MANUFACTURE OF ALUM

… …

A PROJECT REPORT
Submitted by

M.AJITH (612614203001)
K.ARUN (612614203005)
M.SOUNDARRAJAN (612614203037)

Under the guidance of:

Asst.Prof SAMPATH KUMAR .G
In partial fulfillment of the requirements for the degree
of
BACHELOR OF TECHNOLOGY
in
Chemical Engineering

THE KAVERY COLLEGE OF ENGINEERING,

MECHERI, SALEM -636453

APRIL-2018

i
 ANNA UNIVERSITY : CHENNAI-600025

BONAFIDE CERTIFICATE

This is to certify that the report on “MANUFACTURE OF ALUM ” submitted

by AJITH.M(612614203001),ARUN.K(612614203005)&SOUNDARRAJAN.M
(612614203037)in partial fulfillment of the requirements for the award of degree
of Bachelor of Technology in Chemical Engineering at The Kavery College Of
Engineering, Mecheri is an authentic work carried out by him under my
supervision and guidance.
To best of knowledge, the matter embodied in this thesis has not been submitted to
any other university or institute for the award of any degree.

HEAD OF THE DEPARTMENT SUPERVISOR

Prof DR.S.K.MOHAN Asst. Prof SAMPATH KUMAR.G
Department of Chemical Engineering, Department of Chemical Engineering,
The Kavery College Of Engineering, The Kavery College Of Engineering,
Mecheri-636453. Mecheri-636453.

Submitted for the project viva -voice examination held on

INTERNAL EXAMINAR EXTERNAL EXAMINAR

ii
 ACKNOWLEDGEMENT
At this pleasing movement of having successfully completed our project
phase we wish to convey our sincere thanks and gratitude to management of our
college and our honorable chairman & advisor Prof. DR.A.K.NATESAN and
chairman, THIRU.A.ANBALAGAN who provide all facilities to us.

We express our thanks to our secretary Prof. S.K.ELANGOVAN&

coordinator Mrs. S.V.REVATHY ELANGOVAN for their inspiring support. We
would express our sincere thanks to our correspondent Mr. R.RAMANATHAN.

We would express our sincere thanks to our Dean Prof. S.OBLI B for this
encouragement in doing this project. We would like to express our sincere thanks
to our Principal Dr. K.P.KARUPANNAN for forwarding us to do our project and
offering adequate duration in completing our project.

We also grateful to the Head Of The Department in Chemical Engineering

Prof. Dr. S.K.MOHAN for this constructive suggestion & encouragement during
our project.

With deep sincere of gratitude, we extend oue sincere thanks to guide

Asst.Prof.SAMPATH KUMAR.G in Chemical Engineering for his valuable
guideness and encouragement to complete this project.

We also express indebt thanks to our teaching staff and other staff member
of Chemical Engineering department fot rendering their valuable support.

iii
ABSTRACT

iv
 ABSTRACT
The aim of the project is to undertake a process to manufacture the alum
from aluminum sulphate and potassium sulphate to choose the best process to
produce alum Profitably. The analysis of the synthesized alum confirmed the
presence of potassium, aluminum, sulphate, water of crystallization and a melting
point of 92˚C. The yield from aluminum foil was 15.35 g(76%) and aluminum
scrap was 12.74 g(63%). The synthesized alum was found to be more effective
than the commercially available alum in the treatment of muddy and waste water
from fast food industry. The synthesized alum reduces the turbidity level of muddy
and waste water from fast food industry (1839 and 2305 NTU) to 169 (90.8%) and
34 NTU(98.5%) respectively.The technical part involves the development of flow
sheets, process design,Carrying out calculations as well as estimation of raw
materials, labor, utilities and process equipment by sizing and other
subcomponents. The economic part comprises the estimation of working capital,
fixed capital investment, total capital investment and total production costs.It is
required to completely plan out the construction of the plant and its units which
includes the man power requirements, layout and site selection and which doesn’t
harm the environment. The use of synthesized alum in water treatment is more
efficient, economical and eco- friendly compared to the commercial available
alum.

v
 TABLE OF CONTENTS

SI.NO. TITLE PAGE NO.

LIST OF TABLES i

LIST OF FIGURES ii

LIST OF SYMBOLS iii

1 INTODUCTION 1

1.1 Introduction of Alum 2

1.2 History of Alum 3
1.3 Properties of Alum 5
1.4 Application of Alum 7
2 LITERATURE REVIEW 10
2.1 Process Flow Sheet 11
2.2 Major Components 12
2.3 Process description 14
2.4 Material Balance 16
2.5 Energy Balance 22
2.6 Design of equipment 26
2.6.1 Storage tank 27
2.6.2 Evaporator 30
2.6.3 Reactor 34
2.7 Cost Estimation 38

vi
 2.8 Safety Aspects 46
2.9 Plant Layout 57
3 CONCLUSION 59
4 BIBLIOGRAPHY 61

vii
 LIST OF TABLES

SI.NO TITLE PAGE NO.

1 Material Balance 16
1.1 Material balance for reactor 17
1.2 Material balance for settling bank 18
1.3 Material balance for evaporator 19
1.4 Material balance for centrifuge 20
1.5 Material balance for casting unit 21
2 Energy Balance 22
2.1 Data required 23
3 Cost Estimation 38
3.1 Land & Building 39
3.2 Machinery & Equipment 39
3.3 Raw Materials 40
3.4 Salary & Wages 41
3.5 Utilities 41
3.6 Other Expenses 42
3.7 Cost of Production 43
3.8 Turn over 43
3.9 Fixed Cost 45

viii
 LIST OF FIGURES

SI.NO TITLE PAGE.NO

1. Process flow sheet 11

2. Storage tank 29
3. Evaporator 33
4. Reactor 37
5. Plant layout 56

ix
 LIST OF SYMBOLS

S.NO PHYSICAL CONSTANT SYMBOL UNITS

1 Density ρ kg/m3

2 Heat Energy Q KJ/hr

3 Height H M

4 Latent Heat ƛ KJ/kg

5 Length L M

6 Mass M kg

7 Specific Heat Cp KJ/kg

8 Temperature T ˚C or K

9 Volume V m

10 Pressure P atm

11 Mass flow rate M kgs-1

12 Thickness t m

13 Cross Sectional Area A m2

14 Molecular Mass M kg/kg moles

x
INTRODUCTION
1.1. INTRODUCTION

Alum is both a chemical compound and a class of chemical compound. The

specific compound is the hydrated potassium aluminum sulfate(potassium alum) with
the formula KAl(SO4).12H2O. More widely alums are double sulfate salt, with general
formula is AM(SO4)2.12H2O, Where A is a monovalent cation such as potassium or
ammonium and M is trivalent metal ion such as aluminum or chromium. When the
trivalent ions is aluminum,the alum is named after monovalent ion.

TYPES OF ALUM:

Alum is classified into six types. They are

1. Potassium alum

2. Sodium alum

3. Ammonium alum

4. Chrome alum

5. Selenate alum

6. Aluminum sulfate

2
HISTORY

3
1.2. HISTORY :

In the 18th century , Johann Heinrich Pott(1692-1777) and Andreas Sigismund

Marggraf demonstrated that alumina was a constituent. Pott in his Lithogeognosia
showed that the precipitate obtained.

When an alkali is poured into solution of alum is quite different from lime and
chalk , with which it had been confounded by G.E.Stahl. Marggraf showed that alumina
is one of the ingredients in common clay.

He also showed that crystals of alum can be obtained by dissolving alumina in

sulfuric acid and evaporating the solutions , And when a solution of potash or ammonia
is dropped into this liquid , it immediately deposits perfect crystal of alum.

Torbern Bergman also observed that the addition of potash or ammonia made the
solution of alumina in sulfuric acid crystallize , but that the same effect was not
produced by the addition of soda or of lime , and that potassium sulfate is frequently
found in alum.

After M.H.klaproth had discovered the presence of potassium in leucite and

lepidolite, It occurred to L.N. Vanquelin that it was probably an ingredient likewise in
many other minerals .

Knowing that alum cannot be obtained in crystals without the addition of potash ,
He began to suspect that this alkali constituted an essential ingredient in the salt, And in
1797 he published a dissertation demonstration that alum is a double salt , composed of
sulfuric acid, alumina and potash.

4
PROPERTIES OF ALUM

5
1.3. PHYSICAL AND CHEMICAL PROPERTIES

Chemical formula : KAl(SO4)2.12H2O

Molar mass : 473.37g/mole

Appearance : white crystalline solid

Density : 1.757kg/m3

Melting point : 92-930C

Boiling point : 2000C

Solubility in water : very soluble

Solubility : stable under ordinary conditions.

Acidity (pKa) : 3.3-3.6

Specific gravity : 1.157

Odor : odorless.

6
APPLICATIONS

7
1.4. APPLICATION OF ALUM:
1. Water Treatment:

The major area of use for Alum is in water treatment and clarification. Its
clarifying action is attributed to Aluminium hydroxide formation by hydrolysis. This,
in turn, carries down all the colloidal impurities and forms a slimy layer at the bottom.

2. Sizing of paper:

The other major areas of use is in sizing of paper. It reacts with sodium resinate
to give insoluble Aluminium resinate. For sizing of paper, Alum should be free from
ferric ions or else the paper will be discoloured. Ferrous ions do not harm since they
form a soluble colourless resinate which, however, would represent a loss of
resinate.Alum imparts certain degree of resistance to penetration by liquids during
sizing of paper.

3. Miscellaneous Application:

Alum is also required in various other industries like Dyes, Food, Petroleum,
Pharmaceuticals, Fire-proofing, tanning etc.

8
Other Major Uses
In addition to the primary uses in the pulp & papermarking industry and for
water and waste water treatment, alum is also used in:

Cellulosic insulation Additive to cellulosic insulation

Clay manufacturers China clay beneficiation

Dyes Mordant for dyes

Grease manufacturers Manufacture of aluminum soaps and

greases

Industrial wastewater treatment Sewage and industrial wastewater

treatment, emulsion breaking

Soap manufacturers Manufacture of glycerin from soap lyes

Swimming pools, oil well operators, Water treatment

manufacturers

Tanneries Tanning furs and white leathers

Zeolite and catalyst manufacturers Manufatures of zeolites and

aluminosilicate catalysts and carriers

9
2.1. PROCESS FLOW SHEET

10
11
2.2. MAJOR COMPONENTS

12
Some of the major components of Alum plants are

1. Elevators
2. Hoppers
3. Tanks
4. Reactor
5. Settling Tank
6. Evaporators
7. Casting unit
8. Centrifuge

13
2.3. PROCESS DESCRIPTION

14
MANUFACTURE PROCESS:
The raw materials for alums are

1. Aluminum sulfate
2. Potassium sulfate

Aluminum sulfate powder is stored in the bin. The reactor has Lead and AHR
lining. A measured quantity of water or recycled liquor is fed into the reactor. A
measured quantity of potassium sulfate added to the Digester. The temperature of the
diluted Acid rises due to the liberation of heat of dilution. Now, the powdered
Aluminum sulfate is added slowly and carefully. The reaction is vigorous and the
reaction proceeds with frothing. The reaction temperature goes up to 120 0C. The
reaction is taken to the completion by adding Aluminum sulfate to neutralize the
remaining Acid. The agitation with the mechanical stirrer is done as and when
required.

The liquid is drained into the settling pit and allowed to settle for few days.

The decanted liquid is taken to the evaporator where it is heated with steam
coils.As the desired gravity of liquid is achieved, the liquid is taken to the moulds for
casting.

The sludge is washed into a centrifuge. The liquid is recycled and the solid
sludge is used for land filling.

Chemical Reaction:
K2SO4 + Al2 (SO4)3 + 24H2O 2KAl(SO4)2 .12H2O

15
2.4. MATERIAL BALANCE

16
2.4.1. MATERIAL BALANCE FOR REACTOR

Water + mother liquor

Aluminum sulphate

25797.06 kg / day

Product
Potassium sulphate 73136.54 kg /day
13124.48 kg / day

S. COMPONENT INPUT COMPONENT OUTPUT

NO (kg/day) (kg/day)
1. Aluminum sulphate 25797.06 Alum solution 71507.64

2. Potassium sulphate 13124.48 Aluminum sulfate 943.9

unreacted

3. Water 32585.8 Aluminum 50.0

sulphate losses

4. Mother liquor 1628.9 Potassium sulfate 765.00

TOTAL 73136.54 TOTAL 73136.54

17
2.4.2. MATERIAL BALANCE FOR SETTLING TANK

Feed
73136.54 kg/day

Alum solution
69878.74 kg/day

Sludge
1628.9 kg/day

S. COMPONENT INPUT COMPONENT OUTPUT

NO (kg/day) (kg/day)
1. Alum solution 71507.64 Alum clear solution 69878.74

2. Aluminum sulfate 943.9 Sludge 1628.9

Unreacted

3. Aluminum sulfate 50.0

Losses

4. Potassium sulfate 765.00

Unreacted

TOTAL 73136.54 TOTAL 73136.54

18
2.4.3. MATERIAL BALANCE FOR EVAPORATOR

Vapour
19878.74 kg/day

Feed
69878.74 kg/day

Concentrated
solution
50000 kg/day

S. COMPONENT INPUT COMPONENT OUTPUT

NO (kg/day) (kg/day)
1. Alum Clear 69878.74 Concentrated Alum 50000
Solution
2. Vapour 19878.74

TOTAL 69878.74 TOTAL 69878.74

19
2.4.4. MATERIAL BALANCE FOR CENTRIFUGE

Feed
16289.4 kg/day

Mother liquor
1628.94 kg/day

Solid
14660.46 kg/day

S. COMPONENT INPUT COMPONENT OUTPUT

NO (kg/day) (kg/day)
1. Sludge 16289.4 Mother liquor 1628.94

2. Waste solid 14660.46

TOTAL 16289.4 TOTAL 16289.4

20
2.4.5. MATERIAL BALANCE FOR CASTING UNIT

Feed
Liquit alum 5000 kg / day

Solid alum 5000 kg / day

S. COMPONENT INPUT COMPONENT OUTPT

NO (kg/day) (kg/day)

1. Concentrated Solid
KAl2(SO4)2 50000 KAl2(SO4)2 50000
TOTAL 50000 TOTAL 50000

21
2.5. ENERGY BALANCE

22
REQURIED DATA:
S.NO COMPONENT ∆H Cp Molecular
(kj /mole) (kj /kg.k) Weight(g /mole)
1. KAl2(so4)3 -1387.4 3.457 336

2. K2SO4 -814.0 1.38 174

3. H2O -286 4.178 18

4. Al2(so4)3 -1350 0.1855 342

2.5.1. ENERGY BALANCE FOR REACTOR:

∑∆HREACTOR = ∑∆HPRODUCT - ∑∆REACTANT

= 73136.54(-817)-(25794.60)×(-1350)+((13124.48)×(-814))
+((3585.8)×(-286))+((1628.9)×(-817)))
= -59728174.3 + 13072873.95
= -46655300 kj / mole (Exothermic reaction)

23
2.5.2. ENERGY BALANCE FOR EVAPORATOR:

Qin =m Cp ∆T
= 69878.74×(2,335) (423-393)
= 4895005.7kj/day
= 4895005.7 / (24×3600)
= 56.7w

QOUT = m CP ∆T

= 50000×(2.335)× (423)
= 49385250 kj/day

= 571.5w

For vapour
Q = mƛ
Where
ƛ - Laten heat of evaporator
ƛ = 2257 kj/kg
Q = mƛ
= 19878.74×2257
= 44866316.18 kj/day
= 519.3w

24
2.5.3. ENERGY BALANCE FOR COOLER:
Q = m Cp ∆T
= 50000 × (2.335) (423-298)
= 169W

25
2.6. DESIGN OF EQUIPMENT

26
 2.6.1. STORAGE TANK
K2SO4 STORAGE TANK DESIGN:
Density of k2so4 = 2660 kg/m3
`
permissible stress = 1264 kg/m3
Density of material =7850 kg/m3
Welded joint efficiency = 85 %
Mass of the feed = 13124.48 kg/day
Mass of feed three days = 39373.44 kg/ 3day
Volume = 39373.44 /2660
V = 14.8 m3
L/D ratio = 2
Volume of storage tank V = 3.14D2L/4
14.8 = 3.14×2×D3/4
D = 2.11 m
L = 4.22 m
Internal pressure is calculated by
P = ρ (H – 0.3) ×102
= 0.0002660 (4.22 - 0.3) × 103
= 0.1042 g/cm2

Thickness ‘t’ = PD/2fe + c

= (0.048×211) / (2×1204×0.85) + 0.2

= 0.204 cm (or) 2.04 mm

Volume of steel required =3.14×D×H×t

= 3.14×0.204×2.11× 4.22 = 5.703×10-3 m3

27
Weight of sheet required = (0.00204) ×7850
= 16kg
Cost of sheet per kg = 70
= 70×16
= Rs.1120

DESIGN SUMMARY:

Volume of the storage tank V =14.8m3

Internal pressure = 0.1042g/cm2

Thickness ‘t’ = 0.204cm (or) 2.04mm

Volume of sheet = 5.703 × 10-3 m3

Weight of sheet = 16kg

28
 Roof

In

Liquid level Out

STORAGE TANK

29
2.6.2. EVAPORATOR:

S ƛs = V ƛV + F.CPF (TV – TF)

ƛV = 2257 kj/kg .K

CPF = 4.178 kj/kg .K

S (1818.18) = (13.80×2257) + 48.52×4.1

S (1818.18) = 19440.58

S =10.69 kg/sec

Q = S ƛs

=10.69×1818.18

=19436.3kj/sec

Q = UA∆T

19436.3 = 1100×A0×95

A0 = 18.6 m2

A0 = 3.14*d0*L*N

Outside diameter = 45 mm

Inside diameter = 35 mm

L=8m

N = A0 / (3.14×(45×10-3)×8)

= 18.6/ (1.130) = 21

30
No.of tubes required = 21

Cross sectional area of tube (m2)

Ai = (3.14×di2) /4

= 9.616×10 -4 m2

DOWEN CORNER AREA :

AD = 0.5×(Ai×N)

= 0.01 M2

ANNULAR AREA :

AA= ND2T

AA =1.1025 m2

EVAPORATOR AREA :

AE =1.1[AA+AD]

AE =1.223 m2

DE =2×√(AE/ 3.14)

=1.248 m2

VAPOUR SPACE HEIGHT :

=1.5×DE = 1.87 m

31
HEIGHT OF THE EVAPORATOR :
= 3×L

= 24 m

NOZZLE DIAMETER OF THE FEED :

Dnf = f/e.v

V =1.5n/s

Dnf =2.35×10-3 m

NOZZLE OF THE PRODUCT :

V =1m/s

Dnp=P/(ρ×V)p

=0.0442 m

Dn2 =S/(P×V)

Dn = 38.78 m

DESIGN SUMMARY:
1. Outside diameter =45mm
2. Inside diameter = 35mm
3. L =8m
4. No.of tubes required =21
5. Cross sectional area of tube =9.616×10 -4m2
6. Height of the evaporator =24m

32
 STEAM

INPUT

Kg / Day

CONCENTRATE

EVAPORATOR

33
2.6.3. REACTOR:
Volume of reactor

τ = 5min

τ = CA0 V/FA0

CA0 = P/RT

= 1/0.0821× 353

= 0.0345Kmol/m3

FA0 = 3.603kmol/hr

V = τ× FA0/ CA0 = (5×3.603)/ (0.345×60)

V = 8.704 m3

3.14×r2×h = 8.704 m3

d3 = 8.704×4/3×3.14

d = 1.5m

h = 3×1.5

h = 4.6m

Thickness of reactor = 7 mm=0.007 m

D = 1.507 m

Inside diameter = 1.5 m

Outside diameter = 1.507 m

34
JACKET:

Length of the jacket = 3.68 m

Inner diameter of the shell = 1.5 m

Heat transfer area = 3.14×d×1

= 17 m2

Jacket space = 30 cm

Std. thickness of jacket = 5mm

Total outside diameter of the jacket = 1.505 m

BAFFLE:

Impeller diameter = 1.5/3 = 0.5 m

Diameter of the propeller = 0.5 m

Impeller level above the vessel floor = 0.5/4 = 0.12 m

Number of impeller blade = 6

Distance between consecutive impeller = 0.5

Width of impeller = 0.5/5 = 0.027 m

Power requirement = (NP x N x Da x ρ)/gc

= 6 x 11.7 x 1.5 x 742/9.82

Power requirement P = 44hp

35
DESIGN SUMMARY:
1. Volume of the reactor = 8.704 m3
2. Height of the reactor = 4.6 m
3. Diameter of the reactor = 4.6 m
4. Thickness of reactor = 7 mm
5. Outside reactor = 1.8 m
6. Length of the jacket = 3.68 m
7. Inner diameter of the steel = 1.5 m
8. Number of impeller blade = 6
9. Power requirement P = 44 hp

36
37
2.7. COST ESTIMATION

38
FINANCIAL ASPECTS:
SI.No Description Quantity Value (Rs)

(a) Land &building

Total 1500 sq. Mtr. (covered area of 300 s. L.S. 40000

Mtrs. On rent)
(b) Machinery & equipments
(i) Reactor M.S Lead tank, inside Lead
lined covered with acid proof bricks
fitted with mechanical stirrer oprated by 5 1 No. 80000
H.P motor alone with reduction gear
assembly and discharge valves.
(ii) Settling tank with conical bottom & lined
from inner side with acid proof bricks with
discharge valve and other fittings. 1 No. 50000
(iii) Evaporation Tanks M.S Lead bonded
steam coil Heating 1 No. 98000
(iv) Water Softing plant 1 No. 100000
(v) Sulfuric Acid Storage tank 1 No. 120000
(vi) Centrifuge 1 No. 100000
(vii) Acid Pump 1.5’’ x 1’’ complete with 3 H.P.
motor 3 Nos. 50000

39
 (viii) Chain hoist & changing bucket with
supporting girders 1 No. 45000
(ix) Cost of moulds
L.S. 100000
(x) Chemical balance, glassware and misc.
Equipments for chemical laboratory L.S. 57500

(xi) Cost of office furniture & equipments

L.S. 45000

(xii) Electrification & installation charges @ 10%

of the cost of machinery & equipments. L.S. 300000
(xiii) Proeprative Expenses
L.S. 25000
Total 278500

(c) Raw Materials per Month

SI. No. Description Quantity Value (Rs)
(i) Al2 (SO4)3@ Rs.10338/ton 27 ton 279126

(ii) Potassium sulfate (98%)@ Rs.6,000 per 51 ton 306000

MT

Total 585126

40
 (d) Salary & wages per month:

SI. No. Description Quantity Value (Rs)

(i) Manager / Chemist 1 No. 9000
(ii) Skilled labour 3 No. 11000
(iii) Unskilled labour 8 Nos. 22000
Total 42000

(e) utilities per month:

SI. No Description Quantity Valve (Rs)

(i) Power @ Rs.8.5/KWH 55 HP 3334

(ii) Water L.S. 4000
Total 34334

41
(f) other expenses per month:

(i) Rent L.S. 40000

(ii) Postage & stationary
L.S. 2000
(iii) Telephone L.S. 3000
(iv) Repair & Maintenance L.S. 6000
(v) Insurance @ 2% of the cost of
machinery & Equip. L.S. 5000
(vi) Marketing &Travelling Expenses L.S. 11000
Total 67000

(g) Working Capital For One Month (c+d+e+f) : 7,28,460/-

(h) Working Capital For Three Months : 21,85,380/-

(i) Total Capital Invesment (b+h) : 37,60,880/-

42
FINANCIAL ANALYSIS:
(a) Cost of production per Annum:

SI. No Description Value (Rs.)

(i) Raw Materials 5028800

(ii) Salary & Wages 680000
(iii) Utilities 100000
(iv) Other Expenses 690000
(v) Depreciation on machinery & equipments @ 10% p.a. 704100

(vi) Interest on borrowed capital @ 13 % p.a. 791210

Total 7994110

(b)Turnover per Annum:

SI. No Description Value (Rs)

(i) 1500 MT of Alum @ Rs.5,700 per MT 85,50,000/-

43
(c) Net Profit per Year :

Net Profit = Total turnover - Total cost of Production

= 8550000 - 7994110

= 555890/-

(d) Profit Ration on Sales :

Profit Ratio on Sales = Net Profit / Total turnover × 100

= (555890/8550000) ×100

= 6.5 %

(e) Rate of Return (ROR) on Total Capital Investment:

ROR = (Net Profit per annum/Total Capital Investment) ×100

= (555890/3760880) ×100

ROR = 14.78%

44
(g) Break Even Analysis

(i) Fixed Cost:

SI. No Description Amount (Rs)

01. Depreciation on Machinery & equipments @
10% p.a 109500
02. Interest on total capital investment @ 13% p.a 115600
03. 40 % of Salary &Wages 185000
04. 40% Other Expenses 10000
Total 353600

Break Even Point (B.E.P):

B.E.P = (Fixed Cost/ Fixed Cost + Profit) ×100

= (353600 / (353600 + 555890)) ×100

B.E.P = 38.87%

45
2.8. SAFETY ASPECTS

46
PRODUCT NAME

Potassium aluminum sulfate (K Al (SO4)3 .12H2O)

EMERGENCY OVERVIEW

1. Risk of serious damage to eyes.

2. Possible risk of irreversible effects.

3. Irritating to respiratory system and skin.

POTENTIAL HEALTH EFFECTS

ACUTE HEALTH EFFECTS

SWALLOWED

1. Accidental ingestion of the material may be damaging to the health of the

individual.
2. Sulfates are not well absorbed orally, but can cause diarrhea.
Acute toxic responses to aluminum are confined to the more soluble forms.

EYE

1. If applied to the eyes, this material causes severe eye damage.

SKIN

1. This material can cause inflammation of the skin on contact in

some persons.

2. The material may accentuate any pre existing dermatitis condition.

3. Skin contact is not through to have harmful health effects.

47
4. Open cuts, abraded or irritated skin should not be exposed to this material.

5. Entry into the blood - stream, through for example, cuts, abrasions or lesions, may
produce systematic injury with harmful effects. Examine the skin prior to the use of
the material and ensure that any external damage is suitably protected.

INHALED

1. The material can cause respiratory irritation in some persons. The body’s response
to such irritation can cause further lung damage.

2. Persons with impaired respiratory function, airway diseases and conditions such as
emphysema or chronic bronchitis, may incur further disability if excessive
concentrations of particulate are inhaled.

3. Not normally a hazard duo to non-volatile nature of product.

CHRONIC HEALTH EFFECTS

Long- term exposure to respiratory irritants may result in disease of the airways
involving difficult breathing and related systemic problems. Strong evidence exists
that the substance may cause irreversible but non – lethal mutagenic effects following
a single exposure. Exposure to the material may result in a possible risk of irreversible
effects. The material may produce mutagenic effects in man. This concern is raised,
generally, on the basis of appropriate studies using mammalian somatic cells in vivo.
Such findings are often supported by positive results from in vitro mutagenicity
studies. Limited evidence suggests that repeated or long- term occupational exposure
may produce cumulative health effects involving organs or biochemical systems.
Long term exposure to high dust concentrations may cause changes in lung function
i.e. pneumoconiosis; caused by particles less than 0.5 micron penetrating and
remaining in the lung. Exposure to large doses of Aluminum has been connected with

48
the degenerative brain disease Alzheimer’s Disease. Repeated minor skin contact may
result in numbing of fingers. repeated minor ingestion may cause phosphate
deficiency; weakening bones.

FIRST AND MEASURES

SWALLOWED

If swallowed do NOT induce vomiting. If vomiting occurs, patient forward or place

on left side (head-down position, if possible)to maintain open airway and prevent
aspiration.

EYE

If this product comes in contact with the eyes:

1. Immediately hold eyelids apart and flush the eye continuously with running
water.
2. Ensure complete irrigation of the eye by keeping eyelids apart and away from
eye and moving the eyelids by occasionally the upper and lower lids.

SKIN

If skin contact occurs:

1. Immediately remove all contaminated clothing, including footwear

2. Flush skin and hair with running water (and soap if available).

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NOTES TO PHYSICIAN

Manifestation of aluminum toxicity include hypercalcemia, anemia, vitamin D

refractory osteodystrophy and a progressive encephalopathy (mixed dysarthira
apraxia of speech, asterixis, tremulousness, myoclonus, dementia, focal seizures).
Bone pain, pathological fractures and proximal myopathy can occur. Symptoms
usually dietary aluminum loads are excessive.

If fumes or combustion products are inhaled remove from contaminated area.

Lay patient down. Keep warm and rested.

FIRE FIGHITING MEASURES

EXTINGUISHING MEDIA

There is no restriction on the type of extinguisher which may be used. Use

extinguishing media suitable for surrounding area.

FIRE FIGHTING

Alert Emergency Responders and tell them location and nature of hazard. Wear
breathing apparatus plus protective gloves for fire only.

GENERAL FIRE HAZARDS / HAZARDOUS COMBUSTIBLE PRODUCTS

1. Non-combustible
2. Non considered to be a significant fire risk, however containers may
burn.Decomposition may produce toxic fumes of: sulfur oxides (SOX), metal
oxides.
3. May emit poisonous fumes.
4. May emit corrosive fumes.

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PERSONAL PRODUCTION

1. Glasses
2. Chemical goggles
3. Gloves
4. Respirator
5. Type E-P Filter of sufficient capacity

ACCIDENTAL RELEASE MEASURES

MINOR SPILLS

1. Remove all ignition sources

2. Clean up all spills immediately.
3. Avoid contact with skin and eyes.
4. Control personal contact by using protective equipment.
5. Use dry clean up procedures and avoid generating dust.

MAJOR SPILLS

Moderate hazard

CAUTION: Advise personnel in area.

Alert Emergency Responders and tell them location and nature of

hazard

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HANDLING AND STORAGE

PROCEDURE FOR HANDLING

1. Avoid all personal contact, including inhalation.

2. Wear protective clothing when risk of exposure occurs.

RECOMMENDED STORAGE METHODS

1. DO NOT use aluminum, galvanized of tin-plated containers.

2. Polyethylene or polypropylene containers.
3. Check all containers are clearly labeled and free from leaks .

STORAGE REQUIREMENTS

1. Store in original containers.

2. Keep containers securely sealed.

PERSONAL PROTECTION

RESPIRATOR

Type E-P Filter of sufficient capacity

Consult your EHS staff for recommendation

EYE

1. Safety glasses with side shields.

2. Chemical goggles.

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HANTS / FEET

Suitability and durability of glove type is dependent on usage. Important factors in

the selection of gloves include: such as :

1. Frequency and duration of contact,

2. Chemical resistance of glove material,
3. Glove thickness and
4. Dexterity select gloves tested to a relevant standard (e.g. Europe EN 374,USF739)
5. When prolonged or frequently repeated contact may occur, a glove with a
protection class of 5 or higher (breakthrough time greater than 240 minutes
according EN 374) is recommended.
6. When only brief contact is expected, a glove with a protection class of 3 or higher
(breakthrough time greater than 60 minutes according to EN 374) is recommended.
7. Contaminated gloves should be replaced. Gloves must only be worn on clean
hands. After using gloves, hands should be washed and dried thoroughly.
Application of a non-perfumed moisturizer is recommended. Experience indicates
that the following polymers are suitable as glove materials for protection against
undissolved, dry solids, where abrasives particles are not present.
1. Polychloroprene
2. nitrile rubber
3. butyl rubber
4. fluorocaoutchouc
5. polyvinyl chloride gloves should be examined for wear and/ or degradation
constantly

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OTHER

1. overalls.
2. P.V.C apron
3. Barrier cream.
4. Skin cleaning cream.
5. Eye was unit.

CHEMICAL STABILITY

CONDITIONS CONTRIBUTING TO INSTABILITY

1. Presence of incompatible materials.

2. Product is considered stable.

STORAGE INCOMPATIBILITY

1. Metals and their oxides or salts may react violently with chlorine trifluoride and
bromine trifluoride.
2. These trifluoride are hypergolic oxidizers. They ignites on contact (without
external source of heat or ignition) with recognized fuels - contact with these
materials, following an ambient or slightly elevated temperature, is often violent
and may produce ignition.
3. The state of subdivision may affect the results.
4. In presence of moisture, the material ir corrosive to aluminum, zinc and tin
producing highly flammable hydrogen gas.

54
TOXICOLOGICAL INFORMATION

TOXICITY AND IRRITATION

1. Unless otherwise specified data extracted from RTECS - register of Toxic effects
of chemical substances
2. Asthma – like symptoms may continue for months or even year after exposure to
the material ceases. This may be due to a non- allergenic condition known as reactive
airways dysfunction syndrome (RADS) which can occur following exposure to high
level of highly irritating compound . Key criteria for the diagnosis of RADS include
the absence of preceding respiratory disease, in a non – atopic individual, with abrupt
onset of persistent asthma- like symptoms within minutes to hour of a documented
exposure to the irritant. A reversible airflow pattern, on spirometry , with the
presence of moderate to serve bronchial hyperreactivity on methacholine challenge
testing and the lack of minimal lymphocytic inflammation, without eosinophilia, have
also been included in the criteria for diagnosis of RADS. RADS (or asthma)
following an irritating inhalation is an infrequent disorder with rates related to the
concentration of and duration of exposure to the irritating substance. Industrial
bronchitis, on the other hand, is a disorder that occurs as result of exposure due to
high concentration of irritating substance (often particulate in nature) and is
completely reversible after exposure ceases. The disorder is characterised by
dyspnea, cough and mucus production.

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DISPOSAL CONSIDERATIONS

DISPOSAL INTRUCTION

All waste must be handled in accordance with local, state and federal
regulation. Puncture containers to prevent re – use and bury at an authorized landfill.
Legislation addressing waste disposal requirements may differ by country, state and
/ or territory. Each user must refer to laws operating in their area. In some areas,
certain wastes must be tracked.

A Hierarchy of controls seems to be common – the user should investigate

1. Reduction
2. Reuse
3. Recycling
4. Disposal (if all else fails )

56
2.9. PLANT LAYOUT

57
 Aluminium
sulphate Settling tank
hopper

Pottasium Evaporation
sulphate Reactor
storage

Water
storage

58
Centrifuge
Mould
unit
Mother liquor storage

Cooling
Rest Power Waste solid system
room room storage
3. CONCLUSION

59
3. CONCLUSION

This project work is attempt in understating the fundamentals of chemical engineering

principles and its application in industrial practice. Alum fro Aluminum sulfate and
potassium sulfate finds many applications. The material, energy balance, design have
been calculated in quite a realistic manner. The assumption made also are based on
fundamental principles and not wild. The cost estimation is worked out and year
wise projection is made. Plant layout considered the basic principles widely
applicable. The return on investment is prosperous and the project stands with good
scope.

60
4. BIBLIOGRAPHY

61
4. BIBILOGRAPHY:

1. Gopala rao marshall.M(2002) “DRYDEN’S outline of chemicals technology”

,third edition, east west press.
2. Robert H.perry and W.Green, “PERRY’S S CHEMICAL ENGINEER’S HAND
BOOK”, seventh edition, mc Grew Hill.
3. “K.V.NARAYANAN, B.LAKSHMIKUTTY”, “STOICHIOMETRY AND
PROCESS CALCULATIONS”, PHI Learning Pvt. Ltd., 01-jan-2006.
4. “Chemical reactor design” peter Harriott CRC press, 06-NOV-2002
5. Donald E.Garrett “chemical Engineering Economics” van Nostrand Reinhold,
1989.
6. Mass Transfer Operation by Robert Treybal.

URL:
1. http://www.lookchem.com/chempedia/chemical-technology/Organic-
Chemical-Technology /18274.html

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