction.
1.1. History of company 9
1.2. Company profile 10
1.3.
Introduction of product 11
1.4.
Properties of sodium hydrosulphite 12
2. About Training Plant
2.1. List of plant 13
2.2. Product of company. 13
2.3. Application of product in different industries 15
2.4. Raw material 16
2.5. Properties Raw material 16
3. Process Details
3.1. Process details 18
3.2. Block diagram 20
3.3. Process flow diagram 21
3.4. Material balance 23
4. Major Equipments and Instrumentation
4.1. List of equipment 25
4.2. Nutsche filter 25
4.3. Candle filter 26
4.4. Distillation column 27
4.5. Absorption tower 28
4.6. Centrifugal pump 29
4.7. Valve 29
5. Process Utilities
5.1. Fire tube boiler 32
5.2. Smoke cum water tube boiler 33
5.3. Cooling tower 33
5.4. Compressor 34
5.5. Natural gas 34
6. Health, Hazards and Safety
6.1. Introduction 35
6.2. Safety measurements to be taken by industry 35
6.3. Safety equipment. 36
6.4. Helmet indication 37
6.5. NFPA diagram 38
6.6. Fire extinguisher 38
6.7. Compebility chart 39
6.8. Pipe colour coad
7. Plant Location and Layout
7.1. plant location 41
7.2raw material availability and market 41
8. Conclusion 45
9. References 46
8
 CHAPTER 1
INTRODUCTION
1.1 HISTORY OF COMPANY (SIPL)
 Silox India Private Limited is a private incorporated on 29 March, 1996.
 The company traces its origin to the 1960s. When it began, the production of Transparent
Acrylic Sheets as an import substitute, before diversifying into Phosphoric Chemicals and
eventually settling on Zinc, Sulphur and chlorine based chemicals as its core business.
 In 2001, Zinc and Sulphur based chemicals business was transferred into a separate business
unit before entering into a joint venture partnership with Silox, S. A. Belgium for this entity.

1.2 Company Profile

 Silox India Private Limited (SIPL) is a joint venture between Transpek Industry Ltd., India and
Silox S.A., Belgium.
 The joint venture draws its legacy from Transpek Industry Limited, India of the Shroff Group
Companies, with proven capabilities of developing technology to manufacture import
substitutes at the lab scale and translating the same to
commercial levels; and Silox S.A., Belgium, which specializes
in mineral chemistry and global leadership in Zinc, Phosphate
and Sulphur Chemicals.
 Silox India Pvt. Ltd. (SIPL) embodies the synergy between
Indian and International Business cultures that has converged
upon to leverage their complementary strengths in
manufacturing of inorganic chemicals for a wide range of applications.
 This Indo-Belgian joint venture between Transpek Industry Limited, India, and Silox, S.A,
Belgium features contemporary technology, global presence and strong human capital.
 Silox India Private Limited (SIPL) leverages the qualities and strengths of Transpek Group and
Silox Group into a collective vision that incorporates high standards in manufacturing and
distribution, harnessing human capital, ethical business practices, contemporary environment,
health and safety initiatives and commitment towards corporate social responsibility.
 The company has attained a dominant presence in the Indian and Global markets through
continual innovation as well as contemporary technology.
 The company has achieved a definitive edge over competitors and created value for
stakeholders, emerging as the largest producer of Sodium Formaldehyde Sulphoxylate
(SafoliteTM) and Zinc Formaldehyde Sulphoxylate (SafolinTM) in the world.
 It is the only producer in the world with capability to manufacture Sodium Hydrosphere
through dual routes i.e., Zinc route and Sodium Formate route. The company is also equipped
with an integrated zinc chain through which it manufactures products like Zinc Dust, Zinc
Oxide and Zinc Derivates such as Zinc Phosphate, Zinc Carbonate, Zinc Active and Zinc Oxide
HSA.
 Exports to over 65 countries spread across six countries of the world, contributes 35%
to the Annual revenue.

9
 Fig:-2 Products of SIPL

 A company nurtured by the Shroff Group of India, has a rich history in developing import
substitutes at lab scale and then scaling it up to commercial levels. It has rich heritage
spanning across five decades in the manufacture of Inorganic Chemicals.
 The company traces its origin to the 1960s, when it began operations with the production of
Transparent Acrylic Sheets as an import substitute, before diversifying into Phosphoric
Chemicals and eventually settling on Zinc, Sulphur and Chlorine based chemicals as its core
business. In 2001, Zinc and Sulphur based chemicals business was transferred into a separate
Business Unit before entering into a Joint Venture Partnership with Silox.
 Silox India is located at places in Gujrat 1. Atladra 2. Ekalbara 3. Selvas

1.3 INTRODUCTION OF PRODUCT

Name of Product: Sodium Hydrosulphite

 Silox is the largest manufacturer of Sodium Dithionite, commonly known as Sodium
Hydrosulphite (SHS/Hydro) in India. Company has the unique distinction of being the only
company in the world who has the capability to produce it through dual routes i.e. Zinc route
and Sodium Format route in different facilities.
 Sodium Hydrosulphite is used in Vat/Indigo dyeing, reduction clearing of dyed synthetic
fabrics and yarns, cleaning dye -soiled dyeing machines, stripping fabrics before re -dyeing,
as a reductive bleaching agent for recycled pulp, and for bleaching of Kaolin clay.

10
1.4 Properties of Sodium Hydrosulphite

1. Physical state at 20 0C Crystalline powder

2. Colour White
3. Odour Pungent
4. pH of 1.0% solution Approx. 6.0
5. Melting point/range 52 0C (Decomposition)
6. Boiling point Not determined as thermal decomposition
temperature is above 52 0C.
7. Flash point Not applicable.
8. Density 0.90 – 1.2 g/cm3
9. Water solubility 225 g/L at 20 0C, slow decomposition
10. Auto-ignition temperature > 130 0C
(0C)
11. Partition coefficient n- octanol at 20 0C Log Pow: < -4.7
/ water at 20 0C
12. Evaporation rate The product is non-volatile solid.
13. Vapour pressure Not applicable.
14. Relative density at 20 0C 2,500 g/cm3

11
 CHEPTER 2

ABOUT PLANT

2.1 LIST OF PLANT :

There are five plant in the company:

1. Sodium Hydrosulphite (SHS) plant
2. Sulfur oxide plant
3. Old plant
4. Zinc oxide
5. Zinc derivative plant

2.2 PRODUCT OF COMPANY:

Sodium Hydrosulphite :
Silox is the largest manufacturer of Sodium Dithionite, commonly
known as Sodium Hydrosulphite (SHS/Hydros) in India.
Company has the unique distinction of being the only company in
the world who has the capability to produce it through dual routes
i.e. Zinc route and Sodium Format route in different facilities.
Sodium Hydrosulphite is used in Vat/Indigo dyeing, reduction
clearing of dyed synthetic fabrics and yarns, cleaning dye -soiled
dyeing machines, stripping fabrics before re -dyeing, as a
reductive bleaching agent for recycled pulp, and for bleaching of
Kaolin clay.

Fig:2.1 Sodium Hydrosulphite (Image source google)

 Sodium Formaldehyde Sulphoxylate

Silox is currently the largest manufacturer of Sodium Formaldehyde

Sulphoxylate (SAFOLITETM) in the world. SAFOLITE is the Sodium
salt of Hydroxymethanesulphinic Acid. The key uses of this product are,
as a discharge agent in textile printing, as redox catalyst in
polymerisation process for manufacturing polymer/synthetic rubber
such as ABS, SBR, NBR, and as an antioxidant in drug formulations.

Fig : 2.2Sodium Formaldehyde Sulphoxylate (Image source google)

12
  Zinc Phosphate

Silox’s Zinc Phosphate, manufactured from high purity Zinc Salts, offers a
unique advantage of enhanced corrosion production in Zinc rich paint &
anticorrosive paint primer systems

Fig: 2.3 zinc phosphate(Image source google)

 Zinc Formaldehyde Sulphoxylate

Silox is currently the largest manufacturer of Zinc Formaldehyde
Sulphoxylate (SAFOLIN), which is the Zinc Salt of
Hydroxymethanesulphinic Acid, in the world. The key uses of this product
are, as a discharge agent in textile printing and also as redox catalyst in the
manufacturing of polymers for adhesives.

Fig:2.4 zinc formaldehyde Sulphoxylate (Image source google)

 Zinc Oxide
Silox is the single largest manufacturer of Zinc Oxide in India and follows
Continuous Wet Process as the route of manufacturing. In this process, high-
purity Zinc ingots are converted into a complex Zinc Salt which is then calcined
to make Zinc Oxide that is very low on impurity profile, and hence high on
environment friendliness. This unique manufacturing process renders our Zinc
Oxide with 100 % nodular (spherical particles) when compared to acicular
(needle shaped) particles of typical French and American processes, and hence
facilitates faster reaction of fatty acid in rubber application. The company also
holds IP certificate for sales of Zinc Oxide in Pharmaceuticals as well as
Cosmetics industries.

Fig:2.5 zinc oxide (Image source google)

 Zinc Carbonate
Silox manufactures Zinc Carbonate, which is used as a Sulphur absorber in the
petroleum industry, and as a transparent activator in the rubber industry. Zinc
Carbonate also has applications in beauty care & cosmetics/pharmaceutical
products.

Fig: 2.6 zinc carbonate (Image source google)

13
 Zinc Oxide Active
Silox is the leading manufacturer of ‘Active’ grade Zinc Oxide for rubber
applications in India. Active Zinc Oxide that has high surface areas and very low
impurity profile, facilitates reduction in dosage up to 40% when compared to
normal French process Zinc Oxide. Hence, it provides twin benefits of
minimizing the cost of rubber compound, as well as improving the quality, and
environment friendliness of the product.

Fig :2.7 zinc oxide active (Image source google)

 Zinc dust

Silox is the largest manufacturer of Zinc Dust in India. The key use of this
product is as an anti-corrosive agent in a wide range of protective coatings
such as industrial, marine and yacht coatings. It is also a starting material for
many chemical reactions and an intermediate for drug manufacturing
processes in the pharmaceutical industry.

Fig: 2.8 Zinc dust (Image source google)

2.3 APPLICATIONS OF PRODUCTS IN DIFFERENT INDUSTRY

 Textile Industry
The textile industry
is a major consumer
of their product,
which is used For
Dyeing of Vat and
Indigo dyes
Reduction clearing
of Synthetic fabric for stripping of dyes. Dyeing and
printing are the key application stages.

 Pharmaceuticals Industry
Silox supplies reducing agents, stabilizers, and antioxidants for a
wide range of drug formulations. It is used as a reducing agent in pharmaceutical industries.
 Paper & Pulp
Silox offers reducing agent , such as Sodium hydrosulfite
and stabilized bends. Sodium Hydrosulphite is used in
Pulp and Paper industries as de-inking of recycled pulp &
paper.

14
 (Image source google)

2.4 Raw material

 EDTA
 SMBS (wet)
 SMBS (dry)
 Sodium Formate
 Etylene Oxide
 Methanol (MeOH)
 Soda Ash
 MS (MeOH + SO2)

2.5 Properties of raw material

1) Ethylenediaminetetraacetic
acid

Chemical formula C10H16N2O8

Molar mass 292.244 g·mol−1

Appearance Colorless crystals

Density 0.860 g cm−3 (at 20 °C)

2) sodium metabisulfite

Chemical formula Na2S2O5

Molar mass 190.107 g/mol
Appearance White to yellow powder
Oder Faint SO2

Density 1.48 g/cm3

Boiling point Decomposes
Melting point
170°C

Solubility in water • 45.1 g/100 mL (0 °C)

• 65.3 g/100 mL (20 °C)
• 81.7 g 100 mL (100 °C

solubility Very soluble in glysrol

Slightly soluble in ethanol

15
3) sodium format

Chemical formula HCOONa

Molar mass 68.007 g/mol
Appearance White granules
Density 1.92 g/cm3 (20 °C)
Boiling point 253
Melting point decomposes

Solubility in water 43.82 g/100 mL (0 °C)

97.2 g/100 mL (20 °C)
160 g/100 mL (100 °C)
Solubility insoluble in ether
soluble in glysrol , alcohol, formic acid

4) Ethylene Oxide

Chemical formula C2H4O

Molar mass 44.052 g·mol−12

Appearance Colorless gas

Density 0.8821g*cm32
Boiling point 10.4 °C
Melting point −112.46 °C

Oder Like diethyl ether

5) Methanol

Chemical formula CH3OH

Molar mass 32.04 [Link]-1
Appearance Colour less liquid
Density 0.792 g/cm
Boiling point 64.7 °C

Melting point −97.6 °C

Oder Sweet and pungent

16
 CHAPTER 3

PROCESS DETAILS

Manufacturing process of sodium Hydrosulphite

Raw Material

 Caustic Soda Lye

 EDTA
 Etylene Oxide
 SMBS (wet)
 SMBS (dry)
 Methanol (MeOH)
 Sodium Formate
 Soda Ash
 MS (MeOH + SO2)

 Chemical Reaction :-

2HCOOHNa + 2SO2 + 2H2O 2HCOOH + 2NaHSO3

2NaHSO3 + HCOOH Na2S2O4 + CO2 + 2H2O

Na2S2O5 + HCOOH Na2S2O4 + CO2 + H2O

 Overall Reaction :-
2HCOOHNa + Na2S2O5 + 2SO2 2Na2S2O4 + 2CO2 + H2O

 Abbreviations :-
 ML – Mother liquor
 SMBS – Sodium Meta BiSulphite
 SF – Sodium Formate
 EO – Ethylene Oxide
 [Link] –Bisulphite
 CO2 – Carbon Dioxide
 LPH – Litre Per Hour
 KL –Kilo Litre
 GPL – Gram Per Litre
 MT – Metric Tonne

17
3.1 Process Descriptions

 Distillation column

(prepared in visual paradigm software)

We use pure methanol in the production of sodium Hydrosulphite. This pure methanol produce from
crude methanol by distillation Process. Distillation column was made of stainless-steel material. 42
plates are fitted in this distillation column. There are fitted thermocouple on the different number
of plates to measure temperature of feed. Feed inlet provide at middle of the distillation Column.
Top side of column distillate outlet Provided. Residual/ bottom product discharge at the bottom
side.
Filtered methanol by the candle filter was feed in the distillation Column. Feed was fed at the 22,
24 and 26 number of plates. Heat continuously provided by steam in the jacketed area. Crude
methanol was starting to convert in vapour foam at after the plate number 28 to 38. Pure methanol
in vapour foam we get at the plate number 41 and 42. Maintain the pressure at the top side of the
column. Maintained pressure around 0 ATM to 1 ATM. So, minimum load on the column and no
any back pressure issue. The temperature of column at the top side is 65 to because boiling point of
methanol is 64.5 ˚c.67 to 70 ˚c temperature required to convert methanol in vapour phase at the
middle of the column. Lower temperature of column is 103 to 106 ˚c. 67 ˚c. Bottom temperature of
column is 110 to 113 ˚c. This all the temperature are approx. by given DCS.

18
Produced Distillate methanol we use in the production of sodium Hydrosulphite
(SHS)
3.2 Block Diagram

(prepared in visual paradigm software)

19
3.3 Process Flow Diagram

 R1 Reactor
R1 reactor is the semi batch reactor. In the plant R1 A, B and C are placed in the plant for the
production of sodium hydrosulfide. Ensure the cooling water, chilled water, & brine supply on
in respective condenser. Take MS solution in the R1 reactor from the V-1103. Start the agitation
and apply co2 pressure and start the Ethelyn oxide flow in the R1 reactor. Flow of Ethelyn oxide
is 20 lit/hr. start steam in the jacketed reactor. Take sample from R1 reactor and Note Down thio
gpl. And PH at initial stage. Adjust EO charging rate as per thio gpl. If thio content is high then
increase EO rate. Start heating and maintain temperature up to 70-75˚c . check thio gpl. It should
be less than 6 and chack PH. After that start SMBS + MS flow in the R1 reactor from the V-
1104 And also start the flow of sodium Formate + ML in the reactor from the V-1106. Achieve
the fast reaction and maintain the 83-86 ˚c. every 10 min chack thio and PH. Then Achieve 5
PH and above maintain slow reaction. After that flow rate of MS solution 500-1000 lit\hr. and
maintain PH 4.75 to 4.85. then stop the flow of MS solution and increase the flow of EO 20 to
40 lit. continue the starring around 20 -30 min. after that getting 5 gpl thio take sample of batch
and chack in laboratory.
Prepared R1 batch transfer in hydro dryer, hydro dryer is a one of Rota cone Vacuum dryer.

20
 Dryer

 Rota cone vacuum Dryer used of production of sodium Hydrosulphite.

1. Rotary vacuum paddle drier 6. Receiver for solvent

2. Driver unit 7. Vacuum pump
3. Charging door 8. Discharge outlet
4. Dust catcher 9. Rotary joint
5. Condenser

Firstly close all the outlets of dryer. Start batch transfer from R1 reactor to dryer. After that take 2
to 2.5 kg/cm2 pressure of co2 and chack the specific gravity of ML. give the methanol wash around
3000 liter and chack specific gravity and note down. second time give methanol wash around 5000
liter and chack specific gravity and note down. Washed methanol go to another tank of crude
methanol. if required give third time methanol wash and specific gravity must be below 0.800. start
steam in the jacketed dryer and rising temperature around 78˚c slowly. Wait the temperature
increase around 85 ˚c, if temperature was not increase than start steam flow. After that start rotating
moment of dryer for 20 minute. And chack free flow of powder. If the powder does not flow freely,
continue the rotation of the dryer till that powder flow freely. Provide cooling for dryer and
maintain tempurature 70 ˚c than charging soda ash in the dryer according to instruction of
supervisor. when temputarure belove the 60 take the sample of product and go to the laboratoty for
chacking.

21
3.4 Material Balance
Chemical Reaction:

2HCOONa + 2SO2 + 2H2O 2HCOOH + 2NaHSO3

2NaHSO3 + HCOOH Na2S2O4 + CO2 + 2H2O
Na2S2O5 + HCOOH Na2S2O4 + CO2 + H2O

Overall Reaction:
2HCOONa + Na2S2O5 + 2SO2 2Na2S2O4 + 2CO2 + H2O

Material balance based on sodium format (HCOONa)

For reaction (1)
INPUT:
 moles of HCOONa Feed:- 1000/68=14.70 Kmol
 moles of SO2 Consumed= 14.70*64 = 940.8 Kg
 moles of H2o Consumed=14.70*18=264.6Kg OUTPUT:
 mole of HCOOH Produced = 14.70*46=676.2Kg
 moles of NaHSO3 Produced=14.70*104=1528.8Kg
For reaction (2)
INPUT
 moles of NaHSO3 Consumed=14.70*104=1528.8Kg
 moles of HCOOH Consumed= 676.2/2=338.1Kg
OUTPUT
 mole of Na2S2O4 produced=(14.7/2)*174=1278.9Kg
 mole of CO2 Produced= (14.70/2)*44=323.4Kg
 mole of H2O Produced=14.70*18=264.6Kg
For reaction (3)
INPUT
 moles of SMBS Consumed=(14.70/2)*190=1396.8Kg
 moles of HCOOH Consumed=676.2/2=338.1Kg
OUTPUT

 moles of Na2S2O4 Produced=(14.70/2)*174=1278.9Kg

 moles of CO2 Produced=(14.70/2)*44=323.4Kg
 moles of H2O Produced=(14.70/2)*18=132.3Kg

22
OVERALL REACTION:
INPUT
 moles of HCOONa Feed:- 1000/68=14.70 Kmol OR(1000Kg)
 moles of SMBS Consumed=(14.70/2)*190=1396.8Kg
 moles of SO2 Consumed= 14.70*64 = 940.8 Kg
=1000+1396.8+940.8
=3337.3Kg

OUTPUT
 moles of Na2S2O4 Produced=(14.70/2)*174=1278.9Kg
 moles of CO2 Produced=(14.70/2)*44=323.4Kg
 moles of H2O Produced=(14.70/2)*18=132.3Kg
=2(1278.9)+2(323.4)+132.3
=3336.9Kg
SO; INPUT=OUTPUT

23
CHAPTER 4 MAJOR EQUIPMENTS AND INSTUMENTATION

4.1 list of major equipment:

There are major equipment are:

1. Nutsche Filter
2. Candle Filter
3. Distillation column
4. Absorption tower
5. Dryer
6. Boiler: 1) smoke cum water tube boiler
2) water tube boiler

4.2 Nutsche Filter:

Construction:
Nutsche filter is a closed vessel that uses filtration under vessel.
The closed system maintains product quality & hygiene by providing odourless contamination
free & non- pollution working condition

Working:
Feed is passed through the filter. In this filter the filter plate (filter cloth) is fitted.
So, when feed is passed through cloth, moisture of solid particles is on the filter cloth & rest is our
filter. But micro- particle can’t be removed by this filter. In this filter pressure is used filtration. In
our plant crude methanol is passed through the same filter & on cloth most of sodium sulphate
solid particles are filtrated.

24
4.3 Candle Filter:
Construction & working:
Candle filter basically consist of on upper & lower container one or more candle in between a tap
and lid. Tap means water and liquid means removable sheet like construction.
Have a dia. About 30 by 25 cm depth for a treatment capacity of about 8 liter & flow 1-2 lit per
hour candle. It is used for removing micro particle in crude methanol in our plant. Flow is passed
through filter & from the cake on the surface of cloth. Which can be removed by back flash but in
batch process or if we can take break in work by clearing the cake by washing filter.

25
4.4 Distillation Column:
Construction: -
Distillation column was made of stainless-steel material. 42 plates are fitted in this distillation
column. There are fitted thermocouple on the different number of plates to measure temperature.
Feed inlet provide at middle of the distillation column. Top side of column distillate outlet provided.
Residual/ bottom product discharge at the bottom side.

Distillati
on Cooling condenser
column

Chilling condenser

Reboil
er
Bri
m
solu
tion
Reflu
x
tank

Pure CH3OH

Working: -
Filtered methanol by the candle filter was feed in the distillation column. Feed was fed at the 22,
24 and 26 number of plates. Heat continuously provided by steam in the jacketed area. Crude
methanol was starting to convert in vapour foam at after the plate number 28 to 38. Pure methanol
in vapour foam we get at the plate number 41 and 42. Maintain the pressure at the top side of the
column.
Maintained pressure around 0 ATM to 1 ATM. So, minimum load on the column and no any back
pressure issue. The temperature of column at the top side is 65 to 67˚c. Because boiling point of
methanol is 64.5 ˚c. 67 to 70 ˚c temperature required to convert methanol in vapour phase at the
middle of the column. Lower temperature of column is 103 to 106 ˚c. Bottom temperature of column
is 110 to 113 ˚c. This all the temperature are approx. by given DCS.

26
4.5 Absorption Tower SO2 CH3OH

SO2 CH3OH

A B C D
Construction:
Absorption tower are most frequently used for gas absorption (and are used to a limited extent for
distillation) wherein the liquid is dispersed in the form of film and the gas flows as a continuous
phase. These are continuous contact equipment generally operated in a counter current fashion.
A packed column consists of a vertical cylindrical shell constructed out of metal (stainless steel)
and filled with suitable packings which offer a large interfacial area for gas liquid contact for mass
transfer between the phases.
Working:
Start the brine supply in absorption tower. start CH3OH in absorption tower in the D tower from V
2404. Start circulation of D tower and start transferring to C tower. Start circulation of C tower and
start transferring to B tower. Start circulation of B tower and start transferring to A tower. Initially
maintain the level of all tower 25 -50% as per requirement. Keep tower temperature in -5 to -15˚c.
Start so2 flow slowly in tower, when temperature of tower reaches in -8 to -20 ˚c. Increase the flow
rate so2 of of in A tower and increase the CH3OH flow in D tower. so2 flow will move from A tower
to D tower and CH3OH flow will move from D tower to A tower. Maintain so2 and CH3OH flow
in such a way that A tower [Link] 1.000 to 1.040 and collect MS solution in 2411 A\B. If [Link]
increase of A tower, increase CH3OH flow or decrese SO2 flow. If [Link] decrees of A tower decrees,
CH3OH flow or increase SO2 flow.
4.6 Centrifugal pump:
A pump which lifts a liquid from a lower level to higher level the action of centrifugal force is call
as centrifugal pump. It is very widely used in the chemical and petroleum industries because of its
many advantages such as simplicity of design, low initial cost, low maintenance and flexibility of
operation. The centrifugal pump can handle liquid of wide range of properties. It is equally suitable
for handling suspensions with high solid content. It may be construct from a wide rang of corrosion
resistant material it may be directly coupled to an electric motor as it operates at high speed.

27
 In centrifugal pump, power from an outside source
is applied to the shaft, the impeller than rotates
within the stationary casing. The impeller bleads
in revolving produce a reduction in pressure at the
eye of impeller.
Dur to this, liquid flows into the impeller from the
suction pipe. The liquid is thrown outward by the
centrifugal action along the blades. As a result of
high speed of rotation, the liquid acquires high
kinetic energy. The kinetic energy acquired is then
converted into the pressure energy when it leaves
the blade tips and liquid passes into the volute
chamber and finally it is discharge through the
outlet on the pump. This action of the centrifugal
pump is shown in fig.

4.7 Valve:

A valve is a device used either to control the flow rate or to stop the flow of a fluid through pipelines
and to and from process equipment.
1) Gate valve:
A gate valve is the most common valve for water supply
systems. It represents a linear-motion isolation valve and
has a function to stop or allow the flow. Gate valves got their
name from the closure element sliding into the flow stream
to provide shutoff and, therefore, acting like a gate.

2) Globe valve:
Globe valves are used primarily in
situations where
throttling
commodity is o th
required. By
simply rotating the
handwheel, the
rate at which the
commodity flows
through the valve
can be adjusted to
any desired level.
Having the valve
seat parallel to the
line of flow is an
important feature
of the globe valve.

3) Butterfly valve:
28
 The butterfly valve gets its name
from how the movement is similar
to a wing for flight. The rod is
analogous to a butterfly's body, while
the disc moves like a butterfly wing.
A butterfly valve's motion is similar
to that of a butterfly that has landed
with the wings moved up and down
with a 90-degree motion.
Butterfly valve is use in large
size pipeline and operate on the
same principal as a damper in a
stove pipe.

4) Diaphragm valve:
the main purpose of a diaphragm valve is to control the flow of liquids and gases. Diaphragm
valves have a rubber diaphragm that moves up and down within the body of the valve, causing
opening and closing against a hard seat.

5) Ball valve :

A ball valve is a shut-off valve that allows controls the flow of liquids, gases, and vapors in a
piping system by rotating the ball having a bore inside the valve. The ball is mounted against
two seats and has a shaft that connects it to the operating and control mechanism that rotates
the ball.

29
 CHAPTER 5
UTILITIES
Typical process utilities include electricity, process steam, refrigerants, compressed air and municipal
water etc. Unlike other expenses, utility costs do not correlate with conventional price indexes. Some
utilities discussed in SHS SF. Section of SIPL are:

5.1 Fire Tube Boiler

 A fire-tube boiler is a boiler in which fire tubes are immersed in water, and the hot flue gases
produced by the combustion chamber flowinside the fire tubes. The hot flue gases transfer
their heat to the outside water through the conduction process. When heat transfers to the
water, it converts into steam.

Working Pressure: - 6.5 kg/cm2

Steam Production: - 8 ton/hr
Fuel: - Furnace Oil (FO)
Area of Furnace: - 83m2
Furnace Oil Temperature: 110 – 120 °C
FO Inlet Pressure: - 17 kg/cm2
FO Outlet Pressure: - 10 kg/cm2
Feed Water Pressure: - 9 kg/cm2

Fig.6.1Fire Tube Boiler

Construction water space in the middle portion 37 removed. Height, Manhole and hand holes are
provided for cleaning the interior of the boiler shell and cross [Link] boiler consists of a pressure
gauge, water level indicator, safety valve, steam stop valve, and a manhole as mountings to provide
safety and ease of working.
Working
Fuel burns on the grate in the firebox. The resulting hot flue gases are allowed to pass around the cross
tubes. The water surrounding the cylindrical firebox also receives heat by convection and radiation.
30
Thus steam is produced. The water circulation in the boiler depends on the density difference in water,
created by the temperature difference in water. Economizers are thermal mechanical apparatuses that
scavenge the waste heat from thermal exhaust flue gases by passing the exhaust effluent through heat
transfer surfaces to transfer some of the waste heat to a process media. In the boiler room most,
economizers transfer their waste heat to either the feedwater or combustion air preheaters. A Feedwater
Economizer is one of the most economic additions that can be made to any boiler room.
The economizer’s simple technology and lack of moving parts gives it a very long and relative
maintenance free life cycle. The preheating of boiler feedwater is the most common method of utilizing
the waste heat captured from boiler flue gases. As the feedwater flow, the boiler load, and the flue gases
generated are all 38 in proportion, there is a ready ‘heat sink’ in the feedwater to absorb the recovered
heat from the flue gases. It must be noted that economizers are used with modulating feedwater
strategies to prevent overheating and sudden flashing, which would occur with on/off feedwater
applications.

5.2 smoke cum water tube boiler:

Construction
In somke cum water tube boiler 3 pass boiler are present
Maximum pressure capacity of boiler 10.50 kg/cm2
Bed temperature of the boiler is 861˚c.(950 ˚c)
In this boiler fuel gas temperature is 203 ˚c (260 ˚c)
Stuck temperature of chimney is 130.5 ˚c(130 ˚c) Maximum
pressure couantaing capacity of boiler is 7.2 kg/cm2
Inlet water temperature is around 70 ˚c.
Outlet temperature of water around 75 ˚c.
7 tonn steam produced in one hr.
During the whole day we produce 160tonn steam in the boiler.
Fig. 6.2 smoke cum water tube boiler:
Working
First of all coal crused in crusher.
Give sprey of diseal and spark to spark to the burn In the furnace we provide spark to the coal and
start burning.
After that it will burn into the furnace.
Water feed in drum after that some level it will send in tubes.
Heat transfer will be occur between fuel gas and water.
After that water will sent to the boiler shell.
Fuel gas will sent in the steam drum and after that boiler.
Hot steam collected from top of the boiler.
In furnace water is in tubes and in boiler water in shell.
In farnace fuel gases in shell and in boiler fuel gas is in tubes.

5.3 Cooling tower :

31
A cooling tower is a specialized heat
exchanger in which air and water are
brought in to direct contact with each
other in order to reduce the water’s
[Link] this occurs, a small
volume of water is evaporated, reducing
the temperature of the water being
circulated through the [Link],
which has been heated by an industrial
process or in an air-conditioning
condenser, is pumped to the cooling
tower through pipes.
Fig.6.3 cooling tower

The water sprays through nozzles into which slows the flow of water through the cooling tower,
and exposes as much water surface area as possible for maximum air-water contact.
As the water flows through the cooling tower, it is exposed to air, which is being pulled through the
tower by the electric motor-driven fan.

When the water and air meet, a small amount of water is evaporated, creating a cooling action. The
cooled water is then pumped back to the condenser or process equipment where it absorbs heat. It will
then be pumped back to the cooling tower to be cooled once again.

5.4 COMPRESSED AIR

Compressed Air is an essential part of the SHS SF plant, supplied from a
compressor room consisting of five compressors. The pressure is
regularly maintained, and instrumental checks take place every year.

Fig.6.4 Compressed Air

5.5 NATURAL GAS
Natural Gas is supplied by Gas Authority of India Limited, more commonly known as GAIL. It is
distributed with the help of a pipeline network, having safety valves to maintain pressure, assuring
safe and uninterrupted supply. The gas pipeline emerges near the air pipeline [Link] source is
distant from the plant, thereby reducing any hazard. It is used to maintain air/gas ratio before entering
the kiln, for efficient burning and heat production required by the calcination process. The ratio is
maintained by a regulator provided by Wesman Combustion Equipment.

32
 CHAPTER 6 HEALTH, HAZARDS AND SAFETY

6.1 Introduction
Safety is the state of being “safe”, the condition of being protected against physical, social, spiritual,
financial, political, emotional, occupational, psychological, educational or other types or consequences
of failure, damage, error, accidents, harm or any other event which could be considered non-desirable.
This can take the form of being protected from the event or from exposure to something that causes
health or economical losses. It can include protection of people or of possessions.

Accidents are analyses and developed a separate engineering branch of safety and this analysis was
required due to:
 Rising trend of accidents.
 Increased use of machinery.
 Increased material handling.
 Lack of safety standard.
 Lack of training.
 Better reporting of accidents.

No industry can afford to neglect the fundamentals of safety in design and operation of its plant and
machinery. It is important that all the people responsible for management and operation of any industry
should have a good knowledge of industrial safety.

6.2 Safety Measures to Be Taken by Industry

Following safety measures are taken by industry.

 Emergency number is 102(it is only one way dial plant to securityoffice)
 Emergence sirens placed in industry at the 5 place (15-5-15 second)
 In case accident time firstly completed wind up work than run according to guidance.
 Wind direction proived at 5 place in the plant.
 At right of the angle at thr the wind direction should be go and reach at nearst assembly point
in the accident time.
 Testing of fire safety alarm on 11Am of Friday in every week.  In case chemical fall on the
hand that time wash your hand under the water around 15 min.

 Process is inherently safer.

 Unauthorized person is strictly prohibited in plant.
 Complete area of plant is under strict observation of CCTV cameras.
 Smoking, Mobile, Food and Beverages are strictly banned in plant.
 Proper record of shift work and employees responsible for the same is maintained.
 Personal protection equipment is necessary for each employee.
 Complete plant area is assessable with firefighting network.
33
  Hot and cold works are only carried with permission of safety officers.

6.3 Safety Equipment

6.3.1 Respiratory Protective Device

(a) Breathing Apparatus - used while handling gas leakages.

(b) Canister Mask - used while cleaning vessels or reactor inner wall.

(c) Air Mask - used while doing internal cleaning of vessel.

(d) Dusk Mask - used where there is much exposure of dust.

6.3.2 Non-Respiratory Protective Device

 Eye Protection - Safety goggles, Chipper goggles, Gas tight goggles, are used.
 Head Protection – Helmet
 Face Shield - used during welding.
 Hand Protection – Gloves
 Foot Protection - Safety Shoes
 Body Protection - Apron, PVC Suit
 Hearing Protection - Ear Plug/Ear Muff
 Fire Fighting Equipment  Safety Belts and Harness

6.3.3 Head Protection

Head protectors are hard hats, caps, helmets made of aluminum, PVC, fiberglass, laminated plastic or
vulcanized rubber. They may be fitted with breakers for fixing marks, protective faces screen or lamp.
The hats and caps are provided with replaceable harness, which provides sufficient clearance between
the top of the head and shell. Soft caps and hoods are also used for protection against heat, sparks, and
other dangerous material and are made up of appropriate materials.

6.3.4 Eye and Face Protection

Eye injuries can be caused by dust, flying particle, splashes and harmful radiations. Eye protectors are
safety spectacles, mono goggles, impact goggles, wilding goggles, foundry goggles, chemical
goggles, and gas tight goggles, face shield, etc.

6.3.5 Ear Protection

Noise level above 90 DBA is hazards if human body is expose to it for more than 8 hrs./day or 48
hrs./week. It may cause deafness, loss of efficiency, irritation, and also loss of hearing, noise level can
measure by a Noise Average Meter or a Noise Dose Meter, Earplug or Earmuff reduce to at 25 to 49
34
DBA ear plug is made of plastic, rubber of polyurethane foam. Ear Muff covers external ear and
provides better attenuation than earplug.
6.3.6 Body Protection and Foot Protection

Body Protectors are coats, aprons, overall jackets and complete head to toe protective suits. Nature of
potential hazard, degree of hazard involved and nature of activities of the earner are important in the
selection of safety clothing. Although complete of the body and legs are not needed in many cases,
unnecessary safety clothing may hamper the efficiency of the wearer.

Rubber boots protects against chemical splashes, aromatic liquids or solvents and heavy weight.

No. Protection Type of safety appliance

1 head Safety helmet
2 eye Safety goggles, welder’s goggles
3 face Face shield, acid and alkali proof hood
4 ear Ear plug, car muff

5 Hand & finger Canvas hand gloves, canvas leather hand gloves Asbestos hand
gloves, rubber, PVC, surgical hand gloves
6 body Cotton aprons and cotton boiler suit, PVC aprons Pressurized neck to
toe overall, PVC neck to toe overall asbestos suit
7 Foot & leg Safety shoes, gum boots

Table 6.1 list of personal protective equipment

6.4 Helmet Indication

4 types of helmets indicate by their colour:

White colour: this type of colour helmet provide for MD, senior officer, Plant manager and permeant
Workers.
Yellow Colour: this type of colour helmet provide for visitors.
Green Colour: this type of colour helmet provide for contract base workers and labors.
Rad colour: this type of colour helmet provides for fireman and ambulance drivers.

35
 6.5 NFPA Diagram:
The four divisions are typically color-coded
with red on top indicating flammable, blue on
the left indicating level of health hazard, yellow
on the right for chemical reactivity, and white
containing codes for special hazards.

6.6 Fire Extinguisher

Class fire Type of fuel

A Ordinary combustible Wood, paper, cloth etc..

B Flammable liquids Grease, oil, paint etc…
C Live electrical equipment Electrical panel, motor etc.
D Combustible metal Magnesium, aluminum

6.7 Pipe colour Coad:

CONTENT GROUND FIRST SECOND STANDERD

BEND COLOUR COLOUR
BEND BEND
Cooling water Green Dark blue IS2379
Chilling water Green Black Yellow
Condensed steam Green Brown
water
Boiler feed water Green Red
Drinking water Green Dark blue Dark red
Soft water Green Brown Red
Raw water Green
So2 gas line Green Violet ISTL
Air Blue
Compressed air Blue Red
Ethylene oxide Yellow Violet
Ammonia Yellow Violet

36
Nitrogen Yellow Black
Stored co2 Yellow
Natural gas Yellow Red

6.8 COMPABILITY CHART

E. Ch3 etha Formald H2 S H H3 P For ole Hydro Amm Cau So

O oh nol ehyde O4 CL O4 mic um gen onia stic da
acid peroxi soda as
de h
E.O 
CH3OH      
Ethanol      
Formald   
ehyde
H2SO4     
HCL    
H3PO4     
F.A   
Oleum   
Hydroge 
n
peroxide
NH3   
Caustic    
soda
Soda ash    

Sodium    
Salphate
Salpher          
SHS      
Sodium      
format
Smbs      
ZnO       

37
 CHAPTER 7 PLANT LAYOUT AND LOCATION

7.1 Plant location:

Plant location is however one of the most important part of final planning. Selection of suitable location
of the plant is very important because success of the plant is based on this point. The geographical
location of the final plant can have a strong influence on the success of an industrial venture. Much
care must be exercised in choosing the plant site, and many different factors must be considered.
Primarily, the plant should be located where the minimum cost of production and distribution can be
obtained, but other factors, such as room for expansion and general living conditions, are also
important.
An approximate idea as to the plant location should be obtained before a design project reaches
the detailed-estimate stage, and a firm location should be established upon completion of the
detailed- estimate design. The choice of the final site should first be based on a complete survey
of the advantages and disadvantages of various geographical area and, ultimately, on the
advantages and disadvantages of available real estate.
7.2 Raw material availability:
 One of the raw material sodium metabisulphite is produced in plant itself as well as import from
outside, while sodium format and ethylene oxide is purchased from outside company.
Location and market area:
 Plant is located just 50Km Nandesari which is the one of the major hub of small and big chemical
industries. As the product is used in many industries for further manufacturing of other textile
industry pharmaceuticals and paper-pulp industry etc. it is easily sold to respective industry.
Energy availability:
 As the company is located in the developed industrial zone, problems regarding power cuts are not
occur. Constant supply of electricity is being facilitated by M.G.V.C.L..So, for issue like power
cuts, diesel generator is kept at immediate stand-by.
Climate:
 Climate remains steady with some minor variation throughout the year and the place selected for
this plant has the least chance of natural calamity.

 Transportation:

 Best connectivity of plant via road to dispatch product and other raw materials is available.

Water supply:
 Uninterrupted availability of sufficient water from bore well is obtained.

38
 Waste disposal:

 ETP plant is in-cooperated in plant premises. Plant is also nearer to Effluent canal so, for disposal of waste
water canal system is available
Labour and supply:
 As compony is located in rural area which is not highly developed. But as a result, availability of
labour is high. Moreover, company is tied up with organization which provides skilled and unskilled
labour.
Taxation and legal Restriction:
 Gujarat state claims high tax as compared to other states. Regulations on zoning, building codes,
nuisance aspects and other facilities have a major influence on final choice of the plant site.

(Block diagram prepared in visual paradigram) ,It is a block diagram of ETP plant of silox india alpha site

39
No. Capasity
1. HDS feed sump 36kl
2. Hdro Hydrolysis tank 48kl
3. Hydrolysis tank 48kl
4. Ic tower feed tank 64kl
5. Gas buffer tank 1kl
6. Ic tower 140kl
7. HDS tower 30kl
8. HDS oxidation tank 10kl
9. Filter press 2m3/hr.
10. Ventury tube
11. Vent gas condenser
12. Vent tank buffer vessel 15kl
13. Air blower 430 m3/hr.
14. Air blower 430 m3/hr.
15. PAC Solution tank 1kl
16. PAM solution tank 1kl
17. Vent gas purifer 0-2700m3/hr.

40
 NO. DESCRIPTION [Link]
1 SHS PLANT 900.00
2 PENNAL ROOM 152.65
3 PENNAL ROOM -NaF [Link] 60.00
4 N2 UNIT 180.00
5 [Link] WATER [Link] & SOFTENER UNIT 48.00
6 PANIC PIT 42.65
7 CAUSTIC STORAGE YARD 48.00
8 UNDER GROUND METHANOL STORAGE 615.00
9 NaF/ SHS GODOWN 1345.00
10 FILTER PRESS & [Link] AREA 665.00
11 [Link] CABIN 238.00
11A CANEEN 25A
12 COOLING TOWER 5.00
13 TOILET BLOCK 60.00
14 G.O.D.(TANSFOMER)
15 GENRAL STORE 320.00
16 FILTER CUM DRYER ROOM 100.00
17A/B FILTER CUM DRYER ROOM 200.00
18 FIRE WATER STORAGE TANK 116.44
19 SHS SF PACKING 440.00
20 ETP AREA 1206.00
21 NaF RECOVERY PLANT 714.00
22 SOLVENT RECOVERY SYSTEM & UTILITY UNIT 2056.95
22A COOLING TOWER 2056.95
22B UTILITY& M.C.C. ROOM 2056.95
22C KC- 93 COMPRESSOR 105.00
23 SO2 PLANT 252.00
23A SULPHER STORAGE 252.00
23B COMPRESSOR ROOM 144.00
24 BOILER HOUSE 84.00
24A BOILER HOUSE (AGRO WASTE) 204.00
25 CHIMNEY 25.00
25A CHIMNEY (AGRO WASTE BOILER) 25.00
26 F.O. & FEED WATER TANK 36.00
27 F.O. STORAGE AREA 218.75
28 POWER SUB STATION 57.00
29 D.G. SET 27.00
30 NaF STPRAGE 57.00
31 E.O. STORAGE AREA 910.00
32 WARE HOUSE (AGRO WASTE) 204.00
33 COOLING TOWER 25.00
34 DISTILLATION COLUMN 10.24
35 FILTARTION SYSTEM 125.00
36 SMBS PLANT 125.00

41
 8. CHAPTER CONCLUSIONS

During the training period, we got practical knowledge about the plant & process.

In the theoretical portion of regular study shows us the image of working scenario but working actually
has given a clear image of working to do in the future.

During the trainee, we got lot of practical knowledge which had surely added in our knowledge and we
are surely going to implement in our career path.

This has helped us to understand different roles we need to be played once we move in the practical
life. We have learnt being punctual, responsible and accountable to do work allotted to us and also
learnt planning & smart work too.

This has given us lots of ideas to figure out what we need to do in the future.

42
 REFRENCES

Ghawane KA: Mass transfer: Nirali Prakashan

Ghawane KA: Unit opration I : Nirali prakashan
Ghawane KA: Unit operation II: Nirali Prakashan
Treybal . R :Mass transfer operation 1, 3rd ed. McGraw-Hills
Block diagram & process flow diagram

43