AN

INDUSTRIAL TRAINING REPORT

ON
PANOLI INTERMEDIATES (INDIA) PVT. LTD.

Guided by Prepared by
Prof: Nirav Valand Keval Darji m

Id No: 16DCDOD003

2018-2019
Department of Chemical Engineering
Faculty of Technology
Dharmsinh Desai University, Nadiad-387001

2
 Faculty of Technology
Dharmsinh Desai University, Nadiad-387001

CERTIFICATE

This is to certify that Mr. DARJI KEVAL MAHESHBHAI Roll No.DCH-28 Sem. VI of
Diploma Chemical Engineering at D.D.U University, Nadiad has satisfactory completed his
industrial training at panoli intermediate’s(India) pvt ltd. during 10/12/2018 to 02/02/2019 and
submitted training report for partial fulfilment of academic requirement to award Diploma
Chemical Engineering from this university.

Mr. NIRAV VALAND Dr.M.S.RAO

Institute Guide professor and head
Chemical Engineering Dept. Chemical Engineering Dept.
D.D.U. Nadiad; 387001 D.D.U. Nadiad; 387001
 PREFACE

Professional course like engineering is incomplete unless one gets to see in use what one has been
studying in the institute. Its benefits are even more when it is scheduled properly like in our case.
Internship is simply the most needed experience one can get while working at an industry. Among
the numerous advantages the most important lesson learnt during internship is the precautions that
must be kept in mind must be taken while working at the industry. Perhaps the one pre-requisite
that is can ensure a long lasting career in the field.
The principle objective of any training is to know the detailed working operation of the different
equipment’s, operation processes and most importantly, discipline.
Just like cells are the building blocks of human life, these internships will undoubtedly prove to be
the building blocks of our career. And a successful career in this field will not only lead to ones’
betterment but will contribute to the society’s development too.

i
 ACKNOWLEDGEMENT

This training report is prepared not only by a solo effort. A great deal of effort and time has been
involved in preparing this seminar report. Many people are involved in it directly or indirectly.
During the course of my project work had been guided by many without whom this project not
seen the light of the day. It is my sincere desire to thanks for their guidance and support.

I would like to thanks my head of the department Dr. M. S. Rao who allowed me to take training
in Panoli Intermediates Pvt Ltd. would also be thankful to Mr. Nirav Valand who guide me
throughout my training session.

I would like to take this opportunity to thanks Mr. Nikul Patel (Production Manager), who
allows me to take a vocational training in their company.

KEVAL DARJI
 TABLE OF CONTENTS

CHAPTER 1 ...................................................................................................................................1

INTRODUCTION..........................................................................................................................1

1.1 HISTORY OF COMPANY .......................................................................................................1

1.2 OBJECTIVES OF COMPANY .................................................................................................1

1.3 COMPANY DETAILS .............................................................................................................2

1.4 QUALITY POLICY .................................................................................................................2

1.5 PRODUCT RANG OF COMPANY ........................................................................................2

1.6 OVERVIEW OF COMPANY ..................................................................................................3

1.7 ORGANIZATION STRUCTURE OF COMPANY .................................................................3

CHAPTER 2 ...................................................................................................................................4

ABOUT TRAINING PLANT .......................................................................................................4

2.1 INTRODUCTION .....................................................................................................................4

2.2 RAW MATERIAL WITH THEIR PROPERTIES ....................................................................4

2.3 APPLICATIONS OF ONCB & PNCB ....................................................................................9

2.4 VARIOUS SECTION OF PLANT ...........................................................................................9

II
CHAPTER 3 .................................................................................................................................10

PROCESS DETAILS...................................................................................................................10

3.1 CHEMISTRY OF PROCESS .................................................................................................10

3.2 MANUFACTURING PROCESS OF ONCB & PNCB .........................................................11

3.3 MANUFACTURING PROCESS OF 2-4 DNCB...................................................................13

3.4 MANUFACTURING PROCESS OF NITRO BENZENE ....................................................15

3.5 PROCESS PARAMETERS ....................................................................................................17

CHAPTER 4 .................................................................................................................................16

MAJOR EQUIPMENTS AND INSTRUMENTATION ..........................................................16

4.1 REACTOR ..............................................................................................................................16

4.2 DISTILLATION COLUMN ...................................................................................................18

4.3 CONDENSER.........................................................................................................................20

4.4 SEPARATOR .........................................................................................................................20

4.5 CRYSTALLIZER ...................................................................................................................21

4.6 FLAKER .................................................................................................................................22

4.7 INSTRUMENTATION DETAILS .........................................................................................23

CHAPTER 5 .................................................................................................................................24

PROCESS UTILITIES................................................................................................................24

5.1 WATER SOFTENING PLANT .............................................................................................24

5.2 R.O. Plant ................................................................................................................................26

5.3 STEAM ...................................................................................................................................28

5.4 CHILLING PLANT ................................................................................................................29

5.5 COOLING PLANT .................................................................................................................30

CHAPTER 6 .................................................................................................................................31

HEALTH, HAZARDS AND SAFETY ......................................................................................31

6.1 ORTHO NITROCHLORO BENZENE ..................................................................................31

6.2 PARA NITROCHLORO BENZENE .....................................................................................32

6.3 2-4 DINITROCHLORO BENZENE ......................................................................................34

6.4 MONO CHLORO BENZENE (MCB) ...................................................................................35

CHAPTER 7 .................................................................................................................................37

PLANT LOCATION AND LAYOUT .......................................................................................37

7.1 PLANT LOCATION ..............................................................................................................37

7.2 FACTORS AFFECTING PLANT LOCATION ....................................................................37

CHAPTER 8 .................................................................................................................................41

ENVIRONMENTAL ASPECTS ................................................................................................41

8.1. EFFLUENT TREATMENT PLANT (ETP) ..........................................................................42

8.2 CENTRAL EFFLUENT TREATMENT PLANT (CEPT) ....................................................44

8.3 AIR POLLUTION CONTROL ..............................................................................................44

BIBLIOGRAPHY ........................................................................................................................45

IV
 LIST OF FIGURES

FIG 3.2 FLOW DIAGRAM OF PNCB & ONCB………………………………..........………..12

FIG 3.3 FLOW DIAGRAM OF 2,4 - DINITRO CHLORO BENZENE……………..………...14
FIG 3.4 FLOE DIAGRAM OF NITRO BENZENE…………………………………..………..16
FIG 4.1 REACTOR…………………………………………………………………..…………17
FIG 4.2 DISTILLATION COLUMN……………………………………………..……………19
FIG 4.5 CRYSTALLIZER……………………………………………………..……………….21
FIG 4.6 FLAKER……………………………………………………………..………………...22
FIG 5.1 SOFTENER PLANT…………………………………………….…………………….25
FIG 5.2 R. O WATER PLANT…………………………………………..……………………...27
FIG 7.1 PLANT LAYOUT…………………………………………………..………………….40
FIG 8.1 ETP FLOW DIAGRAM……………………………………………………………......43
 CHAPTER 1

INTRODUCTION

1.1 HISTORY OF COMPANY

The company started by a Goyal Group of Industries in 1977. Which is started as small plasticiser
unit at Nandesari near industrial town Vadodara. Today it is one of the India leading manufacturers
of chlorination and nitration process product. If exports dyes intermediates chlorinated aromatic
compound. The turnover of company is more than 130 million USD.

1.2 OBJECTIVES OF COMPANY

 Company with all relevant Environments, Health & Safety (EHS) legislation, regulation and
others requirements.

 Protectively develop and implements EHS system identifying, monitoring and periodically
reviewing EHS practices in order to minimize its impact our business activities.

 Conferring highest importance to continual improvement in all business process to prevent

pollution, reduce wastage, con serve energy, identify and reduce risk as well as health hazard.

 Facilitating knowledge up gradation for all number of the Panoli Intermediates India Pvt Ltd.
Family as well as stakeholder, enabling them to understand and perform their roles and
responsibilities toward improvement of EHS practices.

 Encouraging all number of the Panoli Intermediates India Pvt Ltd. Family actively participate
in EHS practices, including individual EHS performance as one of the criteria in the evaluation
process for career advancement.

 Importance of EHS reviewed at the top management level & the performance is highlighted in
company annual report.

1
1.3 COMPANY DETAILS

Goyal Group of Industries excels as a reputed organisation engaged in the manufacturing & export
of integrated dye intermediates, chemicals, chlorobenzene and derivatives plasticizers and industrial
chemicals. The company successfully incorporates the innovative trends, total quality management
and proficiency in work process through advanced research and analysis.

Committed to quality Panoli Intermediates (India) Pvt Ltd. Engages in the manufacturing and exporting of
dyes intermediates, chemicals, dyes chemicals, chlorobenzene and derivatives plasticizers and industrial
chemicals. Our holistic approach towards customer.

Driven by the latest technology they are able to cater to any specification laid down by our customers. With
a dedicated team and huge infrastructure, we have been able to consolidate ourselves among the leading
names of the industry.

The chemical belt of Gujarat witnessed the birth of Goyal Group of Industries in 1977 which started as a
small Plasticizer unit at Nandesari near the Industrial town of Vadodara.

1.4 QUALITY POLICY

We are committed to provide best quality or our product mono chloro benzene, ortho nitro chloro
benzene, pera nitro chloro benzene, 2-4 Dinitro chloro benzene and their product to our customers
abiding regulation and to that best of their satisfaction.

We will continuously strive to remain competitive and deliver quality product in time and
continuously to improve process performance by review of quality management system.

1.5 PRODUCT RANG OF COMPANY

The company at present products are 2-4DNCB, PNCB, ONCB.
ONCB: ORTHO NITRO CHLORO BENZENE
PNCB: PERA NITRO CHLORO BENZENE

2
1.6 OVERVIEW OF COMPANY

Panoli Intermediates India Pvt Ltd. engages in manufacturing integrated dye intermediates,
chemicals, chloro benzene and derivative plasticizers and industrial chemicals in India. If offers
chlorination product including mono, pera and ortho, di and tri chloro benzenes; hydrogenation
products, which include ortho, pera and meta toluidine’s, as well as dicloro anilines; dyes
intermediate products, including acetanilide flakes.

1.7 ORGANIZATION STRUCTURE OF COMPANY

GENERAL MANAGER

PRODUCTION MANAGER

MAINTAINANCE STORE MANAGER QC LAB PROCES PLA

MANAGER MANAGER MANAGER
SUB CONTRACTOR
SUPERVISOR CHEMIST SHIFT INCHARGE

TECHNITION LAB ASSISTANCE SUPERVISOR

HELPER OPERATORS

HELPER

3
 CHAPTER 2

ABOUT TRAINING PLANT

2.1 INTRODUCTION

Panoli Intermediate (India) Pvt Ltd. have ONCB, PNCB & 2-4DNCB plant in Nandesari.

Established : 1977

Land Area : 9900 sq. m.

Manufactures : Ortho nitro chloro benzene, Para nitro chloro benzene, 2-4Dnitro

Chloro Benzenee

Production Capacity : 2400 TPA

Certified : ISO 9001-2008

2.2 RAW MATERIAL WITH THEIR PROPERTIES

Types of raw material to be used for mfg. ONCB, PNCB, 2-4DNCB are:

Mono Chloro Benzene

Sulphuric Acid as a catalyst

Nitric Acid

Spent Acid as a by product

4
2.2.1 MONO CHLORO BENZENE (MCB)

Physical & Chemical Property

Physical state and appearance Liquid

Odour Almond like
Molecular Wt. 112.56 g/mole
Colour Colourless
Boiling Point 132 °C (269 °F)
Melting Point 45.6 °C (-50 °F)
Specific Gravity 1.1058 (Water = 1)
Vapour Pressure 8.8 mm of Hg at 20 °C
Solubility Soluble in methanol, diethyl ether, very
slightly soluble in cold water

2.2.2 SULPHURIC ACID

Physical & Chemical Property

Chemical Formula H2SO4

Specific Gravity 1.84
Molecular Weight 98 g/mole
Boiling Point 348 °C
Melting Ponit 10-15 °C
Odour Colourless & heavy liquid
Solubility Soluble in water
Corrosiveness Extremely corrosive to skin and body tissues
hence cause severe burns

5
USES

Sulphuric acid is one of the most important in chemical industrial. Major use of the sulphuric acid
is in the production of fertilizers. For ammonium sulphate and super phosphate of lime. It is used in
petroleum refining to wash impurities out of gasoline and other refining product.

2.2.3 NITRIC ACID

Physical & Chemical Properties

Chemical Formula HNO3

Density 1.55 Kg/cm3 at room temp.
Molecular Weight 63 gm/mole
Boiling Point 83 °C
Melting Point -41.6 °C
Form Liquid
Solubility Soluble in CCL4

USES

Manufacturing of inorganic and organic nitrates and nitro compound for fertilizer, dyes
intermediates. Explosive and many different organic chemicals.

Nitric acid is used to make plastic including nylon and polyurethane, the largest use of nitric acid,
however is in the production of ammonium nitrites.

Ammonium nitrites are used as a nitrogen fertilizer and into the manufacturing of explosive mixture.

6
2.2.4 ORTHO NITRO CHLORO BENZENE

Physical & Chemical Property

Chemical Formula C6H4ClNO2

Specific Gravity 1.305 at 20 °C
Molecular Weight 157.56 gm/mole
Boiling Point 245 °C
Flash Point 126 °C
Appearance Light Yellow Flakes
Moisture 0.05% Maximum
Purity 99.90% W/W Minimum

Chemical Properties

ONCB crystallizer in light yellow, monoclinic needles. It is insoluble in water and is very soluble
in benzene, diethyl ether and hot ethanol. ONCB reactions involve the nitro groups, chloro atoms
and aromatic ring. The nitrogen group can be partially reduced to the corresponding intermediate or
fully to the amino group.

The aromatic ring can be nitrated, leading to the formation of 2,4-dinitro-1-chlorobenzene and 2,6-
dinitro-1-chlorobenzene or it can be sulfonated, yielding 3-nitro-4-chlorobenzene sulfonic acid. The
chlorine atom can be displaced easily by o-nitro phenol attack by –OH, -OCH3, -OC6H6, -NH2, etc.
Treatment of o-Nitro chlorobenzene. With aqueous sodium hydroxide at 1300C results in the
formation of o-nitro phenol and with aqueous methanolic potassium hydroxide at high temperature
and pressure, o-nitro anisole is formed.

When o-Nitro chlorobenzene is treated with aqueous ammonia under high temperature and pressure,
o-nitro aniline is formed. O-Nitro chlorobenzene condenses with aniline to form 2-
nitrodiphenylamine.

7
2.2.5 PARA NITRO CHLORO BENZENE

Physical & Chemical Property

Chemical Property C6H4ClNO2

Specific Gravity 1.305 At 20 °C
Molecular Weight 157.56 gm/mole
Boiling Point 245 °C
Flash Point 125 °C
Appearance Light Yellow Flakes
Moisture 0.05% Maximum
Purity 99.04% W/W Minimum

Chemical Property

PNCB crystallizer in light yellow monoclinic prisms. It is insoluble in water and very soluble in
benzene, diethyl ether and hot ethanol PNCB undergoes the same reactions described for the ortho
isomer to yield the analogous para derivatives.

The chlorine atom is activated and as with the ortho isomer can be easily displaced by nucleophilic
attack. Treatment with aqueous ammonia at elevated temperature and pressure results in the
formation of PNCB and with aqueous sodium hydroxide under pressure p-nitro phenol formed.
PNCB reacts with sodium disulphide to form 4,4-dinitrodiphenyl disulphide which is an
intermediate in the preparation of sulphanilamide derivatives.

USES OF ONCB & PNCB

ONCB is used in the synthesis of Azo dye intermediates e.g. O-chloro aniline, O-nitro aniline and
O-amino phenol.

It is also used in corrosion inhibitor, pigments and agricultural chemicals.

PNCB is used principally in the production of intermediates of Azo and sulphur dyes.

Other used include Pharmaceuticals, photo chemicals, rubber chemicals and insecticides.

8
2.3 APPLICATIONS OF ONCB & PNCB

Pesticides

Rubber Chemicals

Intermediates for Dyes

Pigments

Pharmaceuticals

Photo Chemicals

Insecticide

2.4 VARIOUS SECTION OF PLANT

MCB nitration plant

Nitro Benzene Plant

2,4-DNCB

Loading and Unloading Section

Store Section

Utilities Section

1. Boiler Section
2. Chilling Plant
3. Softener Plant
4. R O Plant

ETP Plant

9
 CHAPTER 3

PROCESS DETAILS

3.1 CHEMISTRY OF PROCESS

For production ONCB the first of all HNO3 & H2SO4 are simply mixed in a reactor. Then after the
produce NO2 is react with MCB at Ortho & Para to produce ONCB & PNCB as a product of
company.

3.1.1 PARA NITRO CHLORO BENZENE

50 - 70 °C
1) HNO3 + H2SO4 NO2 + HSO4 + H2O

Cl2 Cl2

2) NO2 +

MCB NO2

PNCB

3.1.2 ORTHO NITRO CHLORO BENZENE

50 - 70 °C
1) HNO3 + H2SO4 NO2 + HSO4 + H2O

CL2 Cl2

NO2

2) NO2 +

MCB ONCB

10
3.1.3 2-4 DINITRO CHLORO BENZENE

50 - 70 °C
1) HNO3 + H2SO4 NO2 + HSO4 + H2O

Cl2 Cl2

2) NO2 +

NO2 NO2

MCB 2-4 DNCB

3.2 MANUFACTURING PROCESS OF ONCB & PNCB

Raw material uses are

 Mono chloro benzene

 Sulphuric acid as a catalyst

 Nitric acid

 Spent acid as a by product

11
 MCB Na2CO3
H2SO4

HNO3 R1 R2 R3 R4 R5

T-50℃

T-75℃
T-65℃
Condenser

Outlet Reflux

Separator

Separator
Separator
Cool
PNCB to
Water
Flaker
Inlet

Distillation Column
Centrifugal
Pump
Water Tank
Spent Acid Recycle
Na2CO3 Tank

635 mmHg Vacuum

R6

Reboiler
Extractive (60-62% ONCB)

(30-35% PNCB)
R D Crystallizer
Nitration Tank

ONCB to
Storage
Heating Coil
Chilling Coil

Coolong Coil

Flaker
C.W out

C.W in

FIG 3.2 FLOW DIAGRAM OF PNCB & ONCB

12
PROCESS DESCRIPTION

As show in the figure the HNO3 & H2SO4 acid are contacted or added in port because of reaction is
highly exothermic so the reactor is blast or explosion will not take place.

Next the NO2 radical is react with MCB in reactor the reactor contained cooling coil so the
temperature can be maintained by cooling water. The agitation is providing by open type impeller
which rotate at 380-390 RPM. After the passing through the series of the rector R-1, R-2, R-3 the
temperature is maintained 50℃, 60℃ and 70-75℃ respectively.

Than the nitro mass is enter in to the separator. Where the spent H2SO4 is removed from bottom of
the separator and the spent acid is recycling to the port by the centrifugal pump. Than after nitro
mass is enter in washing section where the H2O wash is given in R-4. After that washed with soda
ash to remove the acidity because acid nitro mass.

Enter in the column that corrosion will taking place. Than this nitro mass is enter in column where
the water is remove from it. Than this PNCB is heated to convert into liquid and send to flaker
where flakes of PNCB are obtained. From crystallizer Extractive Oil (E.O) is obtained which
contain 60-62% ONCB. This E.O is feed to packed bed column no. 1 from top PNCB & bottom.

ONCB is obtained which 91% pure product. Then it purity & decolorize in second 7 third column.

3.3 MANUFACTURING PROCESS OF 2-4 DNCB

Raw materials used are

 Para nitro chloro benzene

 Sulphuric acid as a catalyst

 Nitric acid

 Spent acid as a by product

13
 PNCB Na2CO3
H2SO4

HNO3 R1 R2 R3 R4 R5

T-60℃

T-66℃
T-64℃
Condenser

Outlet Reflux

Separator

Separator
Separator
Cool
2,4-DNCB
Water
to Flaker
Inlet

Distillation Column
Centrifugal
Pump
Water Tank
Spent Acid Recycle
Na2CO3 Tank

R6

Reboiler
Separator

FIG 3.3 FLOE DIAGRAM OF 2,4 - DINITRO CHLORO BENZENE

14
PROCESS DESCRIPTION

As show in the figure the HNO3 & H2SO4 acid are contacted or added in port because of reaction is
highly exothermic so the reactor is blast or explosion will not take place.

This reaction will be taking place in the port then it enters into series of reactor which is agitated by
open type impeller which is rotate at speed of 390 RPM.

The temperature is maintained in reactor R-1, R-2, R-3 temperature is 60℃, 64℃, 66℃ by
providing cooling coil in which cooling water is circulated.

The spent H2SO4 is recycle back to the port in a reactor below reaction will take place:

Cl2 Cl2

3) NO2 + H2O + HSO4 + + H2SO4

NO2 NO2

Then this nitro mass is entered in washing section where first it will wash with water after that it
will wash Na2Co3 to maintain the pH 7 to 7.5. If acid nitro mass enter in column corrosion will take
place. Na2Co3 will added at rate of 60-65 kg/hr. after that D.M water wash is given to remove
basicity.

Then enter in column from where water is remove and 2-4 DNCB is stored in heating will storage
tank.

3.4 MANUFACTURING PROCESS OF NITRO BENZENE

Raw material used are

 Benzene

 Suphuric acid as a catalyst

 Nitric acid & Spent acid as a by product

15
 Benzen Na2CO3
H2SO4 605 mmHg
Vaccum
HNO3 R1 R2 R3 R4 R5

T-50℃
T- 42℃

T-46℃
Condenser

Outlet Reflux

Separator

Separator
Separator
Cool
Nitro
Water
Benzene
Inlet

Distillation Column
Centrifugal
Pump
Water Tank
Spent Acid Recycle
Na2CO3 Tank

R6

Reboiler

Storage Tank

FIG 3.4 FLOW DIAGRAM OF NITRO BENZENE

16
PROCESS DESCRIPTION

As show in the figure all the three reactors are filled half of spent H2SO4 in the port HNO3 & H2SO4
is contacted following reaction is take place

1) HNO3 + H2SO4 NO2 + HSO4 + H2O

NO2

2) NO2 + HSO4 + H2O + H2SO4 +

Spent acid

From the separator nitro mass is entering in the washing section where it is wash by H2O & Na2CO3
to maintain the pH. After that is purity in the vacuum distillation for column nitrobenzene is stored
in the tank.

3.5 PROCESS PARAMETERS

Manufacturing process of PNCB & ONCB

Temperature of 50 ℃ to 75 ℃

Pressure of 635 mmHg vacuum

Manufacturing process of 2-4 DNCB

Temperature of 60 ℃ to 66 ℃

Pressure of 635 mmHg vacuum

Manufacturing process of Nitro Benzene

Temperature of 42 ℃ to 50 ℃

17
 CHAPTER 4

MAJOR EQUIPMENTS AND INSTRUMENTATION

The equipment’s uses in the plant for production of ONCB & PNCB are as follows:

 Reactor

 Distillation column

 Crystallizer

 Condenser

 Flaker

 Separator

4.1 REACTOR

Material of construction: Mg steel inside clouding with Stainless Steel (SS)

Types of vessel : Closed vessel

Types of Agitator : Curve blade

Capacity : 2.5 KL

Temperature : 50-70 ℃

16
 Outlet

Agitator

Cooling
Coil

Reactor

Cooling
Water Inlet

Curve Blade
Impeller

FIG 4.1 REACTOR

17
4.2 DISTILLATION COLUMN

Material of construction : Stainless Steel

Diameter : 1.3 m

Height : 55 m

Pressure : 635 mmHg

Packing : Structure packing

Top temperature : 165 ℃

Bottom temperature : 179 ℃

Reflux temperature : 140 ℃

H/E temperature : 48 ℃

Reboiler pressure : 13 Kg/cm2 at 0 ℃

Material of construction

Generally, the column is made up of stainless steel because of its corrosion resistance property.

But, the steel is costly so the other portion of column is made up of magnesium steel and inside
clouding with stainless steel and packing are made of stainless steel.

18
 Cooler

Reflux
Rectification Section Distillate

Heat
Exachaner

Feed

Liquid Vacuum
Distributer Port
Stripping Section

Reboiler

Packing Support Steam

Centrifugal Pump

FIG 4.2 DISTILLATION COLUMN

19
4.3 CONDENSER

Type : MS horizontal tube heat exchanger

Dimension : 300 mm (Length)

Diameter : 800 mm ID

Thickness : 8 mm

Bonnets : 250 mm (Length)

Tube : Sheet : 30 mm thick MS

Tubes : 1” OD

Passes : 6” pass

Baffles : 10 Nos, 66 mm thickness

Tube : 35 mm traingular pitch

4.4 SEPARATOR

Material of construction : Mild steel

Drain valve : 1” bolt

Mounting : Filter side bolting side

Size : 19” (Diameter)

Height : 49”

20
4.5 CRYSTALLIZER

Capacity : 40-60 tones

Time : 26-35 hr

It is batch type crystallizer. First the material is feed at temperature of around 100 ℃ in the
crystallizer. First the cooling is carried out at temperature of about 45 ℃. Then the chilling is
carried at temperature of about 1 ℃. So, the PNCB is stick on the wall of the tubes and EO is in
liquid form which getting remove. After that sweating is carried out at 85 ℃ so the PNCB can be
melted and remove from the crystallizer stored in the tank. In crystallizer 55% PNCB is recovery.

Shell Tube

Cooling Water
Heating Water
Material Outlet Chilling Water
Outlet

Material Inlet

Cooling Water
Heating Water
Chilling Water
Inlet

FIG NO: 4.3 CRYSTALLIZER

21
4.6 FLAKER

This is a flaker to cylindrical drum to be rotated in RPM 10-15 liquid material to add outside of
drum and inside of cooling water the work is done by the flaker is liquid material (PNCB) Para
nitro Chloro Benzene to convert flacks. The flacks are cutting in doctor blade and bag packing to
dispatch.

Liquid Materal
Liquid Inlet
Material Inlet

Cylinderical
Crystal RotateRotate
DrumDrim
Cooling
Water Outlet
Inlet
Doctor
Doctor Blade
Blade

Flakes
Flakes
Steam

Plastic Bag
Plastic Bag Packing
Packing

FIG NO: 4.4 FLAKER

22
4.7 INSTRUMENTATION DETAILS

Instruments are very important in equipment for safe condition and prevention of hazard which
take place due to temperature & pressure etc. Few instrument generally used are:

Temperature indicator: If function is to indicate the temperature inside the equipment or reactor.

In separator & reactor for temperature indication the temperature indicator is use.

Pressure gauge: In reactor for pressure indication the pressure gauge is use.

Rota meter: It is the type of flow meter use for measurement of liquid flow.

The plant is operating on DCS (Distribute Control System) system there many type of control
valves is use for control the flow of fluid.

TYPES OF VALVES USE ARE

 Gate valve

 Ball valve

 Butterfly valve

 Nom return valve

23
 CHAPTER 5

PROCESS UTILITIES

 Air

 Water

 Steam

 Electricity

Air - It is naturally available from atmosphere.

Use - Air is compressed by compressor which use for operating auto controlling valve.

Water - Water is obtained from the well which is used in the plant. If the water from well is hard
it is used in process will cause corrosion in reactor. This hard water is used boiler more residue is
obtained due to that the tube will chock up to remove the harness from the water two plant will
working in company.

1) Water softening plant

2) R. O. Plant

5.1 WATER SOFTENING PLANT

The bed of gravel or which sodium resin is putted sodium resin is material which capable of
exchanging its Na+ ions Ca- ions. Hard water contains HCO3 bicarbonate hardness.

CaHCO3 + Nar CaR + NaHCO3

Following reaction will take place. If total TDS - 1800 to 2500 PPM

TH - 650 PPM After softening TH - 30 to 35 PPM

24
If water coming out from resin will contain 200-250 PPM (Total Hardness) then regeneration is
given. Use of water washing in nitration.

Regeneration Process

NaCl dosing is given time of 1-45 hrs. water washing 10 minutes slow speed of water washing &
30-40 minutes at high speed water.

Regeneration solution is made up by dissolving 1200Kg of NaCl in 5000 liter of water.

Capacity of softener 30-40 m3/hrs.

Sand Filter

Raw
Water Hard Water
Tank
Sodium Resin
Softner

NaCl
Solution

Soft Water
Storage Tank

FIG 5.1 SOFTENER PLANT

25
5.2 R.O. Plant

Dosing liquid

 Antiscalent

 HCl

 Sodium hypo chloride

 Sodium meta bisulphate

 Chlorination

RAW water R. O. water Rejected water

10 m3 600 liters 400 liter

14 m3 10000 liters 400 liter

Total hardness is reducing.

TH 650 PPM to 4-5 PPM

TDS 150-250 PPM to 40-50 PPM

Uses of water

Washing

Boiler

Drinking

26
 Soft
Water
Storage WLT HCL Antiscalent
Tank

High Filter
Pressure
Pump

Rejected Water
Recycle
Top
Filter

R.O Water
Middle
Storage
Tank

Bottom

Membrane
Polypropelene
0.05 micron

FIG 5.2 R.O WATER PLANT

27
5.3 STEAM

Steam most important fluid in plant because is used for heat transfer.

Fluidized bed combustion (FBC)

Coal base fire

PC scads system

Made up by park tee

Coal is imported from

First of all, the send is fill in the blast furnace. Then the blower is start when the sand is fluidized
the pressure is 650 mmHg. Then the coal is added slowly and slowly the temperature will
increase.

Temperature of blast furnace 900 ℃

Feed water 12080Kg/hrs.

Stem flow 14100Kg/hrs.

Steam pressure 22.11Kg/hrs.

Use of water

1) For heating the material which solid at room temperature.

2) Used in distillation column to produce vapor of material.

3) Pressure of 605 mmHg vacuum.

28
5.4 CHILLING PLANT

Various Equipment Used:

 Condenser

 Separator

 Compressor Pump

 Receiver

 Expansion tube connected to small cylindrical tank

 Bricked wall large open tank

Process

In this process ammonia is used to cool the water. Liquid ammonia at nearly.

Atmospheric pressure and 0℃ temperature is compressed by a compressor to a pressure of

5kg/cm2 and temperature of 70℃. As a result, liquid ammonia changes is states to a gaseous one.

While compression, some air has entered the gaseous ammonia steam, so it is taken to an oil
separator where the oil is separator from ammonia.

Ammonia gas at 70℃ now goes to a condenser, where water falling from the top. While the
ammonia basses through the coiled pipe. As a result of heat exchange, ammonia cool 50℃ and is
now stored in receiver in liquid form.

From the receiver, liquid ammonia flows through a pipe which is connected to an expansions pipe.
A thus due to sudden expansion temperature of ammonia changes from 5℃ to -15℃ and it is
freezes a bit.

Now it is passed through the coil of the horizontal brick tank, which is filed with 25℃ water. This
water on account of heat exchange cools to 5℃ enters the compressor due to the suction created
by the pump of compressor. Now this liquid is compressed and the process is repeated.

5.5 COOLING PLANT

29
 Equipment

Large vessel

Induced draft fan

Packing material

Process

In a large vessel take some packing material and from a packed bed in the central part. snow water
at 25℃ is distributed through a distributor over the packed bed. At the same time exhaust fan from
the top, sucks air from bottom. Thus due to counter current interaction between water and air inside
the voids of the packing material, water is cooled and leaves from the bottom, while the heated air
leaves from the top.

CHAPTER 6

30
 HEALTH, HAZARDS AND SAFETY

6.1 ORTHO NITROCHLORO BENZENE

HAZARD CLASSIFICATION

Hazard Notice Toxic

Usage Chemical intermediate for carbofuran, a pesticide, other its, e.g. O-nitro
phenol, 2-chloroaniline, dyes.

Storage Store in a cool, dry place. Keep container closed when not in used. Store in a
Temperature cool, dry, well-ventilated area away from incompatible substances.

FIRST AID MEASURE

Ingestion Never give anything by mouth to an unconscious person. Get medical aid. Do
not induce vomiting. If conscious and alert, rinse mouth and drink 2-4 cupful’s
of milk or water.

Inhalation Get medical aid immediately. Remove from exposure to fresh air immediately.
If breathing is difficult, give oxygen. Do not use mouth to mouth respiration.
If breathing has ceased apply artificial respiration using oxygen and a suitable
mechanical device such as a bag and a mask.

Skin Flush skin with plenty of soap and water for at least 15 minutes while
removing contaminated clothing and shoes. Wash clothing before resume.

Eyes Flush eyes with plenty of water for at least 15 minutes, occasionally lifting the
upper and lower eyelids. Get medical aid immediately.

31
 Storage Store in a cool, dry place. Keep container closed when not in use. Store in a
cool, dry, well-ventilated area away from incompatible substances.

6.2 PARA NITROCHLORO BENZENE

HAZARDS IDENTIFICATION

Potential Health Effects

Eye Causes eye irritation. Causes redness and pain.

Skin Causes skin irritation. Toxic in contact with skin. If absorbed mat causes
symptoms similar to those for ingestion.

Ingestion Causes cyanosis characterized by blush colored skin. Causes respirator tract
irritation. May causes anoxia characterized by weakness, headache, dizziness,
confusion, cyanosis, weak and irregular heartbeat, collapse, unconsciousness
convulsions, coma and death. Toxic if inhaled.

Chronic Prolonged or repeated skin contact may cause sensitization dermatitis and
possible destruction or ulceration. May cause liver and kidney damage.

FIRST AID MEASURES

Eye Immediately flush eyes with plenty of water for at least 15 minutes,
occasionally lifting the upper and lower lids. Get medical aid immediately.

Skin Get medical aid immediately. Immediately flush skin with plenty so soap and
water at least 15 minutes while removing contaminated clothing and shoes.

Ingestion Get medical aid immediately. Wash mouth out with water.

32
 Inhalation Get medical aid immediately. Remove from exposure to fresh air immediately.
If not breathing, give artificial respiration. If breathing is difficult, give
oxygen.

HANDLING & STORAGE

Handling Do not breathing dust, vapor, mist or gas. Do not get in eyes, on skin or on
clothing. Use only in a chemical fume hood.

Storage Store in cool, dry place. Store in a tightly closed container.

PERSONAL PROTECTION

Eyes Wear safety glasses and chemical goggles if splashing is possible. Wear
appropriate protective eye glasses or chemical safety goggles.

Skin Wear appropriate protective gloves to prevent skin exposure.

Clothing Wear appropriate protective clothing to prevent skin exposure.

33
FIRE FIGHTING MEDIA

In case of fire use water spray, dry chemical, carbon dioxide or chemical foam.

6.3 2-4 DINITROCHLORO BENZENE

Eye Contact Check for and remove any contact lenses. Do not use any eye ointment. Seek
medical attention.

Skin Contact After contact with skin, wash immediately with plenty of water. Gently and
thoroughly wash the contaminated skin with running water and non-abrasive
soap. Be partially careful to clean folds, crevices, creases and groin. Cover the
irritated skin with an emollient. If irritation persists, seek medical attention.
Wash contaminated clothing before resuming.

Serious Skin Wash with a disinfectant soap and cover the contaminated skin with an anti-
Contact bacterial cream. Seek immediate medical attention.

Inhalation Allow the victim to rest in a well ventilated area. Seek immediate medical
attention.

Serious Evacuate the victim to a safe area as soon as possible. Loosen tight clothing
Inhalation such as a collar, tie, belt or waistband. If breathing is difficult, administer
oxygen. If the victim is not birthing, perform mouth-to-mouth resuscitation.
Seek medical attention.

Ingestion Do not induce vomiting. Examine the lips and mouth to ascertain whether the
tissues are damaged, a possible indication that the toxic material was ingested;
the absence of such signs, however, is not conclusive. Loosen tight clothing
such as a collar, tie, belt or waistband. If the victim is not birthing, perform
mouth-to-mouth resuscitation. Seek immediate medical attention.

34
HANDLING AND STORAGE

Storage Flammable materials should be stored in a separate safety storage cabinet or

room. Keep away from heat. Keep away from sources of ignition. Keep
container tightly closed. Keep in a cool, well-ventilated place. Ground all
equipment containing material. A refrigerated room would be preferable for
materials with a flash point lower than 37.8 ℃ (100°F).

PERSONAL PROTECTION

Personal Splash goggles. Lab coat. Dust respirator. Be sure to use an approved/certified
Protection respirator or equivalent. Gloves. Full suit. Boots. A self-contained breathing
apparatus should be used to avoid inhalation of the product.

FIRE FIGHTING MEDIA AND INSTRUCTIONS

SMALL FIRE: Use DRY chemical powder.

LARGE FIRE: Use water supply, fog or foam.

6.4 MONO CHLORO BENZENE (MCB)

FIRST AID MEASURE

Eye Contact Check for and remove any contact lenses. Immediately flush eyes with
running water for at least 15 minutes, keeping eyelids open. Cold water may
be used. Do not use any eye ointment. Seek medical attention.

Skin Contact If the chemical got into the clothed portion of the body, remove the
contaminated clothes as quickly as possible, protecting your own hands and
body. Place the victim under a deluge shower.

35
 Serious Skin Wash with a disinfectant soap and cover the contaminated skin with an anti-
Contact bacterial cream. Seek immediate medical attention.

Inhalation Allow the victim to rest in a well ventilated area. Seek immediate medical
attention.

PERSONAL PROTECTION

Splash goggles. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or
equivalent. Gloves.

HANDLING AND STORAGE

Precautions Keep container dry. Keep away from heat. Keep away from sources of
ignition. Ground all equipment containing material. Do not ingest. Do not
breath gas/fumes/vapor/spray. Never add water to this product in case of
insufficient ventilation, water suitable respiratory equipment. If ingested, seek
medical advice immediately and show the container or the label. Avoid
contact either skin and eyes.

Storage Flammable materials should be stored in a separate safety storage cabinet or

room. Keep away from heat. Keep away from sources of ignition. Keep
container tightly closed. Keep in a cool, well-ventilated place. Ground all
equipment containing material. A refrigerated room would be preferable for
materials with a flash point lower than 37.8 ℃ (100°F).

36
 CHAPTER 7

PLANT LOCATION AND LAYOUT

7.1 PLANT LOCATION

From all point of view, Nandesari is very appropriate place to establish a chemical plant because
it is connected to National Highway no.8 hence transportation of raw material and finished
products becomes easy.

Panoli Intermediate plant is in Nandesari G.I.D.C therefore it provides required labor to company
at the reasonable cost. This plant is just 12 km from Vadodara so that person with good academic
career and engineer can be obtained.

Requirement of site selection

Any new plant is founding or start, the site of plant is most important there are some factors must
be seen for selection of site for plant.

7.2 FACTORS AFFECTING PLANT LOCATION

There are main two major groups, which is affected factor.

1) Primary factors

2) Specific factors (secondary)

1. Primary factors
 Raw materials supply
 Market
 Power supply
 Water supply
2. Specific factors

37
  Transportation
 Waste disposal
 Labor
 Legal restriction
 Site characteristic
 Flood and fire control

1. Primary factors
 Raw materials supply

Kutch plant is supplies raw materials to Nandesari PI plants. So raw materials are supplied by
Kutch plant roadway.

 Market

AS plant is in industrial area which is linked with national highway central express highway.
So transportation is fast providing big market.

 Power supply

AEC supplies electricity continually as possible. So there is no electric problem in site. And
plant is in G.I.D.C. so that there is no chance of cut of electric power.

 Water supply

The plant site is very near to the river Mahisagar and gets benefits of G.I.D.C., so that all water
requirement of plant is done by the municipality of Vadodara. The water is supplies to the plant
through the pipeline.

 Climate

Around the plant site the climate is less humid so it is beneficial to the plant. The condition of
temperature is beneficial for the plant.

2. Specific factors

38
 Transportation

This plant site is connected to the national highway no.8. So transportation is very easy. The
Vadodara city is just 12 km. from the plant site. The plant is connecting to the Ahmedabad –
Baroda- Bombay highway and Vadodara express highway. Railway station of Nandesari is just
3.5 km. from the plant site so transportation by the railway is also easy the fast.

 Waste disposal

PI does not create high waste. For waste water and other liquid waste PI plant is equipped with
ETP (effluent treatment plant). Which is high efficient and the neutral waste water from PI
plant is finally sent to central Effluent Treatment plant (CEPT), thus PI does not produce water
pollution

 Labor resources

Vadodara is big city, many people are coming from other city and village to find work, so that
good labor is available at low or reasonable cost and also efficient engineers are available from
Vadodara city.

 Legal restriction

Plant site is under developed area of Nandesari, Vadodara. So that all facilities of G.I.D.C are
available to PI plant. As plant is not causing too much pollution thus there are no legal problems
faced by the plant. There is no existence of noise or any other kind of pollution.

 Site characteristics

The soil structure is good at the plant site. It is near to the railway lines of Nandesari. The plant
site is near to the highway and water supply is done through Mahisagar river and the river is
near to the plant. The cost of site is cheaper.

 Flood and fire control

The chances of fire are almost none at the plant site. The occurrence of flood is very less at the
plant site and the flood has not been occurred there yet.

39
 PNT Storage Crystallizer
Canteen

Loading & Chilling Plant

Unloading
PNCB & ONCB
Section
Column

Decolorization of
Waging ONCB
Main
Gate

Security
Office Lab Office
Jumbo Nitration
2,4 - DNCB
Conference DCS Nitro Benzene
Section
Room Control
Gate - 2
Room 1st 2nd

Nitration For MCB

Section

2,4 - DNCB
Storage &
Packing

Workshop
Instrumentation
Workshop
Utilities Section
ETP Plant

FIG 7.1 PLANT LAYOUT

40
 CHAPTER 8

ENVIRONMENTAL ASPECTS

ENVIRONMENT

Surrounding in which an organization operates including air, water, and natural resources. This
definition provides the scope of the integrated EHS (Environmental Health Safety) management
system it includes the air, water and fauna and it includes natural resources. This means that energy
and now materials must be considered within the environment management system. This definition
does not include the need to add the area of safety and industrial within integrated SHE
management system.

INTEGRATED THE MANAGEMENT SYSTEM

The part of overall management system that includes organization structure planning, activities
responsibilities, practices, precedes processes and resources for developing implementing
achieving and maintaining the integrated systems policy.

PREVENTION OF POLLUTION

Use of processes, practices, material or product that avoid reduce or control pollution which may
in include receiving treatment process changes control mechanism efficient use of resources and
material substitution. The organization must to review and include, where appropriate the above
listed techniques in the developing and implementation of its environmental objective target.

41
ENVIRONMENTAL ASPECT & IMPECT OCCUPATIONAL HEALTH AND SAFETY
HAZARDS

Purposes – identification of the environmental aspect and associated impacts of its activities &
services identification of the occupational health and safety hazard and associated risk of its
activities product & services. Evaluation of impacts for determination of significant environmental
aspects. Evolution of risk determination of significant occupational health and safety hazard. To
document the above mentioned impacts, aspect, risk and hazard. To keep the information up to
date. To considered the significant environmental aspect and occupational health and safety hazard
in the designed and implement integrated EHS (Environmental Health Safety) management.

8.1. EFFLUENT TREATMENT PLANT (ETP)

PROCESS DESCRIPTION

The water coming out from the plant is acidic. So this water cannot be directly discarded to outside.
Because if acidic water going out from company. GPCB will seal the company so to remove acidity
& impurities from water the ETP treatment is given.

As shown in the figure the water coming out from the entire nitration unit is stored in a tank. After
that this acidic water is send to equilibration tank where 800Kg of Na2CO3 is dissolve in 5000 liters
of water & stirring is given 30 minutes. In another tank the lime slurry is prepared by dissolving
1000 Kg of lime. After that the lime slurry & Na2CO3 mixed water is mixed in neutralization tank
where maintaining 8-10 ph. After this water is send to clarifier by the centrifugal pump where the
settling process takes place from where the solid is settle at bottom & the aqueous liquid is send
to chlorination tank. In chlorination tank the Cl2 is circulated to remove the impurities in this
process the 900Kg bottom is used. Will the chlorination process 7-8 days? After chlorination the
water pH is range of 2-3 pH so to neutralize the pH 1-2 bags of lime is added in the water. The
7pH water is send to storage tank & discarded by tankers through in Nandesari ETP.

42
 Na2CO3
Lime Slurry
800 Kg

Setling Tank
Nitration

Clearifire
Equilization
Tank

Centrifugal
Pump

Nuetralizer
Tanl Sludge

Aqeous
Layor

Lime

Clorination
Tank

Water send to Nandesari

Effluent Plant (NEPT)
Clorine Cylindet

FIG 8.1 ETP FLOE DIAGRAM

43
8.2 CENTRAL EFFLUENT TREATMENT PLANT (CEPT)

Here, various parameters like pH, Cod, TS, TDS, oil etc. of waste water coming out of ETP are in
their permissible limit (According to norms of GPSB). So, secondary treatment unit like aeration
tank, carbon filter, etc. are not required. Around 7 lacks liters of effluents are treated in the ETP.
The cost of ETP is around 24 Rs./Kg effluent.

ANALYSIS METHOD FOR TOTAL SOLIDS (TS)

Take clean and empty beaker and weight it. Take 50 ml sample in the beaker and put it on the hot
plate. After water completely evaporated. Cool the beaker and weigh the residue.

TS (ppm) = (Final weight – Empty weight) *106 / ml of the sample (50ml)

ANALYSIS METHOD FOR TOTAL DISSOLVED SOLID (TDS)

Take clean and empty beaker and weight it. Take 50 ml effluent and filter it on filter paper. Put
the beaker on the hot plate and complete water from the beaker. Weigh the residue remains in the
beaker.

TDS (ppm) = (Final weight – Empty weight) *106 / ml of the sample (50ml)

Suspended Solids (SS) = Total solids (TS) – Total Dissolved Solids (TDS)

8.3 AIR POLLUTION CONTROL

In PI plant there are only two boiler houses. So pollutant laden gas is not much more generated
and oxides of nitrogen (NOx), oxide of Sulphur (Sox) are not found in harmful concentration. The
measurement of NOx, Sox is done at regular interval of time.

44
 BIBLIOGRAPHY

1. Mass transfer Operation (Robert E. Trybal )

2. Unit Operations (McCabe & Smith)
3. Panoli Process Manuals
4. www.panoliindia.com

45