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Products at glance

INDUSTRY PRODUCT
Fertillizer
Urea, Ammonia Nitro
Phosphate(ANP),
Calcium Ammonium
Nitrate (CAN)
Chemical
Ammonia,
Aniline,Ammonium
Nitrate (melt),
Methanol, Methyl
Formate,
Acetic/Formic/Nitric
Acids,
Toluene di-
isocyanate
High Points
India Largest Producer : Ammonia,
Aniline, Formic Acid,
Acetic Acid, Methanol
Indias only manufacturer of glacial
acetic acid
57 MW power plant
Technology Partner
BASF Germany
Haldor Topsoe, Denmark
Linde AG Germany
Snamprogetti
Italy
Kemira OY
Finland
GE Energy USA
BASF
Technology Partner
BP Chemicals
UK
Toyo Engineering
Japan
Plinke
Germany
UHDE
Germany
MES Co.
Japan
Chematur AB
Sweden
Johnson Matthey
UK
Methanol An Introduction
History
Properties
Large Producer in India
Product Specification @ GVNFC
Name of Company
Productio
n (in
MTA)
Rashtriya Chemical & Fertillizers Co.
Ltd.
45,000
GNFC 1,20,000
Rama Petrochemical Ltd 50,000
Nangal Fertillizers Co. Ltd., 33,000
Assam Petrochemical 33,000
Hindustan Fertillizers Corp.,Haldiya 42,000
Properties of Methanol
Physical State Liquid
Colour Colourless , Water white
Boiling Point (
0
C) 64.5 @ 1 atm
Freezing Point -97.6
o
C
Flash Point (
0
C)

Open Cup:- 16
o
C
Close Cup:- 12
o
C
Solubility Miscible in all proportion with
Water
Odour Pure :- Slightly Alcoholic
Other grade:- Pungent Oily
Density (g/cc) 0.7913 @ 20
0
C
Flamable limit (% by volume in
Air @ STP)
6.72 36.50
Auto ignition Temperature (
0
C)

470
Viscosity (cP) @ 20 (
0
C) 0.614
Threshold limit in Air (ppm) 200
Produces Methanol of quality US federal AA
(99.85 % wt)
Sectoral Usage (%)
Others
20
A.A
9
DMT
2
Pharma
15
MTBE
16
Formaldehyde
38
Uses
Methanol is being used for the following;
Formaldehyde
Drugs & Pharmaceuticals
DMT
Chloromethane
Pesticides
Methyl Amine
Methyl Methacrylate
Fertilizers
Civil Aviation
Solvents
Defence
Fuel
Single cell Protein

Methanol Hazards
It is a Flammable, class C type liquid.
Effects of Exposure/Symptoms:-
High concentrations can produce central nervous
system depression and optic nerve damage. 50,000
ppm will probably cause death in 1-2 hrs. , is absorbed
through skin. Swallowing may cause death or eye
damage.
Eyes:-Liquid may cause conjunctival irritation and
transient corneal damage. vapour may cause
conjunctival irritation.
Skin:-Material may cause irritation. Repeated or
prolonged contact may produce defatting of the skin
leading to irritation and dermatitis.

Continue

Emergency Treatment:-Remove the victim from
exposed area and apply artificial respiration if
breathing has stopped. Induce vomiting and give 2
teaspoons of baking soda in a glass of water. In case of
skin or eyes flush with plenty of water for 15 minutes.
Seek medical aid.
Handling and Storage Precautions:-Use in well
ventilated area. Avoid contact with eyes, skin and
clothing. Keep container tightly closed when not in
use.
Storage should be cool, well ventilated. Store away
from sources of heat or ignition. To avoid moisture
contamination, store under a nitrogen blanket.
Methanol- II plant
Installed Capacity : 300 MTPD
Revamped capacity: 570 MTD

Process Know how / licensors:
I) Steam Reforming of natural gas:
M/s Toyo Engineering corporation,Japan.
II) Methanol Synthesis and Distillation:
M/s. Imperial chemicals industries(ICI),U.K



Basic /Detailed Engineering


I) Steam Reforming : M/s. Toyo, Japan / TEIL,
India
II) Methanol Synthesis: M/s. Linde , Germany / LPTI

III) Methanol Distillation: M/s. Toyo, Japan ,
M/s. FEDO, Cochin

IV) Methanol Distillation Unit : M/s. Lurgi ,
Germany/
India






Project cost
Initial Investment : Rs.80.00 Crores

Revamp cost : Rs. 150.00 Crores

Commencement of Production :04-01-1991

Commercial Production: 01-04-1991

Revamp carried out : June, 2008









Manufacturing Process of
Methanol
The manufacturing process of Methanol is divided into
main 4 parts.

(1) Desulphurization of process Natural Gas(N.G)
(2) Preparation of Methanol Synthesis Gas
(3) Compression & Methanol Synthesis
(4) Methanol Distillation

PROCESS BLOCK DIAGRAM OF METHANOL II PLANT
Raw materials and utility consumption per MT of Methanol
Natural Gas (NM
3
/MT) : 777
CO
2
: 169
Power (KWH/MT) : 190
DM Water (M
3
/MT) : 2.00
CW Make (M
3
/MT) : 3.80
HP Steam (MT/MT) : 0.4
DESULPHURIZATION OF PROCESS NATURAL GAS
SYNTHESIS GAS
METHANOL SYNTHESIS

REACTIONS
CATALYST
N.G
Desulfuriser
Reformer
Catalyst
CO
2

Desulf
uriser

Methanol
Synthesis
Lower
Bed
Upper
Bed
Lower
Bed

Upper
Bed

Active
Ingrednt
ZnO CoO/
MoO
3

NiO
3
NiO ZnO CuO
Shape
Extrusi
on
Extrusi
on

Rings Rings Extrusi
on

Pellets
Life 1 yr 1 yr 3 yr 3 yr 1 yr 3 yr
Some of the Major Equipments

Vessels
Iso thermal Reactor
Heat Exchangers
Pumps
Compressor
Distillation Tower
Learning Experience
Saw different kinds of Process Equipments
A glimpse of work culture in Big Industry
DCS Control Room
Interact with People
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