61 Report

GROUP ID : 303751 SCET (042) SURAT
A REPORT ON
IN-PLANT TRAINING (3180501)
“MAHAVIR SYNTHESIS PVT. LTD.”
Submitted by
DHRUVIL SAVALIYA (190420105061)
In partial fulfilment for the award of the degree

Of
BACHELOR OF ENGINEERING
In
CHEMICAL ENGINEERING
SARVAJANIK COLLEGE OF ENGINEERING AND
TECHNOLOGY
Dr. R. K. Desai Marg,
Athwalines,
Surat-395001
2022-2023
Gujarat Technological University, Ahmedabad

SARVAJANIK COLLEGE OF ENGINEERING AND TECHNOLOGY

2022-2023
CERTIFICATE
DATE:
This is to certify that the In-plant Training at “MAHAVIR SYNTHESIS PVT.
LTD.” has been carried out by DHRUVIL SAVALIYA (190420105061) under
my guidance in fulfilment of the degree of Bachelor of Engineering in Chemical
(4th year, 8th semester) of Gujarat Technological University, Ahmedabad during
the academic year 2022-2023.
Report Approved By:
Prof. Anand Upadhyay Prof (Dr.) Vaishali Umrigar

Internal Guide HOD, Chemical Engg.
SARVAJANIK COLLEGE OF ENGINEERING AND TECHNOLOGY

2022-2023
DECLARATION
We hereby declare that the Internship / Project report submitted along with the
Internship at “Mahavir Synthesis Pvt. Ltd” 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 project
work carried out by me at Mahavir Synthesis Pvt. Ltd. under the supervision of
Prof. Anand 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.
Name of the Student Sign of Student
1.
ACKNOWLEDGEMENT
The internship opportunity I had with Mahavir Synthesis Pvt. Ltd. was a great chance for
learning and professional development. Therefore, I consider myself as a very lucky individual
as I was provided with an opportunity to be a part of it. I am also grateful for having a chance
to meet so many wonderful people and professionals who led me through this internship period.
I would like to convey my heartiest thanks to Mr. Manoj Naik, Laboratory Director, Mr. Param
Naik, Managing Director, Mahavir Synthesis Pvt. Ltd., who heartily welcomed me for the
internship and guided and encouraged me through the summer training.
I express my deepest thanks to Mr. Manoj Patil, HR manager and Mr. Ronit Patel, EHS officer,
who in spite of being extraordinary busy with their duties, took time out to hear, guide and
keep me on the correct path and for arranging all faculties to make the training experience
easier.
I would also like to thank all the department heads and the staff at the manufacturing plant, for
their careful and precious guidance which were extremely valuable for my study both
theoretically and practically.
Last but not the least, I thank my college, Sarvajanik College of Engineering and Technology
(SCET), My mentor Prof. Anand Upadhyay and my head of the department Prof (Dr.) Vaishali
Umrigar for being constant driving force to put to practice the theoretical knowledge to the
practical world during the course of internship.
ABSTRACT
The purpose of this internship is expose the students to the world of careers and working
environment and also offer a chance for them to apply all the theory which has been learnt. The
main goal of this industry training is to enhance student`s knowledge and their skills in their
respective profession in line with the graduates with professional, ethical, skilled, creative and
competent.
During this 3 month of industrial training at Mahavir Synthesis Pvt. Ltd. (MSPL), the objective
and the purpose of the training had been achieve successfully. This report gives an insight of
the summaries working experience gained, knowledge learnt accomplishments and feedbacks
from me during the course of internship at MSPL.
Pioneer in Naphthalene Intermediates in small scale sector in India, Mahavir unfolds its wings
to encompass Pharma, Agro, Pigment, Food, Paper Dye, Ink Dye intermediates, specialty and
functional chemicals. Mahavir is not a commodity product manufacturer; continuously look
for development of new molecules and are open to custom synthesis products.
TABLE OF CONTENT
CHAPTER TITLE OF CHAPTER PAGE NO.

NO
1. INTRODUCTION 01
2. PRODUCTION ASPECTS 04
3. PROCESS FLOW DIAGRAM 08
4. MATERIAL & ENERGY BALANCE CALCULATIONS 11
5. DETAILES OF EQUIPMENTS 14
6. DESIGN OF EQUIPMENTS 23
7. UTILITY CONNECTIONS 33
8. SAFETY & ENVIRONMENT MANAGEMENT SYSTEM 40
9. CONCLUSIONS 48
10. REFERENCES 49
CHAPTER-1 INTRODUCTION
Incepted in 1973, Mahavir is known as one of the pioneers among its peers. After inception, Mahavir
capitalized on the gap in market and became one of the biggest producers of dyes intermediates in
the region. As time went on, Mahavir had to work extensively on product development and export
routes to keep up with the Chinese competition. Many investments were also made around this time,
none more so than in Effluent Treatment and proper Effluent Management Systems. Ever since then
Mahavir has been on-route it’s journey to consolidating of its markets and finding new avenues for
expansion of business.
MSPL has achieved excellence in providing its own effluent management system as well as has
offered the facility for environmental research and trials. MSPL has 10 TPD waste to energy plant
which is operational and energy produced is used for captive purpose. MSPL has introduced Mahavir
Eco Projects Pvt Ltd. (MEPPL). It is an integrated waste management facility at GIDC-Sachin, Surat
with capacity of 60 MTPD of industrial solid waste and 550 MTPD of concentrated effluent from
industries and serving more than 40-member industries.
Mahavir is a technology integrator selecting and approving right technology for the waste generated
by specific industry or cluster. MEPPL has collaboration with M/s Biomass Energy Systems, Inc.
(BESI), USA for the advanced gasification technology. As a conscious & responsible business house,
it tried to create an equitable balance between industrialization and environment protection.
Figure 1.1: Mahavir Synthesis Plant Layout “Courtesy of MahavirSynthesis.com”
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1.1 HISTORY:
❖ 1975
Inception of first manufacturing unit in the name of Mahavir Dye Chem industries. Mr. Dinker Naik,
after having experience of working with leading Indian chemical industries, started activities with 10
people, 1000 Sq. meters of land & with capital of Rs. 0.1 Mn. Manufacturer of Naphthalene
intermediate like Sulfo Tobias acid, Indian K-acid and N-methyl J-acid started with a capacity of 30
MTA.
❖ 1995
Progress: Group had grown over decades and four small scale manufacturing facilities were created
to produce about 2400 MTA of about 30 various intermediates. Second generation entered in the
business. Turnover reached to USD 4 Mn.
❖ 2005
Transformation: To compete with international market, the concept of small scale operations needed
to be changed. Superior manufacturing infrastructure was required to be set up. The group decided
to create a central manufacturing facility rather than having scattered small units in order to optimize
costs. Mahavir Synthesis Pvt Ltd was conceptualized on a land of about 35000 sq. mtrs.
❖ 2001-2007
Strength Development: Chinese influence hindered the capacity expansion during 2000-2005. The
industry worked out on our business structure limitations & transformed from an unorganized firm
structure to a system supported business structure. Custom made ERP system was implemented.
❖ 2014
New investments made in the ETP were realized. Mahavir’s motto is lean manufacture of chemicals
with minimal waste generation, and proper treatment of waste by the appropriate treatment technique.
The new ETP shall help in fulfilling this motto in the future.
❖ 2017
New plants were added to the existing manufacturing facility as a part of the company’s unrelenting
urge to expand product profile and add various core competencies to the company.
2
1.2 AWARDS & ACHIEVEMENTS:
• Gujarat State Awards for Exports in Small Scale Industries- 1992-1994

• Southern Gujarat Chamber of Commerce and Industries awards for excellence in export
performance- 1993-1999.
• Integrated Management System: ISO 9001 QMS, ISO 14001 and OHSAS 18001 (EQHSMS)
• Member: Southern Gujarat Chamber of Commerce and Industries
• Member: Gujarat Dyestuff Manufacturers Association.
• Member: CHEMEXIL: Chemical Manufacturers and Exporters Council
Figure 1.2: Shelf of Awards “Courtesy of MahavirSynthesis.com”
3
CHAPTER-2 PRODUCTION ASPECTS
The production facility of Mahavir Synthesis Pvt Ltd is spread across 35,000 sq. mtrs of area. It can
be summarized as under:
Two major production plant in MSPL namely:

1. MSPL Plant (Mahavir Synthesis Pvt. Ltd. Plant): The major products withdrawn are of sulfonic
acid derivatives & sulfonium group derivatives.
2. NI Plant (Naphthalene Intermediate Plant): The major products withdrawn from the plant are
naphthenic intermediate.
MSPL also have,
ETP (Effluent Treatment Plant)
MEE (Multiple Effect Evaporation System)
W2E (Waste to Energy Plant)
2.1 MACHINERY:
• Total Reactor Capacity: 210 Cu Meters

• Size of Reactors: 3 KL to 20 KL
• MOC of Reactors: GL, SS-316, MS, MSRLTL, HDPE, PP.
• Reaction Temperature: 0 – 180 C
• Filters: Agitated Nutch Filter, P.P. Filter press, Centrifuge, Nutch, Pressure Leaf Filter,
Sparkler Filter
• Dryers: Glass lined Rotary Cone Vacuum Dryer, Fluid Bed Dryer, Flash Dryer, Spray Dryer,
Tray Dryer
• Ventury: Glass, SS, Graphite, HDPE, PP
• Scrubber: Glass FRP Falling film, HDPE Packed columns
• Condensers: Glass, Graphite, SS
• Tube Ice Plant, Chilling Plant With PHe
• Screw Air Compressor
• Cross Flow Cooling Tower, Counter Flow Cooling Tower
4
• Chlorine Storage and Handling Station with vaporize
2.2 RAW MATERIALS USED IN PLANT:
• Ammonia liquid
• Ammonia recovered
• Beta Naphthol
• Sodium Bi-Sulphite
• Sodium Hydrosulphide
• Chloro Sulphonic acid
• Thionyl chloride
• Potassium chloride
• Sulphuric acid
• Hydrochloric acid
2.3 PRODUCTS PRODUCES IN THE PLANT:
• MI-001S
• MI-001R
• MI-001W
• MI-002
• MI-002R
• MI-002B
• MI-003R
• MI-007
• MI-002D
• 1521
• 2398
• AC-10C
5
2.4 UNIT PROCESSES & UNIT OPERATIONS USED IN THE PLANT:
➢ Unit Processes:
The unit process is a process in which chemical changes take place to the material present in the
reaction and results in the chemical reaction is known as the unit process.
• Sulfonation
• Chloro-sulfonation
• Amination
• Hydrolysis
• Reduction
• Chloro-oxidation
• Chlorination
• Neutralization
➢ Unit Operation:
The unit operation involve a physical change or chemical transformation
• Filtration
• Drying
• Scrubbing
• Centrifugation
• Heating
• Mixing
• Cooling
2.5 TYPES OF REACTION:
➢ Amination:
Amination reaction, simply states the process of addition of liquid ammonia and raw material into a
pressurized reactor vessel i.e. autoclave reactors which are used at the pressure of 10 kg/cm2.
➢ Sulphonation:
Sulphonation process indicates the addition of sulphuric acid with raw material into the reactor having
material of construction (MOC) of mild steel, and sometimes, glass lined reactor.
➢ Drawning:
Drawning is the process where we add water in the reactor for product fall out but we cannot separate
6
the product only via drawning. Drawning is to be carried out at the normal temperature.
➢ Isolation:
Isolation is to separate a substance in pure form from a mixture. Isolation is to be carried out by some
chemicals such as Potassium Chloride (KCL) or Sulphuric acid (H2SO4).
➢ Reduction:
Reduction process take place in the manufacturing process of sulphonamides derivatives.
➢ Drying:
Drying is the operation which is done at the end of all products to remove moisture percentage from
the product to dry up the product completely.
➢ Hydrolysis:
Breakdown of larger molecules into smaller ones upon addition of water.
7
CHAPTER-3 PROCESS FLOW DIAGRAM
3.1 MANUFACTURING PROCESS OF MI002:
Figure 3.1: Process flow diagram MI-002
PROCESS DESCRIPTION:
➢ First of all, take 20070 in the autoclave reactor in liquid form. Then, in the reactor add 1R
chemical and SBS (sodium Bi Sulfide)
➢ Before the addition of the chemical start the agitator to start mixing of the chemicals with
liquid ammonia. During this pressurized reaction maintain temperature around 140-150
Celsius.
➢ After 2-3 hrs. Add water in the autoclave reactor to make the slurry more in liquid form. Then
transfer the slurry type product to R1 reactor for the clarification process.
➢ For clarification process R1 reactor has already having 7 lit. Water and then add 20019 in the
reactor. Now, reduce pH of the slurry from 10 to 7 and kept the reaction at 80 Celsius.
➢ After clarification process run the filter press and pass the slurry from the filter press to
remove the 20019 from the slurry. 20019 is used to remove all the impurities form the slurry
and make the slurry free from the impurities. As the product we get mother liquor, then
transfer mother liquor to the D8 reactor for the isolation process.
➢ In Isolation process, add H2SO4 to decrease the pH from 7 to 2 at the temperature of around
100 Celsius. So that our product can fall out and easy to separate when we centrifuge it. Then,
transfer the liquid product to centrifuge reactor.
8
➢ Here, in centrifuge we can separate the product and remove the liquid as waste. Then collect
the product from the centrifuge reactor and dry up the product for final packing.
➢ For the manufacturing of MI-002, the duration of each batch is around 48 hrs.
➢ Here from the above process description, one of the leading reactor which often used for
carrying out pressurized reactor is Autoclave Reactor.
Figure 3.2: Process and Instrumentation diagram of Product MI-002
9
3.2 AMMONIA SCRUBBER SYSTEM:
Figure 3.3: Process Flow Diagram of Ammonia Scrubber System
PROCESS DESCRIPTION:
➢ After the Amination process gets completed then before taking another batch of raw material
to initiate the manufacturing process of MI-002 we have to clean up the whole reactor.
➢ Because, when we transfer the slurry to R1 reactor there are some traces left in the autoclave
reactor, which is to be removed and stored in the vertical vessel situated near the A4 reactor.
➢ After taking NH3 into the vertical vessel, NH3 gets condensed by atmospheric temperature
and some NH3 lest in vapour form which is transferred into the NH3 scrubber tank.
➢ In NH3 scrubber tank we have already taken water which is covered half volume of scrubber
tank.
➢ Then water and ammonia gets reacted and then pump will start so that, solution of NH3 can
transferred into NH3-R storage tank.
➢ In this whole process, the NH3 scrubber tank is get cooled by cooling water.
➢ The reason behind the cooling phenomena is to condense the NH3 vapour
so that it can dissolved into water.
10
CHAPTER-4 MATERIAL & ENERGY BALANCE

CALCULATIONS
4.1 MATERIAL 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 analyse alternative processes to produce
chemicals, as well as to model pollution dispersion and other processes of physical systems.
4.2 MATERIAL BALANCE OF PRODUCT CODE MI-OO2
Fig. Material Balance of Product Code MI-OO2
11
Table 4.1 Material Balance of Product Code MI-OO2
INPUT UNITS OUTPUT UNITS

NH3-L 3960 KG NH3-R 1723 KG
SBS 150 KG DARCO 122.28 KG
MI-001R 1500KG SO2 SCRUBBER 658.5 KG

DARCO 80 KG MOTHER LIQUOR 12601.72 KG
H2SO4 760.5KG MOISTURE 300KG
CSP 2625 KG PRODUCT 1200 KG

H2O 7650 KG
TOTAL = 16605.5 KG TOTAL = 16605.5KG
4.3 ENERGY BALANCE:
Energy balance is the relationship between “energy in” and “energy out” This relationship, which is
defined by the laws of thermodynamics, dictates whether weight is lost, gained, or remains the
same.
ENERGY BALANCE OF TRAY DRYER :
❖ Cp of air = 1.014 (KJ/Kg.K)

❖ Cp of MI002 = 1.75 (KJ/Kg.K)
❖ Cp of H20 = 4.18 (KJ/Kg.K)
❖ Latent heat of water = 2264 kJ/kg
❖ Reference temp = 25 °C = 298 K
❖ Air inlet temp = 120°C = 393 K
❖ Air outlet temp. = 45 °C = 318K
❖ Product inlet temp. = 30 °C = 303K
❖ Product Chamber temp = 75 °C = 348K
❖ Weight of wet solids in (Win) = 1500 Kg
❖ Weights of wet solids out (Wout) = 1200 Kg
❖ Weight of air required (Wair) = 1416 kg
• Rate of Evaporation (E) = 1500-1200

=300 kg
• Total enthalpy in = enthalpy of MI-002 in + enthalpy of water in + enthalpy of hot air in

= 157365.78 KJ
12
• Total enthalpy out = enthalpy of MI-002 out + enthalpy of water out+ enthalpy
of air out + Enthalpy of water evaporated
= 947783 KJ
• Total energy required = Amount of enthalpy out - Amount of enthalpy in

= 790417.32 KJ
• Amount of propane gas required:
Energy produced per gram = 46 KJ /g
Kg propane required = Total Energy required/Energy per kg

= 17.182 Kg for 6 hours of run.
13
CHAPTER-5 DETAILES OF EQUIPMENTS
Observed measuring vessels, globe valve, gate valve, piston valve, plug valve, butterfly valve.
All valves are close if their hand is perpendicular to the pipe and if they are parallel to the pipe,
valves are open. Observed sulphonation reaction up to 90℃ as it exothermic in nature, the
temperature of the process is required to be decreased, so drowning process is done by adding
ice into the vessel. Then isolation is done for separation of products and mother liquor by
adding basic materials if raw materials are acidic and vice versa. Then the slurry is sent for
filtration for further separation.
5.1 OBSERVED DIFFERENT TYPES OF FILTERS:
1) Filter Press - Generally, the slurry that will be separated is injected into the center of the press
and each chamber of the press is filled. Optimal filling time will ensure the last chamber of the press
is loaded before the mud in the first chamber begins to cake. As the chambers fill, pressure inside the
system will increase due to the formation of thick sludge. Then, the liquid is strained through filter
cloths by force using pressurized air, but the use of water could be more cost-efficient in certain cases,
such as if water was re-used from a previous process
Figure 5.1: Filter Press
2) Centrifuge Filter- A centrifuge works on the principle of centrifugal force, which is

created when a device, usually called a basket is rotated at high speeds on a fixed axis
...Separation can be by filtration or sedimentation.
A centrifuge offers a different option for those wanting to process solids from liquids.
14
Figure 5.2: Centrifuge Filter
3) Agitated Nutsche Filter- A typical unit consists of a dished vessel with a perforated plate.
The entire vessel can be kept at the desired temperature by using a limpet jacket, jacketed
bottom dish and stirrer (blade and shaft) through which heat transfer media can flow. The vessel
can be made completely leak-proof for vacuum or pressure service. Agitated Nutsche filter
(ANF) is a filtration technique used in applications such as dye, paint, and pharmaceutical
production and waste water treatment. Safety requirements and environmental concerns due to
solvent evaporation led to the development of this type of filter wherein filtration under vacuum
or pressure can be carried out in closed vessels and solids can be discharged straightaway into
a dryer.
Figure 5.3: Agitated Nutsche Filter
15
Observed utility section. Utility section is basically to provide heating or cooling media to the
reaction by supplying oil, water, steam etc. It mainly contains Thermo pack boiler, boiler and
baby boiler.
5.2 OBSERVED DIFFERENT TYPES OF DRYERS:
1) Spin Flash Dryer (SFD) - Spin Flash Dryer is used for effective and efficient method of
removal of surface or on bound moisture from a feed product. Spin Flash Driers are designed
for continuous drying of cohesive and non-cohesive pastes, filter cakes and high viscosity
liquids. The wet cake appears granular and gets fluidized.
Figure 5.4: Spin Flash Dryer
2) Rotary Cone Vacuum Dryer (RCVD) - Rotary cone Vacuum Dryer is suitable for drying
materials that cannot resist high temperature, easily oxidized materials, volatile materials that
should be retrieved, and potent irritants and poisonous in nature. The Rotary cone Vacuum
Dryer with improved technology integrates during operation under vacuum. The Rotary cone
Vacuum Dryer facilitates enhanced drying efficiency, low-temperature operation, and process
economy by total solvent recovery. It helps cGMP base working by achieving optimum dust
control while offering efficient charging and discharging of materials. The drying unit equipped
with lump breakers initially breaks large lumps and subsequently powders them (in a single
cone). The dryer’s rotary action, together with the breakers’ mechanical action, cuts down
drying time and gives a lump-free product.
16
Figure 5.5: Rotary Cone Vacuum Dryer
3) Fluidized Bed Dryer (FBD) - Fluidized bed dryer (also called fluid bed dryer) is a kind of
equipment used extensively in the pharmaceutical industries to reduce the moisture content of
pharmaceutical powder and granules. The equipment works on a principle of fluidization of the
feed materials. In fluidization process, hot air is introduced at high pressure through a perforated
bed of moist solid particulate. The wet solids are lifted from the bottom and suspended in a stream
of air (fluidized state). Heat transfer is accomplished by direct contact between the wet solid and
hot gases. The vaporized liquid is carried away by the drying gasses. Sometimes to save energy,
the exit gas is partially recycled.
Figure 5.6: Fluidized Bed Dryer

17
5.3 OBSERVED DIFFERENT TYPES OF PUMPS:
1) Centrifugal Pumps:
Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing turbo

machinery. Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically
comes from an engine or electric motor.
Characteristics
Creating a resistance to the flow controls the kinetic energy of a liquid coming out of an
impeller. The first resistance is created by the pump volute (casing), which catches the
liquid and slows it down. When the liquid slows down in the pump casing, some of the
kinetic energy is converted to pressure energy It is the resistance to the pump’s flow that is
read on a pressure gauge attached to the discharge line. A pump does not create pressure,
it only creates flow. Pressure is a measurement of the resistance to flow.
Different Types of Pump Head
Total Static Head - Total head when the pump is not running
Total Dynamic Head (Total System Head) - Total head when the pump is running Static
Suction Head - Head on the suction side, with pump off, if the head is higher than the pump
impeller
Static Suction Lift - Head on the suction side, with pump off, if the head is lower than the
pump impeller
Static Discharge Head - Head on discharge side of pump with the pump off
Dynamic Suction Head/Lift - Head on suction side of pump with pump on
Dynamic Discharge Head - Head on discharge side of pump with pump on.
2) Diaphragm Pumps:
A diaphragm pump (also known as a Membrane pump) is a positive displacement pump that uses a
combination of the reciprocating action of a rubber, thermoplastic or Teflon diaphragm and
18
suitable valves on either side of the diaphragm (check valve, butterfly valves, flap valves, or any
other form of shut-off valves) to pump a fluid.
There are three main types of diaphragm pumps:
Those in which the diaphragm is sealed with one side in the fluid to be pumped, and the other in air
or hydraulic fluid. The diaphragm is flexed, causing the volume of the pump chamber to increase
and decrease. A pair of non-return check valves prevent reverse flow of the fluid.
Those employing volumetric positive displacement where the prime mover of the
diaphragm is electro-mechanical, working through a crank or geared motor drive, or purely
mechanical, such as with a lever or handle. This method flexes the diaphragm through
simple mechanical action, and one side of the diaphragm is open to air.
Those employing one or more unsealed diaphragms with the fluid to be pumped on both
sides. The diaphragm(s) again are flexed, causing the volume to change.
An elastomeric diaphragm can be used as a versatile dynamic seal that removes many of
the limitations found with other sealing methods. They do not leak, offer little friction, and
can be constructed for low pressure sensitivity. With the right material consideration,
diaphragms can seal over a wide range of pressures and temperatures without needing
lubrication or maintenance.
The centrifugal pumps are made of stainless steel and cast iron. The diaphragm of the
diaphragm pump is made up of poly propylene. The suppliers of the pump near to the
location of the plant are G Pumps Valve, Active engineering Valve, Well Tech.
Ahmedabad, and KS Pumps Ahmedabad.
5.4 OBSERVED DIFFERENT TYPES OF VALVES:
1) Ball Valves:
A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting
ball (called a "floating ball") to control flow through it. It is open when the ball's hole is in
line with the flow and closed when it is pivoted 90-degrees by the valve handle. The handle
lies flat in alignment with the flow when open, and is perpendicular to it when closed,
making for easy visual confirmation of the valve's status.
19
Ball valves are durable, performing well after many cycles, and reliable, closing securely
even after long periods of disuse. These qualities make them an excellent choice for shutoff
applications, where they are often preferred to gates and globe valves, but they lack their
fine control in throttling applications.
The ball valve's ease of operation, repair, and versatility lend it to extensive industrial use,
supporting pressures up to 1000 bar and temperatures up to 752 °F (500 °C), depending on
design and materials used. Sizes typically range from 0.2 to 48 inches (0.5 cm to 121 cm).
Valve bodies are made of metal, plastic, or metal with a ceramic; floating balls are often
chrome plated for durability. One disadvantage of a ball valve is that they trap water in the
center cavity while in the closed position. In the event of a freeze, the sides can crack due
to expansion of ice forming. Some means of insulation or heat tape in this situation will
usually prevent damage. Another option for cold climates is the "freeze tolerant ball valve".
This style of ball valve incorporates a freeze plug in the side so in the event of a freeze up,
the freeze plug ruptures, (acts as a sacrificial disk), thus making for an easy repair. Now
instead of replacing the whole valve, just screw in a new freeze plug. This is commonly
called freeze plug technology.
2) Globe valve:
A globe valve, different from ball valve, is a type of valve used for regulating flow in a
pipeline, consisting of a movable disk-type element and a stationary ring seat in a generally
spherical body.
Globe valves are named for their spherical body shape with the two halves of the body
being separated by an internal baffle. This has an opening that forms a seat onto which a
movable plug can be screwed in to close (or shut) the valve. The plug is also called a disc
or disk. In globe valves, the plug is connected to a stem which is operated by screw action
using a hand wheel in manual valves. Typically, automated globe valves use smooth stems
rather than threaded and are opened and closed by an actuator assembly.
Globe valves are used for applications requiring throttling and frequent operation. For
example, globe valves or valves with a similar mechanism may be used as sampling valves,
20
which are normally when liquid samples are being taken. Since the baffle restricts flow,
they are not recommended where full, unobstructed flow is required.
3) Plug Valves:
Plug valves are valves with cylindrical or conically tapered "plugs" which can be rotated
inside the valve body to control flow through the valve. The plugs in plug valves have one
or more hollow passageways going sideways through the plug, so that fluid can flow
through the plug when the valve is open. Plug valves are simple and often economical.
When the plug is conically tapered, the stem/handle is typically attached to the larger
diameter end of the plug. Plug valves usually do not have bonnets but often have the end
of the plug with the handle exposed or mostly exposed to the outside. In such cases, there
is usually not much of a stem. The stem and handle often come in one piece, often a simple,
approximately L-shaped handle attached to the end of the plug. The other end of the plug
is often exposed to the outside of the valve too, but with a mechanism that retains the plug
in the body.
The simplest and most common general type of plug valve is a 2-port valve with two
positions: open to allow flow, and shut (closed) to stop flow. Ports are openings in the valve
body through which fluid can enter or leave. The plug in this kind of valve has one
passageway going through it. The ports are typically at opposite ends of the body; therefore,
the plug is rotated a fourth of a full turn to change from open to shut positions. This makes
this kind of plug valve a quarter-turn valve. There is often a mechanism limiting motion of
the handle to a quarter turn, but not in glass stopcocks.
21
Table 5.1: Types of Control Valve available in Market
Sr. No. Name of Application Selection Criteria

Valves
Spindle Reactor To avoid dead zone in

1 Valve Bottom The reactor Long service life
2 Plug RVD inlet No leakage, Long service life
Valve On off purpose. For handling
Pipe of Hazardous chemicals
3 Gate Waterline On-off purpose , High flow
Valve rate
4 Globe Steam line, Flow regulation , Cheap
Valve No leakage , Low
Hi-thermal oil line
Maintenance, No
maintenance
5 Ball Hot-water, Acid-line, Cheap , repairable
Valve Steam-line, Alkaline- On off purpose Leakage
line, Problems High Pressure
Solvent-line Drop
6 Butter-Fly Air, gas , water, On-Off Purpose
powder material
Valve
22
CHAPTER-6 DESIGN OF EQUIPMENTS

6.1 : REACTOR DESIGN
6.1.1 : Design of Cylinder
Diameter of cylinder-
V = π/4 x D2 *L
Acquired diameter
Di = 1.75 Meters
Assumed height to diameter ratio L/D = 1.5

Height of the cylinder
H = 2.62 Meters
20 % vapor liquid disengment (V-L) - 3.15 Meters

Thickness of cylinder (Tc) = (P*Di) / (2*f*j-P) +C
= 12.562mm + 3 mm
(Tc) = 15.562 mm
Standard assumed (Tc) = 20 mm Outer diameter of cylinder (Od) = 1790 mm
Table: 6.1 –Specifications for Cylinder Design
Specifications Value Units
Design Pressure Of Reactor 17 Kg/cm2
Operating Pressure of Reactor 15 Kg/cm2
Design Pressure Of Jacket 6 Kg/cm2
Design Temperature 280 °C
Operating Temperature 250 °C
Density Of Feed Material 0.77196 Gm /ml
Volume Of Feed Material 6314.28 Liters
23
Table: 6.2- Data for Cylinder of Reactor
Material of construction SA 516 GR 70

Tensile strength 485 Mpa
Yield strength (ultimate) 260 Mpa
Allowable stress (f) 1397.01 kg/cm2
Density of SA 516 GR 70 7860 kg/m3
Checking the Thickness of Cylinder:
Circumferential stress (Fc) = P* (Di +Tc) / 2*Tc

= 73.455 N/mm2
Tangential Stress (Ft)
• Due to internal pressure (f1) =(P*Di ) / 4*Tc
(f1) = 36.312 N/mm2 (tensile)
• Due to weight of vessel and contents (f2) = W / *Tc ( Di +Tc )
(f2) = 0.077046 N/mm2
Total stress in longitudinal direction (fa) = (f1 + f2)

= (36.312 + 0.077046)
= 36.3895 N/mm2
According to stress strain energy theory = (f12 – ft*fa + a2)0.5

= 63.6147 N/mm2 < than 132 N/mm2
Hence the assumed thickness is acceptable
6.1.2: Design of Torispherical Head
Thickness of head (Th) = Pi*Rc *W / 2*f*j + Ca

(Th) = 24.215 mm
24
Standard thickness (Th) = 25 mm
Outer Diameter of Head (Odhead) = Di + 2*Th
= 1.79 mm
Straight Flange (Sf) = 3*Thickness of head
(Sf) = 75 mm
Blank Diameter (BD) = (Odhead + Odhead /24) + ((2*Sf+2)/ (3*Icr))+ Th

Length of the head (OA) = Th + b + Sf
= 25 + 292 + 75
= 392 mm
Internal volume (Vi) = (0.0847*Di3) + (3.14/4 *Di2 *Sf)

(Vi) = 0.66 m3
Weight of head (Whead) = (3.14/4 * BD2 *Th * Density of MOC)/10003
(Whead) = 712 kg
6.1.3 : Design of Torispherical Bottom
Thickness of head (Th) = Pe*Rc*W / 2*f*j + Ca

(Th) = 17.08 mm
Standard thickness (Th) = 20 mm
Outer Diameter of bottom (ODbottom) = Di + 2*Th

(ODbottom) = 1.79 mm
Straight Flange (Sf) = 3 x Thickness of head
(Sf) = 60 mm
Blank Diameter (BD) = (ODbottom + ODbottom /24) + [(2*Sf+2)/ (3*Icr)] + Th

Length of the head (OA) = Th + b + Sf
= 20 + 292 + 75
25
= 387 mm
Internal volume (Vi) = (0.0847 x Di3) + (3.14/4*Di2 *Sf)
(Vi) = 0.57 m3
Weight of head (Whead) = (3.14/4*BD2 *Th*Density of MOC)/10003
(Whead)= 458 kg
6.1.4 : Design of Vessel Shell with Limpet Jacket
Thickness of half coil (Thalf coil) = Pj* Di (coil) / 2*f
(Thalf coil) = 0.20992 mm
Use minimum thickness (Thalf coil) = 4 mm
Total circumferential stress (Fcircumferential stress) = (Pi*Di /2*Ts) + [(Pj x Di (coil)/ (4*Thalf coil
+2.5*Ts)]
(Fcircumferential stress) = 91.890 N/mm2
Total longitudinal stress (Tlongitudinal stress) = Pi*Di/4*Ts+Pj*Di (coil) / 2*Tc +2*Pi*Do2/3*Ts2

(Tlongitudinal stress) = 61.24
N/mm2
6.1.5 : Insulation for Limpet Jacket
Material of Construction: Rock Wool
Table: 6.3- Specification for Insulation for Limpet Jacket
Specifications Value Units

Density 114 Kg/M3
Thickness 50 mm
Length Of Insulation 15.01576304 Meters
Weight Of Insulation 3.098125428 Kg
26
Table: 6.4- Data of Limpet Jacket
DATA GIVEN VALUE UNITS
Diameter Of Limpet Coil(di) 88.9 mm
Jacket Pressure 0.647 n/mm2
Height Of Jacket 2038 mm
Density Of Therminol 66 880 kg/m3
Volume Of Hot Oil 0.64 m3
Mass Of Utility 571.8183056 kg
Design of Baffle
Table: 6.5- Data for Baffle Design
DATA VALUE UNITS

Diameter Of Tank (Td) 1750 mm
RPM 50
Baffle width 1/16 tank dia 130 mm
length of baffle 2100 mm
Thickness 20 mm
6.1.6 : Design of Anchor Type Agitator
Table: 6.6-Specifications for Anchor Type Agitator

Clearance B/W Bottom And Agitator 150 mm
Sweep Diameter of Blade (Sd) = (0.6) Td
= 1050 mm
Width Of Blade = 1/10*(Sd)
=105 mm
Thickness Of Blade 20 mm
Length Of Agitator = [1.5*(Sd)]
= 1575 mm
Length Of Shaft = 1.2*Hc
= 4076.34 Mm
Diameter of Shaft 100 Mm
27
Power Calculation for Agitator
Table: 6.7- Calculation for Agitator

Viscosity Of Liquid 200 Cp
Rps 0.8 Rps
Density Of Material 0.77196 g/ml
Nre = Den*n*DAg2/U(vis)
= 6947.64
Np (From Power Curve Graph) 2.7
So Power Required (PR) = Np*Diag5 *N3 *Density
= 8103.727296 W
Gland Loss & Transmission Loss = 1.2 x 1.1 x PR/ 745.7
= 14.34480358 Hp
Hence Required HP Motor 15 Hp
6.1.7: Design of Lug Support
Table: 6.8- Data for Lug Support Design
Material Of Construction 1S 800

Tension Stress (Ft) 140 N/mm2
Compression Stress (Cs) 123.3 N/mm2
Bending Stress (Bs) 157.5 N/mm2
Design of Base Plate
Table: 6.9- Data for Base Plate
No Of Brackets (Nb ) 4
Ee 75
Max Load (Pml) = Wt*gc / Nb
= 21284.84515 N
Design of Base Plate
a(distance B/W 2 Gusset Plate) 180 Mm
B(width Of Base Plate) 250 Mm
A 250 Mm
28
AVG Pressure On Plate (Pa) = Pml / ( a x B )

= 0.472996559 N/mm2
Thickness Of Base Plate (Tbp) = (0.7*pa*(a4*b2)/(A*4+b*4))/Bs)0.5
= 5.27541 mm
According to standard Tbp 10 mm
Thickness Of Gusset Plate (Gc) = 0.65*B
=162.5 mm
Height Of Gusset Plate (Hgp) 280 mm
T2 10 mm
2
Stress At The Gusset Plate (Fgp) = 3*Pa / T2*Hgp
=13.23515563 N/Mm2
Table: 6.10- Final Conclusion of Reactor Design
PROPOSED CHANNEL
Material of construction ISMC 150
Size 150*75
Area Of Cross Section (A) 2088 mm2
Modulus Of Section (Zyy) 19400 mm2
Radius Of Gyration (Ryy) 22.1 mm2
Height From Foundation 2250 mm2
Equivalent Length Of Fixed Ends (le) 1125 mm2
Slenderness Ratio = le/ (Ryy)
50.90497738
Short Column Stress = w/A*n + w*x*e / n*x*Z
= 61.38066386 N/mm2
29
6.2: DESIGN OF AGITATOR
Require data for Design

Dia. Of Reactor : 2.57 m
Hight of Reactor:2.25m
RPM :35
RPS: 0.583
Density :1.30 gm/ml
Power :10hp=7.45kw
Kt:65
Design of Baffle :
1) Four baffles should be mounted vertically on the tank wall, projecting radially from the wall
and
located 90° apart.
(2) Baffle width should be a tenth to a twelfth of the tank diameter. Baffle height should be at least
two impeller diameters and approximately centered on the agitator.
(3) For baffles set out from the wall, the width may be 1/12th of the tank diameter with an offset of
approximately 1/5th the baffle width.
For large diameter tanks (6 metres and above) the number of baffles may be increased to six and
they may be set out from the wall to reduce the distance from the agitator to the baffle.
Width of Baffle(J) =1/12 D

= 1/12(2.57)
=0.2142 m
P= 7.457=65×(0.583) ×1.3
D =0.85 m
Length of impeller(L) =1/4 Da

=1/2×0.85
=0.212m
Width of impeller(w) =1/5 Da

=1/5×0.85
=0.17m
Hight of Agitator = hight of Reactor

H =2.25m
30
Torque =P/2ΠN
=7450/2×3.14×0.583
= 2034.82 Nm
6.3 DESIGN OF THE CENTRIFUGAL PUMP:

Sulfuric aci
Liquid temperature: 30 °C
Capacity (normal): 25 m3/hour
Suction pressure: 0.72 Kg/cm2g
Discharge pressure: 2.3 Kg/cm2g
Viscosity: 0.00128 Kg/m*sec
Specific gravity: 1.84
Efficiency: 85 %
Seal type: Mechanical
Length of pipe: 30 m
Diameter of pipe: 100 mm (inlet)
: 60 mm (outlet)
MOC used: Carbon steel
Calculation at input:
π
Area, A = 4 * d²
= 0.00785 m2
Velocity, V = capacity/area
= 25/ (0.00785 ∗3600)
V = 0.88 m/sec
ρ∗v∗d
Reynolds No., Nre = µ
= (1840 ∗0.88 ∗0.1)/0.0267
= 6064.41
Calculation at Output:
π
Area A = 4 * d²
= 0.002826 m2
Velocity, V = capacity/area
= 25/ (0.002826 ∗3600)
V = 2.45 m/sec
ρ∗v∗d
Reynolds No., Nre = µ
= (1840∗2.45∗0.06)/0.0267
= 10,159.2809
Friction losses:
31
fs = 0.085 * (Re)−0.25
= 0.085 * (218856.89)−0.25
= 0.036
Head losses:
4∗frictional losses∗ length ∗ velocity2

Head losses = diameter∗g
= (4 * 0.00846 * 30 * 2.452 / (0.06 ∗9.81)
= 10.61 m
Calculation of Head: (From Bernoulli’s Equation)
Head = Head losses + pressure drop + differential head + velocity compound
= head losses + ([(Pb-Pa)/ (ρ*g)) + (g ∗𝑍𝑏 ) + (𝑉 2 / (2g))]
(Zb = 2.5 m suction height from pump base)
= 10.61 + [((2.3 -0.72) ∗98066.5)/1840 ∗ 10 ∗9.81) + (9.81 * 2.5) + (2.452 / (2∗9.81)]
= 10.61 + 0.8584 + 24.525 + 0.306 = 36.29 m
Calculation of Pump Power Required:
Power required = (head ∗density ∗capacity ∗9.81)/ (efficiency ∗106 )

= (36.29 ∗1840 ∗25 ∗9.81)/ (0.85 ∗106 )
= 19.27 KW
Calculation of NPSH:
Vapour pressure (Pv) at 32oC = 400 N/m2

The net positive head available is given by the following equation:
NPSH = [(Ps -Pv)/ (ρ*g) + (𝑉 2 / (2∗g)]
Where,
Ps = suction pressure
Pv = the vapour pressure of the liquid at the pump suction, N/m2
NPSH = [((0.72 -0.04) ∗98066.5)/ (1840 ∗9.81)) + (2.452 / (2 ∗9.81)]

= 3.694 + 0.3059
= 4.00029 m
32
CHAPTER-7 UTILITY CONNECTIONS
In plant, for the cooling and heating purpose hot oil, hot steam, cooling water need to be circulated
inside the jacket.
7.1 TYPES OF UTILITY:
❖ Hot Oil- when temperature requirement is high around 180-200 degree Celsius.
❖ Hot Steam- when temperature requirement is around 100 degree Celsius.
❖ Cooling Water- when temperature requirement is 25-30 degree Celsius.
❖ Chilling Water- when temperature requirement is 5-10 degree Celsius.
❖ Brian Water- when temperature requirement is -21 degree Celsius.
❖ Ice- when temperature requirement is around 0 degree Celsius.
• For heating and cooling purpose, the utilities are used.

• Utilities are circulated inside the jacket, which is attached to the outer surface of reactor.
• Hot steam and hot oil are used for the heating purpose but hot oil is used especially for the
pressurized reactors such as, autoclave reactor.
• The cooling water and chilling water is used for cooling utilities.
• During the utility circulation, we have to be careful that only one utility is circulating inside
the jacket.
7.2 FLOW OF UTILITY CONNECTIONS INSIDE THE JACKET
Hot Utility Circulation Flow Direction:

• The steam is in gaseous form having moisture with limited amount is inserted into jacket from
the upper side of the reactor and the temperature of steam is around 1100-110 degree Celsius.
• When steam is circulated inside the jacket, the steam will condensed into water.
• That’s why if we circulate the steam from bottom to top inside the jacket water and steam can
having counter-current flow and heating will not that much efficient compared to steam
circulating from top to bottom inside the jacket.
33
Cold Utility Circulation Flow Direction:

• Cooling water and chilling water is circulating inside the jacket from bottom to top.
• If they circulated from top to bottom they will get hot when they came in contact with the
mash inside the reactor.
• So, cooling water and chilling water are circulated from bottom to top inside the jacket so
they get more time of contact with the mash and cooling can be effective.
7.3 STEAM HAMMERING:
• Steam hammering is defined as the phenomenon which occurs in steam charging in the
pipeline while there is a presence of condensate in the line.
• This is because of sudden drop in pressure of steam as it comes in contact of condensate.
• This can also occur due to poor heating of steam network before the steam enters into the
system. Piping network remains cool and as soon as the hot steam enters, condensation takes
place and water gets accumulated in the lines forming a Slug.
• As the steam flow increases, steam carries the water with it and lot of momentum is created
and it hammers the line loops with tremendous forces creating a lot of stress.
• Steam hammering condition exists in a steam system where condensate coexists with
generated steam or flash steam.
Effect of Steam Hammering:
• Cracking of steam traps and pressure gauges

• Break pipe weld and even rupture piping systems
• Bend internal system mechanism
• Causes valve failure
• Cause heat exchanger equipment tube failures
• Failure of pipe supports.
Prevention of Steam Hammering:
• Ensure correct steam and condensate design.
34
• Have documented SOP’s (standard operation procedures) for steam system start-ups and shut
downs.
• Proper training for plant personnel.
• Have installation standards for steam components.
• Correct condensate connections of branch lines to the main condensate header and entry only
from the top of the header.
• Use steam traps that are properly sized and appropriate for the application.
• Check or repair the pipe insulation. It saves energy and reduces accumulation of condensate
in the piping system
• Make sure that the condensate pump is in good working condition
7.4 DESCALING PROCESS:
• Descaling process is a metal cleaning process that removes unwanted surface deposits on
metals to provide a smooth surface finish.
• It is a part of the pre-finishing processes which include cleaning, stripping and pickling.
• In Descaling process, the solution of chemicals are often used which have good effect against
scale-formation, corrosion in metallic body.
• For that Sulphamic acid is widely used because of its efficiency as descaling agent.
• Hot utility and cold utility are circulated inside the jacket and that’s why the scale has been
made up inside the jacket after some time.
• If we don’t remove the scale then it will blocks the way of the utility inside the jacket and it
affects the heating and cooling capacity of the utility. So for effective work of utility, the scale
should be removed from the inner surface of the jacket.
• For that Sulphamic acid is used as descaling agent.
• Sulphamic acid is a white crystalline solid which is non-hygroscopic and stable. Sulphamic
acid is a super-efficient agent for descaling. It is used for cleaning a number of domestic
appliances and industrial equipment.
• Sulphamic acid is used as an acidic cleaning agent, usually for ceramics and metals.
Sulphamic acid is a safe and powerful acid, which is suitable for descaling applications and
acid cleaning.
• It is commercially produced from fuming sulfuric acid and urea, and classified as a strong
35
inorganic acid. The Sulphamic acid is considered as less corrosive to metals compared to
other strong acid such as hydrochloric acid.
• As the Sulphamic acid retains a scale solubilizing capacity it is considered ideal for removal
of scale from cooling towers, boilers, coils, condensers, heat exchangers and a wide range of
cooling and heating systems thereby amassing the efficiency of equipment and plant.
Procedure of Descaling Process:
For removing excess rust from tiling or dissolving efflorescence from walls, floors etc.
For descaling equipment use a 10% or 20% solution. Sulphamic acid is safe for steel, iron, glass and
wood equipment. We have to make the Sulphamic acid solution as per our need and according to how
bad is the condition of the jacket form inside. Now, determine the volume of water and mix the
Sulphamic acid at a rate of 100 to 150 gms. Per liter of water and make the solution of the Sulphamic
acid in the water.
It may be necessary to add a corrosion inhibitor to protect mild steel, brass, copper and stainless steel.
Then, circulate the solution at room temperature or heated to a maximum of 60 degree Celsius for
heavier cleaning for several hours until desired results are achieved. Sulphamic acid will not remove
silica or calcium phosphate scales. After rinse thoroughly and check system. Neutralize with 1-2%
sodium carbonate solution with a target pH of 6 to 8.
Use of Sulphamic Acid:
• Descaling agent, rust remover, and cleaner for metals and ceramics.
• Catalyst for esterification process.
• Ingredient in fire extinguishing media.
• Urea-formaldehyde resins coagulator.
• Synthesis of nitrous oxide by reaction with nitric acid.
• Chlorine stabilizer in pulp &paper industry
7.5 HYDRAULIC TEST:

In every industry, it is compulsory to conduct hydraulic test before taking the reactor in services.
• Hydraulic Test or Hydrostatic Test is a process where components such as piping system, gas
cylinders, boilers and pressure vessels are tested for strength and leaks.
36
• Hydro test are often required after shutdowns and repairs in order to validate that equipment
will operate under desired conditions once returned to service.
• Hydrostatic test cannot be performed during normal operations and can’t monitor equipment
for leaks after the test has been perform.
• The procedure involves filling the test system with a liquid i.e. water and pressurizing it to a
specified test pressure, where equipment is assembled pressure tests may also be completed
to prove the mechanical strength and integrity of the whole assembled system including
piping flanged/ coupled joints and equipment connections.
Basic Steps for a Hydraulic Testing:
Pre-test Activities and Site Set Up:
• Any component with the maximum allowable hydrostatic test pressure less than the piping
system test pressure or not part of the pressure test is removed or positively isolated.
• All test battery limits are fitted with fully blind flanges, spade blinds or closed position
spectacle blinds.
• In-line ball valves are kept half open and globe and gate valves fully open.
Test Medium and Temperature:
• Test water is usually neutral pH water, non-toxic, potable or demineralized water.

• The temperature of construction and the testing medium is kept the same as far as is practical.
• The temperature for the test is usually kept to 5 to 48 degree Celsius, so that a factor like
factor like pressure deration does not come into play.
Test Pressure Calculations:
• Usually, process piping is tested to 1.5 times the design pressure.

• Before proceeding with any hydro test, test calculations are required to be made.
i.e. PT= 1.5*P*ST/ S
Where; PT= Minimum Hydrostatic Gauge Pressure

P = Internal Design Gauge Pressure
37
ST= Allowable Stress at Test Temperature
S= Allowable Stress at Design Temperature
Test Arrangement:
• Once the teat procedure is approved, the test arrangement is set up. This includes test
equipment like manifolds, gauges, chart recorders d temperature recorders, as well as
temporary vent valves etc. ass needed.
Filling and Venting:
• System to be hydrostatically tested are filled gradually from a water source or tanker ensuring
the fill rate is according to test procedure.
• System is also vented during filling to ensure elimination of sir pockets.
• Before application of hydrostatic test procedure, the temperature of the test fluids and the
material of the piping are allowed to equalize to within +/- 5 degree Celsius.
Pressurization:
• Pressurization starts after the entire system has been filled and isolated. Pressure is gradually
increased to 50% of test pressure and then the system is allowed to stabilize for a period of
time.
• This is also the time when we inspect for any leaks. With no leaks evident, pressure is
increased to 75% of test pressure and same will be followed till 100% of test pressure.
• Any leaks, deformations, drop in pressure or other issues identified are then corrected
according to design requirements.
Post Test:
• After testing, the equipment and piping system are safely depressurized, completely drained
and dried to prevent corrosion.
38
• During draining vent valves are usually kept open to prevent vacuum, if a piping system is to
be dried by blowing, drains or vents are opened in order to avoid pressuring the system.
• Piping that is hydrostatically tested, is dried by either hot air blowing, or with nitrogen.
39
CHAPTER-8 SAFETY & ENVIRONMENT MANAGEMENT

SYSTEM
8.1 INTRODUCTION:
• Safety is the factor of prime importance in any industry. Safety of man power, equipment’s
and environment is a part of duty of any organization.
• Safety in a plant can be used by appropriate use of personal protective equipment’s. Every
plant has installation of safety equipment’s to protect equipment from damage and industry
from hampering its growth. The control room is also equipped with PPE so in case of any
emergency, these can be used.
• Behavior of any reacting intermediate or product is based on its properties and nature. The
Material Safety Data Sheet involves the whole history of the substance. The reactivity data,
possible hazard and its prevention are the important data to be known by each and every
person in plants concern.
• Safety of workers working on the plant is very important objective for management. So it is
responsibility of management to give knowledge about the accidents which can take place
during operation and also to give them the appropriate solution of accident. Accident can
caused due to corrosion, leakages, failure of equipment, insulation defect, short circuit,
sparking, etc.
• In this industry there are mainly hazardous chemical present like;
Toxic and corrosive Chemical: Sulfuric acid and Schaeffer’s acid
8.2 SAFETY IN PROCESS PLANT:

No industry can afford to neglect the fundamentals of safety in design and operation of its plant and
machinery. It is important that all the people responsible for management and operation of any
industry should have a good knowledge of industrial safety.
8.2.1 SAFETY MEASURES TAKEN IN THE INDUSTRY:

• Smoking is not allowed in any part of industries except smoking booths
• No matches, lighters or any other spark producing devices are allowed inside the gate.
40
• Dry chemicals and CO2 extinguishers are used in case of a fire around electrical equipment.
• Necessary permit / clearance are to be taken before starting any job.
• Fire and safety divisions are also there.
• After opening equipment, any scale or deposit containing pyrophoric iron is kept wet until their
removal to a safe location and burying.
• No more shift electrical connections are made.
• Compressed air is never used to clean up dust, fillings, and clothing.
8.2.2. FIRE FIGHTING:

There is a rapid combustion resulting of heat and light of flame. Flame is luminous hot come of the fire. For
catch fire required three things
1. Combustible Material
2. Air (oxygen)
3. Heat and local temp.
Remove any one and fire will extinguish.
Classes of Fires:
Fires can be placed into different classes depending on what material is burning. This classification
then gives us information on the type of fire extinguisher we should use to put out the flames. Not all
fires require the same type of extinguisher and the correct type has to be used for each blaze.
Class A
❖ Class A fire is burning flammable solids as fuel. Examples of these include paper and wood.
❖ Extinguishers that can be used: Water, Foam, ABC Dry powder, Wet chemical
Class B
❖ Class B fires are burning flammable liquids. Examples include petrol and paint.
❖ Extinguishers that can be used: Foam, CO2 Gas, ABC Dry powder
Class C
❖ Class C fires burn flammable gases. A couple of examples are propane and butane.
❖ Extinguishers that can be used: ABC Dry powder
41
Class D
❖ Class D fires are burning flammable metals. These may include lithium or magnesium.
❖ Extinguishers that can be used: Dry Special Powder
Electrical
❖ Any fire involving electrical equipment is classed as an electrical fire.
❖ Extinguishers that can be used: CO2 Gas, ABC Dry powder
Class F
❖ Class F fires are burning cooking oils or fat.
❖ Extinguishers that can be used: Wet chemical
Types of Fire Extinguishers:

The six main fire extinguisher types are
1. Water
2. Foam
3. CO2
4. Powder
5. Water mist
6. Wet chemical
Each of the different types of fire extinguisher is suitable for different fire classes. It is important that
you purchase the right fire extinguisher for your needs.
8.3 SAFETY RELATED EQUIPMENTS:
8.3.1. RESPIRATORY PERSONAL PROTECTIVE EQUIPMENTS:
1. Self-contained breathing apparatus (SCBA) sets of 30 minutes and 10 minutes

2. Continuous airline masks.
3. Trolley mounted self-contained breathing apparatus set 2.5 hours
4. Canister gas mask.
5. Dust mask/cloth mask. (Air purifying respirator)
42
8.3.2. NON-RESPIRATORY PPEs:
1. Helmet
2. Ear muff and ear plugs
3. Goggles
4. Face shield
5. Hand gloves
6. Aprons
7. Safety Shoes
8. Suits
9. Safety harness
8.3.3. WARNING INSTRUMENTS:
1. Oxygen, carbon dioxide, chlorine, aniline indicator with replaceable sensors. Explosive meters
for measuring explosive range.
2. Fire fly instrument for confined space entry.
8.3.4. GAS LEAKAGE PROTECTION INSTALLATION:
1. Safety Showers
2. Manual water sprinklers
3. Communication systems
An Auxiliary Pump is provided as Boiler feed Pump in boiler section to feed water at failure of
main pump. Also there is an auxiliary Scrubber, which is used if there is any problem in primary
and secondary scrubber.
8.4 HAZOP OF THE PLANT:
• In case of an accident one has to blow safety Alarm.

• After blowing the Alarm try to evacuate yourself and reach to the safety point. Discuss
the problem with the safety engineer and try to follow the instruction given by the safety
engineer.
• In case of fire accident, try to control the fire using the fire extinguishers if it is in a
controllable situation, if not contact the fire brigade.
43
• In case of electrical fire, stop the electrical supply in the particular section and then try to
control the fire.
• In case of any leakage first go for the PPEs and then start the procedure for maintenance.
• If any employee is affected then immediately take him to the Occupational Health Centre
for getting the first Aid.
8.4.1. EQUIPMENT LOCATION ACCORDING TO THE WIND LOAD DIRECTION:
Plant is having four floors. And there is no any tall vertical equipment. So any equipment of plant
is not much affected by wind load.
8.4.2. SAFETY RELATED EQUIPMENT’S THEIR LOCATIONS AND REASONS:
At plant there are around 60 to 65 Nos. of fire extinguishers of different classes which can handle
fire hazards that can be possible in the plant. There are 8 nos. of self-content breathing apparatus
(S.C.B.A) ,They are located near gate and in that part of plant where chlorine gas handling is take
place .So in case of any type of leakage problem it can be easily available.
The safety team of plant is regularly take part in the safety meeting, arranged at every 3 months
and the decision taken in the meeting is carry forward to the safety inspector. This safety
committee consists of employees from various parts of the plant as a member. They are also
arranging safety programs for workers.
8.5 TYPES OF WORK PERMITS:

There are seven main types of work permits:
1. Hot Work Permits
2. Cold Work Permits
3. Confined Spaces Work Permits
4. Chemical Work Permits
5. Height Work Permit
6. Excavation Permit
7. Electrical Isolation Permit
1. Hot Work Permits:

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.
44
2. Cold Work Permits:

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.
3. Confined Spaces Work Permits:

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.
4. Chemical Work Permits:

Authorization to work with harmful chemical substances or in a chemically induced atmosphere that
is either toxic or corrosive by nature. Chemical engineers that mostly work in chemical plants and
labs.
5. 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.
6. 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.
7. Electrical Isolation Permit:

Authorization to work in high voltage zones that are prone to uncontrolled dispersion of electricity.
Common electrical isolation work is to manage and maintain Lock-out systems and site maintenance
by electrical engineers.
45
8.6 POLLUTION CONTROL MEASURES:
8.6.1. WATER POLLUTION CONTROL
EFFLUENT TREATMENT PLANT (ETP):
Effluent is any liquid waste produced during the course of various manufacturing processes in any
industry; sewage system or factory. To treat this liquid waste before discharging it anywhere requires
a series of stepwise systematic processing known as EFFLUENT TREATMENT.
It is very important to meet the ever increasing stringent emission norms of pollution control board
i.e. according to the Gujarat Pollution Control Board (GPCB), which is controlling authority that
examines the discharged treated effluent.
The treatments carried out in three stages:
1. Primary Treatment
2. Secondary Treatment
3. Carbon Treatment& Mono Air Belt Dryer
1. Primary Treatment:
The plant effluent is collected in an equalization tank from all plants. ∙ Lime salutation is prepared in
neutralizer adding final discharge water to ¾th of the tank after the lime is added as per requirement.
The pH of the equalization tank and the lime solution charged through pump in neutralizer is checked
and maintained at the pH of 10 – 20 and the same pH in primary settling tank (PST) is adjusted by
the effluent water flow and lime solution.
The pH of the solution is checked by pH paper. Alum solution in the alum tank is prepared by adding
final discharge water to ¾ th of the tank. Alum is added as per the requirement. The over flow effluent
is allowed to flow from the neutralizer tank to the flash mixer and alum solution is added by the
pump.
The over flowed effluent is allowed to flow from the flash mixer to flocculation tank by gravity
and the pH is always monitored. The treatment up to this stage is known as primary treatment.
46
In the primary treatment about 15 - 20 % of effluent gets treated.
2. Secondary Treatment:
Over flow of the PST goes to the aeration tank 1 and from there water flows to the secondary clarifier
1 by gravity. The over flow from SC 1 is pumped to the aeration tank 2 and flows to the secondary
clarifier 2 by gravity. Over flow of SC2 is collected in the underground tank.
Sludge which is collected in the secondary clarifiers has to be continuously fed bad back to the
aerator and some sludge is to be purged to sludge drying beds. The treatment to this stage is known
as secondary treatment stage and about 70 – 75 % treated effluent is obtained after secondary
treatment. The treated effluent is further pumped to the carbon bed for further treatment.
This treatment is also called Biological treatment because of the use of bacteria in the aeration tanks.
A major part of the organic waste gets degraded by the bacteria here.
3. Carbon Treatment & Mono Air Belt Dryer (MABD):

The effluent after secondary treatment is then collected in the underground tank. From the
underground tank it is pumped to the carbon tower.
In the carbon tower the activated charcoal present adsorbs the absorbable impurities and clear treated
liquid is discharged to the outlet stream of the plant. The inlet and outlet sample of the carbon tower
is given regularly for the analysis to the laboratory.
The sludge removed from the primary and secondary clarifier.
The sludge passes through the MABD.
Is allowed to dry in the sludge ponds, which then packed in polythene bags, which is then sent further
for land filling purpose.
The discharged treated effluent pH is maintained at 7-7.5.
8.6.2. AIR POLLUTION CONTROL

In PI industry the pollutant laden gas and oxides of nitrogen (NOx), oxides of sulphur (SOx) are found
in harmful concentration. The measurement of NOx and SOx is done by Quality Analysis and Quality
Control Labs. By taking samples at regular interval of time.
47
CONCLUSION
➢ This Project work is based on the manufacturing of Naphthalene Intermediate & Sulfonium
Group Derivatives. It is used as a raw material in Pharma, Agro, Pigment, Food, Paper Dye,
Ink Dye intermediates, specialty and functional chemicals.
➢ Various details of equipment’s are provided for easy understanding. Material and Energy
balance are important part of any chemical industry and through which a process is selected
and the plant is operated. Utilities are also very important in a chemical industry. An
engineer must have the knowledge about steam and cooling tower. In every industry, the
equipment’s are labeled with specific codes. These codes must be known before actually
going in the plant.
➢ Designing of equipment is one of the main role of a chemical engineer. To transport the
fluid from one equipment to another, pump along with pipelines and control valves are
required.
➢ Before going in any industry, safety instructions are given. Every industry has some safety
protocol which everyone present inside the company should follow. Plant location should be
appropriate before setting up the plant. By this statement, I mean plant should be located
where there is continuous supply of water, electricity and where transport and raw material
is easily available.
➢ With the assumed costs of each equipment, we can estimate the cost of plant along with
depreciation. And as a reference to these cost, one can estimate the cost of the actual plant
with known costs of each equipment. In the end I would like to conclude that this type of
industry is a large scale industry and requires a huge amount of investment.
48
REFERANCES
1. ASME B31.3 – (2008) Process Piping ASME Code for pressure piping, B31
2. Bharat I Bhatt, Shuchen B Thakore (2011), ‘Stoichiometry’, - McGraw hill education (India) Private
Limited Fifth Edition pp. 346-4053
3. De Dietrich process systems ‘Guidelines and procedure for spark testing glass lined equipment’
Available at: https://www.ddsinc.com Guidelines.
4. DR. K.U. Mistry(2008) Fundamentals of Industrial Safety and Health published by Siddharth
Prakashan.
5. Engineering standard for piping & instrumentation diagrams (P&IDS) original edition (oct.1996) IPS-
E-PR-230. Property of Iranian ministry of petroleum.
6. M V Joshi (1976) “ Process Equipment Design ” published by S G Wasani for The Macmillan
Company Of India Limited.
7. Unit Operation of Chemical Engineering, 7th Edition, Warren L. McCabe, Julian C. Smith & Peter
Harriott, McGraw-Hill.
49

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GROUP ID : 303751 SCET (042) SURAT

“MAHAVIR SYNTHESIS PVT. LTD.”

In partial fulfilment for the award of the degree

Gujarat Technological University, Ahmedabad

SARVAJANIK COLLEGE OF ENGINEERING AND TECHNOLOGY

This is to certify that the In-plant Training at “MAHAVIR SYNTHESIS PVT.

LTD.” has been carried out by DHRUVIL SAVALIYA (190420105061) under

my guidance in fulfilment of the degree of Bachelor of Engineering in Chemical

(4th year, 8th semester) of Gujarat Technological University, Ahmedabad during

the academic year 2022-2023.

Report Approved By:

Prof. Anand Upadhyay Prof (Dr.) Vaishali Umrigar

SARVAJANIK COLLEGE OF ENGINEERING AND TECHNOLOGY

degree of Bachelor of Engineering in Chemical Engineering to Gujarat

Technological University, Ahmedabad, is a bonafide record of original project

Name of the Student Sign of Student

CHAPTER TITLE OF CHAPTER PAGE NO.

3. PROCESS FLOW DIAGRAM 08

4. MATERIAL & ENERGY BALANCE CALCULATIONS 11

8. SAFETY & ENVIRONMENT MANAGEMENT SYSTEM 40

Figure 1.1: Mahavir Synthesis Plant Layout “Courtesy of MahavirSynthesis.com”

1.2 AWARDS & ACHIEVEMENTS:

• Gujarat State Awards for Exports in Small Scale Industries- 1992-1994

Figure 1.2: Shelf of Awards “Courtesy of MahavirSynthesis.com”

CHAPTER-2 PRODUCTION ASPECTS

Two major production plant in MSPL namely:

• Total Reactor Capacity: 210 Cu Meters

• Chlorine Storage and Handling Station with vaporize

2.2 RAW MATERIALS USED IN PLANT:

2.3 PRODUCTS PRODUCES IN THE PLANT:

2.4 UNIT PROCESSES & UNIT OPERATIONS USED IN THE PLANT:

The unit operation involve a physical change or chemical transformation

2.5 TYPES OF REACTION:

CHAPTER-3 PROCESS FLOW DIAGRAM

3.1 MANUFACTURING PROCESS OF MI002:

Figure 3.1: Process flow diagram MI-002

Figure 3.2: Process and Instrumentation diagram of Product MI-002

3.2 AMMONIA SCRUBBER SYSTEM:

Figure 3.3: Process Flow Diagram of Ammonia Scrubber System

CHAPTER-4 MATERIAL & ENERGY BALANCE

4.1 MATERIAL BALANCE:

4.2 MATERIAL BALANCE OF PRODUCT CODE MI-OO2

Fig. Material Balance of Product Code MI-OO2

Table 4.1 Material Balance of Product Code MI-OO2

INPUT UNITS OUTPUT UNITS

MI-001R 1500KG SO2 SCRUBBER 658.5 KG

CSP 2625 KG PRODUCT 1200 KG

4.3 ENERGY BALANCE:

ENERGY BALANCE OF TRAY DRYER :

❖ Cp of air = 1.014 (KJ/Kg.K)

• Rate of Evaporation (E) = 1500-1200

• Total enthalpy in = enthalpy of MI-002 in + enthalpy of water in + enthalpy of hot air in

• Total energy required = Amount of enthalpy out - Amount of enthalpy in

• Amount of propane gas required:

Energy produced per gram = 46 KJ /g

Kg propane required = Total Energy required/Energy per kg

CHAPTER-5 DETAILES OF EQUIPMENTS

5.1 OBSERVED DIFFERENT TYPES OF FILTERS:

Figure 5.1: Filter Press

2) Centrifuge Filter- A centrifuge works on the principle of centrifugal force, which is

Figure 5.2: Centrifuge Filter

Figure 5.3: Agitated Nutsche Filter

Thickness of head (Th) = PiRc W / 2fj + Ca

Blank Diameter (BD) = (Odhead + Odhead /24) + ((2Sf+2)/ (3Icr))+ Th

Internal volume (Vi) = (0.0847Di3) + (3.14/4 Di2 *Sf)

Weight of head (Whead) = (3.14/4 * BD2 Th Density of MOC)/10003

Thickness of head (Th) = PeRcW / 2fj + Ca

Blank Diameter (BD) = (ODbottom + ODbottom /24) + [(2Sf+2)/ (3Icr)] + Th

Weight of head (Whead) = (3.14/4BD2 Th*Density of MOC)/10003

Total longitudinal stress (Tlongitudinal stress) = PiDi/4Ts+PjDi (coil) / 2Tc +2PiDo2/3*Ts2

So Power Required (PR) = NpDiag5 N3 *Density