MCPI Private Limited

(Formerly MCC PTA India Corp. Private Limited)

Materials Chemicals and Intermediaries Private Limited

Summer Training Project Report

Name :- Suryarghya Mukherjee

Department :- Chemical Engineering
Title :- Centrifugal Pump Analysis & Calculation.
Year :- 3rd year
Semester :- 6th (BTech. in Chemical Engineering)
College :- Haldia Institute of Technology , Haldia
Duration :- 1 month (06.05.2024 - 05.06.2024)
 DECLARATION

I hereby declare that the Vocational training report entitled “Analysis of the hydraulic calculation
in a centrifugal pump. Mention the assumptions and losses, while doing the calculation with
future proposal for performance improvement.” is an authentic record of my own work as
requirements of Vocational training from 06.05.2024 - 05.06.2024 for the awards of summer
internship under the guidance of Mr. Sukhen Das.

Sign of Student- ……………………….

Name- Suryarghya Mukherjee

Date- 02 June 2024
Place- Haldia
 ACKNOWLEDGEMENT

It's a great and pleasant opportunity for me to gain experience as well as knowledge in the
industry. The time period that I have given at MCPI has truly motivated me and have
helped me a lot by giving me the opportunity to develop both academically and
professionally.
I would like to thank Mr. Ambar Baran Bhowmik (Vice President Production &
Planning) for his guidance through the MCPI plant, as well his explanations of specific
fields were truly helpful.
I would like to thank Mr. Jayakumar Parasuraman (Process General Manager) for his
guidance through the MCPI plant, as well his explanations of specific fields were truly
helpful.
I would like to thank Mr. Durga Madhab Panigrahy (Process General Manager) for his
guidance through the MCPI plant, as well his explanations of specific fields were truly
helpful.
I would like to thank Mr. Sukhen Das (Process Senior Manager) who overview the
internship as my project guide. I am very grateful for his help in explaining all the
technicalities of the plant functions and his guidance for the project.
I would like to extend my heartfelt gratitude to Mr. Siddhant and Ms. Ankita (Process
Engineer) for their detailed explanations of the equipment’s, machines, and processes
during our field visits.
I would like to express my gratitude to Mr. Subhomoy Das (HR Department). His
guidance and assistance during the internship period in solving any difficulty was truly
appreciated.
In addition to the mentioned above, I would also like to thank all the employees and staff
members at MCPI, for their assistance. Their guidance has helped us a lot in preparing us
for the future. It would not have been possible to gain all the experience and knowledge
without their help.

1
2
 CERTIFICATE

This is to certify that the work contained in the project titled “Analysis of the hydraulic
calculation in a centrifugal pump. Mention the assumptions and losses, while doing the
calculation with future proposal for performance improvement.” has been carried out by Mr.
Suryarghya Mukherjee under our supervision and can be presented in his university for
academic purposes.

…………………………………………………………

Signature of Supervisor
Name: - Mr. Sukhen Das
Department: - Process
MCPI, Haldia

3
 Contents
Page No.

1. Introduction to MCPI 1-3

2. Product and its application 4-5
3. 5S and Safety 6-15
4. CTA Section and PTA Section Flow diagram 16-18
5. Details about the process 19-24
6. Equipment
A. Pump 25-26
B. Blowers and Compressors 26-28
C. Crystallizers 28
D. CSTR 29
E. Shell and Tube Heat Exchangers 29-30
G. Centrifugal Decanter 30-31
H. Conveyor 31-33
I. Valves 33
J. Dryer 33-35
L. Horizontal Belt Filter 35
M. Cooling Tower 36
N. Storage and Conveying of Solids 36-37
7. Main Project 1
A. Centrifugal Pump Analysis Calculation 38-40
B. Conclusion 41

8. Main Project 2 42-51

9. Main Project 3 52-55
10. Bibliography 57
11. Abbreviation 58

1
 INTRODUCTION TO MCPI

 MCPI AT A GLANCE:
MCPI Private Limited is part of The Chatterjee Group (TCG) having interests in Petrochemicals,
Pharmaceuticals, Biotech, Financial Services, Real Estate and Technology sectors in the US,
Europe and South Asia. Till very recently, MCPI was an affiliate of Mitsubishi Chemical
Corporation, Japan (MCC), and a Fortune 500 company. Pursuant to a decision by the
management of MCC, the majority ownership of the Company was transferred to the New York
based The Chatterjee Group (TCG) in November, 2016.

MCPI, with its registered office in Kolkata, was incorporated in 1997 to produce and market
Purified Terephthalic Acid (PTA) at its manufacturing unit in Haldia. The 1st unit in its
manufacturing facility started commercial operations in April 2000, while the 2 ndunit started
commercial operations in March 2010. The total investment in the plant over the years stands at
around Rs. 4,000 crores.

While TCG holds 99.4% stake in the company’s equity and WBIDC 0.6%.MCPI’s endeavour is to
integrate the technology expertise inherited from MCC, Japan with the indigenous talent,
knowledge and human resource along with the market potential in India to consolidate its identity
and emerge as a leading player in the polyester and PTA industry in India.

 COMPANY PROFILE:

Business Manufacturing and selling Purified

Terephthalic Acid (PTA)

Capacity 470,000 tons per annum [Phase I]

800,000 tons per annum [Phase II]

Plant Location Haldia,

Purba Midnapore,
West Bengal
Main Raw
Materials Paraxylene (PX), Acetic Acid (Solvent)

Commercial April 2000 [Phase - I]

Operation March 2010 [Phase - II]

1
 GREEN BELT:
The MCPI Phase-I and Phase-II plants and a green belt of 104 acre are situated within an
approximate area of 324 acres of land.
Seasonal bio diversity study in MCPI’s green belt with respect to various birds and plants was
conducted by West Bengal Biodiversity Board.
The observation related to biodiversity is as follows:

 The green belt houses around 130 species of plants and 12 species of fruit plants with some
horticulture varieties are planted. There are 4 species of plants which seems to be wild crops.
 The water bodies harbour the diversity of flora with different growth forms and several serial
stages of ecological succession. More than 48 plant species have medicinal potentialities
published documents.
 35 bird species are recorded during the visit, 24 butterfly and 12 dragonfly species were
identified in the green belt 3 mammals were spotted in the green land.

Trees filter particulates and are effective as sink of pollutants. Trees also reduce
noise level and regulate the oxygen balance in the area by consuming released carbon dioxide.
Hence, green development shall be part of pollution control measure adopted in the open spaces in
the plant area.

The major highlights of green belt are:

 130 species plants (Trees, Scrubs & Herbs)
 12 species of fruit plants.
 48 medicinal plants.
 35 bird species out of which two species are rare.
 03 mammals were spotted.
 01 reptile found (Varanus Salvator).
 24 Species of Butterflies and 12 species of Dragon Flies.

The major purposes of the green belt are:

 Protect natural or semi natural environments.

 Improve air quality within urban areas.
 Ensure that urban dwellers have access to countryside, with consequent educational and
recreational opportunities.
 Protect the unique character of rural communities.

The benefits of green belt are:

 Proper habitat network for wild plants, animals and wild life.
 Cleaner air and water.
2
 Better land use of areas within the bordering cities.

Wildlife at green belt of MCPI private limited

3
 Product

The product of MCPI Private Limited, Haldia, which is majorly a Business-to-Business Company,
is Purified Terephthalic Acid (PTA).

PTA is a commodity chemical, primarily used in the manufacturing polyester PET, plastic bottles
and clothing. It has also been used in drug research. Applications also exist in the engineering
fields, and it is used in the military as well.
Its toxicity is very low, and has a molecular weight of 166.13

 Main Applications

⮚ Raw material and feed in Poly-Ethylene Terephthalate (PET) production.

⮚ Base reagent in wool spinning factories.

⮚ Additive in animal feed preparation

⮚ As a lubricant in the preparation of industrial adhesives

⮚ The main consumption of terephthalic acid is in production of saturated linear polyester resins
used in production of bottles, thin films and polyethylene terephthalate (PET) fibers.

p-Xylene (PX) Acetic acid

4
PTA Powder

5
 5S AND SAFETY

 5S AND ITS NECESSITY

5S is a system for organizing spaces so work can be performed efficiently, effectively, and safely.
This system focuses on putting everything where it belongs and keeping the workplace clean,
which makes it easier for people to do their jobs without wasting time or risking injury.

The term 5S comes from five Japanese words:

 Seiri
 Seiton
 Seiso
 Seiketsu
 Shitsuke

In English, these words are:

 Sort: Clearly distinguish needed items from unneeded items and remove them.
 Set in Order: Keep needed items in the correct place.
 Shine: Keep the workplace clean and polished.
 Standardize: Make the best practices as per standard.
 Sustain: Make a habit of maintaining the above & develop proper discipline.

Benefits:

 Reduced set up times.

 Increased floor space.
 Safer working area.
 Lower cost and higher quality

5S 6S:
1. Sorting Out
2. Systematic Arrangement.
3. Shine.
4. Serene Atmosphere.
5. Stick to self-discipline.
6. Safety

6
 KIKEN YOCHI (KY)
Kiken Yochi (hazard prediction) training, is a Japanese activity used to motivate members to
recognize and predict hazards. It develops sensitivity to unsafe conditions or hazardous situations.
Thus, improving the ability to better recognize.

 The activity forces the worker to think about the consequences of an accident.
 This activity increases the motivation of workers to practice in teams.
 It uses meetings to sharpen awareness of what constitutes danger.
 Members share information on hazards and improve their problem-solving capabilities by
working to find solutions during this short meeting.
 The primary goal of KY is to increase our member’s awareness of potential hazards.
 Through this activity members take the time to STOP and THINK about what could
happen. Building awareness prevents injuries.
 This activity requires a minimal amount of training to be able to understand.
 Members are trained in hazard recognition by using in-house situations

KY-CALLS:

 MONDAY : Safety First Yosh

 TUESDAY : Use proper PPE
 WEDNESDAY : Hold the Hand rail
 THURSDAY : Watch every step
 FRIDAY : LOTO before hand over
 SATURDAY : Point & Call
 SUNDAY : Do not touch rotating equipment

 NON-VIOLABLE RULES OF MCPI PLANT:

1. Prohibited Activities: Smoking, chewing tobacco & carrying lighter/match box is strictly
prohibited inside factory premises except designated places.
2. Entry to Plant: Unauthorized entry inside plant battery limit is strictly prohibited.
3. Vehicle Safety: Maintain speed limit up to 20 km/hr &use of spark arrester is mandatory in
vehicles inside plant battery limit.
4. Information Reporting: All accidents/incidents must be reported to plant management.
5. Communication: Mobile phone must be kept switched-off condition inside plant battery limit.
6. General PPE: Use of helmet, safety shoe, full sleeve dress & safety spectacles inside plant
battery limit is mandatory.
7. Height Work: Full body harness & proper access (ladder) is mandatory.
8. Confined space work: Spotter, gas testing & full body harness are mandatory.

7
9. Hot work: Isolation of combustible / flammability material is mandatory and hot work to be
confined.

SAFETY CALLS:
1. Safety comes first.
2. Obey and comply all regulations.
3. Conduct all operations in a safe way.
4. Develop & Improve awareness/consciousness.
5. Follow CAPD cycle.
6. Improve/Follow/Review Shutdown safety rules.

8
 HEALTH MANAGEMENT SYSTEM:
MCPI’s Health Management System implements and maintains the best possible occupational
health and hygiene practices. It correlates health indices with the prevailing work environment to
enhance health and productivity of its employees. The Company boasts of a fully functional
Occupational Health Centre which provides 24 hours medical and emergency service. The health
Centre is stocked with the latest medicines to cater to emergencies and is equipped with advanced
medical equipment and facilities, including dressing and stitching facilities, lung function testing
machine, audiometry machine, ECG Machine among others. The health Centre conducts health
surveys, statutory pre-employment and periodic health check-ups, first-aid trainings, health
awareness campaigns, eye check-up, blood donation camps, etc. throughout the year.

 ENVIRONMENT MANAGEMENT SYSTEM

MCPI’s Environment Management System reflects the Company’s commitment towards the
Environment and its policy of strict compliance with the statutory environmental norms laid down
by the State Pollution Control Board as well as those by the Ministry of Environment, Forest and
Climate Change (MOEF & CC), Government of India. Processes like waste water treatment,
online ambient air monitoring system, rain water harvesting, co-processing of Hazardous Waste
along with maintenance of greenery and protection of bio-diversity provides a holistic approach
towards maintenance of the Environment. Activities like 5S, Environment Day Celebrations, CSR
Training programs on Environment to local school & college students are some further steps
towards creating awareness on preserving the environment.
Some of the salient features of our Environment Management System are:

 Process Technology employing.

 Low utility consumption as by-product energy even in low level from the process is
effectively recovered.
 High yield of product from Raw materials.

9
  Low solvent & catalyst consumption.
 Recovery & recycling of products.
 Incinerator for burning waste water treatment sludge & Process sludge.
 ESP for treatment of Incinerator flue gas before emission.
 Low NOX burner installed for controlling NOX emission at source.
 Scrubbers for treating Process off-gas before emission at source.
 Activated sludge with diffused aeration system for Wastewater Treatment.
 Storage of Hazardous Wastes in Integrated Scrap Yard which are finally disposed to
Licensed Treatment Storage Disposal Facility at Haldia.
 Oil separators for arresting any oil spillage.
 Well-equipped Environmental Monitoring Laboratory facility.
 104 acres of Green Belt.
 Signatory of Responsible Care (RC) program.
 Bio-diversity Study of our Green Belt done.

ENVIRONMENT:
1. Zero leakage & zero smell.
2. Solid, Liquid & Gaseous waste reduction.
3. Maintain Regulations.

 HIERARCHY OF CONTROL:
1. Elimination.
2. Substitution.
3. Engineering Control.
4. Administrative Signage

10
 PERSONAL PROTECTIVE EQUIPMENTS (PPE):
Personal protective equipment (PPE) is protective clothing, helmets, goggles, or other garments or
equipment designed to protect the wearer's body from injury or infection. The hazards addressed
by protective equipment include physical, electrical, heat, chemicals, biohazards, and airborne
particulate matter. Protective equipment may be worn for job-related occupational safety and
health purposes, as well as for sports and other recreational activities. "Protective clothing" is
applied to traditional categories of clothing, and "protective gear" applies to items such as pads,
guards, shields, or masks, and others.
The purpose of personal protective equipment is to reduce employee exposure to hazards
when engineering controls and administrative controls are not feasible or effective to reduce these
risks to acceptable levels. PPE is needed when there are hazards present. PPE has the serious
limitation that it does not eliminate the hazard at the source and may result in employees being
exposed to the hazard if the equipment fails.
Any item of PPE imposes a barrier between the wearer/user and the working environment. This
can create additional strains on the wearer; impair their ability to carry out their work and create
significant levels of discomfort. Any of these can discourage wearers from using PPE correctly,
therefore placing them at risk of injury, ill-health or, under extreme circumstances, death. Good
ergonomic design can help to minimise these barriers and can therefore help to ensure safe and
healthy working conditions through the correct use of PPE.

11
 IMPORTANCE OF SAFETY IN INDUSTRIES:
Workplace safety is very important for every employee in the industry because all the workers
desire to work in a safe and protected atmosphere. Health and safety are the key factor for all the
industries in order to promote the wellness of both employees and employers. It is the moral
responsibility of the company to look after the employee’s protection.

 Aware about the surroundings

 Reduce workplace stress
 Use tools appropriately
 Keep crisis exits which are easily accessible
 Update the Supervisor about the unsafe conditions
 Use mechanical assistance

 TYPES OF HAZARDS:

 Working at height
 Poor housekeeping
 Electrical – Extension cords
 Lockout/tag out
 Chemicals
 Confined spaces
 Fall
 Machine guarding
 Powered Industrial Trucks

12
 HANDLING OF CHEMICALS:
The accidents in which chemicals are leaked into the environment can considerable consequences
for a company, not least of which is that they lose trust capital. The chemicals leakage also causes
huge adverse effect to environment causing environmental pollution.

Here are some ground rules that can be useful to have while at work to ensure safe handling of
chemicals:
 Keep track of which chemicals are being used in the business. Keep a list of the substances, the
amounts being used and the risks associated with them. You can read more in Taking
inventory.
 This also applies to gathering information and distributing it to those who need it. Current
safety data sheets are one condition. Read more in Safety data sheets
 Storing and using chemicals in a safe way is a further foundation for working with chemicals.
This introduction deals with this.
 In continuing risk reduction work it is necessary to decide whether a particular chemical is
really needed. All chemical products must be stored and labelled in accordance with the
instructions on the safety sheet
 Chemicals must not be stored together with inflammable material and gas cylinders.
 Do not store acids and alkalis together.
 Do not store strong acids and organic substances together.
 Do not store strongly oxidizing substances together with oxidizable substances.
 Ethers and other peroxide-building substances must be stored in the dark and cool, in tightly
sealed containers.
 Chemical containers must be stored with closed lids when they are not being used.
 Refrigerators and freezers for storage of chemicals must be of such a type that is specially made
for this purpose. Chemicals and similar items must not be stored in refrigerators or freezers that
are intended to store food.
 Chemical stores must not have open floor drains. If there is a floor drain, it must be equipped
with protection to prevent leakage. This means for example tight fitting lids, a manual opening
and closing function in the drain or other comparable arrangement.

13
 MATERIAL SAFETY DATA SHEET (MSDS):
MSDS is a document that contains information on the potential hazards (health, fire, reactivity and
environmental) and how to work safely with the chemical product. It is an essential starting point
for the development of a complete health and safety program. It also contains information on the
use, storage, handling and emergency procedures all related to the hazards of the material. The
MSDS contains much more information about the material than the label. MSDSs are prepared by
the supplier or manufacturer of the material. It is intended to tell what the hazards of the product
are, how to use the product safely, what to expect if the recommendations are not followed, what
to do if accidents occur, how to recognize symptoms of overexposure, and what to do if such
incidents occur.

The Purpose of the Data Sheet

The data sheet is the second element of the WHMIS information delivery system and is intended
to supplement the alert information provided on labels. The third element of the system is the
education of employees in hazard information on controlled products, including instruction in the
content and significance of information on the MSDS.

Information on the MSDS:

 Product Information: product identifier (name), manufacturer and supplier’s names,
addresses, and emergency phone numbers.
 Hazardous Ingredients.

 Physical Data.

 Fire or Explosion Hazard Data.

 Reactivity Data: information on the chemical instability of a product and the substances it
may react with.

 Toxicological Properties: health effects.

 Preventive Measures.

 First Aid Measures.

 Preparation Information: who is responsible for preparation and date of preparation of

MSDS

14
 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA):

The National Fire Protection Association (NFPA) is a global self-funded non-profit organization,
established in 1896, devoted to eliminating death, injury, property and economic loss due to fire,
electrical and related hazards.
The National Fire Protection Association (NFPA) is a United States trade association, albeit with
some international members, that creates and maintains private, copyrighted standards and codes
for usage and adoption by local governments. Its purpose was to standardize the then-new fire
sprinkler systems. In 2018, the NFPA claims to have 50,000 members and c. 9,000 volunteers
working with the organization through its 250 technical committees.

NFPA RATING OF SOME CHEMICALS IN MCPI

Para-xylene

Acetic Acid

15
Sulphuric Acid

Chemical Reaction Formulae

The raw materials required for the production of PTA are: para-xylene (PX), Acetic Acid
(Solvent) and oxygen, which is obtained from air.

Oxidation of Para-xylene (CTA Stage):

Main reaction
CH3-C6H4-CH3 + 3O2  COOH-C6H4-COOH + 2H2O
(Para- xylene) (Terephthalic acid)

Side Reaction
CH3-C6H4-CH3 + 10.5O2  8CO2 + 5H2O
CH3COOH + 2O2  2CO2 +2H2O
2CH2COOH  CH3COOCH3 + CO + H2O

Main Impurities
1) COOH-C6H4-CHO (4-Carboxyl Benz Aldehyde)
2) COOH-C6H4-CH3 (p-Tolueic acid)
3) COOH-C6H5 (Benzoic acid)

Purification of CTA (PTA Stage):

COOH-C6H4-CHO + 2H2  COOH-C6H4-CH3 + H2O

16
 CTA BLOCK FLOW DIAGRAM:

Air PX HBr From PTA unit

CATALYST

Steam Air Compressor Off Gas

Turbine Turbine

HAC MA
High
Pressure
Absorber
Mother
Liquor

Oxidation
Reaction
Dehydration
Distillation
By-produced
Steam
Solvent Waste
Crystallization Recovery Water

Catalyst Regeneration
Filtering
Separation

17
Drying New
Catalyst

CTA

18
PTA BLOCK FLOW DIAGRAM

Water CTA

Slurry Preparation

Pre-Heating

Reaction Hydrogen (H2)

Crystallization
Steam

Re-slurry Waste
Centrifugal Separation Water

Drying To CTA Acetic

Unit Acid

Pure PTA
Powder

19
 Details about the Process

 Main Raw material is Para-Xylene

 CTA Preparation Process is an exothermic process.

 Exothermic process gives out heat which can utilized for other purposes, and heat should not
be released directly into the atmosphere because that may create environmental hazards.

 So the heat released can be utilized in carrying out the endothermic reactions

I) DP Plant

 This plant has been in operation since 2000 (April) the time when the company started its
operation for the first time. Operation Making of this DP Plant is Mitsubishi Heavy Industries.
II) HP Plant

 This plant has been in operation since 2010 (April). It has been installed a decade after the DP
Plant started its operation. Operation Making of this HP Plant is Siemens Germany.

There are two sections in each plant.

I) Crude Section
II) PTA Section

But both the sections CTA and PTA can be run parallelly only for a short period of time because
we store the crude CTA in a small amount.

● Crude Section Reaction is an Exothermic Reaction

● Purification of Crude Terephthalic acid Section reaction is a Hydrogenation Reaction which is an

Endothermic Reaction.

 Oxygen is taken from ambient air.

 Oxidation reactions is taking place in certain conditions not in ambient conditions.

20
  The air must be pressurized, and it is pressurized using compressor.

⮚ Compressor is the heart of the plant. 4 stage compressor is used in HP Plant.

 The outlet pressure is taken at such a stage whose pressure is higher than the pressure required
for the reaction.
 The way through which the compressed ai is supplied may lead to frictional losses thereby
reducing its pressure at the inlet of the oxidation reactor.
 Initial compressor is run by motor which takes electricity.
 Once the plant comes in operation condition then we get some energy from the plant to run the
motor. Reuse of waste heat
 Waste heat is utilized to produce steam by adding water, then steam is taken into rotate the
turbine.
 Compressor means a shaft which must be rotated.
 If we can couple this shaft with the rotating turbine then that rotating turbine can rotate the
compressor.

21
 Finally, the flue gas after giving a good amount of heat almost no energy left in it that flue gas
(contains a little amount of energy) is introduced into a gas turbine.

Gas turbine also known as gas expander. Pressure gets lowered and the gas expands that is the
boiling takes place at lower temperature only.

 Flue gas is taken through a heat exchanger. Gas passes through the tube. Water is taken in
shell side.
 Water gets heated up, and forms steam.
 Gas contains traces amount of acetic acid, moisture. This gas is taken into a condenser pot.
 There are a series of heat exchangers.
 After passing through heat exchanger low energy flue gas is taken into a expander.
 The heat exchanger is known as Boiler.

Series of heat exchanger according to the decreasing order of temperature

T1>T2>T3>T4 and so on.

22
When temperature gets reduced, and the water has to be boiled at that reduced temperature then
the pressure must be lowered. The water will start to boil at low temperature only after reducing
the pressure.

Turbine has different section,

I) One section for the induction of high-pressure steam.

II) One section for the induction of low of low-pressure steam.
III) Another section for the induction of vacuum-steam.

Difference between HP and DP Plant.

CTA Section

HP Plant:
Supply of huge amount of steam, which is enough to rotate the motor of compressor, but then
even so much of heat energy left that the compressor can be converted to a generator.

23
So much amount of steam is there that we can generate electricity in the H.P Plant. Earlier in the
operation of DP Plant we were reducing the amount of power taken from the electricity board
thereby reducing the amount of power required saving the cost. But now in the operation of HP
Plant even after reducing the electricity requirement of the compressor electricity can even be
generated.

Then a synchronous motor is made inside the compressor in the HP Plant. At a time, it can work
as a motor as well as generator at another time. This generation of electricity mechanism is
present in HP plant but not in DP Plant.

Electricity generation Capacity in HP Plant: - 10-11 MW/ hour.

DP Plant PTA Production Capacity 470 kiloton/ year.

HP Plant PTA Production Capacity 800 kiloton/year.

CTA Section reaction.

Raw material: - Para Xylene
Solvent: - acetic acid
Promoter: - HBr
Catalyst: - Cobalt Acetate, Manganese Acetate.

This CTA reaction is same for both the DP Plant as well as HP Plant.
In HP Plant.
L/D <1 (because it is of high capacity)
H.P Plant is of ellipsoid shape in nature.
For CTA Section reaction both the plants use CSTR.
Drawback of L/D<1.Escape velocity of toxic gas particles is high and it can come out easily so
operation should be carried out carefully.

Reactor

Operates at a pressure lower than the pressure at which reactor—I operates.

24
 DP Plant Contains Crystallizer.
Reactor --- I: - Liquid to slurry.
Reactor --- II: - Slurry gets denser.

HP Plant does not contain Crystallizer. HP Plant contain reactor—I then reactor--- II.
DP Plant contain reactor—I then reactor--- II then consecutive 4 crystallizers.
Dry CTA powder is required.
1)DP Plant contains filter, which filters out the liquid from the solid. But after passing from the
filter the solid is wet in nature. Liquid filtered out is again going back to the reactor for recycle
process.

2)To dry the wet solid steam tube dryer is used. Boiler steam is utilized in dryer. In tube side wet
powder is taken. Shell side contains steam.

Dryer will choke if remain stationary, so dryer should always be rotated at an inclined angle

Catalyst Recovery in CTA Section:

 Appropriate quantities of make-up cobalt acetate, manganese acetate and HBr solution from
the storage tanks are fed with a small amount of dilution material from Atmospheric Scrubber
Bottom Pump into the oxidation mother liquor via the suction of t
 he Mother Liquor Pump.
 The bulk of the catalyst feed comprises recycled catalyst metals together with other materials
recovered from the CTA Residue Recovery Unit which is fed to Mother Liquor Drum.

25
 PTA Section

PTA is kept in large silo bags. Some amount of crude T.A is kept in storage so that we can carry
out the PTA section for some days even if CTA section goes out of operation.

Solvent: - Water
Catalyst: Pd and C

Palladium is impregnated on charcoal this catalyst is totally packed in packed bed reactor.
Solid C.T.A is dissolved into water. In C.T.A plant we dry the CTA because liquid CTA contains
acetic acid, which must not enter into PTA section.
To remove acetic acid from CTA we dry the liquid CTA in CTA section. In CT.A section acetic
acid carries moisture.
In PTA section water carries moisture. So acetic acid must be prevented from entering into the
PTA section.
The reaction taking place in PTA section is endothermic.
We give heat thereby temperature rises as a result pressure also rises.

CTA 15.5 kg/cm2 gauge.

PTA 76-78 kg/cm2 gauge.

Dissolved CTA in water is then passed through a series of pre-heaters. Gradually, temperature is
increased in series of pre-heaters and dissolved CTA gets more and more dissolved. Finally, we
get a very dilute solution of CTA in water.
This solution is then passed through PTA packed reactor. Hydrogen is also passed.
Hydrogen is prepared in MCPI plant only by steam cracking of methanol Zn-Cu catalyst. MCPI
do not buy hydrogen from outside.
Reduction Reaction is taking place in PTA
Redox reaction is taking place in hydrogen preparation cracking of methanol. Since it is passed
through a bed of reactor no more reactor is needed to carry out this reaction.
Again, we have to go for crystallization to get the solids i.e., to separate the liquid from solid.

26
 Crystallizer order. I II III IV
From such a high pressure to get down to low pressure we require a very large vessel which is not
economical. So, step by step pressure is reduced. These 4 crystallizers are installed in both the
plants.
76 kg/cm2 gradually gets reduced to 5.5-6 kg/cm2. (Pressure reduction)
Drop in 72 kg/cm2. To reduce the high pressure into such a low pressure we use a series of
crystallizers. Like this
76 kg/cm2

40 kg/cm2 22.5 kg/cm2 12.5 kg/cm2 5 kg/cm2

Reduction in pressure so it will give out heat that heat is utilized in another process going inside
the plant. Solution preparation stage uses heat there we will use the heat rejected by crystallizer.

1.At the latest stage, before entering into final chamber, 288-275oC must be reached.
2. Heat or vapours from crystallizer is not enough to produce that amount of temperature. So, at
the latest we have to use something else which is above 280 oC so it may create a temperature
difference driving force.
3. We use a thermic fluid. Temperature of thermic fluid kept at 320 oC After passing through series
of crystallizer it is passed through a series of decanter. Liquid part is taken into recycle plant.
4. Solid part is taken into dryer (Static dryer). Fluidized Bed Dryer is used in PTA.
5.Inert gas is heated. Bed contains a few holes in it.
6.Hollow steam plates are installed inside. Wet power is given as feed. Wet powder will not settle
down because we are applying hot inert gas it will create a bubbling phase.
7. Wet powder will collide with the steam plate and leave the moisture, zig-zag motion is initiated
through the alternate holes on the steam plate.

Product Dry Powder

Dry powder is packed. Binary distillation takes place in DP Plant to separate acetic acid and
water.77 trays are there. Number of trays are more in DP Plant distillation column. Residue water
must contain acetic acid as low as possible. Acetic acid is costly. Residue wastewater contain
acetic acid =0.9% or 0.8 %. (700-800 ppm).

HP Azeotropic Distillation.
So, size of installation column has reduced A entrainer is introduced into the solution.
Water Acetic acid, Entrainer ----NBA (Entrainer varies company-wise)
MCPI uses NBA
Para-Xylene itself is an entrainer. Entrainer is used to reduce the boiling point of solution. So, the
acid content in residue water decreases. (400 ppm, 500 ppm, 600ppm)
27
 Steam requirement for boiling the feed also decreases i.e., the steam requirement for distillation
decreases. Mo of trays has been reduced as packings are introduced (40-45).

FCB Flexible Container Bags

Within F.C.B products are packed, or big container are used to pack the product.
Inside the crystallizer agitator is used to prevent the crystals from settling down.

Solid-Liquid Separator (Decanter)

It is a centrifugal separator. In the place of crystallizer, we use decanter in H.P. Plant. D.P. plant
also contains one decanter but not in crude section decanter is present in the P.T.A section.
H.P Plant contains hybrid decanter. Horizontal decanter+ Super decanter.
Product from Reactor—II directly enter into hybrid decanter at high pressure. Heavy particles
settle down inside the decanter. Vessel is made which is at a slight negative pressure.
High pressure product from decanter enters into the vessel at a low pressure. Due to high pressure
difference a flushing will take place. Moisture will immediately evaporate due to flushing. Powder
gets dried.
In the place of steam tube drier which is present in the DP. Plant In HP Plant we use a large
vessel.
1)No steam heating is required.
2)No rotation is required.
Nothing, only a large vessel is installed.

28
 Equipment functioning in MCPI- PTA Plant

 Centrifugal Pumps
In this major class of pumps, the mechanical energy of the liquid is increased by centrifugal
action. A simple but very common, example of a centrifugal pump is shown in the Figure. The
liquid enters through a suction connection concentric with the axis of a high-speed rotary element
called the impeller, which carries radial vanes integrally cast in it. Liquid flows outward in the
spaces between the vanes and leaves the impeller at a considerably greater velocity with respect
to the ground than at the entrance to the impeller. In a properly functioning pump, the space
between the vanes is completely filled with the liquid flowing without cavitation. The liquid
leaving the outer periphery of the impeller is collected in a spiral casing called the volute and
leaves the pump through a tangential discharge connection. In the volute the velocity head of the
liquid from the impeller is converted to pressure head. The power is applied to the fluid by the
impeller and is transmitted to the impeller by the torque of the driveshaft, which usually is driven
by a direct-connected motor at s constant speed, commonly art 1,750 or 3,450 rpm.

Figure: Centrifugal Pump

 Multistage Centrifugal Pumps

Usage inside the P.T.A Section of H.P Plant: - Booster pump is used to increase the pressure head
of the slurry coming from the pump in-stalled just after the slurry tank. Booster pump is there just
before the pre-heaters, the slurry after passing through the booster pump directly goes into the pre-
heaters.
The maximum head that is practicable to generate in a single impeller is limited by the peripheral
speed reasonably attainable. A so-called high energy centrifugal pump can develop a head of more
than 650 ft (200 m) in a single stage; but generally, when a head greater than about 200ft (60 m) is
needed, two or more impellers can be mounted in series on a single shaft and a multistage pump so
obtained, the discharge from the first stage provide suction for the second, the discharge from the

29
second provides suction for the third, and so forth. The developed heads of all stages add to give a
total head several times that of a single stage.

 Reciprocating pumps
Piston pumps, plunger pumps, and diaphragm pumps are examples of reciprocating pumps. In a
piston pump, liquid is drawn though an inlet check valve into the cylinder by the withdrawal of a
piston and then is forced out through a discharge check valve on the return stroke. Most piston
pumps are double acting with liquid admitted alternatively on each side of the piston so that one
part of the cylinder is being filled while the other is being emptied. Often two or more cylinders
are used in parallel with common suction and discharge headers, and the configuration of the
piston is adjusted to minimize fluctuations in the discharge rate. The piston may be motor-driven
through reducing gears, or a steam cylinder may be used to drive the piston rod directly. The
maximum discharge pressure for commercial piston pumps is about 50 atm.

 Blowers and Compressors

When the pressure on a compressible fluid is increased adiabatically, the temperature of the fluid
also increases. The temperature rise has a number of disadvantages, Because the specific volume
of the fluid increases with temperature, the work required to compress a pound of fluid is larger
than if the compression were isothermal. Excessive temperature leads to problems with
lubricants, stuffing boxes, and materials of construction. The fluid may be one that cannot
tolerate high temperatures without decomposing.
For the isentropic (adiabatic and frictionless) pressure change of an ideal gas, the temperature
relation is using Equation,

Where,
Ta, Tb = inlet and outlet absolute temperatures, respectively
pa, pb = corresponding inlet and outlet pressures
30
 = ratio of specific heats cp/cv

For a given gas, the temperature ratio increases with an increase in the compression ratio p b/pa.
This ratio is the basic parameter in the engineering of blowers and compressors. In blower with a
compression ratio below about 3 or 4, the adiabatic temperature rise is not large, and no special
provision is made to reduce it. In, compressors, however, where the compression ratio may be as
high as 10 or more, the isentropic temperature becomes excessive. Also, since actual compressors
are not frictionless, the heat from friction is absorbed by the gas, and temperatures well above the
isentropic temperature are attained. Compressors, therefore are cooled by jackets through which
cold water or refrigerant is circulated. In small cooled compressors, the exit gas temperature may
approach that at the inlet, and isothermal compression is achieved. In very small ones, air cooling
by external fins cast integrally with the cylinder is sufficient. In larger units, where cooling
capacity is limited, a path different from isothermal or adiabatic compression, called polytropic
compression is followed.

 Centrifugal Compressors
Usage inside the C.T.A Section of H.P Plant: - Centrifugal Compressor is used to compress the
ambient air and increase the pressure up to 1.75 MpaG and pass the compressed air to the CSTR
oxidation reactor where the oxidation of para-xylene takes place.
Centrifugal Compressors are multistage units containing a series of impellers on a single shaft
rotating at high speeds in a massive casing. Internal channels lead from the discharge of one
impeller to the inlet of the next. These machines compress enormous volume of air or process gas
----- up to 200,000 ft3/min (340,000 m3/h) at the inlet—to an outlet pressure of 20 atm. Smaller-
capacity machines discharge at pressure up to several hundred atmospheres. Interstage cooling is
needed on the high-pressure units. Figure shows a typical centrifugal compressor.
Axial-flow machines handle even larger volume of gas, up to 600,000ft 3/min (1*106 m3/h), but at
lower discharge pressure of 2 to 12 atm. In these units the rotor vanes propel the gas axially from
one set of vanes directly to the next, Interstage cooling is normally not required.

31
 Centrifugal Blowers
A single-stage centrifugal blower is shown in Figure. In appearance it resembles a centrifugal
pump, except that the casing is narrower and the diameters of the casing and discharge scroll are
relatively larger than in centrifugal pump. The operating speed is high--- 3,600 rpm or more.
High speeds and large impeller diameters are required because very high heads, in meters or feet
of low-density fluid, are needed to generate modest pressure ratios. Thus, the velocities appearing
in a diagram like Figure are for a centrifugal blower, approximately 10 times those in a
centrifugal pump.

Fig: Single suction Centrifugal Blower

 Crystallizers
Usage in the M.C.P.I Plant: - Crystallizers are used in series in the C.T.A section of the D.P Plant
and also in the P.T.A section of both H.P Plant as well as D.P Plant. This is used to get the
crystals of C.T.A or P.T.A. It converts the highly diluted solution to a concentrated one.
Most crystallizers utilize some form of agitation to improve growth rate, to prevent segregation
of supersaturated solution that causes excessive nucleation, and to keep crystals in suspension
throughout the crystallizing zone. Internal propeller agitators may be used, often equipped with
draft tubes and baffles, and external pumps also are common for circulating liquid or magma
through the supersaturating or crystallizing zones. The latter method is called forced circulation.
One advantage of forced-circulation units with external heaters is that several identical units can
be connected in multiple effect by using the vapor from one unit to heat the next in line. Systems
of this kind are evaporator-crystallizers.

32
 Continuous Stirred Tank Reactor
A Continuous Stirred Tank Reactor (CSTR) is a reaction vessel in which reagents, reactants and
often solvents flow into the reactor while the product(s) of the reaction concurrently exit(s) the
vessel. In this manner, the tank reactor is considered to be a valuable tool for continuous chemical
processing.
CSTR reactors have effective mixing and perform under steady-state with uniform properties.
Ideally, the output composition is identical to composition of the material inside the reactor, which
is a function of residence time and reaction rate.
In situations where a reaction is too slow or when
two immiscible or viscous liquids are present
requiring a high agitation rate, several Continuous
Stirred Tank Reactors (CSTRs) may be connected
together forming a cascade.
A Continuous Stirred Tank Reactor (CSTR) assumes
ideal mixing.

CSTRs are most commonly used in industrial

processing, primarily in homogeneous liquid-phase
flow reactions where constant agitation is required.
However, they are also used in the pharmaceutical
industry and for biological processes, such as cell
cultures and fermenters.

 Shell and Tube Heat Exchangers

Usage in the M.C.P.I Plant: - Shell and Tube Heat Exchangers has a wide role to play in the
whole process. The preheater unit contains a total of 7 shell and tube heat exchangers arranged
in series. Boiler which is used to produce the steam to rotate the turbine is also a shell and tube
heat exchanger.
In M.C.P.I Plant preheater 1-2 Shell and tube pass heat exchangers are used. An even number
of tube side passes are used in multi-pass exchangers. The shell side may be either single-pass
or multi-pass. A common construction is the 1-2 parallel-counterflow exchanger, in which the
shell-side liquid flows in one pass and the tube side liquid in two passes. Such an exchanger is
shown in the Figure. The tube-side liquid enters and leaves through the same head, which is
divided by a baffle to separate the entering and leaving tube-side streams.
The 1-2 exchanger is normally arranged so that the cold fluid and the hot fluid enter at the
same end of the exchanger, giving parallel flow in the first tube pass and counterflow in the

33
 second. This permits a closer approach at the exit end of the exchanger than if the second pass
were parallel.
Here in M.C.P.I Plant preheater unit; 1 st heat exchanger uses the steam from the condenser as a
shell side fluid to heat up the slurry and dissolve it well, 2 nd and 3rd heat exchanger uses heat
rejected by 2nd and 3rd crystallizer, 4th and 5th heat exchanger uses the heat rejected by 1st
crystallizer, and the last two 6th and 7th heat exchanger uses hot oil therminol-66 as the shell
side fluid.

Fig: 1-2 parallel-counterflow exchanger.

 Centrifugal decanter
A decanter is an equipment used for the separation of suspended solids from a liquid. This
separation is based on buoyancy, where the component with the higher density would fall to the
bottom, and the component with the lower density would be suspended above it. By continuous
rotation, the decanter enables the increase in the rate of settling.
The action of the centrifuge multiplies the g-force considerably, since it is the only variable that
can be altered, provided that inlet conditions remain constant. The increase in the g-force results in
an increase in the settling speed, which further results in the decrease of the time required for
settling.
In order to further increase the efficiency, a bowl is included within the decanter's construction.
This bowl contains both a cylindrical and a conical section, along with a screw conveyor, which
continuously scrapes the solids from the sides of the bowl.

34
The slurry is fed to the centrifuge via a pipe. The conveyor then transports the slurry to a nozzle,
and is transferred through it to the bowl area. The bowl rotates at high speeds to induce
gravitational forces, thus separating the two components. The conveyor then passes the solids,
which are discharged through the nozzle. The purified liquid exits via a different pathway.

 Pneumatic Conveyor
The suspending fluid in a pneumatic conveyor is a gas, usually air, flowing at velocities between
15 and 30 m/s in pipes ranging from 50 to 400 mm in diameter. The principal types of systems
are -
(1) negative-pressure (vacuum) systems, useful in transferring the solids from multiple intake
points (railroad cars, ships, holds, etc.) to a single delivery point. (
(2) positive pressure systems best for one intake point and one or more points of delivery;
(3) vacuum-pressure systems, which combine the advantage of the negative pressure systems and
positive pressure systems; and
(4) pre-fluidized systems, which require less air, and consequently less power, than any of the
other methods.
Materials handled range in particle size from fine powders to 6.5-mm pellets, and in bulk density
from 16 to more than 3,200 kg/m 3. Vacuum systems are typically limited to solids flow rates less
than 6,800 kg/h and equivalent conveyor lengths less than 300 m. Pressure systems operate at 1
to 5 atm gauge and are used for free-flowing solids of particles less than 6.5 mm in size, where
flow rates greater than 9,000 kg/h are needed. Typically, the pressure loss through the system is
about 0.5 atm.

 Belt conveyors

Belt conveyors consist of, an endless belt operating between two or more pulleys, friction driven
at one end and carried on an idler drum at the opposite end. Belt and its load have to be supported
on idlers on both conveying and returning section. Belt conveyors are used for solids conveying
at a distance from meters to kilometers. Heavy duty conveyors have thick belts and these require
large diameter idler and drums. Damage to solids in transport is slight or negligible as there is no
relative motion between belt and solids belt conveyors have carrying capacity.

35
 1. Belt Conveyors carry solid long distance mainly in horizontal plane,
2. Through inclined conveying possible with restricted angle of elevation of 15-20o.
3. Belt Conveyors are used to avoid spillage or run-back,
4. Special belts with corrugated sidewalks and lateral ribs are used for steeper inclination up to
45o.

Belt conveyors have the high installation cost.

Properly designed belt conveyors have long service
life.

 Bucket elevators
Bucket elevators consist of high-capacity units primarily for bulk elevation of relatively free-
flowing materials. They are simplest and most dependable equipment for vertical lifting of
granular materials. Available in wide range of capacity and high efficiency. Material carrying
elements are buckets which may be enclosed in a single housing called a leg or two legs may be
used. Return leg may be located some distance from elevator leg. A single or double chain is
used to attach the buckets.
Important considerations affecting the design and operation of bucket elevators are

● Physical properties of conveyed material (particle size, lump size, moisture content, angle of
repose, flowability, abrasiveness, friability and so on).
● Shape and spacing of buckets.

● Speed at which the elevator is driven.

● Method of loading the elevator.

● Method of discharging the elevator.

Mounting and spacing of buckets will conform into a specific elevator design. Buckets may be
fastened to the chain at the back or at the side if mounted in two chains. Centre spacing of bucket
varies with their size, shape, speed as well as head and foot wheel diameter. Mounting and
spacing of buckets will confirm into a specific elevator design. Buckets may be fastened to the
chain at the back or at the side if mounted in two chains. Centre spacing of bucket varies with
their size, shape, speed as well as head and foot wheel diameter. Methods of loading bucket
elevators: three different ways. Spaced buckets receive part of charge directly from chute and
part by scooping. Continuous buckets are filled as they pass through a loading leg with a feed
36
 spout above the tail wheel. They can also be loaded in a bottomless boot without a clean out
door.

● Methods of discharging of bucket elevators- three different ways

● Spaced-bucket centrifugal-discharge elevators.

Most common and are usually equipped with malleable-iron round-shaped buckets spaced to
prevent interface in loading or discharge. Handle almost any free- flowing fine or small-lump
material. Speeds can be relatively high for fairly dense materials but must be lowered considerably
for aerated or low bulk-density materials to prevent fanning action.

 Screw conveyors
Operate on the principle of a rotating helical screw moving a given material in a trough or a
casing and used to
Handle finely divided powders, damp materials, hot substances that may be chemically active
granular materials of all types batch or continuous mixing, for feeding where a fairly accurate
mass rate is required. Components of screw conveyor

1. Flight
2. Screw formed by mounting flights on axle.
3. Tough or casing.

37
 Check valve (a) lift check (b) ball check (c)
swing check.

 Valves

A typical processing plant contains thousands of valves of many different sizes and shapes.
Despite the variety in their design, however, all valve has a common primary purpose: to slow
down or stop the flow of a liquid. Some valves work best in on-or-off service; fully open or fully
closed. Others are designed to throttle, to reduce the pressure and flow rate of a fluid. Still others
permit flow in one direction only or only under certain conditions of temperature and pressure. A
steam trap, which is a special form of valve, allows water an inert gas to pass through while
holding back the steam. Finally, by using sensors and automatic control system to adjust the
valve position and thus the flow through the valve, the temperature, pressure, liquid level, or
other fluid properties can be controlled at points remote from the valve itself.

 Fluidized Bed Dryer

Usage in the M.C.P.I Plant: - Fluidized Bed Dryer is used in the P.T.A section of the H.P Plant to
dry the wet P.T.A powder.
Dryers in which the solids are fluidized by the drying gas find applications in a variety of drying
problems. The particles are fluidized by air or gas in a boiling- bed unit, as shown in Figure.
Mixing and heat transfer are very rapid. Wet feed is admitted to the top of the bed; dry product is
taken out from the side near the bottom. In the dryer shown in Figure. there is a random
distribution of residence times; the average time a particle stays in the dryer is typically 30 to 120
s when only surface liquid is vaporized and up to 15 to 30 min if there is also internal diffusion.
Small particles are heated essentially to the exit dry-bulb temperature of the fluidizing gas;
consequently, thermally sensitive materials must be dried in a relatively cool suspending
medium. Even so, the inlet gas may be hot, for it mixes so rapidly that the temperature is
virtually uniform, at the exit gas temperature, throughout the bed. If fine particles are present,

38
 either from the feed or from particle breakage in the fluidized bed, there may be considerable
solids carryover with the exit gas, and
cyclones and bag filters are needed for fine
recovery. Some rectangular fluid bed dryers
have separately fluidized compartments
through which the solids move in sequence
from inlet to outlet. These are known as
plug flow dryers; in them the residence time
is almost the same for all particles. Drying
conditions can be changed from one
compartment to another, and often the last
compartment is fluidized with cold gas to
cool the solids before discharge. Dryer of
the kind shown in Figure. may also be
operated batchwise. A charge of wet solids
in a perforated container attached to bottom of the fluidizing chamber is fluidized, heated until
dry, then discharged. Such units have replaced tray dryers in many processes.

 Rotary dryers
Usage in the M.C.P.I Plant: - In the preparation of crude C.T.A after the crystallization operation
is performed Rotary dryer is used to dry the wet C.T.A powder. Rotary dryers are used in the D.P
plant.
A rotary dryer consists of a revolving cylindrical shell, horizontal or slightly inclined toward the
outlet. Wet feed enters one end of the cylinder; dry material discharges from the other. As the shell
rotates, internal flights lift the solids and shower them down through the interior of the shell.
Rotary dryers are heated by direct contact of gas with the solids, by hot gas passing through an
external jacket, or by steam condensing in a set of longitudinal tubes mounted on the inner surface
of the shell. The last of these types is called a steam-tube rotary dryer. In a direct-indirect rotary
dryer, hot gas first passes through the jacket and then through the shell, where it comes into
contact with the solids.
A typical adiabatic countercurrent air heated rotary dryer is shown in Figure. A rotating shell A
made of sheet steel is supported on two sets of rollers B and driven by a gear and pinion C. At the
upper end is a hood D, which connects through fan E to a stack and a spout F, which brings in
wet material from the feed hopper. Flights G which lifts the material being dried and shower it
down through the current of hot air, are welded inside the shell. At the lower end of the dried
product discharges into a screw conveyor H. Just beyond the screw-conveyor is a set of steam
heated extended-surface pipes that preheat the air. The air is moved through the dryer by a fan,
which may if desired, discharge into the air heater so that the whole system is under a positive
pressure. Alternatively, the fan may be placed in the stack as shown, so that it draws air through
the dryer and keeps the system under a slight vacuum. This is desirable when the material tends o
dust. Rotary dryer of this kind is widely used for salt, sugar, and all kinds of granular and

39
 crystalline materials that must be kept clean and may not be directly exposed to very hot flue
gases.

Countercurrent air-heated rotary dryer:

A, dryer shell; B, shell-supporting rolls;
C, drive gear; D, air discharge hood; E,
discharge fan; F, feed chute; G, lifting
 flights; H, product discharge; J, air Horizontal Belt Filter
heater.
Usage in the M.C.P.I Plant: - D.P Plant
contains filter, which filters out the liquid from the solid. When the feed contains coarse, fast
settling particles of solid, a rotary drum filter works poorly or not at all. The coarse particles
cannot be suspended well in the slurry trough, and the cake that forms often will not adhere to the
surface of the filter drum. In this situation a top-fed horizontal filter may be used. The moving belt
filter is shown in Figure. is one of several types of horizontal filter; it resembles a belt conveyor,
with a transversely ridged support or drainage belt carrying the filter cloth, which is also in the
form of an endless belt. Central openings in the drainage belt slide over a longitudinal vacuum
box, into which the filtrate is drawn. Feed slurry flows onto the belt from a distributor at one end
of the unit; filtered and washed cake is discharged from the other. Belt filters are especially useful
in waste treatment.

 Cooling Tower
When warm liquid is brought into contact with unsaturated gas, part of the liquid evaporates and
the liquid temperature drops. The most important application of this principle is in the use of
cooling towers to lower the temperature of recirculated water used for condensers and heat
exchangers in chemical plants, power plants, and air conditioning units. Cooling towers are large-
40
diameter columns with special type of packing designed to give good gas-liquid contact with low
pressure drop. Warm water is distributed over the packing by spray nozzles or a grid of notched
troughs or pipes. Air is passed through the packing by forced-draft or induced-draft fans, or in
some designs it is drawn through by natural convection.
Two of the major types of forced-draft cooling towers are shown in Figure.
The preferred material for the outer shell is corrugated glass-reinforced polyester.
The most type of packing for new installations is cellular fill or film-type packing, which consists
of corrugated sheets of plastic similar to those used in plate-type heat exchangers. Water flows
over the surface of the packing, giving more transfer area per unit volume than splash-type
packings. The plastic sheets are spaced ¾ to 1.0 in. (18 to 25 mm) apart to permit high flow rates
of air and water with only moderate pressure drop. The depth of fill may be only a few sheets, a
small fraction of the total height of the unit. With cellular fill, it is especially important to get
good distribution of water at the top, since redistribution does not occur naturally, as it does with
random dumped packings.

 Storage and Conveying of Solids

Bulk Storage

Coarse solids such as gravel and coal are stored outside in large piles, unprotected from the
weather. When hundreds or thousands of tons of material are involved, this is the most
economical method. The solids are removed from the pile by dragline or tractor shovel and
delivered to a conveyor or to the process. Outdoor storage can lead to environmental problems
such as dusting or leaching of soluble material from the pile. Dusting may necessitate a
protective cover of some kind for the stored solid; leaching can be controlled by converting the
pile or by locating it in a shallow basin with an impervious floor from which the runoff may be
safely withdrawn.

Silos, Bins & Hoppers Storage

A silo is tall and relatively small in diameter. A bin in not so tall and usually fairly wide. A
hopper is a small vessel with a sloping bottom, for temporary storage before feeding solids to
process. These are cylindrical or rectangular vessels of concrete or
metal. All these containers are loaded from the top by some kind of elevator; discharging is
ordinarily done from the bottom.

41
Pressure in bins and silos:
When granular solids are placed in a bin or silo, the lateral pressure exerted on the walls at any
point is less than predicted from the head of materials above that point Furthermore there usually
is friction between the wall and the solid grains, and because of the interlocking of the particles,
the effect of this friction is felt throughout the mass. The friction force art the wall tends to offset
the weight of the solid and reduces the pressure
exerted by the mass on the floor of the container.
The vertical pressure on the vessel floor or the
packing support is much smaller than that exerted
by a column of liquid of the same density and
height. The actual pressure from the solids
depends on the value of K’ for the solids, the
coefficient of friction between the solids and the
vessel wall, and the way the solids are placed in
the vessel. In general, when the height of the
solid’s column is greater than about 3 times the
diameter of the container, additional solids have
Common Hopper no effect on the pressure at the base. The total
Geometries mass, of course, increases if more solids are
added, but the additional mass is carried by the walls and foundation, not by the floor of the
vessel.

In granular solids a high pressure does not always increase the tendency of the material to flow, as
it does in a liquid; instead, pressure packs the grains more tightly together and makes flow more
difficult. In extreme cases the combination of gravitational and frictional forces at some point in
the container causes the solids to arch or bridge, so that they do not fall even when the material
below them is removed. Nearly all large bins contain an arch-breaker, an upward pointing shallow
metal cone set near the bottom to keep the solids at the discharge opening from becoming tightly
packed. Granular solids, especially with angular particles, must be loos in order to flow.

42
 Main Project (1)
PUMPS:
Pumps are mechanical devices designed to move fluids (liquids or gases) from one place to
another by creating a pressure differential. They are essential in various industries, including
agriculture, manufacturing, water treatment, and oil and gas, facilitating the transportation of
fluids for diverse applications.
Types of Pumps:
• Centrifugal Pumps:
Working Principle: Utilize a rotating impeller to impart velocity to the fluid, converting kinetic
energy into pressure energy.
Applications: Water supply, irrigation, chemical processing, and HVAC systems.
Advantages: Simple design, easy maintenance, and suitable for high-flow, low-viscosity fluids.
• Positive Displacement Pumps:
Working Principle: Move fluid by trapping a fixed amount and displacing it into the discharge
pipe. Includes gear pumps, diaphragm pumps, and piston pumps.
Applications: Oil and gas industry, chemical injection, and high-viscosity fluid transfer.
Advantages: Handle viscous fluids well, deliver a constant flow regardless of pressure changes.

43
 ASSIGNMENT: ANALYSIS OF PUMPS AND THEIR
CALCULATIONS

Question: Find the power required to drive a centrifugal pump which delivers
0.04 m^3/s of water to a height of 20 m through 0.15 cm diameter pipe and 100
ml long. The average efficiency of the pump is 70% and the coefficient of
friction ‘f’ = 0.15 in the formula hf=((4flv^2)/(dx2g)).

44
Ans. Given,
Discharge(Q) = 0.04 m^3/s
Height (Hs) = (hs + hd) = 20 m
Diameter of pipe (Ds) = Dd = 15 cm = 0.15 m
Length Ls + Ld = L = 100 m
Overall efficiency n0 = 70 % = 0.70
Coefficient of friction = f = 0.01
Velocity of water in pipe Vs = Vd = V = Discharge / Area of Pipe
= (0.04/((22/7*4)*(0.15^2)))
Friction Head loss in pipe (hfs+hfd)
=((4fLv^2)/(dx^2g)) = ((4 * 0.015 * 100 * (2.26^2))/(0.15*2*9.81))
We get manometric head as :
Hm = (hs + hd) + (hfs + hfd) + ((Vd^)2/(2*g))
= 20 + 10.41 + ((2.26^2)/(2 * 9.81))
= 30.41 + 0.26
= 30. 67 m

Overall efficiency is given by :

n0 = ((WHm/1000)/S.P.) = ((Pg * Q * Hm)/(S.P. * 1000))
S.P. = ((Pg * Q * Hm )/(1000 * n0))
= (((1000 * 9.81 * 0.04 * 30.67)/(1000 * 0.70))
= 17.19 KW Ans.
Therefore, S.P. is the power required to drive the centrifugal pump .

45
 Conclusion

Power required for starting pump = 17.19 kW

46
 Main Project (2)
Distillation
Distillation is a method of separating the components of a solution which depends upon the
distribution of the substances between a gas and a liquid phase, applied to cases where all
components are present in both phases. Instead of introducing a new substance into the mixture
in order to provide the second phase, as is done in gas absorption or desorption, the new phase is
created from the original solution by vaporization or condensation.
In distillation the new phase differs from the original by its heat content, but heat is readily added
or removed, although of course the cost of doing this must inevitably be considered. Absorption
or desorption operations on the on the other hand which depends upon the introduction of a
foreign substance, provide us with a new solution which in turn may have to be separated by one
of the diffusional operations unless it happens that the new solution is useful directly.

Overview of Binary and Azeotropic Distillation:

The separation of components that have nearly the same boiling points is difficult by simple
distillation even if the mixtures are ideal, and complete separation may be impossible because of
azeotrope formation. For such systems the separation can often be improved by adding a third
component to alter the relative volatility of the original components.
Separation of the original mixture may also be enhanced by adding a solvent that forms a
azeotrope with one of the key components. This process is called azeotropic distillation. the
azeotrope forms the distillate or bottom product from the column and is latter separated into
solvent and key component. Usually, the material added forms a low-boiling azeotrope and is
taken overhead, and such materials are called entrainers. The azeotrope will of course contain
some of all components in the feed, but it will have a much different ratio of the keys than the
feed.

47
 Continuous fractionating column with rectifying and
stripping sections.

ASSIGNMENT:
BINARY DISTILLATION: THEORETICAL STAGE CALCULATION BY
GRAPHICAL METHOD AND VERIFICATION BY FUG EQUATION.
Question:

A mixture of a solution in a distillation column is used to be separated water from acetic

acid. The feed is 30 wt% water and 70wt% acetic acid mixture that is a saturated liquid
mixture at atmospheric pressure. The feed rate is 150 m 3/hr to provide a distillate
containing 99.2 wt% water and a residue containing 20wt% water. A reflux ratio of 2.5 will
be used. Relative volatility is 1.5 and tray efficiency is 0.4. Calculation of no. of theoretical
and actual trays and verify by Fenske Equation. Calculate the Reboiler heat duty for this
operation & deduce the feed tray position by assume McCabe Thile method…

Solution: Molecular weight of water= 18gm

Molecular weight of acetic acid= 60 gm
Basis:1 mol
Where, XD= Distillate water + A. A’s mole fraction.
XW= Residue water + A. A’s mole fraction.
XF= Feed Water + A. A’s mole fraction.

TOP
Top product composition: 99.2 wt. % water + 0.8 wt.% acetic acid

Mole fraction of water= ( XD )

Mole fraction of acetic acid= 1-0.998=0.002

Bottom

Bottom product composition: 20 wt. % water + 80 wt.% acetic acid

48
Mole fraction of water= ( XW )

Mole fraction of acetic acid= 1-0.455=0.545

Feed
Feed composition: 30 wt. % water + 70 % acetic acid

Mole fraction of water= ( XF )

Mole fraction of acetic acid= 1-0.589=0.411

Density of acetic acid: 1051 kg/m3
Density of water: 1000 kg/m3
Density of mixture:1051*0.411+1000*0.589 =431.96+589=1020.961 kg/m3
Mass flow rate: density *volume flow rate= 1020.961 kg/m3*150 m3/hr =153144.15 kg/hr
Molecular weight of mixture: 0.411*60+0.589*18=35.262kg/kgmol
Molar flow rate: mass flow rate/molecular weight of mixture=153144.15/35.262=4343.04
kmol/hr (F)

Material Balance:

Overall:
XF*F = XD*D + XW*W
(Where, F= molar feed rate
D= molar distillate flow rate
W= molar residue flow rate)
49
Or, 4343.04*0.589=D*0.998+ (4343.04-D)*0.455
Or, D=1071.7 Kmol/hr
Condenser:
V=L+D
Or. V= RD+D=D(R+1) (Reflux ratio R=L/D=2.5)
V=1071.7(2.5+1)=3750.9 Kmol/hr
Reboiler:
L’=V’+W
Quality of feed for vapor phase: 1-q =(V-V’)/F
or. V’=V-(1-q)F
or, V’=3750.9 Kmol/hr (q=1)

Calculation of Reboiler Heat Duty:

Heat of vaporization for water: 40.65kJ/mol

Heat of vaporization for acetic acid=24.3kJ/mol
Heat of vaporization of bottom product (which Reboiler received)
= 40.65*0.455+24.3*0.545=31.73kJ/mol
Reboiler duty: V’*(Heat of Vaporization mix)= 3750.9 kmol/hr *31.73KJ/mol =11.9*10 10 J/hr
=2.85*107 kcal/hr = 28.5 Gcal/ hr .

50
 Equilibrium Data

VLE data calculation for equilibrium data

X y Relative
volatility
(α) Equilibrium Relation
0 0 1.5
0.1 1.66 1.5
0.2 0.31 1.5
0.3 0.435 1.5
0.4 0.545 1.5 (where α= 1.5 is the Relative Volatility)
0.5 0.643 1.5
0.6 0.73 1.5
0.7 0.8 1.5
0.8 0.88 1.5
0.9 0.942 1.5
1 1 1.5

51
 Theoretical no.of. plate’s calculation (McCabe -Thiele method):

Operating line for Enriching relation:

Slope = (R=Reflux ratio=2.5) Intercept=

= 2.5/3.5 =0.714 =0.998/3.5 = 0.28514

Operating line equation for Feed line:

q =1 (Saturated liquid feed) and XF =0.455

Slope = =0 (q line is parallel to the y-axis )

Number of ideal stages from the graph= 16

The feed is entering the column in the 3rd Tray
In M.C.P.I Total condenser and partial reboiler is used.
So, the no. of theoretical stages without reboiler and condenser will be:

52
 =No.of. theoretical trays-1
=16-1
=15

Given tray efficiency ( ) =0.4

And we know that (Ƞ)=

Or, 0.4= Or, no. of actual trays) =

53
54
 Verification By Fenske Equation

Fenske Equation: - used to find out the minimum number of trays for the desired separation. When
the composition of top distillate and bottom residue are specified.
Assumptions: Constant molal overflow.
(Enthalpy of vaporization = Enthalpy of condensation)
LN=LN+1 ; VN=VN+1
αLK,HK --- constant relative volatility between light key and heavy. key components.

L.KD ----- flow rate of light key in the distillate.

H.KD------ flow rate of heavy key in the distillate.
H.KB------ flow rate of heavy key in the bottom product.
L.KB-------- flow rate of light key in the bottom product.
αLK, HK ------ relative volatility between light key and heavy key.

LK, HK -------- geometric mean of α (at bottom temperature) and α (at distillate temperature).

= [α (TB) * α(TF) * α(TD)]1/3 or also may be = [α (TB) * α(TD)]1/2

Any one of the two equations for finding out the mean volatility at the two temperatures can be
used depending upon the accuracy.
Another form of Fenske Equation,

xHK,D ----- mole fraction of heavy key in distillate.

xLK,D ---- mole fraction of low key in distillate.
xHK,B --- mole fraction of heavy key in bottom product.
xLK,B --- mole fraction of low key in bottom product.

55
D—distillate flow rate.
B---- bottom product flow rate.
By applying constant molal overflow, we get

Since, we do not have the temperature of distillate or bottom we are just going to take the relative
volatility at feed temperature.

Nmin= or, Nmin = or, Nmin = 15.767

(So, by Fenske Equation the no.of minimum ideal or theoretical stages is 15.77 which is
approximately equal to the minimum number of trays given out by the Mc.Cabe Thiele Method)

Conclusion

Mc-Cabe Thiele Fenske Equation

Actual no. of plates 38 39.425

No. of theoretical plates 15 15.77

56
 ASSUMPTIONS

1. Constant molar overflow-

The molar flu rates of vapour and liquid are nearly constant in each section of the column this
also ensures the operating line are straight lines.
2. Heat effect are negligible-
For example heat losses to and from the column are small and neglected
3. For every mole of vapour condensed another mole of liquid is vaporized.
4. The liquid and vapour leaving the tree is an equilibrium with the vapor and liquid
entering the tray.

57
 Main Project (3)
HEAT EXCHANGER
Heat Exchangers are devices designed to transfer heat between two or more fluids without mixing
them. They are crucial in a variety of applications, enabling the efficient use of thermal energy in
heating, cooling, and energy recovery processes.

Types of Heat Exchangers

 Shell and Tube Heat Exchangers:

Design: Consist of a series of tubes, one set carrying the hot fluid and the other the cold fluid.
These tubes are enclosed in a cylindrical shell.
Applications: Power plants, oil refineries, and chemical processing.
Advantages: High efficiency can handle high pressures and temperatures, and easy to clean.

 Plate Heat Exchangers:

Design: Composed of a series of thin, corrugated plates stacked together, creating a large surface
area for heat transfer.
Applications: HVAC systems, food and beverage processing, and pharmaceuticals.
Advantages: Compact size, high heat transfer efficiency, and easy to expand by adding more
plates.

 Air-Cooled Heat Exchangers:

Design: Use air to cool the fluid, typically with the help of fans to increase the airflow over the
finned tubes containing the hot fluid.
Applications: Automotive radiators, industrial processes where water is scarce.
Advantages: No need for cooling water, suitable for remote and arid locations, and lower
operating costs.

Continuous fractionating column with rectifying and

stripping sections. 58
ASSIGNMENT: HEAT EXCHANGER DESIGN:

Question: In a 1-1 pass shell and tube heat exchanger, steam of water flowing in the shell side
at a temperature (Ts) 1500C and the cold water is heated from a temperature (T 1) 200C to a
temperature (T2) 1000C. The energy balance equation for this heat exchanger is

Where, U is the overall heat transfer coefficient, A is the heat transfer area is the mass

flow rate of the cold fluid and is its specific heat capacity. Tube side fluid is in a turbulent
flow and the heat transfer coefficient can be estimated from the following equation:

Where, Nu is the nasal number Re is the Reynolds number and Pr is the Prandtl number.
Condensing heat transfer coefficient on the shell side is significantly higher than the tube
side heat transfer coefficient. The resistance of the wall to heat transfer is negligible. If only
the mass flow rate of the cold fluid is doubled:
a) What is the cold fluid’s outlet temperature at steady state?
b) The percentage saving in heat transfer area, if the counter option is used instead of
co-current?
Given, Mass flow rate of steam and cold fluids are 250 kg/s and 150 kg/s
Assumptions,
 there is no loss of heat to the surrounding.
 The heat exchanger is fouling free.
 The flow rate of the fluids is constant.
Ans: Given,

(a) --------(i)

------------(ii)

From equation (i) & (ii) we get,

where, a is the proportional constant.

59
 Putting this value in equation (i)

Now, Ts = 1500C, T1 = 200C, T2 = 1000C

When mass flow rate is doubled, let’s take the outlet temperature of cold water T 2’

(b) First, we need to find out the outlet temperature of steam, Th0
Thi = 1500C
TCi = 200C, TC0 = 93.430C
CPc = CPh = 4148 J/kg.K
As, ,
So,

We know,

60
 ---------(iii)

For counter current flow:

For co-current flow:

61
62
 Bibliography
1. Fluid mechanics and hydraulic machine (Dr.R.K.Bansal)
Google Images

Https://en.wikipedia.org/

http://www.mcpi.co.in

63
 Abbreviations

C.T. A Crude Terephthalic Acid

P.T. A Purified Terephthalic Acid

H. P Haldia Project
D.P Delhi Project
T Temperature
MW Mega Watt
L/D Length/Diameter
DCS Discrete Control System
CSTR Continuous Stirred Tank Reactor
F.U. G Fenske, Underwood, Gilliland
Pd Palladium
C Carbon
Zn Zinc
Cu Copper
NBA n-butyl acetate
ppm parts per million
rpm rotation per minute
ft feet
MpaG Mega Pascal Gauge
g-force gravity force
atm atmospheric pressure
Nt number of theoretical/ideal plates
Rmin minimum reflux ratio
in inch
m meter
Gcal Giga calorie

64
THANK YOU

65