Miraj 2 PDF

312021 OVERVIEW OF COMPANY
CHAPTER 1
OVERVIEW OF COMPANY
1.1 INDUSTRY PROFILE
 Aarti Industries Limited (AIL) is a leading Indian manufacturer of speciality

Chemicals and pharmaceuticals with a global footprint. Combined process
chemistry and competence (recipe focus) with a scale-up engineering (asset
utilization) for creating a sustainable future.
 Over the last decade, AIL has transformed from an Indian company servicing
global market to a global entity with state-of-the-art manufacturing facilities in
India. AIL manufacture chemicals used in downstream manufacturing of
Pharmaceuticals, Polymers, Agrochemicals, Additives, Surfactants, Pigments and
Dyes.
Fig 1.1 industry profile
GUJARAT TECHNOLOGICAL UNIVERSITY 1 GEC, BHARUCH

OVERVIEW OF COMPANY
312021
1.2 HISTORY OF THE COMPANY
Industries Limited is a leading indian manufacturer of speciality chemicals and

pharmaceuticals with a global footprint. It operates primarily in three segments
namely speciality chemicals pharmaceuticals and home and personal care. Speciality
chemicals is the major revenue- generating segments contributing approximately
78% of the company's sales. The other segments i.e pharmaceuticals and home &
personal care contribute approximately 15% and 7% of sales respectively. Ispeciality
chemicals Aarti Industries is the largest producer of benzene derivatives in India and
one of the leading manufacturers globally. It has integrated itself across the benzene
chain and manufactures a variety of products from benzene. The company globall
ranks between 1st and 4th position for 75% of its specialty Chemical portfolio and is
considered as ‘partner of choice ‘ for various major global and domestic customers.
It has a wide portfolio of over 200 products serving more than 700 customers. The
company is a strong exporter having relationships with over 300 export customers
spread across the globe in 60 countries with consumers across the globe of speciality
chemicals and Intermidiate for Agro chemicals Aromatics dyes fuel Additives
pharmaceuticals pigments polymer Additives printing inks surfactants and various
other speciality chemicals.
Aarti Industries Limited was incorporated on September 28 1984 as Aarti organics

LTD. The Company was promoted by Chandrakant V Gogri and Associates. In the
year of 1986 company commerced commercial operations in sarigam. In the year
1990 company expanded the capacity of PCNB/ ONCB (Organic division) from 1200
TPA to 4500 TPA. During the year they further expanded their organics division in
four phases. Also the name of the company is changed to Aarti Industries Ltd.
In 2018, Aarti industries signed Rs 10,000 cr multi-year supply deal ICC ( Indian
chemical council Conferred the prestigious life achievement award 2018.
In 2019 Aarti industries signed Rs 900 cr supply contract For speciality chemicals
intermediate.

1.3 VISION
To emerge as a global partner of choice for leading consumers of speciality chemicals and
Intermidiate.
1.4 MISSION
Delight stakeholders
1.5 MOTO
Plant to be proud off! Company to be proud off!
1.6 PURPOSE
Right chemistry for a brighter tomorrow
1.7 STRATEGY
Growth with sustainability for a sustainable growth
1.8 DEPARTMENTS
 Mechanical
 Instruments
 Process
 Production
 Electrical
 Environment
 Civil
 Fire
 Safety
●PLANT CAPACITY
1800 ton / month

OVERVIEW OF COMPANY
312021
1.9 LIST OF RAW MATERIALS
2,3 Dichloro nitrobenzene (2,3 DCNB)
Para nitro chloro benzene (PNCB)
Meta Dinitro benzene (MDNB)
About hydrogen
Melting point: -259.2°C
Boiling point: -253°C
Critical pressure: 12.96 bar
Critical temperature: -239.9°C
Critical density: 0.0668 gm/𝑐𝑚3
About methanol
Physical state: liquid
Melting point: -97.8°C
Boiling point : 64.7°C
Flash point: 9.7°C
Vapor pressure: 13.02Kpa
Density: 792 kg/𝑚3
Suitable exhausting media: Water spray ,Dry powder
Fire hazard: Highly Flammable liquid and Vapor
Keep away from heat , hot surface, spark open flames and other ignition source

Reactivity: Highly Flammable liquid
Chemical stability: stable under normal conditions
Effect on body: inflammation of the eye ,recurrent headaches, giddiness, skin
●5-10% palladium on carbon(Catalyst)
Formula: pd
State: solid
Boiling point: 2963°C
Melting point: 1554.8°C
Density: 12.02gm/𝑐𝑚3
Molecular weight:106.42
● 1%platinum on carbon(Catalyst)
State :solid
Melting point: 1772°C
Boiling point: 3800°C
Density:24.4gm/𝑐𝑚3
1.10 INTRODUCTION TO PRODUCTS
2,3 DICHLOROANILINE (2,3 DCA)
It’s chemical name 2,3 dichloroaniline (2,3 DCA). The CAS number of 2,3
dichloroaniline is 608-27-5 and its Chemical formula C6H5Cl2N. The most
common end used in pharma.
1.10.1 Chemical structure

1.10.2 Applications
 Dyes
 Basic pharma
 Agrochemicals
 Polymers
 Pigments
 Fertilizer
 Flavour Fragrance and food beverages
1.10.3 Physical and chemical properties:
Chemical formula C6H5CL2N

State Solid
Color Off white to brown red
Melting point 59 °C
Boiling point 242°C
Flash point 115°C
Molar mass 162.02 g/mol
Auto ignition >600°C
Critical temperature >370°C
Relative density 1.6
Vapor pressure 0.02hpa
Table 1.10.3 Physical and chemical properties
1.11 PERACHLOROANILINE (PCA) It’s Chemical name is 4-chloroaniline.
The CAS number of Para chloro aniline is 106-47-8 and its Chemical formula is C6H6NCl
The most common end used in dyes ,basic pharma and agrochemicals and its various
other synonyms are para chloroaniline.

1.11.1 Chemical structure
1.11.2 Applications
 Fuel eddictives
 Dyes and pigments
 Pharmaceuticals
1.11.3 Physical And chemical properties
Chemical formula C6H6NCL

State Solid
Color White or pale yellow
Melting point 72.5 °C
Boiling point 232°C
Flash Point 113°C
Molar mass 127.57 °C
Solubility in water 2.6 g/l
Table 1.11.2 Physical and chemical properties
1.12 OTHER PRODUCTS
2,4 DCNB 2,4,5 TCNB

2,5 DCNB MDNB
3,4 DCNB ONCB
3,5 DCNB
Table 1.12 other products

312021 MANUFACTURING PROCESS
CHAPTER 2
MANUFACTURING PROCESS
2.1 PROCESS DESCRIPTION
 For hydrogenation process, we use buss loop reactor. When we start the process,
we feed 40 % methanol as solvent into autoclave from methanol dosing tank and
add 4 -5 kg 1%platinum on carbon as catalyst.
 Circulation start by main reaction pump .and temperature reaches 65 °C then after
take 5kg hydrogen and 2,3 dichloronitro into autoclave until 1 ton is reached.
 Circulate mixture by reaction pump and take a sample at bottom. And measure its
PH and GC.
 To start continuous feeding of raw material, solvent and hydrogen when GC and
PH get accurate .
 Continuous feeding of 2,3 dichloronitro at a flow rate of 2500 kg/h and pressure
32 – 34 bar , Continuous feeding of methanol at a flow rate of 1900 kg /h and
pressures 32-34 bar. Also Continuous line up from hydrogen PRS stations and add
into autoclave at a flow rate of 110 kg/h and pressures 45-50 bar.
 Mixture circulated by main reaction pump and Mixture passed through heat
exchanger and inline filter and then passed through venturi , when mixture passed
through Venturi its attain super sonic flow due to venturi narrow shape. And 80%
products made at Venturi.
 Reaction temperature proceed at 92-99 °C
 Reaction temperature maintain by heat exchangers .if the reaction temperature
increases then it is maintained by the cooler and if the Reaction temperature
decrease then it is maintained by heater.
 Also three way valve attached with heater and cooler .it is on cascade mode which
allows process water to heater or cooler according to required temperature.
 Catalyst stay at inline filter and mixture goes to product cooler where material
enter at the top and also out at the other side top.then after it’s going into 18 kl.
 Sample take at the bottom of expansion tank .after every 2 hour collect the sample
and measure GC and PH.

 If the reactivity of the catalyst in the reaction is decrease, and the problem occurs
in autoclave then the material is taken into intermediate vessel and its going into
Funda filter , where catalyst big particles stay and after that fluid goes to the safety
filter where fluid goes to the bottom of Safety filter and also out at bottom of filter
where Catalyst stay and then product goes in 18 kl for storing , 18 kl is one type
of storage vessel.
 For methanol recovery material was fed to a distillation column at 60°C. Column
bottom temperature 98- 100°C and top temperature is 70 - 75°C. In which the
Boiling point of methanol is 64° C so it’s evaporated and goes to the PHE and
there it changed from Vapor to liquid. The it goes to the reflux drum. Where
reflux drum has two outlets.
 An outlet of the reflux drum went back to the column and the second outlet was
going to the methanol recovery tank by the centrifugal pump.
 A column bottom contain material and water, material and water fed to the
Separator at temperature 90 -100 °C, where it is separate by its density because2,3
DCA density is 1370 kg/ m³ and water density is 1000 kg/ m³. And check the level
of water and product, After that open the bottom valve of Separator and bottom
product was going to the vacuum dryer. And then the water is removed from the
Separator .
 But product contain some amount of water moisture so it has put to the vacuum
dryer , where vacuum is created by the ejector system and moisture and water
removed from the product and its send to the ETP plant and dry product was
carried out at the bottom of vacuum dryer. Moisture removed at 400 mmhg
vaccum.

2.2 PROCESS STEPS FOR OPERATIONS
1) Solvent charging
Methanol is taken up to 40% level of autoclave.
2) Catalyst charging
4 to 5 kg Catalyst charge trough high pressures Catalyst vessel or low pressure Catalyst
vessel according to situation of process
3)Pressorization
5-10 bar of hydrogen is taken in autoclave before starting continuous supply of hydrogen
4)Cooling or heating
Provide cooling and heating according to required temperature . It can be maintained by

secondary circuit system which contain heater and cooler for cool or heat material
5)Venting
28-30 kg/cm.cm of hydrogen in autoclave is vented up
6)Storing
Storing the material and check its GC and PH.
7) Distillation
Separation of methanol and products (for methanol recovery from product)
8)Drying
Moisture removal by the using of vaccum dryer, vacuum creates by ejector

2.3 REACTION MECHANISM

Fig 2.3 Reaction mechanism

312021 MATERIAL AND ENERGY BALANCE
CHAPTER 3
MATERIAL BALANCE & ENERGY BALANC
3.1 MATERIAL BALANCE WITH CHEMICAL REACTION
C6H3CL2NO2 + 3H2 = C6H5CL2N + 2H2O
Stoichiometric coefficients 2,3 DCNB=a=1
Stoichiometric coefficients of H2=b=3

Stoichiometric ratio of H2 to 2,3 DCNB=b/a=3
1 Kmol 2,3 DCNB = 1 Kmol 2,3 DCA

2,3 dichloronitrobenzene reacted to produced 1 kmol 2,3 dichloroaniline.
1/1×1= 1 kmol
2,3 dichloronitrobenzene fed to the reactor =1.0 kmol
2,3 dichloronitrobenzene fed to the reactor =1×Molar mass od 2,3 DCNB
=1×192=192 Kg
H2 fed to the reactor =3×2=6 kg
Weight ratio of 2,3 DCNB to H2 feed=192/6 = 32
1Kmol 2,3 DCNB = 1 Kmol 2,3 DCA

192 Kg of 2,3 DCNB =162 kg of 2,3 DCA
Amount of 2,3 DCNB required to produce 1000 kg 2,3 DCA

192
× 1000 = 1185kg
162
Amount of 2,3 DCNB required to produce 2000 kg 2,3 DCA

192
× 2000 = 2370kg
162

3.2 MATERIAL BALANCE OF DISTILLATION COLUMN
Data:
Feed rate-2500 kg/h
Distillate:-99.5%
Bottom product:-99%
Overall material balance
X+Y=2500 here y =( 2500 – x)
Material balance of methanol
0.995x + 0.01y = 2500×0.4
0.995x + 0.01y=1000
0.995x + 0.01(2500-x)= 1000
0.995 + 25-0.01x=1000
(0.995-0.01)x= 1000-25
0.985x=975
975
X= 0.985
X = 989.84 kg/h
Mass flow rate of top product =989.84 kg /h
Methanol in the feed : 0.4 × 2500
= 1000 kg/h
Methanol in top product:- 0.995×989.84
= 984.8908 kg/h
984.8908
% recovery of methanol= × 100
1000
= 98.48 %

3.3 MATERIAL BALANCE OF DRYER
Data:
Vacuum inside dryer : 500 mmhg
Rate of feeding to dryer: 2375 kg/h
Moisture content in feed: 8%
Moisture remove 200 kg/h
Let x be the kg of product obtained and y be the kg of water removed
Moisture in product =8 %
Solid in product =100-8= 92%
Material balance of solid
Solid in wet Solid =solid in product
0.8×2375= 0.92 x
1900
X= 0.92
= 2065.21 kg ( product obtained)
Overall material balance
2375= x + y
Y = 2375-2065
=310 kg ( water removed in dryer )

AUTOCLAVE
Components Flow rate in kg /h Components Flow rate out kg/h

DCNB 2962.96 DCA 2500
Hydrogen 92.59 Water 555
Methanol 1975.31 Methanol 1975.31
Catalyst 5.00 Catalyst 5.00
INLINE FILTER

DCA 2500 DCA 2500
Water 555 56 Water 555.56
Catalyst 5.00 Catalyst 5.00
PRODUCT COOLER

DCA 2500 DCA 2500
Water 555.56 Water 555.56
PRODUCT EXPANSION TANK

DCA 2500 DCA 2500
Water 550 Water 550

312021
18KL
DCA 2500 DCA 2500
Water 555 Water 555.56
Column C701
Components Flow rate in Components Flow rate out Flowrate

kg /h kg/h out kg/h
(Bottom) (Top)
DCA 2500 DCA 2500 0.00
Water 539.00 Water 520.03 18.97
Methanol 1897.09 Methanol 18.97 1878.12
Separator
DCA 2500 DCA 2375 (Bottom)
Water 520 Water 52.00(Bottom)
Methanol 18.97 Methanol 0(Bottom)
Dryer
DCA 2375 DCA 1959.37
Water 52.00 Water 9.80
3.4 Table of material balance

3.5 ENERGY BALANCE
3.5.1 Introduction
 All chemical processes involve certain chemical reactions at particular conditions

of temperature and pressure to produce a desired product. To achieve these
conditions of heating or cooling a stream and for proper functioning of equipment,
various entities such as de-mineralized water, cooling water, chilling water, high
pressure, medium pressure, low pressure steam, electricity etc. are used. These
entities are called UTILITIES. Utilities do not take part in the process but they
only make the conditions favorable for any process.
 Energy balance is a calculation done to calculate the load on utilities. It is used to
calculate the amount of utilities required by the system to reach optimum
conditions. Thus, the load calculation for cooling water is used to determine the
total cooling water requirements and thus used to find the capacity of cooling
tower, size of fans steam etc.Similarly, the load calculation for steam is used to
determine the capacity of boiler.
 Energy balance requires knowledge of thermodynamics. The heat duty on process
side and utility side is matched in order to calculate the load on the utilities.
Proper values of heat capacities, latent heat of vaporization, latent heat of
condensations etc at their respective temperatures are needed to be incorporated in
the calculation.
3.5.2 Specific heat of component
Components Specific heat kj/kg°C

2,3 DCNB 1.30
Hydrogen 0.00
2,3 DCA 1.00
Water 4.18
Methanol 2.63
Table 3.5.2 Specific heat of component

3.5.3 Heat of formation
Components ∆Hf⁰ Kj/mol ∆Hf⁰ kcal/kg

2,3 DCNB 4.18 998
Hydrogen 0.00 0.00
2,3 DCA 48.73 11638.9605
Water -286 -3.7951
Methanol -238
Table 3.5.3 Heat of formation
Heat of reaction= (∆Hf °) Product – (∆Hf°) Reactant
= [ ∆Hf ° DCA + 2∆Hf °H20] – [ ∆Hf ° DCNB+ 3∆Hf °H2]
= [11638.9605 +2(-3.7951)]-[998+3(0)]
=11631.3703-998
= 10633.3703 kcal/ kg
= 44.51 kj/mol
Energy balance for Heat exchanger
Data:
Process side mass mass flow rate kg/h =700000
Cp( Process fluid)= 1 kcal
Process side delta T = 5°C
Utility require = cooling water
Q = m*cp*ΔT
Q=70000×1×5
=3500000 kj / cal
Energy balance for secondary circuit cooler

MATERIAL AND ENERGY BALANCE
312021
Data:
Process side mass flow rate kg/h=350000kg/h
Cp(Process fluid)=1 kcal
Process side delta T = 8 °C
Inlet temperature = 24°C
Outlet temperature = 32°C
Q = m*Cp*ΔT
= 350000 ×1 ×(24-32)
= 350000 ×1×8
=2800000 kcal / hr
Energy balance for secondary circuit heater
Data:
Process side mass flow rate kg/h=35000
Cp(Process fluid)=1 kcal
Process side delta T=10°C
Utility requirement= steam
Q= m*cp* ΔT
= 35000×1×10
= 350000 kcal /hr
Energy balance for product cooler
Data:
Process side mass flow rate kg/h= 8392 kg/ h
Cp (Process fluid)=0.64 kcal/kg°C

Process side delta T =30
Q = m*Cp* ΔT
=8392×0.64×30
=161126.40 kcal/hr.
Energy balance for hot water tank PHE
Data
Process side mass flow rate = 20140.80 kg/h
Cp( Processfluid)=1 kcal
Process side delta T =8
Q=m*Cp* ΔT
=20140.80×1×8
=161126.40 kcal/hr
Energy balance for Reboiler of C701
Data:
Process side mass flow rate:-54075 kg/h
Cp( Process fluid)=0.561 kcal/ kg°C
Process side delta T = 0.1
Q = m* Cp * ΔT
= 54075× 0.561×0.1
=2200041.61 kcal/ hr

MATERIAL AND ENERGY BALANCE
312021
Equipment Process side Cp process fluid Process side Energy

mass flow rate (kcal/kg°c) delta T required
( kg/h) Reboiler
duty
kcal/h
Heat Exchanger 700000 1 5 3500000
Sec circuit cooler 350000 1 8 2800000
Sec circuit Heater 35000 1 10 350000
Product cooler 8392 0.64 30 161126.40
Hot water tank 20140.80 1 8 161126.40

PHE
Reboiler of C701 54075 0.561 0.1 2200041.61
Fig 3.5.2 Energy balance

EQUIPMENT DESIGN
312021
CHAPTER 4
EQUIPMENT DESIGN
4.1 HEAT EXCHANGER DESIGN
Given data:
Heat of reaction: 550 kj/mol
Process water temperature in: 88.31°C
Process water temperature out: 95.68°C
Temperature drop in Process water: 7.37°C
Process water in ( if temperature to be reduced): 99°C
Process water out: 94.50°C
Temperature drop in Process 4.50 °C
Density of methanol: 791kg/𝑚3
Water Density: 1000 kg/𝑚3
Heat capacity of water:4.18 kj/kg k
Heat duty:
Q= m*cp* ΔT Qc = m𝜆
=97.222×4.18× 7.37 =97.222×540
=2995.08kj/kg°C =68.57 Kw
= 1201 kw
Total Qt = Qs + Qc
= 1269.57kw
Mass flow rate of cooling water required
𝑄𝑡 1269.57
m = 𝐶𝑝∗𝑑𝑒𝑙𝑡𝑎 𝑇 = 30.8066

EQUIPMENT DESIGN
312021
=41.21
Mass flow rate of process water
m = 𝑄𝑡/𝐶𝑝ΔT
1269.57
= 18.81
= 67.49 kg/s
LMTD ( log mean temperature difference)
For condensation
ΔT1=99°C
ΔT2= 94.50°C
= 4.61°C
Assumption of overall heat transfer coefficients
For condensation
Q
Apro = 𝑈∗𝐿𝑀𝑇𝐷
= 6.99 𝑚2
For sub cooling
Q
Apro = 𝑈.𝐿𝑀𝑇𝐷
= 0.707 𝑚2
Total area At= 7.687𝑚2
Number of tubes
𝐴
Nt = (𝜋∗𝑑𝑜∗𝐿) = 70.31

EQUIPMENT DESIGN
312021
Tube bundle diameter
nt
Di = d0(k1)^1/𝑛1
= 327.723mm =0.327723 m
Tube side heat transfer coefficients
Dittus Bolter Equation (If Re > 4000)
k 𝜇
ℎ𝑖 = di ∗ 𝑐 * 𝑅𝑒 0.8 ∗ 𝑝𝑟 0.38 ∗ (𝜇𝑤) 0.14
Nt 𝜋
flow area At = Np × 4 𝑑𝑖 2
= 0.00342m²
m
Mass velocity Gt=at =2868.78 kg/m².s
Re = 𝑑𝑖 ∗ 𝐺𝑡/𝜇 Pr=Cp*𝜇/k
= 53118.1 =5.82
Now Tube side mass transfer coefficient
hi= 9619.72 w/m².k
Shall side condensation coefficient
= 1619.69 w/m².k
= 0.001338.
Overall heat transfer coefficient
=795.67 w/m².k

312021 PROCESS & INSTRUMENT DIAGRAM
CHAPTER 5
PROCESS & INSTRUMENT DIAGRAM
5.1 BUSS 2 PLANT P&ID

312021 PROCESS & INSTRUMENT DIAGRAM
Fig 5.1 P & ID of buss 2 plant

PROCESS & INSTRUMENT DIAGRAM
312021
5.2 PROCESS FLOW DIAGRAM
Fig 5.2 Process flow diagram

UTILITIES
312021
CHAPTER 6
UTILITIES
6.1 COOLING TOWER
Industrial cooling tower is device which act as a heat rejection equipment. By rejecting
waste heat from water, it reduces the temperature of water. To reduce the temperature of
water in industries cooling tower is used. And provide cooling water utility for the
process.
Working principle of cooling tower is the principle of evaporation. From top of the
cooling tower, hot water is sprayed and it exchange heat with the atmospheric air. As a
result, temperature of water is reduced. In cooling tower convection mode of heat transfer
used.
There are basically two types of cooling towers are used:
1. Natural cooling tower
2. Mechanical cooling tower
Induced Draft Cooling Tower
Forced Draft Cooling Tower
Induced draft cooling tower
In induce draft cooling tower, one or more fans are located at top of the tower. This draw
air upwards against the downward flow of water. Water is passing around the wooden
decking or packing. Airflow is counter to the water flow so that coolest water is contact
with the driest air. At the top of tower warmest water is contacts with the moist air. This
results in increasing heat transfer efficiency. Induced draft tower comes in square or
round shape and the distribution of water may be done either by static branch system or
by the sprinkler.
The induced draft cooling towers generally offers the most effectively and economical
solutions to most of cooling needs. It’s numerous advantages are follow.
• flexibility

UTILITIES
312021
• cost effectiveness
• easy installation and maintenance
• Low noise level
• constant airflow regardless of ambient air temperature
• adaptability to any water flow
• flexibility of operation by shutting some cells
• adaptability to high thermal performance
• compatibility with all types of structure – wood, FRP, concrete, steel
• compatibility with all types of heat exchange surfaces from splash grids to high
performance film
• Ability to provide excellent protection against icing of the mechanical components
●Water Consumption
Operating time in hr Water consumption in
kg/day
Cooling tower (buss 2) 24 165016.8
Cooling tower (New meoh) 24 144892
Catalyst preparation vessel Required during catalyst 20
Preparation
Vent hold tank 24 166.67
Table 6.1 water consumption

UTILITIES
312021
6.2 STEAM
Boiler is used for generation of steam in plant. It is a closed vessel in which is heat is
produced by combustion of fuel (such as wood, coal, oil, or natural gas) is transferred to
water for its conversion into steam at desired temperature and pressure.
There are mainly two types of boilers:
1) Fired tube Boiler
2) Water tube boiler
• In the fired tube boiler hot gases of combustion from the furnace pass through the tubes
and water is surrounding the tubes. For example, Cochran, Lancashire, Locomotive
Boiler.
• In the water tube boiler, the water is pass through the tubes and hot gases surrounding
the tubes. For example, Babcock and Wilcox Boiler.
There are three types of steam used in AIL.
1) LPS ( Low pressure steam) :- Parameter range: 3-4 kg/𝑐𝑚2 , 120 − 130°𝐶
2) MPS (Medium pressures steam):-Parameter range:7-8 kg/𝑐𝑚2 , 150 − 160°𝐶
3) HPS ( High pressures steam):- Parameter range: 12-14:kg/𝑐𝑚2 , 180 − 190°𝐶
Steam Consumption:
Equipment operation Operating time in hour Steam consume in kg/day
MPS to secondary circuit 24 16034.01
LPS to hot water tank As per require.
LPS to product cooler to As per require

hot water tank
LPS to methanol recovery 24 102355.42
column C 701

UTILITIES
312021
LPS to moisture removal 24 6803.78

column C reboiler
LPS to ST-225 24 34.80
LPS to 18Kl 24 20.40
Table 6.2 Steam Consumption
6.3 NITROGEN LINE
Nitrogen is fed into the reactor to remove unreacted hydrogen , and then it is vented .
The main purpose of nitrogen purging is to removing resident gas from a system before
Introduction of a new gas or gas mixture which may react. Removing impurities from
system delivering a pure gas or sensitive gas mixture. Removing dangerous gas from a
system after use.
Nitrogen Consumption in Plant
Equipment operation Hour Nitrogen consumption

Kg/ day
Product expansion 24 202.218
Vessel
Vent hold tank 24 202.218
Catalyst preparation 0.006 9.986

Vessel
High pressure Catalyst 0.006 9.986
Vessel
Total- 424.409
TablTab.3 Nitrogen consumption

UTILITIES
312021
6.4 POWER
Many types of equipment used in operation at chemical plants, Motor of agitator, pumps
, compressor, fans are driven by electric motor.
Power consumption in Plant
Operating time Motor capacity in Power

HP consumption(watt)
Motor of 24 150 2685.600
Reaction pump
Motor of sec 24 75 1342.800
circuit pump
Motor of IDV 0 7.5 0.000
Pump
Catalyst 0.17 3 0.373

Preparation vessel
Agitator
Motor of hpcv 0 2 0.0000
Agitator
Motor of lpcv 0 0.35 0.0000
Agitator
Motor of RM 24 20 358.080
Dosing pump
Motor of 24 25 447.600
Solvent dosing
Pumps
Table 6.4 Power consumption

312021 STORAGE HANDLING & SAFETY
CHAPTER 7
STORAGE HANDLING & SAFETY
7.1 HANDLING AND STORAGE OF METHANOL
(1) Contamination: when the transferring of storing methanol dedicated systems are
preferable. Non- dedicated system should be cleaned, flushed, and sample before being
used in order to insure product integrity.
(2) Material of construction
Methanol is non corrosive to most metals at ambient temperature exceptions include lead
mg, PT, mild steel is usually selected.
(3) Method of construction
Storage tank and and welded construction are normally satisfactory they should have
secondary contaminants such as dikes or burnds to reduce and prevent large spills.
(4) Grounding
Carbide tipped clamps ( to insure good contact through paint) and dipp tube filling are
generally used to guard against ignition from static electricity.
7.2 INTERLOCK
Interlock are defined as to prevent something happening in the system.
Autoclave Equipment: interlock : above 70 % level , and below 15 % level
Pressure interlock: 32 kg/cm²
Temperature interlock:102 °C
7.3 SPRINKLER SYSTEM
Sprinkler systems are very important in industries. A sprinkler system helps to prevent
fire if the equipment even catches fire.
Sprinkler systems water lines are located above each equipment. It can be start or stop by
distributive control system (DCS).

7.4 SAFETY
Safety denotes continuing and healthful living without injury. The word safety also refers
to the precaution people take to prevent from accident, harms, damage and from air/
water/ environment pollution. Safety is important and necessary to everywhere and at all
times in home, in office, in public, place, on roads, in working in industries etc. Now a
days, “Safety Management is essential and important part of industrial management, it is
one type of management function which connected with the caring of an enterprise that
relate with safety of the personal in an Enterprise.”
7.5 PERSONAL PROTECTIVE EQUIPMENT
Types of PPEs :
1. Respiratory
2. non-respiratory
7.5.1 Respiratory
A Respiratory is a protective device that covers the nose and mouth or the entire
face or head to guard the wearer against Hazardous atmosphere
• Respiratory PPEs Example are :
1. Face Mask
2. Gas Mask
3. PVC Suit
4. Air Line Respirator
5. SCBA ( Self-contained breathing apparatus )
7.5.2Non – Respiratory
Non-Respiratory Personal Protective Equipment (PPE) for use with Chemical

Agents in the Workplace and Maintenance of the Equipment’s.
Non - Respiratory PPEs Example are :
1. Helmet
2. Safety Goggles
3. Safety Shoes

4. Hand Gloves
5. Earmuffs
6. Apron
Fig 7.5 personal protective equipment
7.6 SAFETY TALK
There is various type of Safety Talk for awareness of workers:
• Fire Triangle

312021
• Types of Fire
• Types of Fire Extinguisher
• How to Operate Extinguisher – PASS (Pull-Aim-Squeeze-Spray)
• Awareness of SCBA (Self Contain Breathing Apparatus)
• Assembly Point
• Wind Sock
• Types of Emergency Siren
• First Aid
• Work at Height
• Electrical Safety
• Important of Dyke Wall
• Types of Utilities
• Safety Attitude
• Awareness of control on leakage
• Hot work Permits
• Safety and Scaffolds
• Near miss
• Unsafe Act and Unsafe Condition
• Critical Parameter in Plant
• Permit System
• Flammable Chemical Storage
• Awareness of PPEs
7.7 FIRE HAZARD

312021 STORAGE HANDLING &SAFETY
7.7.1 Fire Triangle
Fig 7.7.1 Fire Triangle
7.7.2 Technique to extinguish fire
1. Cooling : limiting temperature by increasing the rate at which heat is lost from the
burning material.
2. Smothering : limiting oxygen by preventing air from reaching the seat of the fire to
allow the combustion process to reduce the oxygen content in the confined atmosphere
until it extinguishes itself
3. Starvation :limiting fuel by removing potential fuel from the vicinity of the fire,
removing the fire from the mass of combustible materials or by dividing the burning
material into smaller fires that can be extinguished more easily
4. Interrupting: inhibiting the chemical chain reaction by applying extinguishing media to

the fire that inhibit the chemical chain reaction at the molecular level
7.7.3 fire extinguisher
How to operate extinguisher
There are four (4) basic steps for using modern portable fire extinguishers.The acronym
PASS is used to describe these four basic steps.
1. Pull : Pull pin at the top of the extinguisher, breaking the seal. When in place, the pin
keeps the handle from being pressed and accidentally operating the extinguisher.
Immediately test the extinguisher. (Aiming away from the operator) This is to ensure the
extinguisher works and also shows the operator how far the stream travels

312021
2. Aim : Approach the fire standing at a safe distance. Aim the nozzle or outlet towards
the base of the fire.
3. Squeeze : Squeeze the handles together to discharge the extinguishing agent inside. To
stop discharge, release the handles.
4. Sweep : Sweep the nozzle from side to side as you approach the fire, directing the
extinguishing agent at the base of the flames. After an A Class fire is extinguished, probe
for smoldering hot spots that could reignite the fuel.
7.8 NPFA DIAMOND
Fig 7.8 NPFA Diamond
The NPFA 704 Diamond , commonly referred to as the NFPA hazard diamond, provide a
system for identifying the specific hazard of a material and severity of the hazard that
would occur during an emergency Response . The system addresses the health,
flammability ,instability and special hazards presented for short term ,acute exposure that
could occurs as a results of Fire , spills , or similar emergency.
7.9 PIPE COLOR CODE

Pipe color Fluid flow inside pipe

See Green Water
Red Fire fighting water
Violet Acid
Smoke gray Alkali
Light brown Oil
Gray Solvent
Yellow Inert gas
Cladding aluminum Steam
Sky blue Compressed air
White Vacuum
Black Other gas
Green Cooling water
Table 7.9 color coding
7.10 SELF CONTAINED BREATHING APPARATUS.
Self-contained breathing apparatus (SCBA) are used to protect users against oxygen
deficiency, dust, gases and vapors at plants, aboard vessels, at fire and in tunnels. SCBA
has been widely used in such fields as firefighting, rescue operations, escape training at
fire stations, iron works, chemical plants.
Safety Shower

Safety showers, also known as deluge showers, are designed to flush the user's head and
body. Safety showers are provided to wash off hazardous chemicals that may be splashed
on the skin. Large volumes of water should be used to wash away contaminants and it
may be necessary to remove contaminated clothing.
Eye wash station:
An eyewash station is a unit for washing chemicals or substances that might splash into
an individual's eyes before he or she can seek further medical attention. The user needs to
wash their eyes for at least 15 minutes.
OHC (Occupational Health Center)
Occupational health care activities may include employee health and medical
surveillance, assessment of ergonomic factors at the workplace that might affect the
employee’s health, and advice regarding preventive and control measures to eliminate
exposure to hazards.
Occupational health practitioners, such as occupational health doctors, occupational

health nurses, and ergonomists, are usually tasked with carrying out the occupational
health care activities.
Implementing a comprehensive occupational health care program at the workplace will

help employers meet their responsibilities under the OSH Act.
7.11 WORK PERMIT
A safe work permit (also known as a “permit to work”) is a document that includes a
description of the work to be performed, the hazards involved, the precautions to take, the
required authorizations, and other elements. It is a written record authorizing a specific
work at a specific location, and for a specific time.
There are different types of work permit listed below,
Hot Work Permit
Authorization to perform tasks in conditions that produce sparks, flames or any other
source of ignition. Examples of Hot Work Permit include welding, soldering, flammable
gases and other heat inducing operations.
Cold Work Permit

312021
Authorization to operate machinery or other functions that do not generate any form of
heat in the manufacturing process. Mechanically induced bending, shearing, squeezing
and drawing are some examples of Cold Work Permit.
Height Work Permit
Authorization to work on elevated spaces (2m from the ground) be it ladders, scaffolds,
Mobile Elevated Work Platforms (MEWP) and other spaces that are off the ground.
Confined Space Work Permit
Authorization to perform tasks in a narrow space which is prone to hazards like

asphyxiation, a substance that has the ability to engulf, toxic atmosphere, etc. Confined
spaces refer to vents, shafts, sewages, tanks and much more.
Excavation Permit
Authorization for personnel to mine or dig land in order to build infrastructure, extract
resources or unearth hidden artifacts. The risk involved in excavation includes falling,
being trapped, explosions, airborne contaminants etc.

312021 TREATMENT AND HANDLING OF VARIOUS WASTE MATERIALS
CHAPTER 8
TREATMENT & HANDLING OF VARIOUS WASTE

MATERIALS
8.1 SOLID WASTE AND DISTILLATION RESIDUE DISPOSAL
8.1.1 Introduction
Waste management is one of the important aspect of environment management systems.

Out of the total generation from a chemical manufacturing company one of the important
waste that needs to be properly managed is the solid waste .the solid waste generated
from ETP and AFTD.
The residue waste from distillation column DCNB and DCA
The various possible packing and storage are bags ,drums ,jumbo bags etc.
8.1.2 objectives
To collect the solid/residue waste generated from ETP and distillation section. It’s
storage and proper disposal in order to ensure that all the solid residue waste generated
would solid waste dispatch to BEAIL ankleswar and residue waste dispatch to GAPHIL
saurastra as per company policy.
8.1.3 Procedure
1) Collection and storage
The department heads shall allocated a space in their respectively department for the
collection and storage of the waste
Solid/ residue generated on day to day basis .A dedicated area shall be kept in ETP and
new distillation section for the collection of the solid/ residue waste
All the solid and residue waste ad define above the in the introduction shall be. Collected
and stored by ETP and distillation department in there are of operation at a single location
2) Disposal

312021 TREATMENT AND HANDLING OF VARIOUS WASTE MATERIALS
After collection and storage of all the solid residue waste.after the sufficient stole is
collected (15-70 tones) ,solid / residue send to his vehicle for packing. All the solid /
residue waste solid BEIL on a manifest with GPCB online method gate pass and legal
paper shall be handed.
(3) Documentation
Required records
Register for maintaining the quantity of solid/ residue waste solid to the landfilling and
incineration its legal requirements.
8.1.4 Treatment of waste water
The waste water obtained from the process is sent to the ETP plant where its PH, TDS,
COD and conductivity are maintained
PH – Above to 6.30
TDS – Below 3500 ppm
COD- Below 4000 ppm

312021 CONCLUSION
Conclusion
This internship gives us overall idea about how industry works, how to connect
theoretical knowledge to practical applications. It is very beneficial for us to work in
industry in future. We have also learned about how process runs in industry, how
materials handled, maintenance of equipment and different types of safety aspects. In
Nutshell our in-plant training is very productive and useful for gaining practical
knowledge.

REFERENCE
312021
REFERENCE
https://www.aarti-industries.com/
https://chemieorganic.com/products/para-chloro-aniline/
https://www.sigmaaldrich.com/IN/en/product/aldrich/437778
https://www.sciencedirect.com/topics/chemistry/3-4-dichloroaniline

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312021 OVERVIEW OF COMPANY

1.1 INDUSTRY PROFILE

 Aarti Industries Limited (AIL) is a leading Indian manufacturer of speciality

Fig 1.1 industry profile

GUJARAT TECHNOLOGICAL UNIVERSITY 1 GEC, BHARUCH

1.2 HISTORY OF THE COMPANY

Industries Limited is a leading indian manufacturer of speciality chemicals and

Aarti Industries Limited was incorporated on September 28 1984 as Aarti organics

GUJARAT TECHNOLOGICAL UNIVERSITY 2 GEC, BHARUCH

Plant to be proud off! Company to be proud off!

Right chemistry for a brighter tomorrow

Growth with sustainability for a sustainable growth

1800 ton / month

GUJARAT TECHNOLOGICAL UNIVERSITY 3 GEC, BHARUCH

1.9 LIST OF RAW MATERIALS

2,3 Dichloro nitrobenzene (2,3 DCNB)

2,4 Dichloro nitrobenzene (2,4 DCNB)

2,5 Dichloro nitrobenzene (2,5 DCNB)

3,4 Dichloro nitrobenzene (3,4 DCNB)

3,5 Dichloro nitrobenzene (3,5 DCNB)

Para nitro chloro benzene (PNCB)

Meta Dinitro benzene (MDNB)

Melting point: -259.2°C

Boiling point: -253°C

Critical pressure: 12.96 bar

Critical temperature: -239.9°C

Critical density: 0.0668 gm/𝑐𝑚3

Physical state: liquid

Melting point: -97.8°C

Boiling point : 64.7°C

Flash point: 9.7°C

Vapor pressure: 13.02Kpa

Density: 792 kg/𝑚3

Suitable exhausting media: Water spray ,Dry powder

Fire hazard: Highly Flammable liquid and Vapor

GUJARAT TECHNOLOGICAL UNIVERSITY 4 GEC, BHARUCH

Reactivity: Highly Flammable liquid

Chemical stability: stable under normal conditions

Effect on body: inflammation of the eye ,recurrent headaches, giddiness, skin

●5-10% palladium on carbon(Catalyst)

Boiling point: 2963°C

Melting point: 1554.8°C

Melting point: 1772°C

Boiling point: 3800°C

1.10 INTRODUCTION TO PRODUCTS

2,3 DICHLOROANILINE (2,3 DCA)

1.10.1 Chemical structure

GUJARAT TECHNOLOGICAL UNIVERSITY 5 GEC, BHARUCH

1.10.3 Physical and chemical properties:

Chemical formula C6H5CL2N

Table 1.10.3 Physical and chemical properties

1.11 PERACHLOROANILINE (PCA) It’s Chemical name is 4-chloroaniline.

other synonyms are para chloroaniline.

GUJARAT TECHNOLOGICAL UNIVERSITY 6 GEC, BHARUCH

1.11.1 Chemical structure

1.11.3 Physical And chemical properties

Chemical formula C6H6NCL