(Phase II) : Turquoise Blue G Dye

A
Project Report
On
Turquoise Blue G Dye

(Phase II)
Submitted in partial fulfillment towards the Bachelor’s Degree in the field of
Chemical Engineering
Prepared By
VASAVA AKSHAY M.
CH- 127 ( I.D.No. 16CHUTG031 )
Under the Guidance of

Associate Professor
DIPALI N. SHAH
Department of Chemical Engineering

Faculty of Technology, Dharmsinh Desai University
College Road, Nadiad – 387 001
April-2020
1
CERTIFICATE
This is to certify that Vasava Akshay (CH-127, I.D.NO:

16CHUTG031) has duly submitted his/her Project Report on
Turquoise Blue G Dye as a partial fulfillment towards Bachelor’s
degree in Chemical Engineering at Dharmsinh Desai University, Nadiad in the year 2020.
Dipali N. Shah Dr. M.S.Rao

Associate Professor, Professor & Head,
Dept. of Chemical Engg., Dept. of Chemical Engg.
DDU, Nadiad. DDU, Nadiad
DATE: DATE:
DECLARATION
2
I Am Vasava Akshay M. declare that, the project report on Turquoise blue G dye comprises my
original work towards the degree of Bachelor of Technology in Chemical Engineering at Dharmsinh
Desai 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.
VASAVA AKSHAY M.
CH-127 (ID 16CHUTG031),Semester VIII,
Department of Chemical Engineering,
Faculty of Technology,
Dharmasinh Desai University, Nadiad.
PREFACE
3
Practical knowledge of any subject is as important as theoretical knowledge for the technical
students. A technical student cannot be a perfect engineer or technologist without practical
understanding of the actual scenario of the branch. Hence this training provides a golden opportunity
for all the students to nourish their knowledge in the world of technical industries.
The principle objective of the training report is to get details about the operations, processes &
general aspect of all technical details which are carried out in the industries and more about the
equipment’s, instruments and other plant accessories used in the chemical industries. Thus it is
important for every technical person to be exposed to training in some kind of an industry or other to
enhance one’s knowledge.
Acknowledgement
4
I would like to thank everyone who helped and facilitated me in the completion of the internship at
Ami chemicals. It provided me with a great chance for learning and improving technical knowledge.
I express special thanks to Mr. Parimal patel sir, in charge officer in industry, who, in spite of being
extraordinarily busy with his duties, took time out to guide me, and Mr. ajit patel, general manager of
the company for allowing me to take training at their organization. I also acknowledge the operators
and plant in charges in the company for sharing their knowledge with me and helping me get
acquainted with the plant.
My deepest gratitude to the faculties at the university for giving me useful guidelines regularly, my
guide, Miss Dipali N. Shah and Dr. M.S. Rao, Head of Department, for letting me have this chance to
gain necessary exposure.
5
Contents
LIST OF FIGURES......................................................................................................................................................................................... I
LIST OF TABLES......................................................................................................................................................................................... II
ABBREVIATIONS...................................................................................................................................................................................... III
NOMENCLATURE...................................................................................................................................................................................... IV
CHAPTER-1 INTRODUCTION TO TURQUOISE BLUE G DYE
Introduction to TURQUOISE BLUE G DYE
production Capacity of Turquoise blue G dye
Market Value Of Product
Technical and commercial Competitors
Technology providers
Application of Turquoise blue G dye
Properties of turquoise blue G dye
Conclusions......................................................................................................................6
CHAPTER-2 SELECTION OF PROCESS............................................................................................................................................. 7
Routes for synthesis of CPC......................................................................................................................8
Raw materials specifications...................................................................................................................13
Raw Material suppliers............................................................................................................................14
Process Block Diagram...........................................................................................................................15
Detailed Process Description...................................................................................................................16
Process flow diagram..............................................................................................................................18
Conclusions 18
CHAPTER -3 MATERIAL BALANCE................................................................................................................................................. 19
Introduction 20
Sulfonation reactor.........................................................................................................21
Dumping tank.................................................................................................................23
Filter press......................................................................................................................23
Condensation reactor......................................................................................................24
Spray dryer.....................................................................................................................24
Summary of Material balance........................................................................................25
6
Conclusions....................................................................................................................27
CHAPTER-4 ENERGY BALANCE.......................................................................................................................................................... 28
Introduction 29
Steps of Energy balance.................................................................................................30
Dehydration step.............................................................................................................30
Pre-heating in reactor.....................................................................................................31
Reaction step..................................................................................................................31
Vacuum separation.........................................................................................................32
Purification in MSRL.....................................................................................................33
Summary.........................................................................................................................34
Conclusions....................................................................................................................34
CHAPTER-5 PLANT UTILITIES............................................................................................................................................................ 35
Introduction...........................................................................................................................36
Cooling Tower.......................................................................................................................36
Boiler section.........................................................................................................................37
Oil Heating Section...............................................................................................................38
Vacuum system.....................................................................................................................39
Scrubber system.....................................................................................................................40
Conclusions...........................................................................................................................40
CHAPTER-6 EQUIPMENT DETAILS................................................................................................................................................... 41
6.1 Process equipment details...............................................................................................42
CHAPTER-7 EQUIPMENT DESIGN...................................................................................................................................................... 44
Introduction 45
Centrifugal Pump...................................................................................................................49
Batch Reactor........................................................................................................................53
CHAPTER-8 BRIEF INTRODUCTION OF PUMPS AND VALVES............................................................................................... 65
Centrifugal Pump...................................................................................................................66
Valves....................................................................................................................................67
CHAPTER-9 SAFETY, HEALTH AND ENVIRONMENT................................................................................................................. 70
Safety Measures.....................................................................................................................71
Personal Protective equipment (PPE)....................................................................................71
Selection Criteria for PPE.........................................................................................71
Different Personal protective equipment...................................................................72
Fire safety..............................................................................................................................72
Classification.............................................................................................................72
Equipment for fire protection....................................................................................73
Special precautions....................................................................................................73
Types of fire extinguisher..........................................................................................73
Environmental Safety............................................................................................................74
CHAPTER-10 PLANT LOCATION AND LAYOUT............................................................................................................................ 79
Justification of plant location................................................................................................80
Plant layout diagram..............................................................................................................82
Conclusions...........................................................................................................................83
CHAPTER-11 COST ESTIMATION....................................................................................................................................................... 84
Introduction...........................................................................................................................85
Cost Estimation.....................................................................................................................85
Conclusions...........................................................................................................................89
CHAPTER-12 CONCLUSION.................................................................................................................................................................. 90
REFERENCES.............................................................................................................................................................................................. 92
LIST OF FIGURES
Figure 1.1- Dehydrating phthalimide using acetic anhydride...............................................................2
Figure 1.2-Accidental synthesis of the phthalocyanine.........................................................................3
Figure 1.3- Laboratory synthesis of phthalocyanine.............................................................................3
Figure 1.4- CPC structure.......................................................................................................................4
Figure 2.1-Synthesis method for CPC....................................................................................................8
Figure 2.2- Reaction mechanism.........................................................................................................10
Figure 2.3- CPC reaction mechanism adduct (1).................................................................................11
Figure 2.7- Process block diagram.......................................................................................................15
Figure 2.8- Process flow diagram........................................................................................................18
Figure 3.1- Block diagram of GLV........................................................................................................21
Figure 3.2- Block diagram of RVD........................................................................................................23
Figure 3.3- Block diagram of Surge drum............................................................................................23
Figure 3.4- Block diagram of MSRL......................................................................................................24
Figure 3.5- Block diagram of Filter press.............................................................................................24
Figure 3.6- Block diagram of SFD.........................................................................................................25
Figure 3.10 Material balance diagram................................................................................................26
Figure 5.1- Cooling tower....................................................................................................................36

Figure 5.2- 1-2 Pass shell and tube heat exchanger............................................................................38
Figure 5.3- Vacuum System.................................................................................................................39
Figure 5.4- Scrubber System...............................................................................................................40
Figure 7.1- Bracket support.................................................................................................................63
Figure 9.1 ETP flow diagram................................................................................................................75
Figure 10.1- Plant layout.....................................................................................................................82

LIST OF TABLES
Table 1.1- Equipment suppliers.............................................................................................................5
Table 2.1- Raw material suppliers.......................................................................................................14
Table 3.1- Raw material & Product Details..........................................................................................20

Table 3.2- Summary of material balance over GLV...........................................................................22
Table 3.3-Summary of material balance over RVD..............................................................................23
Table 3.4- Summary of material balance over Surge Drum................................................................24

Table 3.5- Summary of material balance over MSRL.........................................................................24
Table 3.6- Summary of material balance over Filter press..................................................................25
Table 3.7- Summary of material balance over SFD............................................................................25
Table 3.8- Summary table...................................................................................................................25
Table 4.1- Properties of components..................................................................................................29
Table 6.1- Glass Lined Reactor Vessel (GLV)....................................................................................42

Table 6.2- Rotary Vacuum Dryer (RVD)...............................................................................................42
Table 6.3- Mild Steel Rubber Lined Vessel (MSRL)..........................................................................43

Table 6.4- Filter press..........................................................................................................................43
Table 7.2- Nozzles Design....................................................................................................................60
Table 7.3- Nozzle dimensions..............................................................................................................61
Table 7.4- Flanges details....................................................................................................................62
Table 8.1- Pumps present in plant.......................................................................................................67
Table 8.2- Types of valves...................................................................................................................69
Table 11.1- Cost of equipment............................................................................................................85

Table 11.2- Cost of fabrication……………………………………………….………………………………………………………86
ABBREVIATIONS
CS Carbon steel
MS Mild steel
SS Stainless steel
MOC Material of construction
LMTD Logarithmic mean temperature difference
NPSH Net positive suction head
SI System of international
PPE Personal protective equipment
ETP Effluent treatment plant
BD Blank diameter
OD Outer diameter
ID Inner diameter
SF Straight flange
CA Corrosion allowance
CAS Chemical abstract service
IUPAC International union of pure and applied chemistry
TEMA ubular exchanger manufacturing association
CETP Common effulent treatment plant
GIDC
Gujarat Industrial Devlopment Corporation
TCI Total Capital Investment
CETP Common effluent treatment plant

GIDC Gujarat industrial Development Corporation
FCI Fixed Capital Investment
WCI Working Capital Investment
TCI Total Capital Investment

NOMENCLATURE
C Specific heat KJ/kg
P capacity Mass flow
η Efficiency - K
M rate Molecular Kg/h
μ Viscosity Poise
M weight our
ƛW Latent heat of vaporization
Diameter KJ/kg
g/gm
D mol
A Area m2
P Pressure KPa
T Temperature K
t Thickness mm
rpm Rotation per minute Rad/s
V Volume m3
NP Power number -
NRE Reynolds number -
J Joint efficiency factor -
Q Amount of heat J
ΔHf Heat of formation J/mol
ΔHr Heat of reaction J/mol
K Rate of constant Concntration1-n

time-1
X Conversion -
f Allowable stress N/m2
E Modulus of elasticity N/m2
ρ Density Kg/m3
CHAPTER-1
INTRODUCTION TO REACTIVE TURQUIOSE BLUE G DYE
1
1.1 Introduction to Turquoise blue G dye
Turquoise blue G dye, by virtue of their exceptionally brilliant shade, high tinctorial
strength, low cost and outstanding fastness properties, have been ruling the textile
Industry ever since their commercial introduction in 1935. In the beginning of the 20th
century, commercially available blue dye consisted mainly of Prussian blue, Indigo
derivatives and some azo derivatives. Unfortunately, none of these had the desired
qualities demanded by the textile industry. Most of these dyes had poor chemical
resistance, unsatisfactory acid and/or alkali resistance, insufficient light fastness and poor
sublimation fastness. The discovery of turquoise blue G dye provided them with a
satisfactory solution to their problems. Turquoise blue G dye proved to be outstanding
reactive dye because of their incredible resistance to chemical attack, good fastness to heat
and light, combined with brightness and cleanliness of shade all the qualities sought by the
textile industry.
1.1.1 Structure of reactive turquoise blue G dye :
Figure 1.1- structure
1.2 Production Capacity:
Monthly capacity of the company is to produce about 30 tonnes of Turquoise blue
1.3 Market Value Of Product :
Price is depend on strength of material

 maximum price of highest strength 457 per kg.
 minimum price of lower strength 137 per kg.
1.4 Technical and commercial Competitors

(1) Sudhir dye chem., vatava.
(2) Mac dye chem., vatava.
(3) Pramukh industries, vatava.
(4) Savil dyestuff and chemicals, vatava.
(5) Sudhis industries , vatava.
1.5 Technology providers
Table 1.1- Equipment suppliers
EQUIPMENT NO OF MATERIAL OF CAPACITY SUPPLIER

EQUIPMENT CONSTRUCTION
1.6
SULPHONATOR 2 MILD STEEL 7000 LIT AMBICA
INDUSTRY
DUMPING TANK 1 HDPE 20,000 LIT BHAVSAR

INDUSTRY
DRYER 1 STAINLESS STEEL 7000 LIT MOJ INDUSTRY
FILTERPRESS 2 M.S., S.S. 6-7 KGF/M2 SACHIN

INDUSTRY
PISTON PUMP 1 MILD STEEL 5 KGF/M2 SAI INDUSTRY
DIAPHRAGM PUMP 2 HDPE 5 KGF/M2 ACTIVE ENGI.
CENTRIFUGAL PUMP 7 MILD STEEL 5 KGF/M2 SAI INDUSTRY
CSA STORAGE TANK 2 MILD STEEL 17 TONNES AMBICA

INDUSTRY
AIR COMPRESSOR 1 MILD STEEL 7 KGF/M2 INGERSOL

INDUSTRY
BOILER 1 MILD STEEL 500 KG BAL KRISHNA

INDUSTRY
BALL MILL 4 MILD STEEL 4 , 1.5,2,2 M T AMBICA

INDUSTRY
PIPES _ _ _ SHRI HARI

INDUSTRY
PCL3 TANK 1 MILD STEEL 1500 LIT AMBICA

INDUSTRY
vi
ii
Applications Of Product
 Textile Industries
 Paper Industries
 Paint Industries
 Ink Industries
1.7 Properties of Reactive turquoise blue G dye
1.Chemical properties
 Colour index No.: 21
 Chemical type: inorga
 Flammibility : Non flamma
 Solubility: water Soluble
2. Physical properties
 Appearance: fine dry blue powder
 Odour: Light And Lively Fragrance
 PH:6 to 8
Conclusions:
It has been concluded that Reactive turquoise blue G dye has a, fastness and intensity it has
been used in different industries like textile industries. Due to its wide range of applications it
has a large demand in global market. So it is decided to set up a plant for production of
Reactive turquoise blue G dye.
ix
CHAPTER-2
SELECTION OF PROCESS
2.1 Raw Material suppliers
Table 2.1- Raw material suppliers
COMPONENT MARKET PRICE SUPPLIER
PER KG
COPPER PHTHALO 255 A ONE CHEMICALS, VATAVA.

CYANINE
CHLORO SULPHONIC 14 KATCHH CHEMICALS, VATAVA.

ACID
PHOSPHOROUS 57 VITAL CHEMICALS, VATAVA.

TRICHLORIDE
SODA ASH 24 SHEEL CHEMICALS, VATAVA.
SODA BICARBONATE 25 SHEEL CHEMICALS, VATAVA.
VINYL SULPHONE 195 ARCHIT META CHEM., VATAVA.
PYRIDINE 225 MAYUR DYE CHEM.,VATAVA.
OCTANOL 105 VINYL ENTERPRIZE, VATAVA.
ICE 1.5
2.2 PHYSICAL AND CHEMICAL PROPERTIES OF RAW MATERIALS

1) Copper Phthalo Cyanine:
 Physical properties:
• State: solid
• Appearance : Fine powder
• Colour: Blue
• Molecular Weight: 576.05
• Density: 280Kg/m3
• Specific gravity : 1.5

 Chemical properties
• Chemical formula :C32H16CuN8
• Solubility With water : insoluble
• CAS No.:147-14-8
Uses:
• Use as catalyst in redox reactions
• Use in ink , coating and many plastics

2) Chloro Sulphonic Acid:
 Physical Properties :
• State: liquid
• Colour: colourless
• Odour: pungent
• Molecular Weight: 116.5
• Boiling Point: 158 degree celcius
• Density: 1.753 gm/cm3

 Chemical Properties:
• Chemical formula: ClSO3H
• Solubility with water: soluble
• CAS No.: 3144-16-9
• Uses:
• Use to prepare alkyl sulphates which is used in detergent.

3) Phosphurus Trichloride
 Physical properties:
 State: liquid
 Appearance:colourless/yellow liquid
 Odour:Pungent /irritating
 Molecular Weight: 137
 Boiling Point: 76 degree celcius
 Density: 1.574 gm/cm3
 Specific Gravity: 1.57
 Chemical Properties
 Chemical formula: PCL3
 Solubility with water: soluble
Uses:
 Use in pesticide
 Use in production of phosphorus oxychloride
 Direct reagent in organic synthesis
4) Vinyl Sulphones:
 Physical properties
 State: solid
 Colour: Colourless
 Molecular Weight : 281.3
 Boiling Point: 234.5 degree celcius
 Freezing Point: -26 degree celcius
 Density : 1.1821gm/cm3
 Chemical formula:C8H11O6NS2
 Solubility with water: soluble
 CAS No.: 77-77-0
5) Hydrochloric Acid:
 state: liquid
 Colour: colourless/ slight yellow
 Odour: pungent/ irritating
 Molecular Weight : 36
 Boiling Point: 127 degree celcius
 Density: 1.639 gm/lit
 Specific gravity: 1.19
 Chemical formula: HCL
 Solubility with water : Water
 CAS No.: 7647-01-0
6) Soda Ash:
 State: solid
 Colour: White
 Odour: Odourless
 Molecular Weight: 106
 Density: 2.54gm/cm3
 Chemical formula: Na2Co3
 Solubility with water : soluble
 CAS No.:497-19-8
Uses:
 Use in manufacturing of glass, paper,rayon,soaps and detergents.
2.3 Process Block Diagram
Figure 2.1 Process Block Diagram

Detailed Process Description
Process of production of reactive turquoise blue G dye is consists of Sections:
1. Sulphonation
2. Pcl3 charging
3. Dumping in ice
4. Filteration and washing
5. Condensation with vinyl sulphone
Chemical reaction :
1. Sulphonation:
C32H16CuN8 + 2 ClSO3H DIRECT BLUE + 2HCl
(copper (chloro (hydro
Phthelo sulphonic chloric
Cyanine) acid) acid)
2.Condensation:
DIRECT BLUE + VINYL SULPHONE PRODUCT + 2H 2O
2.4 Process Description:
1.Sulphonation:
 Copper phthalo cyanine is taken in a MS vessel and Chloro Sulphonic acid is charged gradually.
 The temperature is maintained at 40°C by chilled water circulation.
 Then the mass is stirred for 1 hour.

2.PCl3 Charging:
 The temperature of the mass is maintained at 100°C for 1 hour through indirect steaming.
 Then the temperature is raised up to 128°C and maintained for 3-3.5 hours.
 Then the mass is cooled to 70°C by chilled water circulation and PCl3 was added.
 Then the material is heated up to 100°C & the temperature is maintained for 2 hours.
 Then the mass is cooled up to 70°C.
3.Dumping in ICE:
 The slurry formed is charged into ice maintaining at 0°C.
4.Filteration & Washing:
 The dumped mass is filtered through press filter.

 The mass is given chilled water washing using fresh water.
5.Codensation with VS:
 VS is taken in the condensation reactor and a clear solution is made by the addition of soda ash and water.
 Then ice is added to reduce the temperature up to 5°C.
 Then filtered cake is added gradually.
 Then the pH is maintained at 6 by the addition if sodium bicarbonate & ammonia.
 Then the mass is stirred for 2 hours maintaining the above pH.
 Diazotisation of vinyl-sulphone with soda ash and ice
 Coupling of filtered wetcake with diazotized vinyl-sulphone
6. Spray drying:
 The mass produced is spray dried and packed.

2.5Process flow diagram
Figure 2.2- Process flow diagram
Conclusions:
In this session, different routes for synthesis of Reactive turquoise blue G dye discussed and
by checking feasibility of each route best route for production of Reactive turquoise blue G
dye is selected and reaction mechanism for that is also understood. Overall process operations
are also understood by process flow diagram. Now after selection of process, it is required to
estimate the quantity of raw material required for synthesis of Reactive turquoise blue G dye
material balance will give such idea for quantity of materials.
*Process;Amichemicals(vatva)
CHAPTER -3
MATERIAL BALANCE
 INTRODUCTION
 A Material Balance also called a mass balance,is an application of conservation of mass to the
analysis of physical systems.
 Material balance are important first step when designing a new process or analyzing an existing
one.
 Material balance are nothing more than the application of the law of conservation of mass, which
state that mass can neither be created nor destroyed.
 Mathematically the mass balance for a system is given by,
 input+generation=output+accumulation+consumption
 Actual production capacity=2500 Kg/batch
 Design capacity=(ROLL NUMBER+100)
=227 Kg/batch
3.1 Raw material detail

Component name Molecular weight(g/gmol Density(g/cm3)
Copper phthalo cyanine 576.05 0.28
Chloro sulphonic acid 116.5 1.753
Phosphurus trichloride 137 1.574
Vinyl sulphones 281.3 1.1821
Hydrochloric acid 36 1.639
Soda ash 106 2.54

3.2 Chemistry of process
• 1. SULPHONATION
C32H16CuN8 + 2 ClSO3H DIRECT BLUE + 2HCl
(copper (chloro (hydro
Phthelo sulphonic chloric
Cyanine) acid) acid)
M.W 576 116.5 737 36.5
Mass in 78.76 275.676 0 0
Mole in 0.1367 2.366 0 0
Mol e out 0 2.0926 0.1367 0.1367
Mass OUT 0 243.788 100.7479 9.9791

2. CONDENSATION
DIRECT BLUE + 2V.S Reactive blue G DYE +2H2O
M.W 737 281 1262 18
Weight 100.7479 79.9 0 0
Mole used 0.129865 0.2843 0 0
Mole OUT 0.006835 0.0246 0.129865 0.25973
MASS OUT 5.037 6.9126 163.8896 4.67514

3.3 REACTOR 1 (SULFONATOR)
 Copper phthalo cyanine is taken in a M.S vessel and chloro sulphonic acid and charged gradually.
 78.76kg Copper phthalo cyanine is taken in a ms vessel and 275.676kg chloro sulphonic acid and
charged gradually.The temperature is maintain at 40 deg. Cel. By using chilled water circulation.
the mass is stirred for 1 hour.
 mass is cooled to 70 deg. Cel. By chilled water circulation and 27.24kg pcl3 was added.
And then material is heated up to 100 deg. Cel. and mainatain temperature for 2 hour.
Then mass is cooled up to 70 deg. cel.
component input output
CPC 78.76 0
CSA 275.676 243.81
D.W 0 100.78
HCL 0 9.9823
PCL3 27.24 27.24
H2O 2.25756 2.25756
TOTAL 383.93356 384.07

Block diagram of
sulfonator reactor
3.4 Reactor 2(Dumping Tank)

• The slurry formed and charged into ice and mainatain 0-5 deg. Cel. Temperature.
COMPONENT INPUT OUTPUT
SLURRY (384.07-9.982)=374.0877 0
ICE 1225.8 0
MIXTURE 0 1599.8877
Ice 1225.8 kg
3.5 FILTER PRESS
• EFFICIENCY Of Filter Press is 75%.
• Dumped mass filtrede by a filter press and then wash with chilled water.
• After Filterede cake And Spent Acid are Remove .

MIXTURE 1599.8877 0
CHILLED WATER 1089.6 1089.6
CAKE 0 407.2308
SPENT ACID 0 1192.66357
TOTAL 2689.4877 2689.4877

Chilled water 1089.6 kg
CONDENSATION REACTOR(INLETS)
Vinyl sulphones(V.S) 79.9 0
SODA ASH 18.16 0
PYRIDINE 1.0896 0
OCTANOL 0.454 0
WATER 108.96 0
CAKE 407.2308 0
MIXER 0 615.7987
3.6 MASS BALANCE OVER CONDENSATION REACTOR
• CONVERSION Of raw material is 95%.
• 79.9kg vinyl sulphone is taken in condensation tank and maintain ph 7 by adding 18.16kg soda ash .
Ice is used to reduced temperature up to 5 deg. C .
Mass is stirred for 2 hour.
• 1.0896 kg Pyridine add as catalyst and 0.454 kg add as Deformer.

Direct blue+Cake 407.2308 311.62
Vinyl sulphones 79.9 6.8965
BLUE(PRODUCT) 0 163.94
H2O 108.96 113.6368
SODA ASH 18.16 18.16
PYRIDINE 1.0896 1.0896
OCTANOL 0.454 0.454
TOTAL 615.7987 615.7987

3.7 NEUTRILIZATION
• Obtain wet product is neutrilization by adding sodium bicarbonet.
• Some extra dade volume remain in the tank at last with dry product.
MIXTURE 615.7987 0
SODIAUM BIC. 45.40 0
IN TANK 0 1.5436BLUE(Produ
FOR DRYER PRODUCT 0 659.6552
TOTAL 661.1987 661.1987

3.8 SPRAY DRYER
• The Obtaning wet product is dry in spray dryer and moisture cont. remove from product.
• 659.655kg dry material enter Into Spray Dryer and Getting 227 Kg of Final Product.
DRYER MATERIAL (661.1987-1.5436)=659.655 0
PRODUCT 0 227
MOISTURE CONT. 0 432.152636

Summary of Overall Material balance
3.9- Summary table of overall mass

balance
COMPONENT MASS IN MASS OUT

SULPHONATOR
Copper phthelo cyanine 78.76 0

Chloro sulphonic acid 275.676 243.81
Direct blue 0 100.78
Hcl 0 9.9823
phosphorous trichloride 27.24 27.24
H2O 2.25756 2.25756 Moisture Cont. 43
TOTAL 383.93356 383.93356
DUMPING TANK
Slurry 374.0877 0
ice 1225.8 0
mixture 0 1599.8877
TOTAL 1599.8877 1599.8877
FILTER PRESS
Mixture 1599.8877 0
Chilled Water 1089.6 1089.6
cake 0 407.2308
Spent acid 0 1192.66357
TOTAL 2689.4877 2689.4877
CONDENSIATION
D.B+Cake 407.2308 311.62
V.S 79.9 6.8965
Blue(Product) 0 163.94
H2O 108.96 113.6368
Soda ash 18.16 18.16
pyridine 1.0896 1.0896
Octanol 0.454 0.454
TOTAL 615.7987 615.7987
NEUTRILIZER
Mixture 615.7987 0
Sodium bicarbonate 45.40 0
In tank 0 1.5436
For dyer product 0 659.6552
TOTAL 661.1987 661.1987
SPRAY DYER
659.655 0
Dyer material
0 227
Product
0 432.152636
Moisture Content
TOTAL 659.655 659.655
Conclusions
From above calculation of material balance, we have obtained amount of raw material, solvent and catalyst
require for production of Reactive Turquiose blue G dye by selected route Material balance provides other
benefits to optimize the space for the storage of raw materials as well as product. This material balance
data is very useful for calculation of energy required by each plant operations
CHAPTER-4
ENERGY BALANCE
Introduction
Amount of raw materials needed for production is known from material balance calculation.
But production will do not proceed by itself. For smooth operations, its need that all
processes are occurring at operating condition. To maintain such operating conditions in
operation its required to know how much heat will be utilized in each operation of process. In
such situation energy balance calculation is useful to calculate heat needed in operations. By
doing energy balance calculation, amount of heating medium or coolant needed for
operations is known.
According to the first law of thermodynamics, in accordance to the law of conservation of

energy, the total isolated energy of a system is constant, i.e. energy can only be transformed
from one form to another, but cannot be created or destroyed.
Energy Balance, as referred to as heat balance, in which enthalpy is conserved. It can be
categorized into mainly-
 Sensible Heat- Heat related to changes in temperature. It is calculated by M×Cp×ΔT.
 Latent Heat- Heat required for changing the physical state from solid to liquid, liquid
to gas, or solid to gas. It is calculated by Mλ.
 Heat of Reaction- Heat involved during a reaction, which may be released to or
absorbed from the surroundings. It is calculated as (ΔH°f, products - ΔH°f, reactants)
Table 4.1- Properties of components

Component Density(kg/m3) Heat Capacity(J/kg⸰C)
1600 1154
Copper phthelo
cyanine
1750 740.6
Chloro sulphonic acid
phosphorus trichloride 1570 874
.6 4496
Steam
cooling water 996 4190
Steps of Energy balance
Reactor 1(Sulfonetor)
Given data:
CPC = 78.76kg
CSA = 275.676 kg
PCl3 = 27.24kg
heat of reaction(J) = -3660000
• 1)40 DEGREE MAINTAIN BY COOLING WATER
t1 40
t2 25
T1 35
T2 9
MASS OF COOLING WATER REQUIRED(m1) = m*CP*(t1-t2)=m1*cp1*(T1-T2)
m1=((1049.9*78.76)+740.6*275.676))*(40-25)/4190*(35-9)
= 39.49731 kg
• 2) 100 DEGREE MAINTAIN BY STEAM
t1 100
t2 40
T1 200
T2 110
MASS OF STEAM REQUIRED(m1)) = m*CP*(t1-t2)+(HEAT OF REACTION)=m1*cp1*(T1-T2)
=((((740.6*275.676)+(1049.9*78.76))*(100-40)/((4496*(220-110))
=33.48988 kg
• 3)128 DEGREE MAINTAIN BY STEAM
t1 128
t2 100
T1 200
T2 110
MASS OF STEAM REQUIRED(m1)) = m*CP*(t1-t2)=m1*cp1*(T1-T2)
=((1049.9*78.76)+(740.6*275.676))*(128-100)/((4496*(200-110)
= 19.84965 kg
• 4) 70 DEGREE MAINTAIN BY COOLING WATER
t1 128
t2 70
T1 35
T2 9
=(((1049.9*78.76)+(740.6*275.676)+(874*27.24))*(128 70)/((35-
9)*4190))
= 165.3982 kg
• 5) 100 DEGREE MAINTAIN BY STEAM
t1 40
t2 25
T1 35
T2 9
MASS OF STEAM REQUIRED(m1) = m*CP*(t1-t2)=m1*cp1*(T1-T2)
=(((740.6*275.676)+(1049.9*78.76)+(874*27.24))*(100-70)))/((4496*(200-110))
= 23.03259 kg
• 6) 70 DEGREE MAINTAIN BY COOLING WATER
t1 100
t2 70
T1 35
T2 9
=(((1049.9*78.76)+(740.6*275.676)+(874*27.27))*(100-70)/((4190*(35-
9))
= 85.55082 kg
 Energy Balance on Dryer
Temp c
SOLID INLET 40
SOLID OUTLET 90
AIR INLET 210
AIR OUTLET 85
ATMOSPHERIC AIR 35
TOTAL TIME 14 hr
TOTAL SLURRY 659.6552 kg
MOISTURE INITIAL 63%
FINAL MOISTURE 0%
Inlet Quantity X1(Kg/Kg dry solid = (.63/1-.63)
= 1.702702703
X2(Kg/Kg dry solid) = 0
MASS FLOW RATE = (659.6552/14)/3600
= 0.013088397 kg/sec
Inlet Quantity H1(Kg/kg dry air) = 0.036
H2(Kg/kg dry air) = 0
1)MOISTURE BALANCE
Ms*(x1-x2)=ma*(H2-H1)
ma*(H2-.036)= .01308879397*(1.102702703-0)
=0.022286
REFERENCE TEMP.= 0 DEGREE
T0(K) =273
2)ENTHALPY OF SOLID AT INLET

is1=Cs(ti-0)+x1*CL(ti-0)
Cs=1.43 (KJ/Kg K)
CL =4.1868 (KJ/Kg K)
is1=(143*(40-0))+(1.702702703*4.1868*(40-0))
= 342.355
3)ENTHALPY OF SOLID AT OUTLET

is2=Cs(tO-0)+x2*CL(tO-0)
=1.43*(90-0) +0
=128.7 KJ/Kg of dry solid
4)ENTHALPY OF INCOMING AIR

iwB1(FROM APPENDIX) =2565.4 KJ/KG at 35 ©
Dry bulb temp.(TdB) = 210
Dew point of air(TdP1)=35
CH1(Humid heat ) = 1.006+( 1.48*.0036)
= 1.07224 KJ/Kgof dry air.K
ia1=1.006(TdP1-0)+H1*iwB1+CH1*(TdB-TdP1)
=((1.006*(35-0)+0.036*2565.4)+(1.07224*(210-35))
= 315.2064 KJ/Kg of dry air
5)ENTHALPY OF OUTGOING AIR

Ms*is1+ ma*ia1=Ms*is2+ ma*ia2 +QL
Where QL is heat loss = 10% of heat input
eQ 1 = (0.9*((0.01308897*342.355)+(0.557141*315.2064)-(0.013088397*128.7)-
(0.557141*329.9587)
= -23.4321
assume TDP2 = 46.6
H2 = 0.076 (Kg/kg of dry air)
iwB2 = 2592
ia2=(1.006(TDP2-0)+H2* iwB2 +(1.006+1.84 H2)*(85-TDP2)
= 287.8719 KJ/Kg of dry air

Ma =0.22286/(0.076-0.036)
= 0.557141 kg/sec
At 4 Bar
specific enthalpy(KJ/Kg) = 2133
heat duty of boiler
Q=ma*(ia1-iaa)
iaa(at 35 degree) = 127.56 (KJ/Kg dry air)
Q = 0.557141/(315.2064-127.56)
=104.5455 KW
STEAM CONSUMPTION = 104.5455/2133
= 0.049013 (kg/sec)
Conclusions
From calculation of energy balance, Amount of cooling water and steam required for heating and cooling
purpose is known for each operations. By maintaining such operating condition side reaction can be
arrested. Energy balance calculation is also very useful to set capacity for the utility section. With optimum
use of each and every parameter like material, energy and utility will decrease the overall cost for the
production.
CHAPTER-5
PLANT UTILITIES
Introduction
Energy balance data as well as material balance data are available for production of Reactive
turquoise blue G dye by specified route. But maintaining operating conditions over each
process is such a big deal. Process requires certain basic necessities like cooling water, air,
steam, electricity, etc. without which it would be impossible to function. This are called
utilities. It is one of the most important section of plant. By proper utilization of utilities
overall cost of production can be minimized.
→Following utilities are being used for various processes:
1. Cooling tower
2. Boiler section
3. Scrubber system
Cooling Tower
Function: - To cool water from Temperature of 35 ⸰C to 28 ⸰C. (Capacity: - 40 TOR).
Principle: - Evaporative cooling
Type: _ Induced Draft Counter Flow Tower.
Packing material: - PVC
Description
Induced Draft cooling tower consists of ID fan which pull the air from atmosphere. Hot
water from the condenser enters into cooling tower. Nozzles are used to spray the water onto
the “fill media or packing”, which slows the water flow and provides maximum surface area
for heat Transfer. Air comes in contact with water and small amount of water evaporates,
lowering the temperature of circulating water.
*open source
image.
Figure 5.1- Cooling tower*

Boiler section
Type of boiler: - fired water tube boiler
Heating media: - Coal fired
Capacity: - 10 tons of
steam/hour Pressure: - 7
kg/cm2
Size: - 8 tons
MOC: - Shell→mild steel
Tube→stainless steel
Description:
This type of coal heated boiler mainly consist of furnace in order to burn the coal and
generate heat. Air is heated in air preheater for better combustion of coal. Heat generated by
burning of coal is transferred to water inside the tube and boiling of water is take place and
steam is generated.
Soft water is used in the boiler for steam generation, so industry requires water treatment
plant. But the quality of water supply in MOL is good, so industry doesn’t have and water
treatment plant.
Terms and attachments:
(a).Furnace:
It is the chamber above the grate where combustion take place.
(b).Grate:
It is a platform in furnace upon which fuel (coal) is burnt.

(c).Main Stop valve:
Function: It is used to stop the supply of steam to plant if necessary.

(d).Manhole:
Function: It is used to clean he tubes and shell when the plant is not in operation. Any defect
in the boiler can be easily detected.
(e).Air vent valve:
Function: To avoid the formation of vacuum. It comes in to action when condensation of

steam occurs and it is an automatic operation.
(f).feed check valve:
Function: Used to supply water to the boiler according to steam requirement.

(g).Safety relief valve:
Function: To maintain the pressure inside the boiler section.

Scrubber system
Hydrochloric acid vapour is poisonous if it is inhaled in great quantities and its lesser amounts can cause
irritation in eyes, nose, and throat. So, it is required to control the emission of Hydrchloric acid vapour in
atmosphere.
Chemical scrubbers have been demonstrated to effectively remove HCl in exhaust streams by using water.
Unlike particulate scrubbers, HCl scrubbers remove pollutants via a soluble in water and not by injecting
liquid into the gas stream.
Here, Sulfonator releases the hydrochloric acid so, it absorbs in water by scrubber system.
Conclusions
For better yield of process its need to maintain operating conditions in each operation for that different
types of utilities are used which are discussed over here. Capacity of these utilities are decided based on
required amount of heating-cooling medium like steam and cooling water which are calculated in energy
balance calculation.
CHAPTER-6
EQUIPMENT DETAILS
6.1 Process equipment details
Table 6.1- SULPHONATOR
Sr. No. Parameters Type/Quantity
1 Capacity 7000 lit
2 Weight kg
3 Diameter-Height 2 m - 3.2 m
4 Agitator Anchor type
Table 6.2- DUMPING TANK

1 Capacity 20000 lit
2 Agitator Paddle type
3 Rpm 45
Table 6.3- SPRAY DYER
1 Capacity 7000lit
2 MOC Stainless steel
Table 6.4- Filter press

Sr.No. Parameters Type/Quantity
1 Total Filter press 2
2 No of plates 100
3 Pressure 7 kgf/cm2
4 Plate size 600mm×600mm
5 Filter cloth material Polypropylene
6 Water flowrate 550 kg/min

CHAPTER-7
EQUIPMENT DESIGN
INTRODUCTION
 The processing, storage or transportation of any raw material, product or utility requires specific
equipment to serve its purpose. These equipments are to be designed keeping in mind optimum
conditions of the process, its residence time and its orientation to get maximum yield.
 Designing is the most creative work carried out by Chemical Engineers. Equipment designing can be
classified in two parts
1.Process design
2.Mechanical design
 Process design is a basic design done by the chemical engineers which includes calculations of volume
and residence time in case of Reactors, number of stages, feed location, design of down comer, weir
design in case of a distillation column, overall heat transfer coefficient, dirt factor and pressure drop
calculations in case of Heat exchanger and NPSH calculation in case of pump design.
 Mechanical design deals with the calculations of height, diameter, thickness of shell, thickness of head,
thickness of nozzles, flanges, no of bolts and calculation for supports.
 Thus design of any equipment is the one of the main aspect in the industry. Somewhat over design is
provided by the design engineers considering the safety aspect but too much overdesign is also
unfavorable.
Design Of Batch Reactor
 PROCESS DESIGN
Data Required
CHEMICAL WEIGHT
CPC
78.76 kg
CSA 275.676 Kg
PCL3
27.24 kg
H2O 2.25756 Kg
CHEMICAL DENSITY
CPC 1620 Kg/m3
CSA 1753 Kg/m3
PCL3 1570 Kg/m3
H2O 997 Kg/m3
 Moles of CPC=0.1367 mole

 Conversion=95%=0.95
 Batch Time=20 Hr
 Volume of CPC=78.76/1620
=0.048617 m3
 Volume of CSA=275.676/1753
=0.15726 m3
 Volume OF PCL3=27.24/1570
=0.01735 m3
 Volume of H2O=2.25756/997
=0.002264 m3
 Initial Concentration Ca0=(0.1367*0.001)/(0.048617+0.15726)
=0.000664 mole/lit
 Rate constant
K=(-Ln(1-0.95))/20
=0.149787 Hr-
 Total Volume Of Reactore
=0.048617+0.15726+0.01735+0.002264
=0.225492 m3
 Excess Volume due To Agitatore (25%)
=0.225492*0.25
=0.056373 m3
 Excess Volume Due To Coil(10%)
=0.225492*0.1
=0.0225492 m3
 New Volume
=0.225492+0.056373+0.0225492
=0.304414 m3
 Final Volume=4 m3
 Assume L/D=2
 V=(3.14/2)*D3
 D=(4*3.14/2)^(1/3)
=1.365799 m
 Lenth L=(2*1.365799)
=2.731598
 Mechanical Desing
 Pressure Of Reactor=0.101325 N/mm2

 Material of Construction(Mild Steel)
 Allowable Stess(f)=112.35 N/mm2
 Young Modulas(E)=21000000
 Possion’s Ratio=0.33
 Joint Efficiency Factor(j)=0.85
 Density Of MOC=7850Kg/m3
 Corrosion Allowance=2mm
 FOS=4
 Lenth of Reactor=2.73159732 m
 Diameter Of Reactor=1.365798966 m
 Thickness Of Shell
 ts=(PD*1000)/(2fj-P)
=(0.101325*1.365798966*1000)/ ((2*112.35*0.85)-0.101325)
=0.724956342mm
 td=(2+0.724956342)
=2.724956342mm
 Fabrication thickness tf=5mm

 Inside diameter Di=1.365798966*1000
=1365.798966mm
 Outside diameter Do
=1365.798966+(2*5)
=1375.798966 mm
 L/Do=(2.731597932*1000)/1375.798966
=1.985462992
 t/Do=5/1375.798966
=0.003634252
 Model Brown Check

Pcr=2.638*E*(t/Do^(5/2))/(L/Do-0.45*(t/Do)^0.5)
=2.638*21000000*(0.00363452^2.5)/(1.985462992- (0.45*(0.003634252^0.5))
=22.52395738 N/mm2
 P allowable
=22.52395738/4
=5.630989345 N/mm2
 Here From Calculation we Can say that
P allowable >Pi hence, the Design Is Safe.

Torispherical Head
 Rc=Do=1365.798966mm
 Rk=0.06*Rc
=0.06*1365.798966
=81.94793797 mm
 Cs=(1/4)*(3+(1365.798966/81.94793797)^(1/2))
=1.77
 Distance
b=Rc-((Rc-Rk)*(Rc-Rk)- (Di/2)(Di/2))^(1/2)
=1365.798966-((1365.798966)^2- (1365.798966/2)^2)
=278.6367158mm
 Thikness Of Head
th= PDiCs/(2fjP(Cs=0.2))
=(0.101325*1365.798966*1.77)/(2*112.35*0.85-0.101325(1.77-0.2))
=1.283561068 mm
 Design thickness td=1.283561068+2
=3.283561068 mm
 Fabrication Thickness tf(top)=5 mm

tf(bottom)=5 mm
 Agitator Design
 Parameter
 Viscosity of Mixture=20cp
 Density of Mixture=1725 Kg/m3
 Speed of Agitator(N)=45 RPM
 Height of Liquid In Tank
 (Hi)=((Vtotal*10^9-0.085*Di^3)*4)/(3.14*Di^2)
=((0.225492*10^90.085*1365.788966^3)*4)/(3.14*1365.788966^2)
=6.0989759 mm
• Length of Agitator BTN Bearing and Agit
=1.2 *Hi
=1.2*6.0989759
=7.3187711 mm
• Width of Blade (W)=150mm
• No. Of Baffles in Tank Wall(NB)=2
 Shaft And Agitator Blade Material
= IS 2062 Grade ST 42-W
 Ultimate Tensile Stress(U)=857 KGF/cm2
 Yeild Stress(Y)=2518.69 KGF/cm2
 Max Allowable Shear Stress In Shaft(S)=2549.29KGF/cm2
 Modulas Of Elasticity(E)=214100000KGF/cm2
 Turbine Diameter(Da)=0.5*Di
=0.5*1365.798966
=682.89948 mm
 Reynold Number (Nre)=1725*(682.89948)^2*45/(20*60*1000)
=30167.126
 Power Number (From Curve)=5
 PowerRequirement(P)
=Np*1725*(N/60)^3*(Da/1000)^5/9.81
=55.088102 KGFm/sec
 Power Requirement(P)=0.734508 HP
 Actual Power Requirement(P actual)=0.734508*1.1*1.2
=0.9695506 HP
 Power Input From Motor(P’)=1 HP

 Shaft Diameter Calculation
 Parameter
 Avg. Rated Torque on Shaft(Tc)=(1*60*75)/(2*3.14*45)
=15.923567 KGF.m
 Max Torque Include in Shaft(Tm)=1.5*15.923567
=23.88535 KGF.m
 ShaftDiameter(D)
=((23.88535*1600/(2549.29*3.14))^(1/3)
=1.6838403 cm
 Worst case bending force(FM)=23.88535/(0.75*682.89948/(1000/2)
=23.317585 KGF
 Bending Moment(M)=(1.6838403*23.317585)/1000
=0.0392631 KGF.m
 Equivalent Bending Moment(ME)
=0.5*(0.0392631^2+0.0392631^2)^0.5
=11.962323 KGF.m
 Stess Created(F)
=11.962323/(3.14*(1.6838403/10)^3/32)*100
=2553484 KGF/cm2
 which is Greater Than Allowable Yeild Stress.

 Shaft Diameter(D)=2.5cm
 Max Deflection in Shaft(Theta)
=23.317585*(7.3187711/10)^3*64/(3*19.5*10^5*3.14*2.5^4)
=8.153^(-7)
 Critical Speed(Nc)=60*4.987/(8.15^-7)^0.5)
=331378.53
 N/NC , Here N/NC is B/W 50 TO 65%=2.5cm
 Blade Thickness Calculation

 Parameter
 Endurance Limit For Carbon Steel(F)
=0.5*857
=428.5 KGF/cm2
 Thickness Of Blade(BT)
=23.88535*100/(428.5*(150/10)^2/6)*10
=1.4864473 mm
 Actual Thickness Of Blade(BTS)=5 mm
 Design Of Cooling Coil
 Inside Diameter of Coil=0.0254 m
 Pitch of Coil=0.35 Radian
 Overall Coil Height=L=2.731598m
 Velocity at Discharge =1.8*(2*9.81*1.365799*0.035/(3.14*0.02529))
=21.25875
 B=0.184*(1+35*(0.0254/1.365799))*(0.0254*979/8.9*0.0001)^(-0.2)
=0.025291
 Reynold Number(Nre)
=(979*21.25875*0.0254)/(8.9*0.001)
=593963.6
 So,Friction Factor(Straight Tube)
=64/593963.6
=0.000108
 Mean Radius Of Coil(R)=D/2
=(1.365799/2)
=0.682899
 Friction Factore For Coil
=64/Nre*(1+0.4533*(Di/R)*(Nre^0.2)+0.564*(Di/R)^(4.5)*(Nre^0.2)
=64/593969.6*(1+0.4533*(0.0254/0.682899)*(593969.6^0.2)+0.564*(0.0254/0.682899)
^(4.5)*(593969.6^(0.2)))
=0.000134
 Design of Centrifugal Pump

Here, purpose of Centrifugal pump is used to transfer water from cooling tower.
Liquid handled: Water
Temperature = 30 ℃
Capacity = 20 m3/hr
Suction Pressure = 0.72 kgf/cm2
Discharge Pressure = 3.7 kgf/cm2
Viscosity = 0.89*10-3 kg/ms
Specific gravity of fluid = 1
Efficiency* = 55%
Length of pipe = 30 m
Diameter of pipe = 10 cm [ inlet]

= 6 cm [outlet]
MOC = Carbon steel

Calculation:
Inlet calculation:
Area=π*d2
=π*(0.1)2/4
=7.85*10-3 m2
Velocity = Capacity/Area
= 20/(3600*7.85*10-3)
= 0.707 m/s
Reynolds No. Nre= ρ*v*D/µ
=(1000*0.707*0.1)/(0.89*10-3)
= 79,478.12
Friction loss Fs =0.085*Nre-0.25
=5.062*10-3
Outlet calculation:
Area=π*d2/4
=π*(0.06)2/4
=2.827*10-3 m2
Velocity = Capacity/Area
= 20/(3600*2.827*10-3)
= 1.964 m/s
Reynolds No. Nre= ρ*v*D/µ
= (1000*1.964*0.06)/(0.89*10-3)
= 1,32,463.54
Friction loss Fs =0.085*Nre-0.25 = 4.45*10-3
Head losses = 4*fs*l*v2/d*g
= (4*4.45*10-3*30*1.9642)/(0.06*9.81)
= 3.5 m
Head = Head loss + Pressure drop + diff. of head + Velocity componen
v z∗v z
( ρgp − pρg1 )+( z ¿¿ 2−0)+
¿ 3.5+
2g
¿
3.7−.72
( 1000∗9.81
¿ 3.5+ )+2+ 1.964∗1.964
2∗9.81
=35.5 m
Power required = head*ρ*capacity*g/Ƞ
= 35.5*1000*20*9.81/0.55/3600
= 3517 kw = 4.71 hp ~ 5 hp
NPSH:
Vapour Pressure =31.8 mmHg = 4239.65 N/m 2
=(72*9.81*10000)/(1000*9.81)+(1.986/(9.81*2))
=7.828 m
Nozzles Design
Table 8.2- Nozzles Design
ON TOP CLOSURE
N1 FEED NOZZLE
N2 PCl3 INLET
N3 VAPOR OUTLET
N4 EXTRA NOZZLE
N5 AGITATOR NOZZLE
ON BOTTOM CLOSURE
N6 PRODUCT OUTLET
N7 DRAIN
Table 8.3- Nozzle dimensions
(mm) N1 N2 N3 N4 N5 N6 N7
Dni 600 100 150 200 100 200 50
Trn .27 .05 .07 .09 .05 .18 .05
Tdn 2.27 2.05 2.07 2.09 2.05 2.18 2.05
Tfn 5 5 5 5 5 5 5
Dno 610 110 160 210 110 210 60
A 976.06 168.0 248.86 329.6 832 3672 972
4 64 4 64
As 835.93 143.9 213.13 282.3 208 408 108
6 36 6 36
Ho 42.57 17.66 21.49 24.74 17.66 24.74 12.7
3
Hi 24.58 10.2 12.41 14.28 10.2 14.28 7.35
Ao 232.43 104.1 125.93 143.9 104.1 139.5 75.1
22 94 14 8 94 336 0
Ai 49.16 20.4 24.82 28.56 20.4 28.56 14.7
An 281.59 124.5 150.75 172.5 124.5 168.0 89.8
22 9 4 9 9 0
Ar - 141.46 - 100.4 - 115.02 - 125.2 499.4 3095. 774.
6 1 9 1
Compensa NO NO NO NO NO NO NO
tion
Tpf - - - - - - -
Flange design:
 FLANGE MATERIAL = Mild steel*
1. f =98000000 N/m2
 GASKET MATERIAL ASBESTOS
1. Y = 20 MN/m2
2. GASKET FACTOR = 2.5
*Refer Appendix D.
CHAPTER 8. BRIEF INTRODUCTION TO PUMP AND VALVES
3. N = 10 m
BOLT MATERIAL 5% Cr Mo STEEL Fb = 138000000
Table 8.4- Flanges details
DIMEN N1 N2 N3 N4 N5 N6 N7
SIONS
(mm)
Dni 600 100 150 200 100 200 50
Type Loose Loose integral Integral Loose loose loose
Dfi 612 112 160 210 112 212 62

Bolt size 10 8 8 10 8 10 8
No 44 16 20 16 16 16 12
C1 684.45 182.45 228.45 280.45 182. 284. 132.
45 45 45
Dno 714.45 210.45 256.45 310.45 210. 314 160.

45 45
Bs 39 28 28 45 28 46 27
Tff 18 14 14 16 14 16 14
Horizontal storage tank :
Storage capacity = 4380 ton
Wt % of PCL3 = 99%
Density = 1834 kg/m3
Density of solutuion = 1630.07 kg/m3
Corrosion allowance = 2mm
Volumetric capacity = 2686 m3
J = 0.75
Corrosion allowance = 2 mm
Density of material = 7800 kg/m3
E =193000000000 N/m2
Height = 19.74 m
Diameter = 13.1638 m
Pressure = 0.1013 N/mm2
Allowable stress = l12.35 N/mm2
Shell thickness = 7.91 mm
Td = 9.98 mm
Fabrication thickness = 10 mm
Head design :
Crown radius = 13.164 m
Knuckle radius = 0.789 m
Thickness = 14.022 mm
Td = 16.022 mm
Fabrication thickness = 18 mm
Nozzle design :
 Operating pressure = 1.033 kgf/cm2
 Design Pressure P = 1.14 kgf/cm2
 C = Corrosion Allowance = 2 mm
 thdesign = 1.41 mm
 th fabrication = 5 mm Let Dni = 400 mm
Thickness of nozzle, tn
tn = PDn/2×f×J = 0.02 mm
tn + C = 2.02 mm
A = Area that requires compensation
A = (Dno + (2*C))*t
= 0.2389 cm2
As = Compensation area provided by shell
As = (Dno + 2C)*(ts fabrication – ts design –C)
= 0.0712 cm2
Ar = Compensation area provided by nozzle
= 0.0243 cm2
Compensation area required = 0.1404 cm2
Thickness of reinforcement pad = 5.89 mm
Td = 7.89 mm
Fabrication thickness = 8mm
Flange design :
m = gasket factor
= 2.5
Inside diameter of Gasket Gi,
Gi = (Dn + 2tn) +0.001 m
= 413 mm
Outside diameter of Gasket Go, Go = 2Nmin + Gi
= 414.1 mm
N = Nmin + 5 mm = 15 mm
bo = Basic gasket seating width
b = Effective gasket seating width
bo = N/2 = 7.5 mm
if bo<= 6.3 mm then G = (Go + Gi)/2 & b = bo
if bo> 6.3 mm then G = Go – 2b & b = 2.5* b 0.5 bo = 7.5 mm

o
Thus b = 6.84 mm
G = Mean diameter of gasket G = Go – 2b = 234.30 mm
H = Total Hydrostatic end Force
= π/4*G2 *P = 1362.87 kgf
Hp = Force required to keep the gasket without leaking or in leaking condition
= π*(2b)*Gmp = 466.056 kgf
Wm1 = Bolt load required for tightening the gasket after operation Wm1 = Hp + H
= 1828.80 kgf
Wm2 = Bolt load required for tightening the gasket before operation Wm2 = πGbY
= 17558.18 N
Wm = greater of (Wm1, Wm2) = 17558.18 N
Am2 = Wm1/fbb
= 2025.5 mm2
Number of bolts required Nb, Nb = Am/Ar
= 20.59
Nb = 24
bolts Diameter of bolt db, db= 11.2 mm
g1 = 1.415go = 25.47 mm
go = (Dno – Dni)/2 = 18 mm
C1 = Bolt circle diameter C1 = Dni + 2(g1 + R)
= 497 mm
Outside diameter of flange Dfo, Dfo = C1 + 20 + db
= 528.9 mm
tf = Thickness of flange
= 15.71 mm = 16 mm
Conclusions
From the design of equipment for given capacity based on material balance, the fabrication details are obtained. It helps to
differentiate between standard equipment available in market and specially design equipment needed for specific purpose. If
equipment of given capacity is not available in market, then fabrication details are sent to fabricator for fabrication.
CHAPTER-8
BRIEF INTRODUCTION OF PUMPS AND VALVES
Centrifugal Pump
Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy
to the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an
engine or electric motor.
Characteristics:
Creating a resistance to the flow controls the kinetic energy of a liquid coming out of an
impeller. The first resistance is created by the pump volute (casing), which catches the liquid
and slows it down. When the liquid slows down in the pump casing, some of the kinetic
energy is converted to pressure energy. It is the resistance to the pump's flow that is read on a
pressure gauge attached to the discharge line. A pump does not create pressure, it only create
pressure, and it only creates flow. Pressure is a measurement the resistance to flow.
Figure 8.1- Centrifugal pump*
*Fluid mechanics and Hydaulic machines, Dr. R.K. Bansal.

Table 8.1- Pumps present in plant
Sr Name of pump Specification Application MOC Suppliers
no.
1 Centrifugal Pump Q=18 m3/hr In Primary S.S. KSB pvt.
N=1140 rpm Scrubber & Ltd.
Impeller=Closed C.S.
Seal=Gland
2 Centrifugal Pump Q=30 m3/hr In Primary M.S. KSB pvt.
N=2855 rpm Scrubber Ltd.
Impeller=Closed
Seal=Gland
3 Centrifugal Pump Q=18 m3/hr Batch tank M.S. KSB pvt.
N=1140 rpm Ltd.
Impeller=Closed
Seal=Mechanical
Valves
Different types of valves used in the industry are:
 Ball valve
 Gate valve
1. Ball Valve:
A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball
to control flow through it. It is open when the ball's hole is in line with the flow and closed
when it is pivoted 90-degrees by the valve handle.
Ball valves are durable, performing well after many cycles, and reliable, closing securely
even after long periods of disuse. These qualities make them an excellent choice for shutoff
and control applications, where they are often preferred to gates and globe valves, but they
lack their fine control in throttling applications.
The ball valve's ease of operation, repair, and versatility lend it to extensive industrial use,
supporting pressures up to 1000 bar and temperatures up to 752 °F (400 °C), depending on
design and materials used. Sizes typically range from 0.2 to 48 inches (0.5 cm to121 cm).
Valve bodies are made of metal, plastic, or metal with a ceramic; floating balls are often
chrome plated for durability. One disadvantage of a ball valve is that they trap water in the
centre cavity while in the closed position. In the event of a freeze, the sides can crack due to
expansion of ice forming. Some means of insulation or heat tape in this situation will usually
prevent damage.
2. Gate valve
Gate valves are widely used for all types of applications and are suitable for both above
ground and underground installation. Not least for underground installations it is paramount
to choose the right type of valve to avoid high replacement costs.
Gate valves are designed for fully open or fully closed service. They are installed in pipelines
as isolating valves, and should not be used as control or regulating valves. Operation of a gate
valve is performed doing an either clockwise to close (CTC) or clockwise to open (CTO)
rotating motion of the stem. When operating the valve stem, the gate moves up- or
downwards on the threaded part of the stem.
Gate valves are often used when minimum pressure loss and a free bore is needed. When
fully open, a typical gate valve has no obstruction in the flow path resulting in a very low
pressure loss, and this design makes it possible to use a pipe-cleaning pig. A gate valve is a
multi-turn valve meaning that the operation of the valve is done by means of a threaded stem.
As the valve has to turn multiple times to go from open to closed position, the slow operation
also prevents water hammer effects.
Gate valves can be used for a vast number of fluids. Gate valves are suitable under the
following working conditions:
Potable water, wastewater and neutral liquids: temperature between -20 and +70 °C,
maximum 5 m/s flow velocity and up to 16 bar differential pressure. Gas: temperature
between -20 and
+60 °C, maximum 20 m/s flow velocity and up to 16 bar differential pressure.
Table 8.2- Types of valves
Sr no. Name of valves Application Selection Supplier MOC

criteria
1 Spindle valve Reactor bottom To avoid dead AUDCO C.S.
zone in reactor, (L & T) M.S.
long service life S.S.
2 Plug valve RVD inlet pipe No leakage, long AUDCO S.S.
service life, on- (L & T) M.S.
off purpose
3 Gate valve Water line On-off purpose, AUDCO M.S.
High flow rate, (L & T) GUN metal
Cheap, No C.S.
maintenance
4 Globe valve Steam line, High Flow regulation, AUDCO C.S.
therm oil line No leakage, Low (L & T) M.S.
maintenance Brass
5 Ball valve Hot water, Acid Cheap, on-off AUDCO S.S.

line, Steam line, purpose, high (L & T) Rubber coated
Alkaline line, pressure drop P.E.
Solvent line P.P.
6 Butter fly valve Air, gas, water, On-off purpose AUDCO C.S.
powder material (L & T) M.S.
S.S.
7 Diaphragm valve Solvent, soft water, On-off flow AUDCO P.E.
D.M. plant, acid regulation (L & T) P.P.
8 Niddle valve Pressure gauge, for On-off purpose AUDCO C.I.
sampling point (L & T) S.S.
M.S.
CHAPTER-9
SAFETY, HEALTH AND ENVIRONMENT
Safety Measures
 Accidents & Incidents are investigated & records are maintained. Employees are
informed about the cause of accident. Internal Safety Inspection is done regularly by
safety officers.
 Work Permit is also issued for work like hot work, Cold work, confined space entry,
work at height are available.
 To ensure safe, healthy and clean environment various health and safety policies like
SHE policies, Quality policy, Energy Management policy, Training and development
policy are developed.
 Occupational Health centre is present in plant with working of 24 hrs. under guidance
of doctor. For emergency purpose they have ambulance service.
 To deal with fire, water lines are provided in entire plant. Fire extinguisher are also
provided at each places in plant for fire safety.
 Mock drills are conducted in plant to ensure working of fire alarm.
 Personal protective equipment is provided to each and every employees and worker to
minimize the accidents.
 To avoid fire cause of static electric charge equipment is grounded. Fire alarm is
provided at each site of plant. To ensure safety of equipment safety interlocks like
safety valve, rupture disc, pressure safety valves are also installed.
 The waste generated from process will be treated in ETP. Hazardous waste is sent to
TSDF (B.E.I.L.) site for disposal purpose. In addition, proper care is taken to prevent
any spillage/leakage. Proper storage facility is provided for raw material and
hazardous waste. So, there is no hazardous effect on ground water and surface water
quality.
 Safety department provides training to all operators and trainees.
 Adequate safe assembly point is mentioned at some location in plant where workers
can gather in case of any emergency.
Personal Protective equipment (PPE)
Selection Criteria for PPE
(1) It should give adequate protection against the nature, severity & type of hazard
(2) It should be of minimum weight, should give minimum discomfort with protective
efficiency
(3) Attachment to the body should be flexible yet effective
(4) The wearer should not be restricted in movement
(5) It should be durable & attractive
(6) It should not give any hazard through its material, design, defect, use or failure
(7) It should conform ISI(BIS) and tests required
(8) It should be easy to clean, repair, and maintain. The parts, piece and service should be
easily available.
Different Personal protective equipment

 Helmet
 Ear muff and ear plugs
 Goggles
 Face shield
 Hand gloves
 Aprons
 Safety Shoes
 Suits
 Safety harness
 Gas masks
Fire safety
Classification:
a) Fire of ordinary combustible material such as wood, paper etc. can be cooled by
water Extinguisher.
b) For flammable liquid like oil, solvent, petroleum can be extinguished by

CO2 Extinguisher or dry chemical powder is used.
c) Fire involving gaseous substances under pressure where it necessary to dilute burning
gas at very fast rate- inert gas or dry powder is used.
d) Firing of material like Mg, Al where metal can be extinguished by fire

extinguisher discharging special dry chemical powder
e) Fire from electrical equipment where extinguisher should be non-conductor fire

extinguisher with halogen and CO2 or dry chemical powder is used.
Equipment for fire protection
 Fire extinguisher
 Fire lines
 Foam tank
 Smoke detector
Industry have around 170 fire extinguishers, Smoke detectors in Warehouse and fire lines in
all sections of plant.
Special precautions
Containers of Explosive materials is must be closed when not in use. It is Stored at a dry
place and away from excessive heat & open flames. Good housekeeping should also be
maintained avoiding dust build up. According to good industrial practice, each chemical
should be handle with care and avoid unnecessary exposure.
Types of fire extinguisher Dry chemical powder type:
For Class B & Class C.
 Cartridge type
 Stored pressure type
AFFF Mechanical foam type:
For Class A & Class B.
 Foam is created by mechanical agitation
CO2 type:
For Class A & Class B.
 For fire type B and C

As per safety concern plant has occupational health centre for emergency purpose. OHC
contain all basic medicines which can be used in case of health hazard.
Safety department is also responsible for maintenance work is going on at anywhere inside
the plant. Safety department has to issue work permit for any type of maintenance work to be
done in plant.
Good housekeeping is also good practise to prevent possible hazard. Industry should be very
conscious regarding employees’ safety that housekeeping is done at proper interval of time in
each day.
Environmental Safety
Pollution control measures
Every industry some pollution control measures to prevent soil, water and air pollution.
To prevent Soil and Water Pollution Company have their own ETP plant which generates
330MT/month of waste and Gypsum which is disposed at & B.E.I.L. (Bharuch Enviro
Infrastructure Ltd.)
Industrial Effluent Generated in plant is treated in ETP plant, Re-used and sludge is discharged.
Total industrial Effluent generated in plant is 217 M3/Day, which treated in primary,
secondary and tertiary section of ETP plant.
Table 9.1- Permissible limit
Sr. No Parameters Permissible limit
1 Ph 5.5 to 8.5
2 Temperature 40℃
3 Total Suspended Solids 100 mg/L
4 Total dissolved solid 2100 mg/L
5 BOD 30 mg/L
6 COD 100 mg/L
7 Oil and Grease 10 mg/L
8 Ammonical Nitrogen 50 mg/L
9 Chlorides 600 mg/L
10 Sulphates 1000 mg/L
11 Copper 2 mg/L
Effluent treatment plant (ETP)
Figure 9.1 ETP flow diagram

ETP is divided into following three parts:
1. Primary treatment plant,
2. Secondary treatment plant,
3. Tertiary treatment plant.
PRIMARY TREATMENT: -
Primary treatment involves various physical unit operations. The raw effluent from various
plants is collected in three different collection tanks.
1. utralizer:
Function: To neutralize the acidic nature of the waste water. From each of the collection
tank waste water is brought into 4 Neutralizers. Here calcium carbonate solution is added
to neutralize the pH.
Effluent from the plant mainly contains sulphuric acid and this effluent is fed into the 4
neutralizer along with calcium carbonate. The acid material in effluent is reacting with
calcium carbonate to produce gypsum, carbon dioxide and water. The gypsum is collected
from the bottom of neutralizer and dries it into atmosphere.
2. Equalization Basin:
Function: To dampen the flow rate variations of the waste water so that a constant flow
rate is achieved and thus loadings are eliminated. Variations in the flow rate causes lot of
operational problems in the working of equipment’s related to physical unit operations.
This lowers the performance. So the flow rate of the waste water has to be equalized. Here
constant stirring and aeration is provided by floating aerators so that the biological mass
does not settle at the bottom.
3. Filter press
Function: To remove large solids.
From each of the equalization tank, the waste water enters 4 Filter press. Filter press has
porous filter through which all liquid and small size solids pass, while the large solids are
blocked and removed. Block solid remove and dries it into the atmosphere.
4. Chemical Treatment:
Function: To coagulate very small solid particles.
Filtrate from filter press is transfer into the chemical treatment unit along with fed small
quantity of polyelectrolyte such as magma floc and Alum to form large size particle.
5. Primary Clarifier:
Function: To remove very small solid particles.
Clarifier has paddle type agitators which move slowly through the waste water and
promote mixing. Increased paddle contact will promote floc growth. However, if agitation
is too vigorous, the shear forces set up will break up the floc into smaller particles.
Agitation is controlled so that the floc particles will be of suitable size and will settle
readily.
SECONDARY TREATMENT:
Secondary treatment involves chemical and biological unit operation.

1. Aeration tank:
Function: To degrade the organic matter and then to remove it.
The clarified and flocculated waste water now enters the aeration tank into which from the
beginning cow dung is added (it has bacteria). Also urea and Di-amino Phosphate (DAP)
are added for the growth of bacteria. Also constant aeration is provided. Under these
conditions the bacteria degrade the organic matter into its components. Then the contents
are taken to a settling tank where the biomass settle at the bottom.
2. Secondary Clarifier:
Function: To remove very small solid particles.
Clarifier has paddle type agitators which move slowly through the waste water and promote
mixing. Increased paddle contact will promote floc growth. However, if agitation is too
vigorous, the shear forces set up will break up the floc into smaller particles. Agitation is
controlled so that the floc panicles will be of suitable size and will settle readily.
TERTIARY TREATMENT:
1. Activated Carbon Filter:
Function: To remove the dark bluish colour and other refractory pollutant of the waste
water.
This filter comprises of activated carbon particles as filter medium. As the coloured waste
water passes through it, the colour containing organic particles and refractory pollutants are
absorbed by the activated carbon and finally light coloured water is obtained which has
neutral pH of 7. Thus water is directly send into the sand filter.
Sand Filter:
Function: to remove fine suspended particle.

The filter comprises of sand as a filter medium. As the waste water from the activated carbon
is passes through it, the particle is removed and finally clear liquid is obtained which is
directly discharge.
To prevent air pollution,
1. During the process Ammonia is generated which is passed through Scrubber system and
then disposed in to environment. Concentration of Ammonia is kept below the permissible
limit.
2. After the drying process air containing small particles of CPC powder is passed through
scrubber to remove these Suspended particulate matter-SPM and keep them within the
permissible limit.
3. To prevent air pollution by burning of coal in Boiler Company follows Air Pollution
Control and Measures -A.P.C.M. Rules.
Company uses coal of good quality which have less of Sulphur content.
Company contains cyclone, bag filter/E.S.P., water scrubber and chimney to prevent emission
of suspended particulate matter, SO2 and NOx in environment.
Table 9.2- Air pollutant permissible limit

Stack Attached to Air pollution Parameter Permissible limit
control System
Reactor of CPC blue Three stage Water Ammonia 175 mg/NM3
Scrubber
Spin Flash Dryer Cyclone Separator, S.P.M. 150 mg/NM3
Bag filter,
Single stage
Scrubber
Boiler Bag filter, S.P.M., 150 mg/NM3
Cyclone, SO2, 100 ppm
Water scrubber NOx 50 ppm
CHAPTER-10
PLANT LOCATION AND LAYOUT
Justification of plant location
The plant site is located at Plot No.21/21/1, GIDC Ind. Estate, vatva in the state of
Gujarat.The choice of final site selection should be based on a complete survey of advantages
and disadvantages of various geographical areas and ultimately on advantages and
disadvantages of available real estate. The following factors must be considered in selecting a
plant site:
 Raw material availability:
Raw materials required in plant are purchased from nearby industries in Gujarat. Like, ONT
is purchased from Deepak nitrite, Nandesari. Urea is purchased from KRIBHCO hazia, Surat.
 Location and market area:

Plant is located at vatva G.I.D.C. which is the major hub of small and big chemical industries.
There are many industries in this which use CPC as raw material, so large market is available
for selling of product.
 Energy availability:
As the company is located in the developed industrial zone, problems regarding power cuts
are rare. Company also have generators in case of power cut.
 Climate:
Climate change in this region is steady and have some minor variation throughout the year
and the place selected for this plant has the least chance of natural calamity.
 Transportation:
Plant is just 1 km far form highway and 4 km away from railway station. So, plant have good
transportation facilities for raw material supply and product dispatch.
 Water supply:
Uninterrupted availability of sufficient water (from GIDC authority) is obtained.
 Waste disposal:
ETP plant is incorporated in plant premises. Plant is also nearer to common environmental
infrastructure; like TSDF-BEIL,
 Labour and supply:
vatva which is the major hub of chemical industries. As a result, availability of labour is high.
Moreover, company is tied up with organization which provides skilled and unskilled
labours.
 Site characteristics:
Plant is located at G.I.D.C. Estate which an industrial zone so, there are no ecological
sensitive areas such as tropical forests, biosphere reserve, and important lakes or coastal areas
rich in coral formation which can be affected by the plant.
Plant layout diagram

Figure 9.1- Plant layout
Conclusions
From justification it is concluded that selected location of plant is fulfilling all the necessary requirement which are best
suited for ideal plant like raw material availability, energy requirement, transportation, waste disposal, etc. So, location
is suitable to set up production facility for production of Copper Phthalocyanine.
CHAPTER-11
COST ESTIMATION
Introduction
Before setup of any plant, it is necessary to find investment required for plant construction,
operation and maintenance. To estimate this investment, it is required to do cost estimation of
overall plant.
Cost Estimation
Table 10.1- Cost of equipment
EQUIPMENT NO OF EQIPMENTS TOTAL COST

(IN LACS)
SULPHONATOR 2 18
DUMPING TANK 2 11.4
FILTER PRESS 1 15
STORAGE TANK 2 17.5

CSA
STORAGE TANK 2 1.4
SLURRY
PUMPS 6 1.5
DRYER 1 40
ATOMIZER
COMPRESSOR 1 3
PIPES & _ 2
VALVES
CYCLONE 1 2.5
SEPARATOR
Total Equipment Cost = Sum of cost of all above equipment
ETP(8 LACS) = 120.6 LACS
Table 11.2- Direct Cost :
ITEMS %OF PURCHASED

EQIPMENT TOTAL COST (LACS)
10
INSTALLATION COST 12.06
15
INSTRUMENT & 18.09
CONTROLS
13
ELECRICAL 15.678
INSTALLATION
25
SERVICE FACILITIES 30.15
10
LAND 12.06
15 18.09
BUILDING
40
SIZE REDUCTION 48.24
(EQUIPMENT)
TOTAL COST 154.368
Total Direct cost (D) = 154.368 LACS
INDIRECT COST:
ITEMS % OF EQUIPMENT TOTAL COST

PURCHASED
(LACS)
ENGINEERING & 30 36.18
SUPERVISIONS
CONSTROCTION & 16 19.269
CONTIGENCY
CONTRACTORS FEES 10 12.06
TOTAL COST = 67.536 LACS
CAPITAL INVESTMENT COST:
Fixed Capital cost = Direct cost + indirect cost + purchased equipment cost
=342.504 lacs
INITIAL WORKING COST = 15 % OF TOTAL INITIAL COST
TOTAL FCI = 393.8796 LACS
TATAL CAPITAL INVESTMENT = FCI + WCI

TCI = 393.8796 + 0.15 × WCI
SO, TCI = 463.3877 LACS
WCI = 69.508 LACS
CALCULATION OF TOTAL PRODUCTION COST:
Total production cost = manufacturing cost + general expenses
Manufacturing cost = direct production cost + fixed charges + plant overhead cost
DIRECT PRODUCTION COST:(By considering 180 lacs & ideal – 192 batchs)
RAW MATERIAL ANNUAL COST (LACS)

REQUIREDMENT
(TONNS)
CPC 144 367.2
CSA 522 13.18
PCL3 54 8.64
SODA ASH 36 22.5
SODIUM 90 1.8
BICARBONATE
SALT 30 315.9
VINYL SULPHONE 162 4.86
PYRIDINE 2.16 0.945
OCTANOL 0.9 32.059
ICE 2466 863.163
TOTAL COST = 863.163 LACS
OTHER PRODUCTION COST :
ITEMS BASIS COST (LACS)

UTILITYS 15 % OF PURCHASED 18.09
EQUIPMENT
MAINTAINANCE & 5 % OF FCI 19.69
REPAIRS
OPERATING SUPPLIERS 0.012 % OF FCI 4.72 /100
OPERATING LABOUR 10 % OF TPC
LABORATORY 10 % OF TPC
CHARGES
TOTAL = 37.8272 + 0.2 × (TPC)
FIXED CHARGES:
ITEM BASIS COST
DEPRICIATION 19.899
INTEREST 10 % OF TCI 46.338
LOCAL 4 %OF FCI 18.535
INSURANCE 1 % OF FCI 4.6338
TOTAL = 89.4058 LACS

NOW,
FCI = 393.8796 LACS
SALVAGE VALUE = 50 LACS
LIFE OF PLANT = 20 YEARS
BY, STRAIGHT LINE METHOD
Depreciation = 393.8796 - 50
20
= 19. 899
Manufacturing cost = Direct production cost + fixed charges
= 863.163 + 37.8272 + 0.2 (X) + 89.4058
= 990.396 + 0.2 X
GENERAL EXPENSES :
BASIS
Administrative cost 1.5 % OF TPC
Distribution & marketing cost 10 % OF TPC
R&D 4 % OF TPC
TOTAL = 0.155 (X)
Total Production cost = manufacturing cost + general expenses
X = 990.396+.2*X+.155*X
X =1535.49 LACS
CALCULATION OF PROFIT:
Sale price dye = 450 rs/kg
Total production per year = 450 tonn
Annual income = 450 × 450 × 1000
= 2025 lacs
= 2025 - 1535.49
GROSS ANNUAL EARNING = 489.51 LACS
Taxable income = 489.51 – 19.899
=469.611 lacs
INCOME TAX = 30 % OF TAXABLE INCOME
= 140.88 LACS PER YEAR
SURCHARGE = 3 % OF INCOME TAX
= 4.22 LACS/YEARS
Net annual earning = gross annual earning – income tax – surcharge – depreciation
NET ANNUAL EARNING = 324.511 LACS/YEAR
Rate of return = (net profit / TCI) × 100
= (324.511/463.387) ×100
=70 %
PAY BACK PERIOD:
= FCI / NET PROFIT
= 393.8796 / 324.511
= 1.21 YEARS
BREAK EVEN POINT:
= Raw materials cost (year) / total product (year)
= 863.163×105 / 180×2500
= 191.81 Rs
450 × n = 191.81 × n + 672.327 ×105
258.19 n = 672.327×105
n = 260400 kg (year)
so , 260400 / 2500 = 104.1 batch (year)
CONCLUSION :
In this chapter we estimated total investment required, annual profit form the project, rate of return, and
payback period. Based on these calculations it is concluded that this project is economically viable. So, it
is beneficial to establish the plant.
CHAPTER-12
CONCLUSION
This project work is based on the manufacturing of Pigment CPC
blue. Pigment CPC blue is a very important product in the chemical
industry. It is mainly used to manufacture dyes and intermediates.
Best process route for production of CPC is selected from all
available routes. Various details of equipment are provided for easy
understanding. Material and energy balances are important part of any
chemical industry for estimation of raw material requirement, waste
generated and heating-cooling medium. Utilities are also very
important in a chemical industry. In every industry, the equipment are
labelled with specific codes. These codes must be known before
actually going in the plant. Designing of equipment is one of the main
roles of a chemical engineer. To transport the fluid from one
equipment to another, pumps along with pipelines and control valves
are required. Before going in any industry, safety instructions are
given. Every industry has some safety protocol which everyone
present inside the company should follow. Plant location should be
appropriate before setting up the plant. Plant should be located where
there is continuous supply of water, electricity and where transport
and raw material is easily available. With the assumed costs of all
equipment, we can estimate the cost of plant along with depreciation.
And as a reference to these costs, one can estimate the cost of the
actual plant with known costs of each equipment, which helps to
decide economic feasibility of project.
REFERENCES
Books
 M.V. Joshi, Mahajan V.V. process equipment design McMillan India Ltd. 1999
 Richardson J.F., Coulson J.M., and Sinnot R.K. chemical engineering
 Kern D.Q. Process heat transfer McGraw Hill Publications: 1965
 Process Engineering and Design, Thakore S.B. and Bhatt B.I. Stoichiometry, 5th edition
 Chemical Engineering Plant Design, Vilbrandt & Dryden, 4th Edition
 Plant Design and Economics for Chemical Engineers, Peters Max S. and Timmerhaus Klaus
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Turquoise Blue G Dye

Under the Guidance of

Department of Chemical Engineering

This is to certify that Vasava Akshay (CH-127, I.D.NO:

Dipali N. Shah Dr. M.S.Rao

Figure 2.1-Synthesis method for CPC....................................................................................................8

Figure 2.2- Reaction mechanism.........................................................................................................10

Figure 2.3- CPC reaction mechanism adduct (1).................................................................................11

Figure 2.4- CPC reaction mechanism adduct (2).................................................................................11

Figure 2.5- CPC reaction mechanism adduct (3).................................................................................12

Figure 2.6- CPC reaction mechanism adduct (4).................................................................................12

Figure 2.7- Process block diagram.......................................................................................................15

Figure 2.8- Process flow diagram........................................................................................................18

Figure 3.1- Block diagram of GLV........................................................................................................21

Figure 3.2- Block diagram of RVD........................................................................................................23

Figure 3.3- Block diagram of Surge drum............................................................................................23

Figure 3.4- Block diagram of MSRL......................................................................................................24

Figure 3.5- Block diagram of Filter press.............................................................................................24

Figure 3.6- Block diagram of SFD.........................................................................................................25

Figure 3.10 Material balance diagram................................................................................................26

Figure 5.1- Cooling tower....................................................................................................................36

Figure 5.4- Scrubber System...............................................................................................................40

Figure 7.1- Bracket support.................................................................................................................63

Figure 9.1 ETP flow diagram................................................................................................................75

Figure 10.1- Plant layout.....................................................................................................................82

Table 2.1- Raw material suppliers.......................................................................................................14

Table 3.1- Raw material & Product Details..........................................................................................20

Table 3.4- Summary of material balance over Surge Drum................................................................24

Table 4.1- Properties of components..................................................................................................29

Table 6.1- Glass Lined Reactor Vessel (GLV)....................................................................................42

Table 6.3- Mild Steel Rubber Lined Vessel (MSRL)..........................................................................43

Table 7.2- Nozzles Design....................................................................................................................60

Table 7.3- Nozzle dimensions..............................................................................................................61

Table 7.4- Flanges details....................................................................................................................62

Table 8.1- Pumps present in plant.......................................................................................................67

Table 8.2- Types of valves...................................................................................................................69

Table 11.1- Cost of equipment............................................................................................................85

MOC Material of construction

LMTD Logarithmic mean temperature difference

NPSH Net positive suction head

PPE Personal protective equipment

ETP Effluent treatment plant

CAS Chemical abstract service

IUPAC International union of pure and applied chemistry

TEMA ubular exchanger manufacturing association

CETP Common effulent treatment plant

CETP Common effluent treatment plant

FCI Fixed Capital Investment

WCI Working Capital Investment

TCI Total Capital Investment

rpm Rotation per minute Rad/s

NRE Reynolds number -

J Joint efficiency factor -

ΔHf Heat of formation J/mol

ΔHr Heat of reaction J/mol

K Rate of constant Concntration1-n

f Allowable stress N/m2