“DEEPAK NITRITE LTD”

AN INTERNSHIP REPORT

A PROJECT REPORT

Submitted by

Mr. Kishan V. Sakariya

200470105026

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

In

Chemical Engineering Department

VVP Engineering College,

At Virda-vajdi, Kalavad road

Rajkot

Gujarat Technological University, Ahmedabad

August,2023
 VVP Engineering college, Rajkot

CERTIFICATE

This is to certify that the project report submitted along with the project entitled
In-plant training at Deepak nitrite has been carried out by SAKARIYA
KISHAN VIJAYBHAI, 200470105026 under my guidance in partial
fulfillment for the degree of Bachelor of Engineering In Chemical Branch, 8th
Semester of Gujarat Technological University, Ahmadabad During the academic
year 2023-24.

Prof. Dhara upadhyay Prof. Dr. Piyush vanzara

Internal Guide Head of the Department

 VVP Engineering College,

At Virda-Vajdi, Kalavad Road, Rajkot

DECLARATION

We hereby declare that the Plant Training report submitted along with the Plant
Training at Deepak nitrite submitted in partial fulfillment for the degree of
Bachelor of Engineering in Chemical Engineering to Gujarat Technological
University, Ahmedabad, is a bonafide record of original training carried out by
me at VVP Engineering College, Rajkot under the supervision of Prof . Dhara
upadhyay and that no part of this report has been directly copied from any
students’ reports or taken from any other source, without providing due
reference.

Mr. Kishan Sakariya

Name of Students Sign of student

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Gujarat Technological University VVP Engineering College, rajkot
 ACKNOWLEDGEMENT

 It is indeed a great pleasure and honor to have the opportunity to pursue

Industrial internship at Deepak nitrite Ltd, Vadodara.where I had gained a Lot
of practical learning which in turn led to my professional development.
 I would like to thank Mr. Huzefa patel HR, Deepak nitrite Ltd, Vadodara. for
giving me the opportunity to do an internship.

 I would like to thank Mr.Keyur shah, Production manager, that they helped me
to complete my internship and I gained knowledge about different reactor,
pump, valve, heat exchanger, and etc.

 I also would like to thank all the process engineers, operators and workers to
Help me during direct or indirect way. They keep me free to ask them questions
and any Doubts without hesitating despite being busy in their own work within
the his Industry

 I’m great full to the company as well to provide me different necessary

facilities like safety equipment, transportation, canteen etc. I also hope to have
a continue Co-operation with company in my upcoming future.

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Gujarat Technological University VVP Engineering College, rajkot
 ABSTRACT

 This report is a detailed overview of my internship journey at Deepak Nitrite

Ltd. During my Internship I have learned a lot about how the industry of
leading Manufacturing of integrated flavor, fragrance and aroma chemical
manufacturing, Plant safety, require utilities, equipment etc.
 What are the parameters, how to work on an actual project, how to work in a
flow of team work. I have known about the work flow of Chemical Process
Plant .I have learned to work in a corporate space which not only enriched me
professionally but also helped me grow personally as well.
 My contribution was appreciated by my supervisor and other members of the
department. The career path I would be selecting for myself is quite influenced
from my internship as I have had a great opportunity to practically see how
chemical process plant sector is working and evolvingin the entire Globe.
 However, this report has been written in a short time. I have tried my level best
to make it meaningful by reflecting my works at the Company.

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Gujarat Technological University VVP Engineering College, rajkot
 LIST OF FIGURES

Figure 1 Process Flow diagram................................................................................................. 7

Figure 2 Process flow diagram ................................................................................................ 8
Figure 3 Block flow gia for HAS............................................................................................. 9
Figure 4 Block flow diagram of MPP-2................................................................................... 9
Figure 5 Block diagram of MPP-1 ......................................................................................... 10
Figure 6 Steam system ........................................................................................................... 27
Figure 7 Boiler ...................................................................................................................... 28
Figure 8 Cooling tower ..........................................................................................................29
Figure 9 Batch reactor ............................................................................................................ 30
Figure 10 Half pipe coil jacket............................................................................................... 31
Figure 11 Scrubber ................................................................................................................. 32
Figure 12 Heat exchanger ...................................................................................................... 33
Figure 13 Centrifugal Pump................................................................................................... 34
Figure 14 Screw pump ...........................................................................................................35
Figure 15 AOD pump ........................................................................................................... 35
Figure 16 Steam tap ............................................................................................................... 36
Fi0gure 17 Different types of Valves..................................................................................... 39
Figure 18 Fire extingushers.................................................................................................... 41

Gujarat Technological University IV VVP Engineering College, rajkot

 LIST OF TABLE

Table 1 Production Of MAHCL Plant .....................................................................................3

Table 2 Mass Balance across reactor RT 003 ........................................................................ 13
Table 3 Heat formation data................................................................................................... 14
Table 4 Shows the Specific Heat of Components ..................................................................15
Table 5 Cp Calculation........................................................................................................... 15
Table 6 Energy Balance across reactor RT 003(Enthalpy In)................................................ 16
Table 7 Enthalpy .................................................................................................................... 16
Table 8 Table of Summery...................................................................................................... 25

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Gujarat Technological University VVP Engineering College, rajkot
 TABLE OF CONTENTS

Acknowledgement ....................................................................................................................II

Abstract ...................................................................................................................................III

List Of Figures ........................................................................................................................ IV

List Of Table .............................................................................................................................V

Table Of Contents ................................................................................................................... VI

CHAPTER 1 : OVERVIEW OF COMPANY...................................................................... 1

1.1 History & Introduction Of Deepak Nitrite Limited...................................................... 1

1.2 Business Overview (International) .............................................................................1

CHAPTER 2 :PRODUCTION OF MAHCL PLANT ......................................................... 3

2.1 Process Description ......................................................................................................4

2.2 Process Flow Diagram.................................................................................................. 7

2.3 Block Flow Diagram ....................................................................................................8

CHAPTER 3 : MASS BALANCE .......................................................................................11

CHAPTER 4 : ENERGY BALANCE .................................................................................14

4.2 Energy Balance Across Reactor RT003 ..................................................................... 16

CHAPTER 5 : DESIGN OF HEAT EXCHANGER.......................................................... 18

CHAPTER 6: DIFFERENT TYPE OF UTILITIES ....................................................... 27

6.1 Electricity: .................................................................................................................. 27

6.2 Steam Generation Plant : ............................................................................................ 27

6.3 Cooling Water ............................................................................................................ 29

CHAPTER 7 :EQUIPMENT AND INSTRUMENTS ....................................................... 30

7.1 Batch Reactor ............................................................................................................... 30

7.2 Half Pipe Coil Jacket : ................................................................................................ 30

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Gujarat Technological University VVP Engineering College, Rajkot
 7.3 Scrubbers ....................................................................................................................32

7.4 Shell & Tube Heat Exchanger : .................................................................................. 33

7.5 Types Of Pumps Used In Deepak Nitrite Ltd. ........................................................... 34

7.5.1 Centrifugal Pump :............................................................................................... 34

7.5.2 Positive Displacement Pump: ...............................................................................34

7.6 Steam Trap–............................................................................................................... 36

7.7 Types Of Valves Used In Pidilite Industries: ............................................................ 36

7.7.1 Pressure Safety Valve (Psv)................................................................................. 36

7.7.2 A Pressure Relief Valve (Prv) ............................................................................. 37

7.7.4 Ball Valve: ...........................................................................................................37

7.7.5 Pinch Valve:......................................................................................................... 37

7.7.6 Control Valve:...................................................................................................... 37

CHAPTER 8 : SAFETY IN PROCESS PLANT................................................................ 41

8.1 Fire Extinguishers....................................................................................................... 41

8.2 Emergency Run Out Way:.......................................................................................... 42

8.3 Safety Equipments Box: .............................................................................................42

8.4 Personal Protective Equipment (Ppe): ........................................................................ 42

8.5 Fire Hydrant Point: ..................................................................................................... 42

CHAPTER 9 : CONCLUSION............................................................................................ 43

CHAPTER 10 : REFERENCE ............................................................................................44

Gujarat Technological University VII VVP Engineering College, rajkot

267589 Overview of Company

CHAPTER 1 : OVERVIEW OF COMPANY

1.1 HISTORY & INTRODUCTION OF DEEPAK NITRITE LIMITED

 Deepak Nitrite Limited is a leading chemical manufacturing company based in India. The
company was established in 1970 by Mr. C.K. Mehta, a chemical engineer, with a vision
to manufacture quality chemicals that catered to the needs of various industries.
 Deepak Nitrite initially started with the production of Nitro Toluenes and expanded its
portfolio to include a wide range of chemicals such as phenol, acetone, and chloroform.
In the 1980s, the company diversified into the production of fine and specialty chemicals,
including dyes and pigments.
 In the 1990s, Deepak Nitrite further expanded its product portfolio by setting up a plant
for the manufacture of bulk drugs and intermediates. The company also established a
research and development center to develop new and innovative products.
 Today, Deepak Nitrite is a diversified chemical company with a wide range of products
and applications. The company operates in three business segments: basic chemicals, fine
and specialty chemicals, and performance products.
 Under the basic chemicals segment, Deepak Nitrite produces nitro aromatic compounds,
which are used as intermediates in the manufacture of dyes, agrochemicals, and
pharmaceuticals. The fine and specialty chemicals segment includes the production of
specialty chemicals such as optical brightening agents and agrochemical intermediates.
The performance products segment produces high-performance chemicals such as fuel
additives, corrosion inhibitors, and surfactants.
 With a focus on innovation and sustainability, Deepak Nitrite has established itself as a
leading chemical manufacturer in India and has a strong presence in the global market.

1.2 BUSINESS OVERVIEW (INTERNATIONAL)

 Deepak Nitrite has a strong international presence and exports its products to over 30
countries across the globe. The company’s international business accounts for a
significant portion of its overall revenue.

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267589 Overview of Company

 Deepak Nitrite’s international business includes exports of its range of basic chemicals,
fine and specialty chemicals, and performance products. The company has established
long-term relationships with customers in various industries such as agrochemicals,
pharmaceuticals, and textiles.
 In addition to exports, Deepak Nitrite has also made strategic acquisitions to expand its
international footprint. In 2018, the company acquired a specialty chemical
manufacturing facility in Germany, which gave it access to the European market. This
acquisition also allowed the company to expand its product portfolio to include a range
of specialty chemicals used in various applications.
 Deepak Nitrite has a strong focus on innovation and sustainability, which has helped it
establish a strong reputation in the global market. The company’s products are known for
their high quality, consistency, and reliability. Its commitment to sustainable
manufacturing practices and environmentally friendly products has also helped it attract
customers who are looking for sustainable solutions.
 Overall, Deepak Nitrite’s international business is a key driver of its growth and success.
The company’s strong global presence and focus on innovation and sustainability have
positioned it well for continued success in the global chemical industry.

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267589 Production of MAHCL Plant

CHAPTER 2: PRODUCTION OF MAHCL PLANT

Table 1:- Production Of MAHCL Plant

Product name MAHCL

Chemical name Methoxylamine hydrochloride

Chemical structures

Empirical Formula CH5NO HCl

Boiling Point 105 - 110 ºC

Molecular weight 83.51

Appearance Colorless liquids

Density 1.15 g/cm3

Solubility In water

Crystallization Point -10 ºC

DNL plant at Nandesari

There are main three plant

 SNI Plant
 MAHCL Plant
 NITRO Plant

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267589 Production of MAHCL Plant

Raw materials Product

1. Sodium nitrite 1. Methoxyl amine

2. Sulphur dioxide hydrochloride [MAHCL]
3. Sodium hydroxide 2. Sodium sulphate
4. Dimethyl sulphate
5. Sulphuric acid
6. Hydrochloric acid
7. Activated carbon
8. Sodium bicarbonate
9. Ammonia

The main products has main 4 plant to produce MAHCL :

 HAS plant
 MPP 1 plant
 MPP 2 plant
 MPP 3 plant

2.1 PROCESS DESCRIPTION

Initially, in the pre-mix tanks 7200 lit. of RO water is charged by means of RO water pump,
after that 1.8 MT of SNI is charged manually and 1450 lit. of 47.3 to 49% w/w of caustic is
charged from storage tank of caustic by means of pump.

 After that pre-mixture is agitated for 1 to 2 hr. approximately. And then after sample of
same is checked for the percentage of CSL (11.2 to 12% w/v) and SNI (18.5 to 19.5%
w/v).
 After this pre-mix is stored in storage tank by means of pump.

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267589 Production of MAHCL Plant

 Then this pre-mix is sent in HADS reactor by means of gravity.

 For HADS intermediate formation sulphur dioxide is required, for that first SO2 is sent
for the vaporization in vaporizer from SO2 tonner storage. From vaporizer SO2 vapor is
receive in SO2 receiver.
 Then SO2 is sent in HADS reactor and insert in reactor from bottom by means of sparger.
 In the HADS reactor around 3.5 pH is maintained by means of SO2 flowrate.
 Also, temperature of 10 – 12 0C is maintained by means of brine circulation in coils
around reactor as well as there is a provision of a shell and tube heat exchanger in which
reactor mass is circulated and cooled down by means of brine solution.
 This HADS formation is done in continuous reactor. So, from this reactor continuous
overflow of product is removed of approximately 17 – 18% of HADS in it.
 This overflow is then sent to another continuous reactor for alkylation of HADS to form
Alkaline HADS.
 In this reactor 10 – 30 0C temperature is maintained, there is continuous ad- dition of
caustic and RO water according to ratio of 1.15 caustic and 0.7 RO water of incoming
overflow from HADS reactor.
 From this reaction mass is sent to Double pipe heat exchanger to bring reac- tion mass at
temperature of around 35 0C, because at lower temperature salt formation is occur, after
DPHE reaction mass is stored.
 Now this Alkaline HADS is sent to batch reactor according to batch size requirements,
in batch reactors initially temperature is raised to 60 0C, at this time Dimethyl sulphate
and caustic is added slowly in reactor, this reaction is highly exothermic in nature, so
cooling water flow is started when DMS and Caustic addition is started.
 In this reactor MADS is formed, which is then stored.
 After this, MADS liquor is sent for alkaline recovery. For this temperature in reactor mass
is raised above 100 0C, then vapor is removed from top is then condensed and stored in
tanks and then sent to ETP latter.
 After alkaline recovery is done then temperature is lower down to 40 to 45 0C, after that
for acidic recovery sulfuric acid is added up to 2 pH is achieve, then increased temperature

Gujarat Technological University VVP Engineering College, rajkot

267589 Production of MAHCL Plant

of reaction mass above 100 0C. So, vapors from top of reactor is removed, condensed
and stored in tanks for ETP treatment.
 The reaction mass is further cool down up to 45 0C. then reaction mass is transferred in
another batch reactor, where MABASE is formed by addition of Caustic and temperature
is maintained around 60 0C by means of cooling water and pH is maintained around 8.3
to 8.5.
 At the same time in another batch reactor corresponds to previous one, HCl is received
and circulated through eductor to create vacuum in previous rector.
 In reactor having MABASE vacuum is created due to which after applying steam
MABASE is vaporized leaving sodium sulphate and other impurities in reactor itself.
 MABASE vapor is then condensed and sent to reactor having HCl which is MSGLR.
 In MSGLR crude MAHCL is formed which is then sent for further increase concentration
up to 30% in another reactor and after that it is stored in tanks.

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267589 Production of MAHCL Plant

2.2 PROCESS FLOW DIAGRAM

SS Reactor for HADS mfg.

17 – 18 % soln.

SS Reactor for ALK. HADS mfg.

T= 10 – 30 °C

Methylation At MPP-2

T= 70-72 °C

Storage Tank

MPP-1

Hydrolysis of MADS
liquor SS reactor T=
100 – 110 °C

Neutralization of Methoxy
Amine Base

MAHCL Conc. 30%

Solid MAHCL Plant MSGLR under

Vaccum T= 60 –
65
°C

Figure 1 Process Flow diagram

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267589 Production of MAHCL Plant

2.3 BLOCK FLOW DIAGRAM

CAUSTIC
SODA

CONTINUO

RO US
AGITATE AGITATE
WATER STIRRED
D TANK PREMI ACIDIC
NANO TANK ALKLINE
HADS D TANK
2 30 TO X HADS
REACTOR
CAUSTIC SODA LIQUO
35 C
R 5 TO 10C

SO2
LIQ
SO2 VAPORIS

ER

Figure 2 Process flow diagram HAS PLANT

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 267589 Production of MAHCL Plant

NAOH NAOH
NANO NANO
2
2
WATE
WATE R
R

SO
SO 2
2

Figure 3 Block flo w dia for HAS

Figure 3 BLOCK FLOW DIAGRAM OF HAS

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267589 Production of MAHCL Plant

REDUCER

Figure 4 BLOCK DIAGRAM OF MPP-1

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Gujarat Technological University 0 VVP Engineering College, rajkot
267589 Mass Balance

CHAPTER 3: MASS BALANCE

A mass balance, also called a material balance, is an application of conservation of mass to the
analysis of physical systems. By accounting for material entering and leaving a system, mass
flows can be identified which might have been unknown, or difficult to measure without this
technique. The exact conservation law used in the analysis of the system depends on the context
of the problem, but all revolve around mass conservation, i.e. that matter cannot disappear or
be created spontaneously.

Therefore, mass balances are used widely in engineering and environmental analyses. For
example, mass balance theory is used to design chemical reactors, to analyses alternative
processes to produce chemicals, as well as to model pollution dispersion and other processes
of physical system.

ALKALINE HADS (13% w/v):

 Actual Capacity of plant is 60 KL per day
 Density of alk.HADS solution is 1.29 kg/lit
 So, mass of alk.HADS solution (13% w/v) is 0.13×60×1000= 7800 kg/day

 Moles of HADS Prodeced= =30.116 kmol/day

 Raw Material Require:
 NAOH (48% w/w): 2×30.116×40=2409.28 Kg/day
 CSL (Caustic Soda lye) required:2409.28/0.48=5019.33 kg/day
 SNI required (Solid form) =30.116×69=2078.004 kg/day
 SO2 required =2×30.116×64=3854.848kg/day

Conversion is 100%

 Acidic HADS formation (10 to 12 exothermic reaction)

2NaOH + 2NaN02 + 4SO2 2HON(SO3Na)2

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267589 Mass Balance

Crystal Sodium nitrate Sulfur dioxide Acidic HADS

2* 40. 2*69. 4*64 2*23

7

 Alkaline HADS formation (10 to 30 c exothermic reaction)

2HON(SO3Na)2+2NaOH−→2NaON(SO3Na)2+2H2O

HADS CSL Alk.HADSWater

Material balance for reaction 1

NANO2
RT -003
Acidic HADS
CSL
.
SO2

 CS Lye (NaOH) Solution Fed =(5019.33/2)=2509.665

kg/day
 Having NaOH= 1204.6392 kg/day
 H2O=1305.0258 kg/day
 Acidic HADS produced =30.116×237=7137.92 kg/day
 Density of Acidic HADS solution=1.29 kg/lit
 Density of MADS solution=1.32 kg/lit
 Weight of solution : 17.5 w/v % =7137.92/Volume of solution
 Volume of solution =40788.11429 liter
 Weight of solution =1.29×40788.1142
 =52616.66743 kg Water in Acidic HADS =52616.66743-7137.92=45478.74743
kg
 RO water required =45478.74743-1305.0258=44173.72163 kg/day

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 267589 Mass Balance

 Conversation 100% Assumed to be

 Mass Balance across reactor RT 003 (reaction 1)

Table 2 Mass Balance across reactor RT 003

Component Name Mass In Mass Out

C1 Acidic HADS - 7137.92

C2 NaOH 1204.6392 -

C3 H2O 45478.74743 45478.74743

C4 Nano2(Sni) 2078.004 -

C5 SO2 52616 -

Total 52616 52616

Note: Unit of in and out mass in kg/day

Gujarat Technological University 13 VVP Engineering College, rajkot

267589 Energy Balance

CHAPTER 4 : ENERGY BALANCE

HADS formation (10 to 12 exothermic reaction)

2NaOH + 2NaN02 + 4SO2 2HON(SO3Na)2

Crystal Sodium nitrate Sulfur dioxide Acidic HADS

2* 40. 2*69. 4*64 2*237

Heat of formation Data: (at 273 K)

Table 3 Heat formation data

Reactants Product

ΔHfo NaNO2 =-358.65KJ/mol ΔHfo HADS= -1542.19 KJ/mol

ΔHfo SO2= -296.83KJ/mol

ΔHfo NaOH = 425.61 KJ/mol

Heat of Reaction: (ΔHR o) at 273 K

ΔHRo= (ΔHfoProducts) –(ΔHfoReactants)

= (ΔHfoHADS) – (ΔHfoNaNO2 + 2×ΔHfoSO2 + ΔHfoNaOH)

= (-1542.19) – (-358.65 + 2×(-296.83) +425.61)

ΔHRo= -164.27 KJ/mol of NaNO2 reacted (Exothermic Reaction)

Mol of NaNO2 reacted = 30.116 kmol/day

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267589 Energy Balance

Specific Heat (Cp) Data:

Table 4 Shows the Specific Heat of Components

Component Name Cp (KJ/kg-K)

C1 Acidic HADS 1.542

C2 NaOH 2.161

C3 Water 4.183

C4 Alkaline HADS 1.409

C5 NaNO2 (SNI) 1.683

C6 SO2 1.27

Specific heat calculations:

Acidic HADS [HON(SO3Na)2]
Table 5 Cp Calculation

Molecules Heat
weight capacity

H 1 28.836

O 7*16
7*29.378
N 14
29.124
A 2*32
2*22.75
Na 2*23
2*28.230

Total =237 365.566

Cp=365.566/237=1.54 KJ/Kg K

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Gujarat Technological University VVP Engineering College, rajkot
267589 Energy Balance

4.2 ENERGY BALANCE ACROSS REACTOR RT003

Reference Temperature: 0 0C /273 K

Enthalpy In (25 0C)

Table 6 Energy Balance across reactor RT 003(Enthalpy In)

Components Name Enthalpy in (m* Cp* (25-

0)(kg/day)

C1 Acidic 0×1.5425×(25-0) 0
HADS

C2 NaOH 1204.6392×2.16×(25-0) 65050.5168

C3 H2O 45478.74743×4.183(25-0) 4755940.012

C5 NaNO2 2078.004×1.683×(25-0) 87432.0183

(SNI)

C6 SO2 3854.848×1.2733×(25-0) 122709.449

Total Enthalpy In = 5031131.996

KJ/day

Enthalpy Out (10 0C)

Table 7 enthalpy

C1 Acidic 7137.92×1.5425×(10-0) 110102.416

HADS

C2 NaOH 0×2.16×(10-0) 0

C3 H2O 45478.74743×4.183(10-0) 1902376.005

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267589 Energy Balance

C5 NaNO2 0×1.683×(10-0) 0
(SNI)

C6 SO2 0×1.2733×(10-0) 0

Total Enthalpy out = 2012478.421

KJ/day

Mol of NaNO2 reacted = 30.116 kmol/dayBy Heat balance for exothermic reaction,
Total Enthalpy In

= Total Enthalpy Out + Q (Heat Removed) + Heat of Reaction (ΔHR )

Q (Heat Removed) = Total Enthalpy In - Total Enthalpy Out - Heat of Reaction

(ΔHR )

=5031131.996– 2012478.421 – (-164.27)×30.116×103

= 7965808.895 KJ/day

So, Coolant flowrate required = Q / (CpBrine×ΔT × time for cooling)

= 7965808.895 / [2.439×{3.6-(-1.1)}×24×3600]

= 8.04 kg/s

Energy balance block diagram

H2O(4755940.012 H2O
KJ/day) (1902376.005KJ/day)
NaNO 2
(87432.0183KJ/day)
Acidic HADS (110102.416
NaOH (65050.5168KJ/day) RT 003 KJ/day)
SO2(122709.449 Q removed (7965808.895
KJ/day ) KJ/day)
ΔHR= - 4947155.32
KJ

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267589 designing

CHAPTER 5 : DESIGN OF HEAT EXCHANGER

It is required to cool HADS solution from 10.10 0C to 5.40 0C at the rate of 8.04 kg/s. Chilling
Brine solution enters into shell at -1.1 0C and leaves at 3.6 0C. The maximum permissible
pressure drop on either side is50kN/m2.

DATA GIVEN :

 SHELL SIDE FLUID :

 Specific heat of Brine Solution = 2439.275 J/kg k
 Density of Brine Solution = 1200kg/m³
 Viscosity of Brine Solution = 0.00155 kg/ms2
 Thermal Conductivity of Brine Solution = 0.6 watt/m²K

 TUBE SIDE FLUID :

 Density of HADS Solution ( 𝜌H)= 1290kg/m³

 Specific heat of HADS Solution = 1.54 KJ/kg k
 Viscosity of HADS Solution = 0.003 kg/ms2
 Thermal Conductivity of HADS Solution = 0.8 watt/m²K

 Logarithmic Mean Temperature Difference

T₁(283.1 K
)
T ₂ (278.4
t₂(276.6K
K ) t₁ (
)
271.9 K)

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267589 designing

 T1 = Inlet Temperature of HADS Solution = 10.1oC

 T2 = Outlet Temperature of HADS Solution = 5.4oC
 t1= Inlet Temperature of Chilling Brine Solution = -1.1oC
 t2= Outlet Temperature of Chilling Brine Solution= 3.6oC.

Here, Temperature Difference is Constant.

 So, ∆Tlm = 6.5 oC
 Correction Factor f = 0.9
 ∆Tlm= 0.9 ×6.5 = 5.85

Heat load :

 From energy balance =7965808.895 KJ/day

= 92196.86221 J/sec

 So, required flowrate of chilling brine,

Q = mCp∆T

92196.86221 = m ×2439.275 (276.6-271.9)

m= 8.04 kg/sec (mass Flowrate)

Assume Overall Heat Transfer Co-efficient, U = 900 W/ m2 K

 Now, Q = U × A× ∆Tm

∴Area of Heat transfer, A = Q / (U × ∆Tm)

= 92196.86221 / (900 × 5.85)

A = 17.51 m2

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267589 designing

 Calculation of Number of Tubes : Required

 Tube Outer Diameter ( Do ) = 19.05mm
 Thickness of Tube (t ) = 2.5 mm
 Length of the Tube, (L) = 2.4384m

So, Outside area of Tube = 𝜋×Do × L

= 𝜋× 0.01905 × 2.4384

= 0.146 m²

Shell side fluid is relatively clear so, we

∴Number of Tubes Required = Heat transfer area required/Outside area of Tube

= 17.51 / 0.146

= 119.93

∴Nt= 120

As, Shell side fluid is relatively clear, we can take Triangular Pitch

Pt = 1.25 Do

Tube bundle diameter Db =DO (Nt /K1) ^(1/m)

=0.01905 (190/0.249)^1/2.207

Db =0.3855 m

Where, K1 = 0.249

Nt = 2.207

 Calculation of tube side heat transfer coefficient:

 Cross section area of tubes = (π/4)×Di2

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= (π/4)× 0.014052

=0.000155 m2

 Number of tubes per pass = 120/2 =60 tubes

 Total flow area = 60 ×0.000135

= 0.0093 m2

 Total mass velocity of HADS solution = Flow rate / Flow area

= 20 /0.0093

= 2150.54 kg/m2 sec

 Linear velocity = mass velocity / density

=2150.54 /1290

Vt = 1.66 m/s

 Re = ρVtDi /μ =1290×1.66×0.01405/0.003

= 10028.89

 Prandtl Number (Pr) =μCp / k

=0.003× 1542.5 / 0.8 = 5.7844

For turbulent flow,

 Dittus-Boelter equation,

Nu = hi*Di/k = 0.023×Re0.8 ×Pr0.4

hi×0.01405/0.8.
= 0.023 × 10028.890.8×5.78440.4
hi = 4198.045 W/m2 K

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 Shell side heat transfer coefficient:

 Pitch = Pt =1.25 Do

= 1.25 ×0.01905

= 0.02381 m

 Tube bundle diameter Db = 0.3855 m

 Shell inside diameter Dis = Db + C

= 0.3855 + 0.012

= 0.3975 m

 Where, C = clearance between shell and tube bundle diameter = 12 mm

 Shell side equivalent diameter,
 De = 1.1/Do ×[Pt2 –0.907Do]

=1.1/0.01905 [0.023812 -0.907×0.019052]

=0.01373 m

 Baffle spacing (BS):

BS = 0.3 to 0.6 of Dis

= 0.4 × 0.3975

=0.159 m

Flow area for shell side fluid (AS)

AS = [(Pt - DO)/Pt]× Dis× BS

= [(0.02381-0.01905)/0.02381] × 0.3975 ×0.159

= 0.012635 m2

 Mass velocity = flow at shell side /AS

= 8.04 / 0.012635

GS =636.33 kg/m2

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 Reynolds No. (Re) = De GS / μ

= 0.01373 ×636.33/0.00155

= 5636.63

 Pr = μCp/k = 0.00155 × 2439.275 /0.6 = 6.301

For, Turbulent flow

 Nu = ho×De /k = 0.36 × Re0.55 Pr0.33 (μ/μo)0.14

= ho× 0.01373/0.6 = 0.36 × 5636.630.55× 6.3010.33 (1)0.14

Ho = 3339.2516 W/m2K
 Overall heat transfer coefficient:
(1/Uo) = [(1/ho)+(1/hod)+(DO/2kt)×(ln(Do/Di) +(Do/Di)×(1/hid) +(Do/Di)(1/hi) ]

=[(1/3339.25)+(1/5500)+(0.01905/2×50)×ln(0.01905/0.01405) +
(0.01905/0.01405)×(1/5000)+(0.01905/0.01405)×(1/4198.045)]

Uo = 886.139 W/m2K

Heat transfer area requirement:

Ar = Q /(Uo∆Tm)

= 92196.8221 / 886.139 ×5.85

Ar = 17.78 m2

Percentage excess area require:

= (Ar – A)/A×100

= (17.78-17.51)/17.51 ×100

= 1.542 %
 Pressure dropCalculations:
 Tube side:
∆Pt = Np [8×fj×(L/Di)×(μ/μo)-0.25 + 2.5]ρVt2 /2

= 2×[8× 0.00963×(2.4384/0.01405)×(1) + 2.5]×1290×1.662/2

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∆Pt = 46.33 kPa

 Shell side:

∆Ps = 8×[fj×(Ds/De)×(Ls/Bs)×(μ/μw)-0.25 + 2.5]ρV 2 /2

s

= 8×[0.00719×(0.3975/0.01373)×(2.5/0.159)×(1)]×1200×0.532/2

∆Ps = 4.41 kPa

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Table 8 Table of Summery

Tube Side Fluid HADS Solution

Shell Side Fluid Chilling Brine Solution
Outside Diameter of Tube, ( Do) 19.05 mm
Inside Diameter of Tubes, ( Di) 14.05 mm
Length of Tubes, (L) 2438.4 mm
Number of Tubes ( Nt) 120
Required,
Number of Tube Side ( Np) 2
Pass,

Tubes Arrangement Triangular pitch

Pitch of Tube, ( Pt) 23.81 mm
Tube Bundle Diameter, ( Db) 385.5 mm
Tubes Side Heat Transfer ( hi)
4198.045 W/m2 K
Co-efficient,

Shell Diameter, ( Ds) 397.5 mm

Shell Side Equivalent ( De) 13.73 mm
Diameter,
Baffle spacing, ( Bs ) 159 mm
Number of Baffle ( Nb) 12
Required,

Shell Side Heat Transfer ( ho) 3339.2516 W/m2 K

Co-efficient,
Overall Heat Transfer Co- ( Uo) 886.139 W / m2 K
efficient,

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Requirement of Heat ( Ar ) 17.78 m2

Transfer Area,

Provided Heat Transfer ( A)

17.51 m2
Area,
Shell Side Pressure Drop, ( ∆Ps) 4.41 KPa
Tube Side Pressure Drop, ( ∆Pt) 46.33 KPa

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267589 Different Types of Utilities

CHAPTER 6: DIFFERENT TYPE OF UTILITIES

Utilities are essential services that play a vital role in industries.

1. Electricity
2. Steam
3. Brine
4. Cooling tower
5. Compress air

1. ELECTRICITY:

DNL gets it at the subsidized rate from the nearby GEB. The consumption of the electricity
about 6000 kWh. The electricity required for the operation of the nearby all processes and also
for the domestic purpose. It is obtained at the rate of 0.55 Rs./KWh.

2. STEAM GENERATION PLANT :

Steam is use dmainly the heating purpose in the plant and obtained from the boiler house of
the company, which is produced the steam is given in the mention section in salting section:

Raw Filte Softenin

Water r g
Unit Point

LPS
Feed Water
MP
Boile
S
r HP
S
Figure 4 steam system

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267589 Different Types of Utilities

Steam is produced in boiler.

 High pressure steam is coming from boiler in pressure reduce .

 The type of boiler is water tube boiler. Capacity of boiler is 28TPH(Ton per hour).RO
water is used to produce steam. Fuel in boiler isthe coal.

Figure 5 -Boiler

Brine

 Brine is circulated in plant from Chiller. The capacity of chiller is 40 TR and flow
rate is 30 m^3/hr. Mono-ethylene glycol is used as coolant.

Chiller
 A glycol chiller plant is composed of a refrigeration component and tubing containing
a glycol-water mixture as coolant. Chilled fluid from the refrigeration unit is
channeled through the piping associated with a thermal exchanger surrounding a

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267589 Different Types of Utilities

heated process. After absorbing heat from the associated process, the warmed coolant
is returned to the refrigeration unit for cooling after which the process is repeated.

Figure 6 cooling tower

6.3 COOLING WATER

 Cooling water of 30 to 31 degree celcius is used in plant. Cooling tower is used to

cool the water.

Cooling tower

 The working principle of the counterflow cooling tower is no different than what is
generally true regarding cooling towers: Increasing the water surface area as it flows
through the fills and water cool down via convective heat transfer to the passing air.
 Here at industry cooling tower was of induced draft countercurrent type. Which
ensures low power consumption. Fills are designed such that they have maximum
contact area of air – water. The water temperatures (hot water in and cold water out),
the wet bulb temperature of the site of installation and the required water flow are
the 3 major factors in order to select a wet cooling tower.

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 267589 Equipment and instrument

CHAPTER 7 :EQUIPMENT AND INSTRUMENTS

7.1 BATCH REACTOR

A batch reactor is a closed vessel in which Reactions happen and it is a non-continuous type
of reactor. The Reactants are fed in to the reactor all at once initially.

Figure 7 Batch reactor

The vessel contains an agitator. The purpose of the agitator is to mix the reactants thoroughly
so that the contact makes them react together efficiently and produce products.

7.2 HALF PIPE COIL JACKET :

Pipe is cut into 1wo pieces and half pipe

Coil is welded to the vessel wall. It helps to provide high velocity And high turbulence. It
also helps to provide strength to the vessel

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 267589 Equipment and instrument

Wall and thereby reduce the cost of vessel. It provides structural Rigidity which is an advantage
for high temperature operation. To Have flexibility and high efficiency the half coil jacket can
be Divided into multiple zones.

Half coil jacket is usually made from carbon steel. Stainless Steel,and other alloys can also be
used for the fabrication of half Coil jacket.

Figure 8 Half pipe coil jacket

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7.3 SCRUBBERS

Some of the most commonly used air pollution control devices in Manufacturing and processing
facilities, industrial air scrubbers Employ a physical process which removes Particulates and
gases from industrial emissions, such as smokestack Exhaust , before they are released into the
atmosphere. There are Two main categories of scrubbers—dry scrubbers and wet scrubbers.

Figure 9 Scrubber

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7.4 SHELL & TUBE HEAT EXCHANGER :

The shell and tube exchanger consists Of four major parts:

Front Header—this is where the fluid enters the tubeside of the Exchanger. It is sometimes
referred to as the Stationary Header.

Rear Header—this is where the tubeside fluid leaves the exchanger or Where it is returned to
the front header in exchangers with multiple Tubeside passes.

Tube bundle—this comprises of the tubes, tube sheets, baffles and tie Rods etc. to hold the
bundle together.

Shell—this contains the tube bundle.

Figure 10 Heat exchanger

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 267589 Equipment and instrument

5. TYPES OF PUMPS USED IN DEEPAK NITRITE LTD.

1. CENTRIFUGAL PUMP :

Centrifugal pumps are employed to move the fluid through the transfer of rotational energy
from the rotor, this device is known as an impeller. The fluid enters the rotating impeller and is
ejected by centrifugal force through the vane tip of the impeller.

This action of the impeller causes the fluid velocity and pressure to increase and also directs it
towards the outlet. The pump casing is specially designed to compress fluid from the pump
inlet, direct it into the impeller and control the fluid before discharging.

Figure 11 Centrifugal Pump

7.5.2 POSITIVE DISPLACEMENT PUMP:

A positive displacement pump uses the reciprocating, rotary, or pneumatic motion to move the
liquid through the pump.

Here, the discharge of the fluid occurs in the form of pulses instead of a smooth liquid flow.

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Screw Pump : These types of pumps use one or several screws to move The liquid along the
screw axis. A screw pump generates pressure by Using additional axial acceleration in the fluid
within its clearance area. Screw pumps operate using two rotating screw rotors, arranged in such
A way that they rotate towards each other.

Figure 12 Screw pump

AOD/AODD Pump: Air operated Double Diaphragm pump operated by the Alternate and
repeated back and forth movement of two flexible diaphragms mounted on Common shaft. It
mostly used for sludge, slurry abrasive and thick viscous fluids.

Figure 13 AOD pump

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7.6 STEAM TRAP–

Self contained valve which automatically drains the condensate from a steam containing
enclosure while remaining tight to live steam, or if necessary, allowing steam to flow at a
controlled or adjusted rate. Most steam traps will also pass non-condensable gases while
remaining tight to live steam.

Figure 14 Steam tap

7. TYPES OF VALVES USED IN PIDILITE INDUSTRIES:

1. PRESSURE SAFETY VALVE (PSV)

Is a type of valve used to quickly release gasses from equipment in order To avoid over
pressurization and potential process safety incidents. PSVs are activated automatically When

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Gujarat Technological University VVP Engineering College, rajkot
 267589 Equipment and instrument

pressure exceeds prescribed pressure limits in order to return equipment pressure to a safe
Operating level.

7.7.2 A PRESSURE RELIEF VALVE (PRV)

Is a type of valve used to release stored gas in various equipment in order To maintain an optimal
pressure level. PRVs open gradually as pressure builds up in order to release the Necessary
amount of pressure. While the term PRV is sometimes used interchangeably with PSV, there is
A difference between the two. A PRV opens gradually in relation to the pressure, while a PSV
is opened Suddenly once the pressure hits a certain level in order to avoid overpressurization
and a potential Process safety incident.

4. BALL VALVE:

Ball valve has a spherical plug. The spherical plug is a controlling element. They are widely
Used in chemical process industries. It is used where throttling and shut off combination is
required. It Offers good flow characteristics.
It is compact and requires low maintenance l, the valve can be closed or Opened.

Butterfly valve: In butterfly valve the controlling element is a disc called as blade, vane or
flapper, which Rotates in horizontal or vertical direction and allows the fluid to flow. Butterfly
valve is suitable for Throttling or on-off operation at low pressure drop.

5. PINCH VALVE:

It can be used for on-off and throttling operations. The valve has a sleeve which is Replaceable.
It has low maintenance cost, low pressure drop and low initial cost. It can be used for Handing
slurries. Its operation mechanism is completely isolated from fluid. This eliminates problems of
Corrosion and contamination. Pinch valve is fitted in air Header.

6. CONTROL VALVE:

It is necessary for automatic process control system. It can be used either for controlling Level,
flow rate, temperature, pressure etc. The selection of control valve involves its operation
Mechanism, process conditions as well as requirements. It can be manual or power operated.

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The main parts of a control valve are actuator and body. The signals from the process are
received by

Pressure sefty valve (PSV) Pressure Relief Valve (PRV)

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Pinch
Valves Ball
Valves

Control Valve

Figure 15 different types of Valves

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Gujarat Technological University VVP Engineering College, rajkot
 267589 Safety In Process Plant

CHAPTER 8 : SAFETY IN PROCESS PLANT

8.1 FIRE EXTINGUISHERS:

 A fire extinguisher is an active fire protection device used to extinguish or control

smallFires, often in emergency situations. Fire extinguishers are classified according to the
type of fire they are designed to extinguish. The most common classifications are:

Class A: for fires involving ordinary combustibles such as wood, paper, or cloth.

Class B: for fires involving flammable liquids such as gasoline or oil.

Class C: for fires involving electrical equipment.

Class D: for fires involving flammable metals such as magnesium or titanium.

ClassK:forfiresinvolvingcookingoilsandfats,commonly foundinkitchens.

Figure 16 Fire extingushers

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267589 Safety In process Plant

8.2 EMERGENCY RUN OUT WAY:

 There is a special indication of run out way in case of emergency situation in plant under
safety evacuation plan.

8.3 SAFETY EQUIPMENTS BOX:

 It is kept on each floor nearer to control room. So, one can enter the plant with suitable

8.4 PERSONAL PROTECTIVE EQUIPMENT (PPE):

 It is also kept on each floor so, one can easily understand for particular Activity/Procedure
which PPEs are required.PPEs includes Helmet, Safety Shoes, Goggles, Face/Welding
Shield, Mask, Airline, Hand Gloves, Apron, Fall body suit, Gum boot, Safety belt, Ear
plug/Earmuff

8.5 FIRE HYDRANT POINT:

 A fire hydrant, also called fireplug, is a connection point by which firefighters can tap
into a water supply. It is a component of active fire protection. The user attaches a hose
to the fire hydrant, then opens a valve on the hydrant to provide a powerful flow of water,
on the order of 350kPa (50 lbf/in²) (this pressure varies according to region and depends
on various factors including the size and location of the attached water main).It is located
in the corner of each floor in the plant.

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267589 Conclusion

CHAPTER 9 : CONCLUSION

 In this intership I learned the communication skills, work culture and how different
departments like engineering department, utility, staff, plant operator etc. are work
together with their goals.
 The internship was also good to find out what my strengths and weaknesses are. This
helped me to define what skills and knowledge I have to improve in the coming time.
At last, this internship has given me new insights and motivation to pursue a carrier.

 I am very grateful that I received this opportunity.

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 267589 Refrence

CHAPTER 10 : REFERENCE

 H. ScottFogler,Elements of Chemical Reaction Engineering,3rd Edition, Prentice-

Hall of India,2004

 Treybal, R.E., Mass Transfer Operations,3rdEd.,McGraw-Hill,198

 J. M. Coulson, J. F. Richadson, R. K. Sinnott, An Introduction to Chemical
Engineering Design, Vol.6, Robert Maxwell, M.C., 1989.
 Daniel Crowl and Joseph F. Louvar, Chemical Process Safety. 2nd Edition,
Prentice-Hall of India,2002

 MSDS suppliers: Deepak Nitrite Limited, Nandesari.

 Software used: Microsoft office Word 2013, Microsoft Excel 2013&Paint.

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