Hopl Final Report

Semester Internship Report
A REPORT ON
SEMESTER LONG TERM

INTERNSHIP IN
Harmony Organics Pvt. Ltd. Kurkumbh

Submitted to the Chemical Engineering Dept.
VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

In Partial Fulfilment of the Requirements
For the Award of the Degree of
BACHELOR OF TECHNOLOGY (CHEMICAL)

SUBMITTED BY
VIKAS LATE
(GR. NO. 162045)
Department of Chemical Engineering

BRACT’S Vishwakarma Institute of Technology,
666, Upper Indiranagar, Bibwewadi, Pune – 411 037
1
Bansilal Ramnath Agarwal Charitable Trust’s

VISHWAKARMA INSTITUTE OF TECHNOLOGY
(An Autonomous Institute Affiliated to University of Pune)
666, Upper Indiranagar, Bibwewadi, Pune – 411 037
December 2018
CERTIFICATE
It is certified that the project work entitled
SEMESTER LONG INTERNSHIP REPORT
Submitted by
VIKAS DATTATRAY LATE
(G.R.NO: 162045)
is the original work carried out by them under the supervision of Prof. S.R.Inamdar is approved
for the partial fulfilment of the requirement of Chemical Engineering Department, VIT Pune, for
the award of the Degree of Bachelor of Engineering (Chemical). This Project Work has not
been earlier submitted to any other Institute or University for the award of any degree or
diploma.
Prof. Dr. S. R. INAMDAR Mr. NILESH THAKUR Prof. Dr.M.P. DEOSARKAR

Examiner Internal Guide General Manager Head
Dept. of Chemical Engg. Harmony Organics Pvt.Ltd. Dept. of Chemical Engg.
VIT, Pune VIT, Pune
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ACKNOWLEDGMENTS
I take this opportunity to thank & express our sincere gratitude towards Mr.
Ravi Nangia (Managing Director) Harmony Organics Private Limited, Pune for providing us an
excellent opportunity to gain exposure to professional world. We also express sincere gratitude
towards Prof. Dr. Shrikant Kulkarni to allow us undertaking the training.
Mr. Ravi Nangia from HOPL Pune, Managing director deserves our deepest
gratitude for providing continuous support guidance throughout the training .We would like to
express our gratitude towards all ours teacher Prof. Dr. M.P. Deosarkar (HOD, Chemical Engg.
Dept. VIT, Pune) and Prof. Dr. S.R.Inamdar. Last but not the least we would like to thanks all
Harmony Employees to have helped in minor necessities in the process of learning.
Mr. VIKAS D. LATE

B-Tech Chem Engg.
G.R.No: 162045
VIT, Pune
3
DECLARATION
I declare that this written submission represents my ideas in my own words and where
other ideas or words have been included, I have adequately cited and referenced the original
sources. I also declare that I have adhered to all principles of academic honesty and integrity and
have not misrepresented or fabricated or falsified any idea/data/fact/source in my submission. I
understand that any violation of the above will be cause for disciplinary action by the institute
and can also evoke penal action from the sources which have thus not been properly cited or
from whom proper permissions has not been taken when needed.
Mr. VIKAS D. LATE

B-Tech Chem Engg.
G.R.No: 162045
VIT, Pune
4
ABSTRACT
Humble beginning with a plant in New Bombay 30 years ago for

manufacture of aroma and specialty chemicals, mainly for the fine chemical industry. The
company has made products like phenyl ethyl alcohol involving use of highly hazardous material
like ethylene oxide.
Harmony has been a regular participant in industry conferences and a
member of key trade organizations. As the Company grew in size and tonnages the original
manufacturing site at Mumbai became constraining in terms of expansion potential and hence in
the year 2006 the company established a new manufacturing location at a Chemicals
Manufacturing Hub located at Kurkumbh near Pune, India. This current manufacturing facility is
located on a 6 acre plot at Kurkumbh MIDC ( 70 km from Pune & 300 km from Mumbai) and
manufactures Phenyl Ethyl Alcohol, Styrene Oxide and Methyl-Pentenone as key products
(combined tonnage of 3000 TPA) in addition to several smaller products including Styrallyl
Acetate, Para Cresyl Methyl Ether, Anisole etc. Large customers include the S H Kelkar group &
Oriental Aromatics and Lupin Industries (Pharma). We have successfully executed export orders
to customers in EU & North America.
The company is committed to future growth in the Aroma Chemical
industry with a focus on large tonnage products. Sustainability, environment friendliness and the
safety of our employees and neighborhoods are non-negotiable goals for Harmony. The company
is invested in the welfare of its employees and has continuing investment in upgrading their
skills. Mr. Nangia is always proud to mention the number of highly skilled & devoted operators
that have been with the company more than 30 years.
5
Sr. No. Content Page No.

1. Introduction 4
1.1 Phenyl Ethyl Alcohol 4

1.2 Methyl Pentanone 5
1.3 Cinnamaldehyde (CNMD) 6
2. Properties of Materials 7
2.1 Physical Properties 7
3. Phenyl Ethyl Alcohol (PEA) 8
3.1 Production of SCH crude 8
3.2 Production of SO crude 8
3.3 Distillation of SO crude to SOTTO 10
3.4 Hydrogenation of SOTTO 11

3.5 Recovery of Methanol in JD column `
3.6 Distillation of PEA crude to PEA main
3.7 Process Block Diagram Of PEA
3.8 Material Balance Of PEA
4. 3 – Methyl -2-Pentanone
4.1 Production of MPO crude
4.2 Recovery of MEK in LD column
4.3 Distillation of MPO crude to MPO main
4.4 Process Block Diagramm of MPO Production
4.5 Material Balance of MPO
5. Design Of Continues Distillation Column
6. ADDITIONAL ASSIGNMENTS
6
4.1 Calibration Of Storage Tanks 26
4.2 Piping And Instrumentation Diagramm 26
4.3 Tracing And Labelling Of Lines 26
4.4 Removal Of Unusual Pipes And Electrical Wires 29
4.5 Plant Monitoring 29
7
INTRODUCTION
Humble beginning with a plant in New Bombay 30 years ago for manufacture of aroma
and specialty chemicals, mainly for the fine chemical industry. The company has made products
like phenyl ethyl alcohol involving use of highly hazardous material like ethylene oxide.
Harmony has been a regular participant in industry conferences and a member of key
trade organizations. As the Company grew in size and tonnages the original manufacturing site at
Mumbai became constraining in terms of expansion potential and hence in the year 2006 the
company established a new manufacturing location at a Chemicals Manufacturing Hub located at
Kurkumbh near Pune, India. This current manufacturing facility is located on a 6 acre plot at
Kurkumbh MIDC ( 70 km from Pune & 300 km from Mumbai) and manufactures Phenyl Ethyl
Alcohol, Styrene Oxide and Methyl-Pentenone as key products (combined tonnage of 3000
TPA) in addition to several smaller products including Styrallyl Acetate, Para Cresyl Methyl
Ether, Anisole etc. Large customers include the S H Kelkar group & Oriental Aromatics and
Lupin Industries (Pharma). We have successfully executed export orders to customers in EU &
North America.
The company is committed to future growth in the Aroma Chemical industry with a focus
on large tonnage products. Sustainability, environment friendliness and the safety of our
employees and neighborhoods are non-negotiable goals for Harmony. The company is invested
in the welfare of its employees and has continuing investment in upgrading their skills. Mr.
Nangia is always proud to mention the number of highly skilled & devoted operators that have
been with the company more than 30 years.
Harmony Organics owns a 6 acre manufacturing site at the notified industrial area at
Kurkumbh. The site is fully approved for chemicals manufacturing activity and directly falls
within a zone identified by the Indian Government for the setup of chemicals manufacturing
units. Abundant water supply is available from a dedicated water supply reservoir for the
industrial area. Unlike other areas in India the Kurkumbh site enjoys uninterrupted electrical
power supply with no load shedding.
8
The site area is currently about 70% utilized thereby retaining abundant scope for future
expansion projects. The manufacturing plants on the site are divided into several distinct
functional areas:
 A Reaction Plant
 Distillation Plant
 Hydrogenation Plant
 Blending and Packing Area
The highlight of the plant is a section of large capacity Glass Lined Reactors which enable
versatile handling of a variety of chemical reactions handling corrosive reagents. Other
reactors include graphite lined and polymer vessels also suitable for corrosive media.
Additional processing capacity in the form of Carbon Steel and Stainless Steel reactors are also
available in a variety of sizes. Another highlight of the facility is the presence of six
hydrogenators of various capacities ranging from 1000 L to 8000 L and capable of handling up
to 50 barg pressure.
Harmony recognized the critical utility of good separations capacity for the aroma industry due
to exacting requirements of olfactory quality & hence the removal of trace impurities. As a
result we have invested in tall, high vacuum distillation columns with the best-in-class, high-
efficiency structured packing and this is a key factor responsible for the high quality of our
aroma products.
A common utility area includes a coal fired boiler that provides steam to the entire site and also
cooling water, compressed air and other shared utilities. The boiler includes full pollution
control equipment including cyclones, scrubbers and bag filters to comply with the latest
standards for particulates and other emissions. We have our own on-site Nitrogen generation
plant that gets utilized for safety & inerting applications as well as for various blending,
maturation and drum filling needs. In addition we have also invested in a state-of-the-art food-
grade compressed air drying & filtration plant so that any fluids that contact our final products
will comply with the highest standards of hygiene as required by the food / flavor safety codes.
We are in the process of installing an on-site Hydrogen generation plant as well; to further
acquire a competitive advantage for hydrogenation-products.
9
We have a modern Quality Control Lab that is operating 24x7 with an Agilent GC for
delivering the best product quality and purity to customers.
A significant capital investment has also been made on water / effluent treatment infrastructure
for the entire plant. We have two trains of triple effect evaporators that cater to all the
inorganic dissolved salt loads of our effluent. This is followed up by conventional treatment
(primary / secondary and tertiary) in a dedicated Effluent Treatment Area. Biological treatment
in aeration basins ensures that the quality of the finally discharged water complies with all
applicable rules. In fact, a significant portion of the water is already being recycled for process
and utility applications. A major project for up-gradation of our water treatment capacity is
currently in progress at the end of which we will more than triple our waste water treatment
and recycling capacity.
Quality Control & Quality Assurance :-
Harmony has established systems in place to ensure that Quality becomes an integral
part of everything we do. Quality Control is integral to our operations, right since the design
stage and not added as an afterthought. Some of the key features of our Quality Control
/Quality Assurance systems are as follows:
 Quality Control Systems certified by an independent, third party auditor as per ISO
9001:2015 and ISO 22000
 Bi-annual internal audits and yearly external surveillance audits of all QC systems
 Meticulous attention to record-keeping and plant logs with immediate corrective action
for any deviations
 Strict, written, documented change-control procedures
 Dedicated QC Lab fitted with all requisite equipment for measurement of parameters
like Refractive Index, Density, Moisture content etc. On-site lab uses a World class Gas
Chromatograph (Agilent) with GC-MS option at an associate lab.
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1.1 Phenyl Ethyl Alcohol :

Phenyl ethyl alcohol is a good flavoring agent and preservative. It is extensively used in
manufacture of synthetic rose perfumes, orange blossom, Jasmine etc. and also in the synthesis
of rose oils. Practically, all rose perfumes are compounded with Phenyl ethyl alcohol. It is used
as perfumery chemical in the cosmetic formulations like detergents, soaps, perfumes, cosmetic
powder and lotions, paste cream etc.
Figure 1:- Structure of PEA
Phenyl ethyl alcohol is largely used in agarbathi, perfumery, cosmetic and soap sector.
PEA does not have any other chemical substitute which can compete with its price structure,
though Linalool is used to mimic PEA to some extent. There are reported to be over 260
agarbathi producers in Karnataka state itself and around 450 units in the country. Phenyl ethyl
alcohol is used for providing flavor properties to toilet soaps, particularly catering to the
requirement of higher income group Phenyl ethyl alcohol are generally used in the formulation
of perfumery compounds used in product such as face powder, scent, handkerchief perfumes,
shaving cream, cigars etc.
1.2 Methyl Pentanone :

3-methyl-2-pentanone is aliphatic ketone and isomer of 2- hexanone.Harmony organics
produces methyl pentanone on contract manufacturing bases. Methyl pentanone is ketone and
solvent of minor importance . it is comparable to MEK , but has lower solvency and is more
expensive.
11
Figure 2:- Structure of MPO
It is used widely in pharmaceutical as well as aroma chemical companies.
1.3 Cinnamaldehyde (CNMD):-
Cinnamaldehyde is an organic compound with the formula C6H5CH=CHCHO.

Occurring naturally as predominantly the trans (E) isomer, it gives cinnamon its flavor and
odor.It is a flavonoid that is naturally synthesized by the shikimate pathway.
Figure 3:- Structure of CNMD
This pale yellow, viscous liquid occurs in the bark of cinnamon trees and other species of
the genus Cinnamomum. The essential oil of cinnamon bark is about 50% cinnamaldehyde.
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2. PROPERTIES OF MATERIALS
2.1 Physical Properties :
The list of Physical properties of some materials which Harmony organics

produces and which reactants required for production as :
Table 01:
Molecular Boiling Point Flash Point Sp. Gravity

Name of Material weight (O Celsius) (O Celsius)
Styrene 104.15 145 31.1 0.906

H2O2 34 108 12 1.2
HCl 36.5 110 1.2
SCH 156 1.2

SO 120 194 80 1.05
Phenyl Ethyl Alcohol 122 220 96 1.02
Methyl Ethyl Ketone 72 79 -09 0.805

H2SO4 98 337 1.84
Acetaldehyde 44 21 -38 1.52
Benzaldehyde 106 179 64 1.04

Methyl Penta none 86 138 34 0.805
Cinnamic Aldehyde 132 252 71 1.05
1,3-Butanediol 90 207 121 1.005
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3. PENYL ETHYL ALCOHOL

Phenyl Ethyl Alcohol Produced in three steps:-
1. Production of Styrene Chlorohydrin (SCH) Crude. ….. (Plant -1).
2. Production of Styrene Oxide (SO) Crude. ….. (Plant –2).
3. Production of PEA Crude (Hydrogenation of SOTTO). ….. (Hydrogenation plant)
Reaction :-
Plant :-1
1) Styrene + 30% H2O2 + 32%HCL Styrene chlorohydrin + H2O
Plant :-2
2) Styrene chlorohydrin + 20% NaOH Styrene Oxide + H2O + NaCl
Hydrogenation plant:-
3) Styrene Oxide + Hydrogen(H2) P.E.A. Crude
1. Production of SCH crude:
Initially we take certain quantity of water in GLR but the water should have acidity
between 2-3% and iron content below 2 ppm. Then we will add certain quantity of styrene
(98%), H2O2 (30%), HCl (32%) after reaching the temperature of water upto 90°c and addition
will continues for 6 hrs. and rate of addition will be the same for all the chemicals. The reaction
occurs is highly exothermic, so after digestion of 2 hrs the temperature will raise upto 98°c and
the reaction involved is,
Styrene + H2O2 + HCl SCH crude
After the digestion, the sample of SCH crude will be sent to GLC and from that report
we will get to know the different contents and also the styrene contain should be less than 0.5%
and SDC between 7% - 9% and we will get SCH crude of 85% - 88%.
14
Then further heating will be start to gain temperature of 116°c - 118°c and we have to maintain
this temperature and pressure 1.5 – 2kg/cm2 .
Once this temperature is reached then 4 hrs. of digestion will be taken for the purpose to
nil the SDC and after this, the temperature will be reduced upto 90°c and GLR will be leaved for
settling of 1 hr. Due to the high density of SCH crude it will settle down and transferred to
R3/R4 reactor for further cooling and water which is formed as byproduct will be drain out in the
SCH wash water tank. If reaction is not completed i.e. un-reacted styrene is more than 0.5% then
add H2O2 as per un-reacted styrene percentage in GLC.
The temperature of SCH crude in R3/R4 will be decreased from 90°c - 40°c and settling
of 1 hr. and separation of half hr. takes place and SCH crude is transferred for further reaction
i.e. FR/BR/SR.
2. Production of SO crude:
Start addition of caustic lye (30%) solution from tank in reactor and maintain temperature
of reactor between 40°c - 42°c.
SCH crude + Caustic lye (30%) SO crude.
After completion of caustic lye addition, digest reaction mass for 1 hr. and after digestion take
sample from reactor and give it for GC checking. If SCH is greater than 0.5% then add caustic
lye and digestion of 1 hr. takes place again and settling of 1 hr. also takes place and remaining
alkaline water will be drop in ETP and the SCH crude is transferred to GD/DD.
SO crude is charged to GD/DD for half hr. and heating takes place to raise temperature upto
100°c for 1 hr. The reaction occurs is,
SO crude SOTTO
Charge certain quantity of Nitrosonapthol powder with SO crude by vaccum, when SO crude
charging is over then start heating. After the heating, when distillation start, first SOTTO starts to
come out and it will take nearly 10 hrs. for completion and raise upto temperature 130°c . After
15
the distillation, cool it upto 110°c and release vaccum and drop SO residue in drum. Formed
SOTTO will be transferred to A3/A5 hydrogenation.
3.Production of PEA crude:
SOTTO when reacts with hydrogen gas in presence of methanol, SBC, caustic lye
palladium catalyst and forms PEA crude. This is an exothermic reaction.
SOTTO + H2 Palladium PEA crude
Charge certain amount of methanol from tank and start stirrer followed by catalyst
applying vaccum in reactor and also the caustic flakes. Carryout flushing of reactor with N2 gas
by taking N2 pressure in reactor and release N2 by opening vent valve. Repeat this process 3
times to ensure all the air inside reactor has been displaced with N2 gas. Do the same procedure
for H2 gas. Raise the temperature of reactor at about 65°c. The addition will be over in 10-11
hrs. and after dosing of SOTTO over, give sample for testing and if SO is nil then reaction occurs
in right manner and PEA crude formed will be minimum of 96% and after this reduce
temperature upto 45°c and settling of 5 hrs. will be done and PEA crude is transferred to JD
column for methanol recovery.
JD column is a continuous column with jacketed vessel and condenser and it is having
provision for continuous feeding of PEA crude and continuous removing of rec. methanol and
PEA RBM. First add certain quantity of PEA crude and start heating and after some time
methanol will start boiling and condensed in the over heat exchanger. Continue recovery till
bottom temperature of 120°c and also ensure that temperature of rec. methanol which is entering
in storage tank does not more than 80°c. Send the sample for GC testing and after the report it
will come to know the purity of PEA crude of 97% - 98% and rest is methanol which is
recovered. Then further it sends for ND-1 and ND-2.
Then charge certain PEA Fraction from storage tank under vacuum by using level
indicator provided on storage tank. Start heating in column by opening related steam valve.
When distillation starts maintain top and bottom temp 80°C and 100°C resp.
PEA Fraction PEA Tops + PEA Fraction + PEA RBM
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Now PEA Tops fraction starts to come out, at that time keep certain take off rate and
certain reflux rate and collect that fraction in receiver then transfer it in drums by releasing
vacuum.
Take vaccum in column by steam and water jet ejector and start feeding of RBM with the
help of vaccum and pump. Start the heating and bring the column to reflux and note the
temperature of top and bottom and start cutting of fraction. Put the column on reflux ratio and
continue fraction till purity 99.5% then collect PEA main in blending tank and further sample is
given for quality check and finally it is dispatched.
Time cycle of Production of PEA
Operations Standard Time
Production of SCH crude 18 hr
Cooling of SCH crude 6 hr
Production of SO crude 18 hr
Distillation of SO crude to SOTTO 18.5 hr
Hydrogenation of SOTTO 20 hr
Methanol Recovery in JD column
Distillation of PEA crude to PEA main
Blending of PEA main
Total
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Process Flow Block Diagram Of Phenyl Ethyl Alcohol
Receiving of Raw materials (A1)
Sampling of Raw Materials (A2)
Unloading of Raw materials (A3)
Storage of Raw Materials (A4)
Transfer of Raw materials to day Tanks (A5)
Transfer of RM to dosing Tanks (A6)
Reaction in GLR 1/3/4/5 reactors (A7)
Neutralization of effluent water (A11)

Cooling & Settling in R3 (A8)
Multiple effect
evaporation (A12)
Epoxidation reaction in FR/BR reactor (A9)
Biological treatment
(ETP) (A13)
Transfer of SO crude To T-28/T-7 (A10)
Water Recycle to
Cooling Tower (A15)
18
SO crude in T-28/T-7 (A10)
Total take off of SO crude in JD/HD/GD column (A16)
Transfer of SO TTO to T-23 (A19)

SO residue Drumming (A17)
Transfer of SO TTO to T-3/4 (A20)

Transfer to Designated Area (A18)
Hydrogenation of SO in the reactor A3/A5 (A21)

Dispatch of SO residue (A18’) HYDROGEN
PEA crude transfer to T-1 (A22)
Solvent Recovery in BD/FD column (A23)
Recovered Solvent transfer in T-41/T-53 (A24)

PEA 1st RBM transfer in T-24 (A25)
PEA 1st RBM transfer from T-24 to ST-6 (A26)
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PEA 1st RBM in ST-6 (A26)
Distillation of PEA RBM in ND-1 column (A27)
Transfer of PEA fraction to T-2 Bottom Material transfer to ND-2 Column (A29)
(A28)
PEA main to Receivers (A30) Transfer of PEA 2nd RBM into ST-17 (A31)
PEA main to blenders (A32)

Distillation of 2nd RBM in Distillation column (A33)
Analysis of FG (A34)
PEA TTO to ND-2 (A35) PEA residue for

drumming (A36)
Drumming of FG (A37)
Transfer of PEA Residue drums

in designated area (A38)
Packaging of FG (A39)
Dispatch (A41)
Labelling (40)
Dispatch of PEA FG (A42)
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MATERIAL BALANCE OF PHENYL ETHYL ALCOHOL
1. Production of Styrene Chlorohydrin (SCH) Crude. ….. (Plant -1).

2. Production of Styrene Oxide (SO) Crude. ….. (Plant –2).
3. Production of PEA Crude (Hydrogenation of SOTTO). ….. (Hydrogenation
plant)
Reaction :-
Plant :-1
1) Styrene + 30% H2O2 + 32%HCL Styrene chlorohydrin + H2O
Plant :-2
2) Styrene chlorohydrin + 20% NaOH Styrene Oxide + H2O + NaCl
Hydrogenation plant:-
3) Styrene Oxide + Hydrogen(H2) P.E.A. Crude
1. Production of Styrene Chlorohydrin (SCH) Crude.
Plant :- 1
Equipment name :- Glass Line Reactor(GLR 1/2/3/4/5)
Capacity :- 12500 lit.
Raw material :- Styrene, H2O2, HCL, Water.
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Some material & there properties which we used in the production of SCH Crude.
Quantity Mol. Density B.P.

Material Purity Quantity(lit.) (kg) Wt(g/mol) (g/cm^3) (◦C)
Styrene 100% 2412 2200 104.15 0.909 145
H2O2(30%) 30% 2210 2453 34 1.11 150
HCL(32%) 32% 2109 2450 36.5 1.161 84
Water 4000 4000 18 1 100
SCH
(produced) 95% 2700 3142 156.6 1.16 254.9
SO - - - 120.15 1.052 194
From Reaction 1 :-
1 kmol Styrene = 1 kmol of H2O2 = 1 kmol of HCL = 1 kmol of SCH crude = 1 kmol of H2O
104 kg of styrene reacted = 156.6 kg of styrene chlorohydrin produced.
104 kg styrene = 156.6 kg SCH Crude
2200 kg styrene = X amount of SCH Crude
Amount of SCH Crude formed (X) = (2200*156.6)/104
= 3307 kg.
Amount of SCH crude produced when 2200 kg of styrene reacted = 3307 kg.
Amount of Water produced = (2200*18)/104
= 380 kg.
Material Balance of GLR ( CSTR ) = Input = Output
Input = 4000 + 2200 + 2453 +2450 = 11103 kg.
Output = 4000 +(0.7*2453) +(0.68*2450) + 3142 + 380 = 10905 kg.
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% Yield of SCH crude = (moles of SCH produced)/(moles of styrene consume).
= ((3142/156.4)/(2200/104.6))
= 95 %.
Plant – 2:-
2) Production of Styrene Oxide (SO) Crude.
Equipment name :- Reactor (FR/BR/SR)
Raw material :- SCH Crude, Caustic lye(20%), Water.
Quantity Quantity Mol. Wt. Density B.P.

Material Purity (lit.) (kg) (g/mol) (g/cm^3) (◦C)
2709.073
SCH Crude 95% 5 3143 156.6 1.16 254.6
Caustic lye 48% 1080 1303.236 40 1.2067 110
Water - 2250 2250 18 1 100
SO - - - 120.15 1.052 194
PEA - - - 122.16 1.017 219
NaCl - - - 58.44 2.179 1465
From Reaction :- 2
1 Kmol of SCH = 1 Kmol of NaOH = 1 Kmol of SO.
Material Balance of Reactor = Input = Output
Amount of Styrene Oxide formed = Amount of SCH reacted.
156.6 kg of SCH consumed = 120.15 kg of styrene Oxide formed.
156 kg SCH = 120.15kg SO Crude.
3142 kg SCH = X amount of SCH Crude.
Amount of SO crude formed (X) = (3142*120.15)/156
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= 2411 kg.
Amount of SO produced when 3142 kg of SCH reacted =2411 kg.
Purity of SO crude = approxi. 92%.
Actual amount of SO produced = 2218 kg.
= 2108 lit.
Amount of water produced =
156.6 kg of SCH consumed = 18 kg of Water formed.
156 kg SCH = 18 kg water.
3142 kg SCH = X amount of Water.
Amount of water produced = 361 kg.
Amount of Salts produced =
156.6 kg of SCH consumed = 58.44 kg of Water formed.
156 kg SCH = 58.44 kg salts.
3142 kg SCH = X amount of salts.
Amount of Salts produced = (3142*58.44)/156
= 1172 kg.
Material balance of Reactor = Input = Output

Input = 3142 + 1303 + 2250 = 6695 kg.
Output = 2218 + 361 + 1172 + 2250 + (.52*1303) = 6678 kg.
Distillation of SO crude :-
Equipment name :- Distillation Column (GD/DD)
Capacity :- ------
24
Raw material :- Styrene Oxide.
Distillation:- S. O. Crude S.O.TTO.(98% to 99%).
After a distillation of SO crude in DD/GD column we get 90 to 93% composition of top product
i.e SOTTO & get residue 7-10%.
Material Balance of Distillation column :-

F*Xf = D*Xd + W*Xw
F = Feed rate to column.
Xf =mole fraction of SO in feed.
D = Mass flow rate of Distillate.
Xd = mole fraction of SO in Distillate.
W = feed rate of bottom product.
Xw = mole fraction of SO in bottom product.
F = 2230 kg. Xf = 0.925
D = 2070 kg. Xd = 0.985
W = 160 kg. Xw = 0.15
F =D+ W
W=F - D
F*Xf = D*Xd + (F - D)*Xw
= D*Xd + F*Xw - D*Xw
D = (F*Xf - F*Xw)/(Xd - Xw)
= (2230*0.925 – 2230*0.15)/(0.985 – 0.15)
= 2070 kg/hr
W = F - D
= 2230 – 2070 = 160 kg/hr.
Amount of SOTTO formed in GD/DD Column = 2070 kg.
25
Hydrogenation plant:
3) Production of PEA Crude (Hydrogenation of SOTTO):-

Equipment name :- Autoclave Reactor A5. (A3/A5/A6).
Raw Material :- SOTTO, Methanol, Palladium Catalyst, S.B.C, Caustic Flakes, Soda Ash.
Hydrogen Gas (H2).
Mol.
Quantity(kg Wt(g/mol Density(g/
Input Purity ) ) cm^3) B.P.(◦C)
Methanol 100% 2121.76 32 0.792 64.7
Hydrogen - 79.57 2 0.08988 -252.9
SOTTO 4780.3 120.15 1.052 194
Caustic flakes - 25.5 - - -
SBC - 53 - - -
Pd catalyst - 0.3 - - -
Output
PEA crude 97.35 4860.2701 122.16 1.017 219
From Reaction 3 :-
1 kmol of SOTTO = 1 kmol of H2 = 1 kmol of PEA
Conversion of SOTTO = 100%.
Amount of PEA formed = Amount of SOTTO reacted.
120 kg of SOTTO consumed = 122.16 kg of PEA formed.
120 kg SOTTO = 122.16 kg PEA Crude
4780 kg SOTTO = X amount of PEA Crude
Amount of PEA crude formed (X) = (4780*122.16)/120
=4860 kg.
26
Amount of PEA produced when 4780 kg of SO reacted = 4860 kg.
Purity of PEA = 97.35 approxi.
Actual amount of PEA produced = 4731 kg.
= 4652 lit.
Amount of H2 reacted =
120 kg SOTTO = 2 kg H2
4780 kg SOTTO = X amount of H2
Amount of hydrogen reacted = (4780*2)/120
= 79.54 kg.
Overall Material balance of Autoclave reactor = Input = Output.
7060 kg = 7061 kg.
Recovery of Methanol in JD column:-
F=D+ W
Material balance of methanol component:-

Xf =mole fraction of Methanol in feed.
Xd = mole fraction of Methanol in Distillate.
Xw = mole fraction of Methanol in bottom product.
F = 1000 kg/hr. Xf = 0.2971
D = 2070 kg/hr. Xd = 0.9885
W = 710 kg/hr. Xw = 0.015
F =D+ W
27
W=F - D
= (1000*0.2971 – 1000*0.015)/(0.9885 – 0.015)
= 290 kg/hr.
Methanol recovered in JD column = 290 kg/hr.
Distillation of PEA crude in ND-1 and ND-2 column:-
PEA 1ST RBM PEA Main + PEA Fraction + PEA 2nd RBM
PEA crude (1st RBM ) send to ND-1 distillation column. After distillation in ND-1 column we
get purity of PEA (bottom product) 98% to 99% purity. These bottom product send to ND-2
column for better purity and we get 99.8 + percent purity.
28
29
4. 3-Methyl-2-Pentanone (MPO)
Reaction:-
Main Reaction :-
1) M.E.K + Acetaldehyde 98% H2SO4 MPO + H2O.
For Neutralization of PH (MPO crude Washing) :-
2) H2SO4 + Na2CO3 + H2O Na2SO4 + CO2 + 2 H2O.
Production of MPO crude:
M.E.K. when reacted with Acetaldehyde in presence of catalyst Sulphuric Acid

(98%) forms Methyl Pentenone. The reaction is exothermic and this is an aldol condensation.
M.E.K. + Acetaldehyde + Caustic lye (30%) H2SO4 Methyl Pentenone
First add certain quantity of MEK in GLR and give sample to lab analysis which takes
about 2 hrs. and start agitator, after this add certain quantity of sulphuric acid to it and it takes
approx. half hr. then raise the temperature of reactor mass to 55ᵒc. and at the same time add
acetaldehyde under the nitrogen pressure and it will take around 4-5 hrs. for completion and with
that maintain the temperature between 60ᵒc - 62ᵒc. After Acetaldehyde addition over, start
digestion for 2 hrs. by maintaining temperature up to 65ᵒc -70 ºC. Start cooling upto 55ᵒc for
about 1 hr. Add soda ash in it and allow it for settle for about half hr. Check acid layer and
prepare for second soda ash wash and after the wash, allow it for settle for about half hr. Separate
aqueous layer separation and check PH and it should be between 7 – 8. If PH is ok then add
some quantity of BHT and transfer it to further distillation.
Caustic wash and soda ash wash is required to make the crude slightly alkaline in nature
and to remove impurities present in the crude. M.P.O. crude is distilled to remove wet MEK
from top and MPO RBM from bottom.
MPO Crude Recovered M.E.K + M.P.O. RBM
30
First check the distillation column and start dosing of MPO crude through heat exchanger
reboiler. After the completion of dosing start heating upto bottom temperature 140ᵒc for
distillation. When distillation starts, start dosing of MPO crude, maintain Take off rate and reflux
rate and also maintain top and bottom temperature by heating and cooling. After maintaining all
the parameters of distillation column, check sample of MEK and MPO and drop in different
tanks. After GLC report, we come to know the composition of wet MEK i.e. it contains MEK of
96% – 97% and MPO of 2% - 3% and that of MPO i.e. MPO of 88% - 89% and MEK 1% - 2%
and HB 10% - 12%. If we get these composition then continue MEK recovery otherwise
continue this process.
After getting MPO RBM then we will further distil it under vaccum and we will get
MPO main.
MPO RBM-1 M.P.O Main + MPO RBM-II + Rec MEK + Fraction
First check column and take vaccum in column and start dosing of MPO RBM- 1. After
the addition, start heating and give sample for GC for initial testing, after heating distillation
starts and MEK first comes out then increase the vaccum slowly and drop MEK in a tank and
start fractionation. Start first fraction and give sample for GC and if we get report ok then drop
fraction in tank now MPO main starts to come out and when it starts to come out then maintain
top temperature between 65ᵒc - 70ᵒc and bottom temperature 85ᵒc. Maintain reflux rate and
takeoff rate and MPO main goes from different receivers i.e. receiver- 1, 2, 3 and finally from
GLC report we get MPO main as purity of minimum 96% and then drop this MPO main in a
tank.
M.P.O. RBM-II containing MPO = 25% - 40 %, HB = 60-75% when distilled under
vacuum, we will get MPO LP Main and HB Main.
MPO RBM-II M.P.O LP. Main +MPO HB MAIN + MPO RESIDUE
First check column and take vaccum in column and start dosing of MPO RBM- II and if
MPO HB main is available then charge and adjust level. After the addition, start heating and give
sample for GC for initial testing. After heating when distillation starts, MPO LP. starts to come
31
out first and drop in a tank and then start first fraction and give sample for GLC and if all
parameters are ok then start fractionation. Now MPO main starts to come out and when it starts
to come out then maintain top temperature between 65ᵒc - 70ᵒc and bottom temperature 85ᵒc.
Maintain reflux rate and takeoff rate and MPO main goes from different receivers i.e. receiver- 4,
5, 6 and finally from GLC report we get MPO main as purity of minimum 99% and then drop
this MPO main in a tank and residue in different tank and prepare distillation column for next
batch.
Time cycle of Production of MPO
Operations Standard Time
Production of MPO
1st /2nd Washing
MEK recovery in LD column
Flash Distillation of MPO
Total
32
Process flow Block Diagramm of MPO Production
Receiving of Raw materials (A1)
Sampling of Raw Materials (A2)
Unloading of Raw materials (A3)
Storage of Raw Materials (A4)
Transfer of Raw materials to Tanks (A5)
Reaction in GLR 6/7 reactors (A7)
MPO Crude to NR (A8)
1st Wash 2nd Wash 3rd

Wash
MEK recovery in LD (A9)
IBC Tank IBC Tank
NF
Filter
Recovered MEK (A10) 1st RBM to KD/HD (A10)
MPO Main (A11) 2nd RBM to ID (A11)
FO tank (A12)
Dispatch Area (A13) 33
Material Balance Of 3-Methyl-2-Pentanone (MPO).
Production of 3-Methyl-3-Penten-2-One :-
Reaction:-
Main Reaction :-
1) M.E.K + Acetaldehyde 98% H2SO4 MPO + H2O.
2) H2SO4 + Na2CO3 + H2O Na2SO4 + CO2 + 2 H2O.
Plant :- 1
Equipment name :- Glass Line Reactor(GLR - 6/7).
Raw material :- M.E.K, Acetaldehyde, Sulfuric acid, Soda ash, Water.
Some material & there properties which we used in the production of MPO Crude.
Quantity(lit Quantity(kg Mol. Density(g/

Material .) ) Wt(g/mol) cm^3) B.P.(◦C)
Input
M.E.K 4160.24845 3349 72 0.805 79.64
Acetaldehyde 815.05102 639 44 0.784 20.2
Sulfuric acid 279.580153 293 98 1.048 337
Soda ash 124.409449 316 106 2.54
Water 54 54 18 1
Output
Sodium 424.551020
sulfate 159.605647 4 142 2.66
131.551020
CO2 119.483216 4 44 1.101
Water 18 1
34
1423.22727
MPO 1750.58705 3 98 0.813 116
From Reaction 1 :-
1 kmol Acetaldehyde = 1 kmol of MPO = 1 kmol of H2O
44 Kg Acetaldehyde reacted = 98 kg of MPO produced.
44 kg Acetaldehyde = 98 kg MPO Crude
639 kg Acetaldehyde = X amount of MPO Crude
Amount of MPO produced = (639*98)/44
= 1423 kg.
Purity of MPO crude = 52%
Actual amount MPO produced = 0.52*1423 =740 kg.
= 910 kg.
Amount of MEK reacted =
44 Kg Acetaldehyde reacted = 72 kg of MEK reacted.
44 kg Acetaldehyde = 72 kg MEK
639 kg Acetaldehyde = X amount of MEK
Amount of MEK reacted = (639*72)/44
= 1046 kg.
Plant :- 2
Equipment name :- REACTOR.
35
From Reaction 2 :- (Neutralization of PH )
1 kmol H2SO4 = 1 kmol of Na2CO3 = 1 kmol of H2O = 1 kmol of Na2SO4 = 1 kmol ofCO2
Amount Na2CO3 required to neutralised PH upto 7 to 8 =
1 kmol H2SO4 = 1 kmol of Na2CO3
98 Kg H2SO4 reacted = 106 kg Na2CO3
98 Kg H2SO4 reacted = 106 kg Na2CO3
293 H2SO4 kg = X amount of Na2CO3
Amount of Na2CO3 required = (106*293)/98
= 316 kg.
Amount of Sodium sulfate formed =
98 kg H2SO4 reacted = 142 kg of Sodium Sulfate formed.
98 Kg H2SO4 reacted = 142 kg Sodium Sulfate.
293 H2SO4 kg = X amount of Sodium Sulfate.
Amount of Sodium sulfate formed = (142*293)/98
= 132 kg.
Recovery of MEK in distillation Column :-
F=D+ W
Material Balance of MEK Component,
F*Xf = D*Xd + W*Xw

Xf =mole fraction of MEK in feed.
36
Xd = mole fraction of MEK in Distillate.

Xw = mole fraction of MEK in bottom product.
Componun
t Xf Xd Xw
MEK 0.43 0.96 0.02
MPO 0.52 0.03 0.86
HB 0.05 0.001 0.12
F = 1000 kg. Xf = 0.43

D = 441 kg. Xd = 0.95
W = 559 kg. Xw = 0.02
F =D+ W
W=F - D
= (1000*0.43 – 1000*0.02)/(0.95 – 0.02)
= 441 kg/hr.
W=F - D
= 1000 – 441 = 559 kg.
MEK in distillate = 0.95*441 = 419 kg.

MEK in 1st RBM ( Bottom product) = 0.02*559 = 11.18 kg.
MPO in distillate = 0.03*441 = 13 kg.
MPO in 1st RBM ( Bottom product) = 0.85*559 = 481kg.
Flash Distillation of MPO in distillation column:-

Distillation of MPO in HD/ED column :-
37
MPO 1ST RBM MPO Main + Fraction + MPO 2ND RBM
Material Balance of Distillation column :-( Batch distillation).

F=D+ W
Material Balance of MPO Component,
F*Xf = D*Xd + W*Xw

Xf =mole fraction of MPO in feed.
Xd = mole fraction of MPO in Distillate.
Xw = mole fraction of MPO in bottom product.
Componu
nt Xf Xd Xw
MEK 0.02 0 0
MPO 0.85 0.99 0.3
HB 0.12 0.005 0.7
F = 5691 kg
D = 4535 kg.
W = 1156 kg.
F =D+ W
W=F - D
= (5691*0.0.85 – 5691*0.3)/(0.99 – 0.3)
38
= 4535 kg.
W=F - D
= 1156 kg.
MPO in distillate = 0.99*4535 = 4490 kg.
MPO in 2nd RBM ( Bottom product) = 0.3*1156 = 405 kg.
HB in distillate = 0.005*4535 = 23 kg.
HB in 2nd RBM ( Bottom product) = 0.7*1156 = 809 kg.
39
Design Of Column (LD Column)
Basis:- 900 lit/hr feed fed to distillation column.
Feed flow rate (F) 900 LPH

Take off flow rate 466.30
(D) 5 LPH
Reflux Flow rate
(L) 230 LPH
gm/
Density of feed 0.812 cm^3
Density of gm/
distillate 0.805 cm^3
Density of gm/
Residue 0.809 cm^3
F 730.8 Kg/hr
375.375
D 5 Kg/hr
L 186.76 Kg/hr
Components XF F*XF XB B*XB XD D*XD

0.50 371.977 0.35542 371.621
Methyl ethyl ketone 9 2 0.001 4 0.99 8
0.46 341.283 3.75375
methyl pentanone 7 6 0.9 319.882 0.01 5
D,XD
40
F,XF Distillation Column

Overall Material Balance:-
F=B+D
731 = B + D
Material balance of component:-
F*XF = B*XB + D*XD
731*0.509 = (731-D)*XB + D*XD
372 = (731-D)*XB + D*XD
D = (731 – 372)/(0.99 – 0.001)
D = 375 Kg/hr.
B = 731 - 375 = 355 kg/hr.
MEK in distillate = 0.99*375 = 371 kg/hr.

MEK in 1st RBM ( Bottom product) = 0.001*355 = 0.355 kg/hr.
MPO in distillate = 0.01*375 = 3.75 kg/hr.
MPO in 1st RBM ( Bottom product) = 0.9*355= 319 kg/hr.
Properties Methyl ethyl ketone Methyl pentanone

Antoine Constant
6.1844 6.3128
A 4 6
B 1259.2 1546.9
41
2 3
221.75 220.09
C 8 3
T (ᵒC) 78 139
101.32 101.32
Total pressure 5 Kpa 5 Kpa
Temp(ᵒC
) log(Pa) log(Pb) Pa Pb Xa Ya Alpha (ɑ)
78 1.983651 1.123439 96.30556 13.28738 1.060462 1.00793 7.247899
84 2.066085 1.225831 116.4354 16.82018 0.848313 0.97482 6.922361
91 2.15826 1.340296 143.966 21.89251 0.650694 0.92453 6.576041
98 2.246399 1.449722 176.3597 28.16583 0.493672 0.85925 6.261478
105 2.330762 1.554437 214.1718 35.8457 0.367188 0.77613 5.974827
112 2.411587 1.654737 257.9803 45.15825 0.263914 0.67194 5.712806
119 2.48909 1.750896 308.3829 56.35029 0.178448 0.54311 5.472604
126 2.563474 1.843165 365.9938 69.68919 0.106768 0.38565 5.251801
133 2.634922 1.931776 431.4413 85.46263 0.045848 0.19522 5.048304
139 2.693956 2.004979 494.2607 101.153 0.000438 0.00213 4.886268
α(avg)= 5.935439
42
X-Y Diagram
1
0.9
0.8
0.7
0.6
0.5
Y
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
F 730.8 kg/hr XF 0.509

375.375
D 5 kg/hr XD 0.99
355.424
B 5 kg/hr XB 0.001
0.49323
Reflux Ratio = 9
0.66298
Intercept = 8
min. Reflux Ratio 0.19729
= 6
0.82686
Intercept = 3
Components Cp(J/ XF λ(J/ Cpi*Xi λi*Xi
43
kg°c) Kg)
44400 1114.7 22599
Methyl ethyl ketone 2190 0.509 0 1 6
36400 16998
methyl pentanone 2140 0.467 0 999.38 8
80800 2114.0 39598
Total 4330 0.976 0 9 4
Tbp 78 °C
Tf 40 °C
q =(Cp(Tbp-Tf)+λ)/λ
Tan(ѳ) = q/(q-1)
1.20287
q = 5
Tan(ѳ) 5.92913
= 3
ѳ = 80.43
X Y
VLE Data 0 0
Y= α(avg)*X/(1+(α(avg) - 1)X 0.1 0.397406
α(avg) = 5.935439 0.2 0.597401

0.3 0.717814
0.4 0.798263
0.5 0.855813
0.6 0.899022
0.7 0.932657
0.8
44 0.959582
0.9 0.981624
1 1
1 X Vs Y
0.9
0.8
0.7
0.6
0.5
Y
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
X
1/(Yi-
Y Yi Y) Area
0.98 0.99 100 2.25
0.95 0.97 50 1.25
33.3333
0.92 0.95 3 2.5
16.6666 1.23809
0.82 0.88 7 5
14.2857 1.28571
0.74 0.81 1 4
9.09090 1.61079
0.63 0.74 9 5
1.88221
0.42 0.58 6.25 2
0.15 0.28 7.69230 2.05128
45
8 2
33.3333
0.05 0.08 3 1.25
0.02 0.04 50 0.5
Kmol/
Kx*a 300 Ky*a 140 hr.m^3
Kmol/
Kx*a 400 Ky*a 200 hr.m^3
100
90
80
70
60
1/(Yi-Y)
50
40
30
20
10
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Y
V = D(R+1)
V' = V = 561 kg/hr.
Lo = 185 kg/hr.
L' = 916 kg/hr.
Cross-sectional area,
Diameter of column = 0.4 m.
46
A = 0.1235 m2
Molecular wt. of MEK = 72.11
Molecular wt. of MPO = 100
Average Molecular wt. = 83.47
V = 6.71 kg/hr.
V’ = 6.71 kg/hr.
Vapour Flow rate (V) = 53.46
Vapour Flow rate (V') = 53.46
(HG) rectification Section = (V/Ky*a) = (53.46/140) = 0.39
(HG)Stripping Section = (V’/Ky*a) = (53.46/200)= 0.27
(NG) rectification Section = 4.16
(NG)Stripping Section = 11.2
Height = ((V/Ky*a)* 4.16) + ((V’/Ky*a)* 11.2))
Height = 4.75 m.
Np = 10
HETP = H/Np = 4.75/10 = 0.475 m.
5. ADDITIONAL ASSIGNMENTS
4.1 Calibration of storage tanks:
For vertical storage tank it is easy to calculate volume of liquid per cm. we just calculate
volume by formulae of cylinder. But for horizontal storage tank we have to calibrate of volume
for every centimetre.
47
4.1.1 Types of Heads:
Flat Head
Semi Ellipsoidal or Elliptical Head
Torispherical Head
4.1.2 Calibration of vertical tanks:
For calibration of vertical tank we used formula of cylinder: pi*r2*h
If head of vertical cylinder is flat, we don’t need to mention dish volume.
Dish volume: volume of head.
4.1.3 Calibration of horizontal tanks:
Calibration of horizontal storage tank is different from vertical tank as equal amount of liquid
does not get added in tank as level increases.
Foe horizontal storage tank we must consider total amount of liquid getting filled which includes
fluid in cylindrical part plus head.
4.2 Pipe and instrumentation diagram:
Piping and instrumentation diagram can be done equipment wise or for the whole plant which
involves how the connection is.
We did P&ID for distillation columns, glass line reactor, cooling reactor, hydrogenation reactor
etc. to illustrate how and where exactly where pipe and valves are situated which can be further
used to increase safety and control system.
4.3 Tracing and labelling of lines:
We traced and labelled pipes from reactors to distillation columns. Making it easier for the
workers in the company to a quick action in case of any accident.
4.4 Removal of unused pipes and electrical wires:
After tracing the pipes we eliminated those pipes which are not in used also brought in attention
which is critically damaged which could lead to a major accident.
48
4.5 Monitoring:
Monitoring of Glass line reactor is also necessary as the parameters as in many cases. These
parameters keep on changing which needs to stabilized for a better yield.
Documentation :
We were also involved in documentation involving the daily stock as well as amount of
product produced in a week by production department. The maintenance routine data of pumps
and heat exchangers was also documented by us.
CHAPTER : 08
Plant View
49
Figure 6:- Plant 01
Figure 7:- Dosing pump
50
Figure 8:- Condensor
Figure 9:- Cooling Tower
51
Figure 10:- Styrene batch Tank
52
Figure 11:- R-3 Cooling Tank
53
Figure 12:- Intermediate Storage Tank
54
Conclusion
The desired purity of the aromatic chemical Phenyl Ethyl Alcohol was achieved which
was (>99.80%) better than the RM (Raw Material) Specifications i.e. 99.87%. This purity
resulted in better olfactive note. The odour panel was satisfied by the tests carried on the PEA
samples of better purity.
I as a student learnt to be a chemical engineer in production department, quality
control department, R & D Department, Maintenance Dept., Dispatch, etc. A series of training
taught the working of Aldol Condensation, Hydrogenation process, Vacuum Distillation process
in Batch as well as Continuous manner. Training developed overall professional aspect of a
chemical engineer.
55
References
1. Bhatt BI, Thakore SB(2007). “Stoichiometry”, Fifth Edition, 325-400.
2. M.V Joshi,V.V Mahajani(1996), “Process Equipment design”,Third Edition,209-235.
3. Robert E. Treybal(1980). “Mass Transfer Operations”, Third Edition, 565-585.
4. Perry,R.H and Green(2008), D.W. “Perry’s Chemical Engineers Handbook”, 9th Edition
5. Binay .K. Dutta(2009). “principles of Mass tranfer and seperation Processes”,Third
Edition,319-421
6. D. Q. Kern(1983). “Process Equipment Design”,21st Edition,113-700
7. www.nptel.ac.in
8.
https://www.wikipedia.org/
56

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Semester Internship Report

SEMESTER LONG TERM

Harmony Organics Pvt. Ltd. Kurkumbh

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

BACHELOR OF TECHNOLOGY (CHEMICAL)

Department of Chemical Engineering

Bansilal Ramnath Agarwal Charitable Trust’s

Prof. Dr. S. R. INAMDAR Mr. NILESH THAKUR Prof. Dr.M.P. DEOSARKAR

towards Prof. Dr. Shrikant Kulkarni to allow us undertaking the training.

Harmony Employees to have helped in minor necessities in the process of learning.

Mr. VIKAS D. LATE

have not misrepresented or fabricated or falsified any idea/data/fact/source in my submission. I

Mr. VIKAS D. LATE

Humble beginning with a plant in New Bombay 30 years ago for

Sr. No. Content Page No.

1.1 Phenyl Ethyl Alcohol 4

2.1 Physical Properties 7

3. Phenyl Ethyl Alcohol (PEA) 8

3.1 Production of SCH crude 8

3.2 Production of SO crude 8

3.3 Distillation of SO crude to SOTTO 10

3.4 Hydrogenation of SOTTO 11

4.1 Production of MPO crude

4.2 Recovery of MEK in LD column

4.3 Distillation of MPO crude to MPO main

4.4 Process Block Diagramm of MPO Production

4.5 Material Balance of MPO

5. Design Of Continues Distillation Column

4.1 Calibration Of Storage Tanks 26

4.2 Piping And Instrumentation Diagramm 26

4.3 Tracing And Labelling Of Lines 26

4.4 Removal Of Unusual Pipes And Electrical Wires 29

4.5 Plant Monitoring 29

 Blending and Packing Area

Quality Control & Quality Assurance :-

1.1 Phenyl Ethyl Alcohol :

Figure 1:- Structure of PEA

1.2 Methyl Pentanone :

Figure 2:- Structure of MPO

It is used widely in pharmaceutical as well as aroma chemical companies.

1.3 Cinnamaldehyde (CNMD):-

Cinnamaldehyde is an organic compound with the formula C6H5CH=CHCHO.

Figure 3:- Structure of CNMD

The list of Physical properties of some materials which Harmony organics

Molecular Boiling Point Flash Point Sp. Gravity

Styrene 104.15 145 31.1 0.906

SCH 156 1.2

Methyl Ethyl Ketone 72 79 -09 0.805

Benzaldehyde 106 179 64 1.04

1,3-Butanediol 90 207 121 1.005

3. PENYL ETHYL ALCOHOL

1) Styrene + 30% H2O2 + 32%HCL Styrene chlorohydrin + H2O

2) Styrene chlorohydrin + 20% NaOH Styrene Oxide + H2O + NaCl

3) Styrene Oxide + Hydrogen(H2) P.E.A. Crude

1. Production of SCH crude:

Styrene + H2O2 + HCl SCH crude

SCH crude + Caustic lye (30%) SO crude.

3.Production of PEA crude:

SOTTO + H2 Palladium PEA crude

PEA Fraction PEA Tops + PEA Fraction + PEA RBM

Time cycle of Production of PEA

Operations Standard Time

Production of SCH crude 18 hr

Output = 4000 +(0.72453) +(0.682450) + 3142 + 380 = 10905 kg.