Internship report

INTERNSHIP AT PIDILITE INDUSTRIES LIMITED,
DAHEJ
AN INTERNSHIP REPORT
Submitted by
Arif Raza
And
Sanchit Nangia
In partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
in
Chemical Engineering
National Institute Of Technology Warangal
June,2024
GOVERNMENT ENGINEERING COLLEGE, VALSAD
Between BKM Science College and Government
Polytechnic, Tithal Road, Valsad-396001.
CERTIFICATE
This is to certify that the Internship report submitted along with the project entitled
Internship at PIDILITE INDUSTRIES LIMITED, DAHEJ has been carried
out by RAVAL PRATIK KUMAR JITENDRA KUMAR under my guidance
in partial fulfilment for the degree of Bachelor of Engineering in Chemical, 8th
Semester of Gujarat Technological University, Ahmedabad during the academic
year 2024-25.
Prof. A.V. PATEL Prof. N. M. Patel
Internal Guide Head of Department
Gujarat Technological University Warangal ,Telangana

COMPANY CERTIFICATE

DECLARATION
I hereby declare that the Internship report submitted along with the Internship
entitled Internship at Pidilite Industries Limited, Dahej 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 Pidilite Industries Limited under the supervision
of Prof. A.V. PATEL 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 Student Sign of Student
RAVAL PRATIK KUMAR JITENDRA KUMAR

ACKNOWLEDGEMENT
I would like to express my deep and sincere gratitude to my guide Prof. A.V. PATEL,
Department of Chemical Engineering, for guiding me to accomplish this industrial internship.
I express my sincere gratitude to Dr. N. M. Patel, Head of Chemical Engineering Department,

for his valuable guidance and constant encouragement. I am very thankful to Dr. V. S. Purani,
Principal of Government Engineering College, Valsad.
I would also like to acknowledge the PIDILITE INDUSTRIES, DAHEJ for allowing me to
undergo the Industrial Internship at their organization. MR. NITESH ACHARYA is
acknowledged for providing the information and help during training period.
Last but not least, it would not have possible for me to do the training without support of my
family members. Constant encouragement and support of my father and mother made me
possible to do the work with full enthusiasm.
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National Institute of Technology Warangal , Telangana
ABSTRACT
 This report documents the practical experiences gained during industrial training, focusing on the
operations, equipment design, utilities management, and safety protocols observed at PIDILITE INDUSTRIES
LIMITED, Dahej. The primary objective of this training was to apply theoretical knowledge to real-world
industrial scenarios.
 Company Overview
PIDILITE INDUSTRIES LIMITED, Dahej, specializes in the manufacture of polymer products. The facility is
equipped with comprehensive infrastructure necessary for a polymer industry. All manufacturing processes
adhere strictly to established safety standards, ensuring a secure working environment.
 Training Objectives
The training aimed to:
 Gain insight into equipment processing and design specific to polymer production.
 Understand the utilities management crucial for efficient industrial operations.
 Familiarize with and implement stringent safety measures practiced in industrial settings.
 Develope discipline and grasp industrial management practices.
 Key Learnings
Throughout the training period, significant insights were acquired in:
 Processing and Equipment Design: Practical application of theoretical knowledge in the design and
operation of polymer manufacturing equipment.
 Utilities Management: Observing the effective management of utilities essential for sustaining
operational efficiency.
 Safety Protocols: Hands-on experience in implementing and adhering to rigorous safety protocols,
ensuring a hazard-free workplace.
 Discipline and Industrial Management: Exposure to organizational discipline and insights into
industrial management practices crucial for operational success.
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National Institute of Technology Warangal , Telangana
LIST OF FIGURES
Figure 1.1-1 Company profile...................................................................................................1

Figure 2.11-l Theoretical Foundations of Chemical Processes in Polymer Manufacturing….13
Figure 2.11-2 Class of fire extinguisher...................................................................................14
Figure 2.11-2 Safety equipment...............................................................................................15
Figure 3.1.2-1 Cooling tower...................................................................................................18
Figure 3.1.3-1Brine & chilling system.....................................................................................19
Figure 4.1-1Block flow diagram..............................................................................................20
Figure 4.2-1 Process flow diagram..........................................................................................21
Figure 5.5.1-1 Stainless steel reactor.......................................................................................24
Figure 5.5.2-1 Water scrubber..................................................................................................25
Figure 5.5.3-1 Centrifugal pump..............................................................................................26
Figure 5.5.3-2 AOD pump.......................................................................................................26
Figure 5.5.3-3 Screw pump......................................................................................................27
Figure 5.5.4-1 Globe valve.......................................................................................................29
Figure 5.5.4-2 Gate valve.........................................................................................................29
Figure 5.5.4-3 Ball valve..........................................................................................................30
Figure 5.5.4-4 Air to open & close valve.................................................................................31
Figure 5.5.4-5 Pressure safety valve........................................................................................31
Figure 5.5.4-5 Pressure relief valve.........................................................................................32
Figure 8.3.1-1 Equalization tank..............................................................................................42
Figure 8.3.2-1 Aeration tank....................................................................................................43
Figure 8.3.4-1Sludge thickener................................................................................................44
Figure 9.2.1-1 Sewage treatment plant....................................................................................45
Figure 10.1-1 Plant layout........................................................................................................48
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National Institute Of Technology Warangal , Telangana
LIST OF TABLES
Table 1.11-1 List of raw material...............................................................................................3

Table 1.12-1 Physical and Chemical Properties of Styrene.......................................................3
Table 1.12.2 Physical and Chemical Properties of Ethyl acrylate.............................................4
Table 1.12-3 Physical and Chemical Properties of Acrylo nitrile..............................................5
Table 1.12-4 Physical and Chemical Properties of Methyl Methacrylate..................................5
Table 1.12-5 Physical and Chemical Properties of Acrylic acid................................................5
Table 1.12-6 Physical and Chemical Properties of Methacrylic acid........................................6
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National Institute Of Technology Warangal ,Telangana
LIST OF SYMBOLS, ABBREVIATIONS
AND
NOMENCLATURE
 List of symbols used at Pidilite industries limited
1) Poison / Toxic
2) Oxidizer
3) Corrosive
4) Flammable
5) Danger to the Environment
6) Explosive
7) Health Hazard
8) Serious Health Hazard
9) Do not use matchstick
10) Wear Gloves
11) Wear Goggles
12) Wear Soundproof
13) Wear Face shield
14) Wear Helmet
15) Wear PPEs
16) Wear Safety Shoes
 List of Abbreviations used at Pidilite industries limited

1) RM - Raw Material Tank farm
2) FG - Finished Good Tank farm
3) SSR - Stainless Steel Reactor
4) HE - Heat Exchanger
5) BD - Blow Down
6) BL - Blender
7) V - Vessel
8) SAC - Screw Air Compressor
9) CWT - Chilling Water Tank
10) RT - Receiver Tank
11) VRT - Vacuum Receiver Tank
12) ETP - Effluent Treatment Plant
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13) QA - Quality Assurance
14) QC - Quality Control
15) P.D Lab - Process Development Lab
16) EHS - Environment Health and Safety
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TABLE OF CONTAINT
CERTIFICATE..........................................................................................................................................2
COMPANY CERTIFICATE.....................................................................................................................3
DECLARATION.......................................................................................................................................4
ACKNOWLEDGEMENT.........................................................................................................................1
ABSTRACT...............................................................................................................................................2
LIST OF FIGURES....................................................................................................................................3
LIST OF TABLES.....................................................................................................................................4
LIST OF SYMBOLS, ABBREVIATIONS AND.....................................................................................5
TABLE OF CONTAINT...........................................................................................................................1
CHAPTER 1: INTRODUCTION............................................................................................................1
CHAPTER 2: SAFETY MEASURES AT PLAT SITE..........................................................................7
CHAPTER 3: UTILITY USED AT PIDILITE INDUSTRIES LIMITED...........................................16
CHAPTER 4: BLOCK AND PROCESS FLOW DIAGRAM..............................................................20
CHAPTER 5: PROCESS DESCRIPTION............................................................................................22
CHAPTER 6: MATERIAL AND ENERGY BALANCE.....................................................................33
CHAPTER 7: EQUIPMENT DESIGN.................................................................................................37
CHAPTER 8: EFFLUENT TREATMENT PLANT (ETP)..................................................................44
CHAPTER 9: SEWAGE TREATMENT PLANT (STP)........................................................................48
CHAPTER 10: PLANT LAYOUT........................................................................................................50
CONCLUSION........................................................................................................................................53
REFERENCES.........................................................................................................................................54
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INTRODUCTION
CHAPTER 1: INTRODUCTION
1.1 Compony Profile:
Pidilite Industries Limited is a prominent Indian manufacturer of adhesives and chemical products,
headquartered in Andheri (East), Mumbai. Renowned as the leading adhesives company in India, Pidilite's
operations span diverse verticals including art materials, stationery, food and fabric care, automotive products,
adhesives, sealants, and specialty industrial chemicals such as pigments, textile resins, leather chemicals, and
construction chemicals.
Core Values and Commitment to Quality
Pidilite is deeply committed to consumer-centric values of quality and innovation. With a legacy of pioneering
products tailored for both household and industrial applications, Pidilite has established strong connections
with a broad spectrum of consumers. The company's dedication to continuous innovation ensures a dynamic
and expansive product portfolio that includes adhesives, sealants, waterproofing solutions, construction
chemicals, industrial resins, polymers, and more.
Market Leadership and Brand Trust
As a market leader in adhesives, Pidilite's brands have become synonymous with reliability and effectiveness
in both domestic and industrial settings. This leadership position is underpinned by a robust and expanding
distribution network that enhances accessibility across diverse demographics and geographies.
Figure 1.1-1 Company Profile

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INTRODUCTION
1.2 Capacity:
 In this year our company makes new milestone, that make a productivity level at 3000
metric tons per annum in Dahej – D3 Plant
1.3 Research Center:
 We develop most of our products in-house with the help of a strong, research-driven
innovation overlaid with consumer insights. A well-equipped and well-staffed R&D center
continuously develops and enhances products for consumers, craftsmen and industries.
Pidilite also established a state-of-the-art research Centre in Singapore that is now a member
of Singapore Chemical Industry Council (SCIC).
1.4 Researching Ground Breaking Ideas:
 At Pidilite, we are always in motion, looking for the next opportunity to turn into a different
idea. We search for new ideas in everything we do, and more than two thirds of our sales
happen through in-house innovation. We have three fully-equipped in-house R&D centers in
India and five state-of-the-art technical research and innovation centers in Singapore,
Thailand, Brazil, Dubai and USA. Over 150 professionals use a customer-focused innovation
process to bring to fruition the learnings from these interactions. This is why Fevicol,
Fevikwik, M-Seal and Dr. Fixit are not just market leaders, but also names that have become
synonymous with the product category.
1.5 Sustainable Development:
 Since inception, our growth has been strongly linked with that of our nation. In today’s world,
sustainable development is an imperative for all businesses. At Pidilite, we comprehend the
impact of our business on the environment and the society at large and strive to make
sustainability an integral part of our actions. We consider environmental management as a
material topic and are committed towards minimizing our environmental footprint by
thoughtful use of resources such as fuel, electricity, water and raw materials.
1.6 Recycling Partners:
 Pidilite is committed to minimize environmental impact through its partner network of

collection centers. Search local business listings for Stuckists in your area to drop-off your
plastic recyclables
1.7 A Global Presence:
 At Pidilite, we ensure our products reach as many people as possible. Today, we are a mega
organization with multiple product lines, connecting the country and the world.
1.8 Global Impact:
 We understand the importance of maintaining global perspectives in a shrinking world. That’s

why Pidilite has enhanced its international presence through various ventures around the
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INTRODUCTION
globe.
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INTRODUCTION
1.9 Pidilite Company Brands:
 Fevicol
 Dr. Fixit
 Fevikwik
 M-Seal
 Fevistik
 Hobby Ideas
 Fevicryl
1.10 Industrial Products:
 Textile & Paper Chemicals

 Industrial Resins
 Leather Chemicals
 Industrials Adhesives
 Footwear Adhesives
 Organic Pigments & Preparations
 Industrials Bonding Solution
1.11 LIST OF RAW MATERIAL:
Sr. No Product
1 Styrene
2 Butyle Acrylate
3 Ethyl Acrylate
4 Acrylo Nitrile
5 Methyl Methacrylate
6 Acryli Acid
7 Methacryloic Acid
Table 1.11-1 List of Raw Material
1.12 PROPERTIES OF RAW MATERIAL:
i. Chemical & Physical Properties of Styrene: -
Molecular weight 104.15 g/mol

Molecular formula C8H8
Appearance Oily liquid
Odor Aromatic hydrocarbon Odour
Melting point 31 Cº
Color Colorless to yellowish
Boiling point 145 Cº
Upper exposure limit 6.1%
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INTRODUCTION
Lower exposure limit 1.1%
vapor pressure 670 Pa @ 20c Cº
Density 906 kg/m3 @ 20 Cº
Solubility in water 0.29 kg/m3 @ 20 Cº
viscosity 0.7 m Pa.s @25 Cº
Auto ignition temperature 490 Cº
Table 1.12-1 List of chemical & physical Properties of Styrene
ii. Chemical & Physical Properties of Butyl Acrylate: -

Molecular formula C7H12O2
Appearance Liquid
Odor Strong like fruit
Melting point 64.6 Cº
Color Colorless
vapor pressure 5hPa @ 22.2 Cº
Density 0.9 g/cm3 @20 Cº
Solubility in water 1.7 g/L @ 20 Cº
Dynamic viscosity 0.88 mPa.s @ 20 Cº
Auto ignition temperature 292.8 Cº
Flash point 37 Cº
Table 1.12-2 List of chemical & physical Properties of Butyl Acrylate
iii. Chemical & Physical Properties of Ethyl Acrylate: -

Appearance Colorless liquid
Odor Stench
Specific gravity 0.920
Vapor pressure 29.5 mmHg@ 20 Cº
Vapor Density 3.45
Viscosity 0.58cp @ 20 Cº
Flash point 16 Cº
Table 1.12-3 List of chemical & physical Properties of Ethyl Acrylate
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INTRODUCTION
iv. Chemical & Physical Properties of Acrylo Nitrile: -

Molecular formula C3H3N
Odor Odor Like Garlic
Melting point 83.5 Cº
Boiling point 77.3 Cº
Vapor pressure 120 mBar @ 20 Cº
Vapor Density 1.83
Flash point 0.2 Cº
Upper exposure limit 17%
Solubility Soluble in water
Table 1.12-4 List of chemical & physical Properties of Acrylo Nitrile
v. Chemical & Physical Properties of Methyl Methacrylate: -

Odor Pungently
Vapor pressure 37 hPa @ 20 Cº
Vapor Density 3.46
Flash point 9c
Solubility 15.3 g/L @20
Table 1.12-5 List of chemical & physical Properties of Methyl Methacrylate
vi. Chemical & Physical Properties of Acrylic Acid: -

Appearance Liquid
Odor Acrid odor
Vapor pressure 5 hPa @ 20 Cº
Vapor Density 2.49 @ 20 Cº
Flash point 46c
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INTRODUCTION
Solubility Miscible in water
Density 1.051 g/cm3
Table 1.12-6 List of chemical & physical Properties of Acrylic Acid
vii. Chemical & Physical Properties of Methacrylic Acid: -

Odor Like rotten egg
Vapor pressure 0.8 mBar @ 25 Cº
Vapor Density 1
Flash point 76 Cº
Solubility Soluble in water
Table 1.12-7 List of chemical & physical Properties of Methacrylic Acid
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SAFETY MEASURES AT PLANT
SITE
CHAPTER 2: SAFETY MEASURES AT PLAT SITE
2.1 STATUTORY COMLIANCE FOR SAFETY
 Company is having well-established safety department along with well-qualified safety

Manager. Following all the statutory requirements.
1) Various types of work permit systems.

2) Third party safety audit.
3) Updating of ONSITE emergency plan.
4) Safety manual.
5) Rehearsal of Onsite emergency plan (Mock Drill).
6) Safety training at various levels.
7) Equipment testing by competent persons recognized by Director of Health and Safety,
Government of Gujarat.
8) Plant inspections.
9) Internal safety audits at different levels at Plant level, GM level and corporate level.
10) Contractor workmen get safety trainings at regular intervals.
11) Use of Personal Protective Equipment’s is enforced 100%.
12) Pre employment medical checku p and periodical medical checku p of all employees
and competent medical authority is carrying out contractor workmen.
13) Company has also made facility available for Occupational Health Center.
14) 24 hrs. Well-equipped ambulance is made available with driver.
15) Fire hydrant system and fire extinguishers are made available as per fire load.
16) Machine guarding which is statutory requirement is followed strictly.
17) For electrical safety all necessary arrangement is made available.
2.2 GENERAL SAFETY GUIDELINES
 Following steps is taken by the management to meet general safety guidelines of organization.
i) Dematching at main gate.

ii) Electronic equipment’s like mobile, camera, laptop is restricted at main gate.
iii) Flameproof electrification is made available in plant area & store area.
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SITE
iv) Earthing, bonding & jumpers are provided at required places.
v) Firefighting team is ready round the clock to meet emergency.
vi) No maintenance or repairing work is done without work permits.
2.2.1 GENERAL SAFETY GUIDELINES FOLLOWED BY EMPLOYEES

AND WORKERS OF PIDILITE INDUSTRIES LIMITED
 It is responsibility of employee to play his/her role in team. It is responsibility of

employee in team to contribute for success of the organization.
 It is responsibility of employee to work in safe and healthy workplace, use of safety
equipment and discuss with employer if there is any issue.
 Maintaining good work culture, follow all safety rules and regulation, always respect one
another in an organization irrespective of their gender.
 Always wear Personal Protective Equipment (PPEs) at manufacturing or plant area.
 Use boot caps, gouns, gas masks, hand gloves at powder processing area.
 Follow Standard Operating Procedures in manufacturing area and disinfect hands with
disinfectant.
 Inform supervisors if found any safety issue or irregularity.
 Always follow Material Safety Data sheet while working with any dangerous chemicals.
 Use safety Shower if anyone would come in contact with any dangerous chemical.
 Use fire extinguisher immediately if found there is little or minor fire taking place.
2.3 RESPONSIBILITY OF SUPERVISORS OF ALL PLANTS
 To check safety of all workers and employees, who work under him.
 Report EHS department if anyone hurt or injured while working.
 Always motivate his/her juniors for work in team and for success of organization.
 Maintain record of all raw material coming to plant and maintain safety regulation for the
same.
 Maintain all plant equipment’s and use same for solving troubleshoot.
 Maintain quality of products and prepare report to be submitted to management.
 Supervise efficient all plant equipment’s to achieve all plant objectives.
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SITE
2.4 WORK PERMITS
 Work permit is defined as the written documents stating that what work is to be done,
possible hazard involved and preventive safety measures to be taken.
2.4.1 TYPES OF WORK PERMITS
1) Hot work permit

2) Height work permit
3) Confined space work permit
4) Excavation work permit
5) Loading and unloading work permit
 Hot work permit
 Hot work permit is needed when there is work include ignition of any material, flammable
materials that can be considered as fire hazard.
 Hot work permit is in the Red Color.
 Height work permit
 Height work permit is needed when maintenance work is to be done at height above 2 -3
meters. It includes cleaning of chimney tops, building repairing and many other.
 Height work permit is in the Blue Color.
 Confined space work permit
 Confined space work permit is needed when work is to be done in confined space where
air and lights are not available. In this cleaning of reactors, cleaning of inside of chimney,
distillation column.
 Confined space work permit is in the Yellow Color.
 Excavation work permit
 Excavation work permit is needed when work include any excavation activity like
cutting, digging etc.
 Excavation work permit is in the White Color.
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SITE
 Loading and unloading work permit
 It is needed when there is activity is to be done like loading of raw materials and
unloading of products. It is in the Green Color.
2.5 PROCESS SAFETY
 Identify product
 Check the label
 Wear PPEs
 LOTOTO (log out tag out)
 Do not mix any chemicals
 Dilute chemicals correctly
 Provide ventilation
 If any doubt stops immediately
 Inform supervisor immediately and clean chemicals as per Material Safety Data Sheet
(MSDS) in case of accident.
 No smoking.
 Wash exposed skin immediately with safety shower.
2.6 PPES USED AT PIDILITE INDUSTRIES LIMITED
 Helmet
 Safety Shoes
 Gas mask
 Googles
 Boot caps
 Face shield
 Hand gloves
 Head caps
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SITE
2.7 5-S SAFETY FEATURE AT PIDILOITE INDUSTRIES LIMITED
 SETRI (Sorting)
 SEITON (Set in order)
 SEISO (Shine)
 SEIKETSU (Standardize)
 SHITSUKE (Sustain)
2.8 COLOR CODING
 Various types of pipes color coding used at Pidilite Industries Limited are as mention below:
Fire line (Red)

Vacuum line (White)
Air line (Sky blue)
Cooling water line (Green)
Process water (Light Green)
Chilled water line (silver)
Steam line (White)
Table 2.8.1 Pipe color coding
2.9 SAFETY ASPECTS IN INDUSTRY
 Standard operating procedures

 Handling of hazardous materials
 Water supply and drainage
 Floors and floor coverings
 Emergency exits
 Backup plan if anything goes wrong
 Specially trained personnel Health polices and insurance
 DCS (Distributed Control System)
 PRV(Pressure Relief valve)
 PSV (Pressure Safety Valve)
 Air to Open & Closed XV
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 TCV (Temperate Control Valve) SITE
 FCV (Fluid Control Valve)
 SCABA (Self Contained Breathing Apparatus)
 Written procedures
 Safety audits
 Risk analysis
 Mock drill
 Appropriate training and education to employee
 Regular monitoring of workplace
 Create awareness of the environment
2.10 FIVE STEP ACTION PLAN FOR SAFETY MANAGEMENT
1. Understand Occupational Health and Safety management and ISO 45001

2. Examine current system
3. Engage stakeholders
4. Establish Occupational Health and safety Management system
5. Determine priority and establish goals
2.11 SAFETY SYMBOLS
 Safety has its own specific color and sign shape that remains consistent around the world
as per safety regulations.
 By getting to know the key characteristics of each type of symbol, you’ll be able to easily
identify whether a sign is asking you to stop doing something, start doing something, take
precautions, or advising you of emergency equipment or facilities.
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SITE
2.11.1 INTERNATIONAL HAZARD SYMBOLS
Figure 2.11-1 Figure of International hazard Symbols
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SITE
2.11.2 UNDERSTANDING FIRE CLASSES
 There are four classes of fire extinguishers – A, B, C and D – and each class can put
out a different type of fire.
 Class A extinguishers will put out fires in ordinary combustibles such as wood and
paper.
 Class B extinguishers are for use on flammable liquids like grease, gasoline and oil.
Class C extinguishers are suitable for use only on electrically energized fires.
 Class D extinguishers are designed for use on flammable.
Figure 2.11-2 Figure of Classes of Fire Extinguisher
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SITE
2.11.3 SAFETY EQUIPMENT SYMBOLS
Different type of safety equipment symbols used in industry are mention below:
Figure 2.11-3 Figure of safety Equipment Symbols
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UTILITY USED AT PIDILITE
CHAPTER 3: UTILITY USED AT PIDILITE INDUSTRIES

LIMITED
 Utilities are most important parts of manufacturing processes. It is used in every

manufacturing process to utilize the process in very good manner and improve processes.
Utility plays an important role by run the process smoothly. Utilities neither a reactant nor
a product, but utility required for maintaining adequate condition of manufacturing unit.
 There are several utilities used at Pidilite Industries Limited are mention below:
1. Hot Utility
2. Cold Utility
3. Other Utility
 HOT UTILITY: Steam, Hot water

 COLD UTILITY: Cooling water, Chilled water.
 OTHER UTILITY: Air, Vacuum, Electricity, soft Water, Demineralized water.
3.1 UTILITY THAT ARE MAINTAINED BY ENGINEERING

AND MAINTENANCE DEPARTMENT OF PIDILITE
INDUSTRIES LIMITED
 Following utilities are maintained by E & M department of Pidilite Industries Limited:
3.1.1 STEAM
 Steam is generated in boiler house, where it is produced by evaporate the soft water in
boiler drum. There is fire tube boiler with 2000 kg/hr evaporation rate. At Pidilite
Industries Limited. It has the following equipment:
i. Gas filler(Natural gas)

ii. Mobry (Maintain level in boiler)
iii. PSV
iv. PRV
v. Water Preheater
vi. Economizer
vii. Boiler drum
17
viii. Furnace
ix. Chimney
 Water cycle in boiler house:
 Water is first feed into soft water tank.

 Then water is sent to water preheater to preheat water and then sent to economizer.
 In economizer water is further evaporated to several temperature and then sent to
boiler drum to vaporizer to produce steam.
 Working Pressure in the boiler is 10.55kg/sq.cm.
 Then steam is sent to different plant to utilize it into processes.
3.1.2 COOLING WATER (CW)
 Cooling water from the cooling tower system is frequently used to reject process heat in
chemical industries. Cooling water is used in process to cool temperature of product up to
20 – 25 °C. It is generated in the cooling tower. There is only Induced type of cooling
tower used at Pidilite Industries Limited.
 Cooling tower has following components:
i) Liquid Distributor
ii) Fill
iii) Induced Draft Fan
iv) Drift Eliminator
v) Basin
 Working of cooling tower: -
 Warm water from different reactor jackets come to cooling tower top. After it comes to
top it is distributed in liquid distributor and is discharged through spray nozzles inside the
tower. Spray nozzle spray warm water evenly over the entire fill. The water passes
downward in fill.
 Air passes upward direction.
 As water travels downward direction it exchanges heat with air and some portion of
water gets evaporated and not evaporated water gets cooled and collected in basin by
18
gravity.
19
 A portion of evaporated water is reclaimed by drift eliminator, whilst rest is discharged

through the top of tower as water loss.
Figure 3.1.2-1 Induced draft Cooling Tower
3.1.3 BRINE AND CHILLING WATER (CHW)
 Brine and chilling water is generated in chiller. The temperature of brine and chilling
water is - 10 °C and +5 °C respectively. Brine is the salt solution of calcium, magnesium
or methanol also preferred.
 Brine and chilling generation department has same equipment’s those are given below :
a) Chiller
b) Chilled water tank
c) Brine tank
d) Compressor
e) Ammonia condenser
f) Ammonia receiver
 Generation of brine and chilling water:
 At first brine/ chilling water is circulated in chiller.

 In chiller compressed ammonia is circulated to exchange heat with brine/ chilling water.
20
 Then vaporized ammonia is get condensed in ammonia condenser to get liquid
ammonia in ammonia receiver tank.
Figure 3.1.3-1: Brine and Chilled Water System
3.1.4 SOFT WATER
 Soft water is water which has relatively low concentration of calcium carbonate and other
ions. It contains less than 85.5 parts per million of calcium carbonate/
 The water that lathers with soap easily is called or known as soft water. It describes type of
water that contain few or no minerals like calcium (Ca) or magnesium (Mg) ions. The term is
usually relative to hard water, which does contain significant amounts of such ions.
 Soft water is generated in the DM plant.
 Soft water is generally used as boiler feed water in the Pidilite industries.
3.1.5 ELECTRICITY
 The electric power industry covers the generation, transmission, distribution and sale of
electric power to the general public and industry. The commodity sold is actually energy,
not power,
e.g. consumers pay for kilowatt-hours, power multiplied by time, which is energy.
 All forms of electricity generation have positive and negative aspects
 Electric power transmission is the bulk movement of electrical energy from a generating
site, such as a power plant, to an electrical substation.
21
BLOCK AND PROCESS FLOW DIAGRAM
CHAPTER 4: BLOCK AND PROCESS FLOW DIAGRAM
4.1 BLOCK DIAGRAM
Figure 4.1-1 Block flow diagram
22
BLOCK AND PROCESS FLOW DIAGRAM
4.2 PROCESS FLOW DIAGRAM
Figure 4.2-1 process flow diagram
23
PROCESS DESCRIPTION
CHAPTER 5: PROCESS DESCRIPTION
5.1 VESSEL CODE AND THEIR FUNCTION: -
 V101 → Secret Product

 V102 → Pre-Emulsion Vessel
 V104 → Secret Product
 V105 → Continue Catalyst
 V109 → Dump Catalyst
 V107 → Chaser
 V108 → Chaser
 V111 → Preservative
 V146 → Preservative
 T122 → pH Adjustment
 T123 → pH Adjustment
 V103 → V102 + Monomer from Tank farm + V101
 R101 → V104 + V109 + (V103 + V105)
 BD101 → R101 + V107 + V108
 BL101 A/B → BD101 + V111 + V146
5.2 RAW MATERIAL

 Monomer
 Potassium Persulfate
 Water
 Ammonia
 Secrete solution
5.3 PROCESS DESCRIPTION
 In manufacturing of polymer product, we use batch process in this plant that’s why
manual charging the vessel.
 First make Vessel V-102 Pre-Emulsion or Surfactant Vessel, this is use in mixing of
monomer and water properly.
 After if required then manually make Vessel V-101.
 V-102 dump into V-103 and add Monomer from Tank farm is added into a vessel and
ready the vessel and V-103 is known as Premix Vessel. V-103 is ready from DCS.
 Then make V-104, V-105, and V-109.
 In reactor first Add V-104 material and then add V-109 is known as dump catalyst
which is Direct dump into the reactor then start feeding of V-103 and V-105 which
starting time and Ending time is set the flowrate of two vessel for proper reaction and
Complete Particle Size of Product.
24
PROCESS DESCRIPTION
 During Reaction we can observe Temperature of Reactor and Flowrate of V-103 and V105.
 After reaction transfer batch into Blowdown Vessel. In Blowdown Vessel add V-107
and V-108 which is use as a Chaser which means to react free monomer inside the batch
to complete Reaction. In Blowdown Vessel Provide cooling into jacket to cool down the
temperature of Batch.
 After Blowdown Formulation then transfer into the Blender. In blender add V-111 and
V- 146 which is use as a Preservative which means Protect Product from external
environment and increase life of Product.
 In blowdown tank also add from T-122/T-123 which is pH increase solution which is add
in Product and maintain pH of Product in range.
 After checking product Viscosity, pH and Solid Content in QC and In Process Lab And
all Parameter in range then final the product.
 Final Product based on requirement Fill the Drum, Transfer to Tanker or Transfer to FG
Tank farm.
5.4 OPERATION USED
 Chemical mixing
 Blending
 Blowdown
 Filtration
 Eton filtration
 Basket filtration
5.5 EQUIPMENT USED IN INDUSTRY
1) Stainless Steel Reactor (SSR)

2) Water Scrubber (WS)
3) Pump (P)
4) Valve
5) XV
6) Premixer
7) Emulsifier
8) Blender (BL)
9) Blowdown (BD)
10) Vessel (V)
11) Heat exchanger (HE)
12) Cooling Tower (CT)
13) Basket Filter (BF)
14) Air hose (AH)
15) Tank (T)
25
PROCESS DESCRIPTION
16) Eton Filter (EF)

17) AOD Pump
5.5.1 STAINLESS STEEL REACTOR (SSR)
 These reactors are made up of only stainless steel. SS – 304 or SS – 316 are generally
used to manufacture these kinds of reactors.
 The material of construction (MOC) i.e. stainless steel offers good protections to the
basic reactions.
 Mainly basic reactions and neutral reactions are performed in this kind of reactors.
 These reactors are not preferred for acidic reactions because they are not fully corrosion
resistant.
 Stainless Steel Reactors (SSRs) possess a better heat transfer effect because of
enhanced thermal conductivity.
 These take more time to clean and doesn’t require very careful handling. Jacket is
provided for heating and cooling purpose.
 It has sample point, manhole, agitator shaft, raw material inlet, reflux point, Vapor outlet
at top of the reactor and bottom outlet for discharge of reaction mass.
 Steam inlet is provided from top of jacket for heating and outlet tap also provided on
top, while cooling water and cooling utility inlet and outlet is provided bottom.
Figure 5.5.1-1 Stainless Steel Reactor

26
PROCESS DESCRIPTION
5.5.2 WET SCRUBBER (WS)
 Wet scrubber is custom designed to capture Dust particles, VOCs, chemical fumes,
and other water / chemically soluble fumes and Vapors’ generated in industrial
process. The dust laden impure air enters through the inlet.
 Here hydraulically atomized droplets of scrubbing liquid collide with the incoming
gas and Impinge with the particulates. Here some of the water-soluble pollutants gets
absorbed by Spray droplets.
 They are special device used to remove a variety of pollutants from exhaust gas.
 These devices use a scrubbing liquid to remove the pollutants.
Figure 5.5.2-1 Water Scrubber
5.5.3 PUMPS (P)
 There are many types of pumps are used for transportation of product, in Tank farm, in
production plant from one place to another Place.
 Types of pumps used in industry: - 1) Centrifugal pumps

2) AOD pumps
3) Screw pumps
1) Centrifugal pump:
- A centrifugal pump converts rotational energy, often from a motor, to energy in a moving
fluid. A portion of the energy goes into kinetic energy of the fluid. Fluid enters axially
through eye of the casing, is caught up in the impeller blades, and tangentially and radially
27
PROCESS DESCRIPTION
outward until it
28
PROCESS DESCRIPTION
leave through all circumferential part of the impeller into the diffuser part of the casing. The
fluid gain both velocity and pressure while passing through the impeller.
- Horizontal centrifugal pumps are mechanical devices that use centrifugal force to transport
fluids. They are widely used in various industries for their ability to efficiently move liquids,
including water, chemicals, oil, and more. These pumps are designed with a horizontal shaft
and are known for their reliability, ease of maintenance, and versatility.
- Horizontal centrifugal pumps play a crucial role in many applications. They are commonly
used in water supply and distribution systems, HVAC systems, process industries, irrigation
and agriculture, the oil and gas industry, and power generation. These pumps are vital for
maintaining water pressure, circulating coolants, transferring chemicals, and ensuring the
smooth operation of numerous industrial processes.
Figure 5.5.3-1 Horizontal Centrifugal Pump
2) AOD PUMP
 AOD stands for Air-Operated Diaphragm.

 AOD pumps are industrial pumps that use compressed air to move liquids. They are versatile
and commonly used in various industries for transferring liquids with solids, slurries, or
chemicals because of their ability to handle a wide range of fluids and their robust design.
 These pumps consist of two flexible diaphragms that move back and forth to create a
pumping action, making them suitable for applications. Where other types of pumps might
fail. AOD pumps are known for their reliability and are used in industries like chemicals,
mining, wastewater treatment, and more.
Figure 5.5.3-2 AOD Pump
29
PROCESS DESCRIPTION
3) Screw pumps
 Screw pumps, also known as progressive cavity pumps or helical rotor pumps, are a type
of positive displacement pump commonly used in various industries. These pumps
operate using the principle of a helical rotor (screw) turning within a stator, creating
cavities that progressively move fluid from the inlet to the outlet.
Figure 5.5.3-3 Screw Pump
5.5.4 Valve
 A valve is a device that regulates, directs or control the flow of a fluid by opening & closing.
 Industrial valves are devices that are used to regulate liquids, gases, and slurries.
 The flow of liquids or gases can be controlled using these valves
 This can be done through pipes and other passageways by opening, closing, and
partially obstructing the passageway or pipe
 Valve function:
 Stopping and starting fluid flow.

 Controlling the direction of fluid flow.
 Varying the amount of fluid flow.
 Valve selection consideration:
 Pressure
30
PROCESS DESCRIPTION
 Temperature
 Type of fluid:
1) Liquid
2) Gas
3) Dirty
4) Corrosive
 Flow considerations:
1) On – Off & Throttling
2) Velocity
 Operating conditions:
1) Frequency of operation
2) Overall space & Size available
3) Manual & Automated control
4) Fire safe design
 Different types of valves:
1) Globe valve
2) Gate valve
3) Ball valve
4) Air to open & Air to close
5) PRV & PSV
1) Globe valve:
 A globe valve is a linear motion valve used to stop and regulate fluid flow Globe Valve
are used primarily for throttling purpose.
 Advantage:
o Recommended for throttling application.
o Good for frequent operation.
o Easy to repair.
 Disadvantage:
o Globe valve are more costly than alternative valve.
31
PROCESS DESCRIPTION
Figure 5.5.4-1 Globe Valve
2) Gate Valve:
 Gate is used for stopping or starting flow. (i.e. either fully open or fully close).
 It is not used to regulate flow because partially open position can damage valving element.
 Advantage:
o Good choice for ON – OFF service.
o Full flow, low pressure drops.
 Disadvantage:
o It is not suitable for throttling application.
Figure 5.5.4-2 Gate Valve
3) Ball valve:
 Ball valve is a rotational motion valve that uses a ball shaped disk to stop or start fluid flow.
32
PROCESS DESCRIPTION
 Advantage:
o Maintains and regulated high volume, high pressure, and high temperature flow.
o Low purchase and maintenance costs.
o Time of valve operation is minimized.
o Can be used for throttling service.
 Disadvantage:
o Difficult to clean.
Figure 5.5.4-3 Ball Valve
4) Air to Open & Air to Close Valve
 Air to open valves are normally held closed by the spring and require air pressure (a
control signal) to open them – they open progressively as the air pressure increases.
 Air to close valves are valves which are held open by the valve spring and require
air pressure to move them towards the closed position.
 The reason for the two types of valves is to allow failsafe operation.
 In the event of a plant instrument air failure it is important that all control valves fail in
a safe position (e.g. an exothermic reactor’s feed valves (or, perhaps, just one of the
valves) should fail closed (air to open) and its coolant system valves fail open (air to
close)).
 What Is a Fail Close Valve?
 A fail close valve is a safety industrial valve designed to close automatically in the event of a
system failure. This type of valve is often used in critical applications where a loss of
pressure could lead to catastrophic consequences. Fail close valves are typically installed in
locations where there is a risk of leakages, such as pipelines, chemical storage tanks, and
pressure vessels.
 When a fail close valve is installed in a system, it is typically connected to a monitoring

system that can detect when a failure has occurred. The fail close valve automatically closes
when a failure is detected, preventing further pressure loss. In some cases, the fail close valve
may also open to release pressure before it closes, depending on the severity of the failure.
33
PROCESS DESCRIPTION
 What Is a Fail Open Valve?
 A fail open valve is a type of valve that is designed to stay open when there is a failure in the
system. This type of valve is typically used in systems where it is vital to maintain a constant
flow, such as in a water or gas line. Fail open valves are an essential part of many systems
and can help to prevent damage and failures. Fail open valve may be the right choice when
designing a system that needs to maintain a constant flow.
Figure 5.5.4-4 Air to open & Air close Valve
5) Pressure Safety Valve
 Pressure Safety Valve (PSV) is a type of valve used to quickly release gasses from
equipment in order to avoid over pressurization and potential process safety incidents. PSVs
are activated automatically when pressure exceeds prescribed pressure limits in order to
return equipment pressure to a safe operating level.
Figure 5.5.4-5 Pressure Safety Valve
34
PROCESS DESCRIPTION
6) Pressure Relief Valve
 A relief valve or pressure relief valve is a type of safety valve used to control or limit the
pressure in a system; pressure might otherwise build up and create a process upset,
instrument or equipment failure, or fire.
 PRV is used when dealing with liquids and opens gradually with gradual increase in pressure
whereas PSV is used when dealing with incompressible fluids especially gas phase where the
opening must be spontaneous with the sudden increase in pressure
Figure 5.5.4-5 Pressure Relief Valve
35
Material and Energy Balance
CHAPTER 6: MATERIAL AND ENERGY BALANCE
6.1 MATERIAL BALANCE
Introduction:
Material balance gives us an idea about the quantity of feed entering and the product leaving
along with unreacted material of particular equipment. It also helps us to determine the
composition in the feed and in the product which is unreacted for given conversion.
6.1.1 PROCEDURE OF POLYMER

Individual Material Balance for Addition emulsion polymerization. Reaction Involved:
 Basis: 20 kl of polymerization Product.
Monomer 14.2kl Product 20 kl

Reactor
Seed solution 3.5kl
Catalyst 0.36kl
Initiator 0.24 kl
Water 1.7 kl
Where,
Monomer Mass = v*ƍ

= 14.2 * 1 kg/lit
= 14,200 kg
99% conversion rate
Polymer mass = 14200 kg * 0.99

= 14058 kg
36
Where,
Total reactant Mass IN = Mass of Monomer + Mass of Seed solution + Mass of Catalyst +
Mass of Initiator + Mass of Water
= 14200 kg + (3.5 kl * 1 kg/lit) + (0.36 kl * 1 kg/lit) +(0.24kl* 1 kg /lit)

+ 17000 kg
= 20000 kg
Unreacted Monomer = 14200 * (1-0.99)

= 142 kg
Total Reactant Mass = 18300

kg Polymer Mass = 14058
kg Unreacted Monomer = 142
kg
6.2 ENERGY BALANCE
Introduction:
Energy Balance is done based on Heat of Reaction, Heat Capacities, Expected Temperatures and
Pressure at various points to calculate amount of heating and cooling needed at various places and
to size equipment.
In this chapter, energy balance of Reactor at various is given. There us one major conservation
law which provides an additional equation called Law of Conservation of Energy. E denotes the
entire amount of energy in system.
Law of Conservation of Energy:
Ein – E out = E accumulated
Kinetic Energy and Potential Energy are generally very small compared to the enthalpy, except
in case of very rapid flow or when there are no significant temperature changes occurring in the
system. Therefore, they are often neglected in performing energy balances.
Here Cp values are found using Kopp’s Law and heat of formation is found using group
contribution method.
37
Monomer
Seed solution
Catalyst
Initiato
Product Polymer
Heat Capacity of Monomer: 1.4KJ/kg K
Heat Capacity of Seed solution: 4.18KJ/kg
K Heat Capacity of Initiator : 4.18 KJ/kg K
Heat with Reactants:
Qmonomer = m*Cp*∆T
= 140200*1.4*(82.09-63.05)
= 372536.68 KJ
Qseed solution= m*Cp*∆T
= 3500*4.18*(77.09-83.04)
= -87.25 KJ
38
Qinitiator= m*Cp*∆T
= 240*4.18*(72.25-76.47)
= -4.23 KJ
Qtotal = Q1+Q2+QQ3
= 372536.68 – 87.04 – 4.2
=372445.41 kJ
Following Reaction is exothermic so we have to pass cooling water in jacket
39
Equipment design
CHAPTER 7: EQUIPMENT DESIGN
7.1 MECHANICAL DESIGN OF HEAT EXCHANGER

 Data: Design a heat exchanger to sub-col condensate from a Isobutanol condenser from 95
ºC to 40 ºC. Flow rate of isobutanol 100, 000 kg/h (cp = 2.84 kJ/kg0C). Brackish water (cp =
4.2 kJ/kg0C) will be used as the coolant with temperature rise from 25 ºC to 40 ºC.
Isobutanol Inlet temp = 95 ºC
Isobutanol Outlet temp = 40 ºC
Isobutanol flowrate = 27.78 kg/sec
Cp of Isobutanol = 2840 J/kg ºC
Brackish water inlet Temp.= 25 ºC
Brackish water outlet Temp.= 40
ºC Cp of water = 4200 J/kg ºC
density of water = 995 kg/m³
viscosity of water = 0.0008 Pa.s
thermal conductivity =0.59
W/m.k
 Step-1
Qisobutanol = 4338889 J/sec (4339 KW)
Comparing Q Isobutanol = Qwater
Mass flowrate of water= 69 kg/sec
(247937kg/hr) Delta T1= 55

DeltaT2= 15
LMTD= 31
R= 3.7
S= 0.21
From graph value of F is= 0.85
so CMTD=
40
Equipment design
F*LMTD so
CMTD= 26.2
41
Equipment design
Assume Overall heat transfer coefficient value Uo= 600 W/m²k
Q= U*A*CMTD
Heat transfer area A= 276.3 m²
 Step 2
Calculate No of tube Assume:
standard tube size
Di= 0.016 m
5/8"=16mm
tube thickness= 0.002 m
3/4"=19mm
Do= 0.02 m
1"=25.4mm
length of tube= 06
m No of tubes= 733
 Tube side calculation:

Tube OD Do= 0.02 m
Tube ID Di= 0.016
m Pitch= 0.025 m
Length of tube= 6 m
Pt=1.25*Do = 375
Assume no of Tube side Pass= 2
we know tubeside flowrate = 69
kg/sec tube side area available for flow =
0.074 m²
42
Equipment design
Tube side velocity = 0.94 m/sec Q=A*u*density
density of water = 995 kg/m³
43
Equipment design
viscosity of water = 0.0008 Pa.S (neglect viscosity ration)
 Step-3 : inside Heat transfer coefficient
Re=Di*u*density/vicosity
= 0.016*0.94*995/0.0008
= 18692 (turbulent)
based on L/Di ratio from graph Jh= 0.0039 from
graph Pr= Cp*viscosity / kw
= 4200*0.0008/0.59
= 5.7
Hi= 0.0039*18692*(5.7^0.33)*0.59/0.016
= 4773W/m²c
 Step-4 tube side pressure drop (neglect viscosity ratio)
Jf= 0.0043 from graph

Tube side pressure drop= 2*(((8*0.0043*(6/0.016)) +2.5) *((995*0.9*0.9/2))
= 13519 Pa
0.13 bar *Acceptable
0.35 bar
Overall Heat transfer Coefficient:
fouling coefficients:
hf-isobutanol= 5000
W/m2C hf-brackish water= 3000
W/m2C
Hs 2642 W/m2C
Hi 4773 W/m2C
do= 0.02 m
di= 0.016 m
K tube material= 45 W/m2C (*Assume carbon steel tube)
44
Equipment design
1. 0.0003784.9 Do/Di*1.25
2. 0.002
3. 4.95875
4. 0.000261912
5. 0.000416667
1/U= 0.001306656
U= 765.3 w/m2k * Calculated Overall heat transfer Coeff.
Area based on calculation U= 217 m² Q=
U.A.CMTD Q=U (calc) * (A actual area) * CMTD
% excess area= 28 sufficiently high enough for heat transfer
 Shell side
Calculation Tube
pinch= 0.025 m Ki=
0.249 m
Ni= 2.207
Tube bundle diameter= 0.75 m
Clearance between tube bundle & shell =68
mm Baffle Spacing (Bs)= 0.2 m
Cross-sectional area for (As)= shell side flow 0.333 m²
Equivalent Dia of shell (de)= 0.0142 m
Isobutanol mean temp= 67c
Density of isobutanol= 750
kg/m3
Viscosity of isobutanol= 0.00034
Pa.s K isobutanol=0.19 w/m.C
velocity of shell side fluid= 1.12 m/sec
(ms=As*U*density) Reynold number= 34995
(De*u*density/viscosity)
Prnadlt number= 5.08
 Step-5: outside heat transfer coefficient
45
Equipment design
46
Equipment design
jh for 25% baffle cut= 0.0033 from graph

hs = 2642 W/m2C
 Step 6 : shell side pressure drop
jf= 0.0043 form graph

shell side pressure drop= 27207 Pa
*assume
*bundle Dia + Clearrance
*shell Dia/no of baffles
47
Equipment design
48
Equipment design
49
CHAPTER 8: EFFLUENT TREATMENT PLANT (ETP)
8.1 INTRODUCTION
 Mounting demand of fresh water and unexpected decline in fresh water resources have led
humans control their environment contaminating activities. Impact; however is much
unexpected resulting into extinction of species as well as decline in health friendly
atmosphere. Water constitutes major portion of living beings including all kinds of flora and
fauna. Consumption of water is amongst basic need of every living being whilst many
ecosystems are inside water which makes water conservation increased attention.
 Industrial usage of water is also crucial in reactions, domestic usage sewage, process waters,
utilities and many more. But quality on inlet and outlet needs some stringent monitoring and
justice before coming out of the premises. But we should not forget if chemicals and
processes make water polluted then its big role of chemicals and processes to make pure.
With modern technologies and innovative methods, humans have reached methods to make
water of ultimate purity but not as economical as we can get from nature.
 Industrial usage of water is also crucial in reactions, domestic usage sewage, process waters,
utilities and many more. But quality on inlet and outlet needs some stringent monitoring and
justice before coming out of the premises. But we should not forget if chemicals and
processes make water polluted then its big role of chemicals and processes to make pure.
With modern technologies and innovative methods, human shave reached methods to make
water of ultimate purity but not as economical as we can get from nature.
8.2 PARAMETERS
a) Inlet Wastewater Parameters
Sr.no Parameter Unit Inlet

1 pH - 6-7
2 Total Dissolved Solids mg /L < 500
3 COD mg / L 8000 – 9000
4 BOD mg / L < 800
5 Suspended Solids mg / L < 5000
6 Oil & Grease mg / L 50
Table 8.2.1 Table of waste water parameter inlet
b) Outlet Wastewater Parameters
Sr.no Parameter Unit Inlet

1 pH - 5.5-9.0
2 Total Dissolved Solids mg /L It may vary depending on
chemical dosing
3 COD mg / L 150
4 BOD mg / L 30
5 Suspended Solids mg / L 20
6 Oil & Grease mg / L 10
Table 8.2.2 Table of waste water parameter outet

Effluent & Sewage treatment plant
8.3 PROCESS DESCRIPTION
8.3.1 Pre – Treatment
1) Equalization Tank 1 & 2: To absorb variation in quantity and quality of effluent water and
to provide uniform flow at the downstream treatment process, equalization tanks was
provided. This will avoid shock loading and process upsets of the treatment plant. The
effluent shall be pumped by a set of collection pit Effluent Transfer Pump to the Equalization
Tank of MSFRP construction having liquid holding capacity of 50 m3 each.
 To maintain homogenous quality of effluent and to avoid settling of suspended solids in
these tanks, the equalization tanks was provided with coarse bubble diffusers & (1W+1S) Air
Blowers.
 Two number of equalization tanks are provided so that we can keep one in receiving mode
while the other transferring the effluent to further operation.
2) Reactor Tank 1 & 2: The equalized effluent from equalization tanks shall be pumped by a
set of Reactor Feed Pumps to the Reactor I & II wherein 10% Lime solution shall be dosed to
increase the pH of equalized effluent to 10.5 to 11.
 To maintain homogenous quality of effluent and to complete the reaction of chemicals the
reactors are provided with agitator in SS316 construction and pH analyser.
 Two reactors are provided so that we can keep one in receiving mode while the other
transferring the effluent to further operation.
3) Flash Mixer Tank: The chemically treated effluent shall be pumped by a set of Flash mixer
feed pump to Flash mixer. The Flash Mixer was in MSFRP construction and to complete the
reaction of chemicals the Flash Mixer was provided with high speed agitator in SS304
construction wherein 10% PAC solution shall be dosed to lower the pH of effluent to 8.0 to
8.5.
4) Flocculator Tank: The chemically treated effluent from Flash Mixer goes to Flocculator by
gravity. The Flocculator was in MSFRP construction and to formation of flocs the flocculator
was provided with slow speed agitator in SS304 construction wherein 0.1% anionic
Polyelectrolyte solution shall be dosed.
5) Primary Tube Settler: The flocculated water will enter the tube settler below the tube
media by gravity. The water will rise through the media where the flocculated mass will be
separated. Clear water will rise to the surface of tube settler and over flow in the outlet
launders.
Figure 8.3.1-1 Equalization Tank

45
8.3.2 Secondary Treatment
 Aeration Tank I & II: The Settler overflow shall be taken to Aeration Tank I followed by
aeration tank II by gravity.
 The Aeration Tank provides a suitable aerobic environment for heterotrophic and facultative
microorganisms to assimilate carbonaceous organic matter as a source of energy. The end
products of this process, known as Activated Sludge Process, are the production of new cells,
carbon dioxide and water.
 In the aeration tank sufficient aeration time shall be provided to obtain good growth of the
biomass. The oxygen required for the bio growth shall be provided by the Air Blowers
(1W+1S) and a suitable diffuser system.
 Each diffuser shall be suitably sized so as to ensure that the required amount of oxygen is
uniformly transferred into the surrounding effluent in the form of fine micro-bubbles. Air
manifolds with tubular diffusers extending on either side shall be installed and fastened at the
bottom of the Aeration Tank such that the entire assembly remains submerged even at low
liquid level in the aeration tank. A suitable lifting arrangement was provided capable of
hauling the diffusers out of the Aeration Tank for maintenance without stopping aeration
system (retrievable type diffusers). In order to maintain the amount of bacteria in the form of
MLSS, 1Kg/day of Bio culture to be added in Aeration tank i.e. half Kg in Aeration tank-l &
half kg in Aeration tank-ll.
 Secondary Tube Settler: The biologically treated water will enter the tube settler below the
tube media by gravity. The stabilized solids are subsequently removed in a Secondary Tube
Settler which immediately follows the Aeration Tank.
 The Secondary Tube Settler provides a quiescent environment that allows microorganisms
synthesized during aeration to settle thereby separating them from the clarified supernatant
overflow.
 The sludge which settles at the bottom of the secondary tube settler shall be recycled to
Aeration tanks to maintain required MLSS and excess sludge shall be taken to sludge drying
beds.
 The overflow from the secondary tube settler shall be collected in Filtered water tank.
Figure 8.3.2-1Aeration Tank
46
8.3.3 Tertiary Treatment
 Multi Grade Sand Filter & Activated Carbon Filter: Multi Grade Sand Filter (MGF) &
Activated Carbon Filter (ACF) is mainly provided to remove the Suspended Solids, COD
and traces of colour to meet the treated water quality for reuse.
 The MGF & ACF shall be vertical type and is constructed of FRP. The water pass through the
MGF & ACF shall be collected in treated water tank. The filters will be taken up for
backwash operation one at a time based on the differential pressure and as selected by the
operator. However, PSF is to be back washed at least once in a day irrespective of differential
pressure with the help of filter backwash pumps with treated water. The backwash water
shall be collected in equalization tanks. In the filters sufficient free board is provided to arrest
the escape of filter media while back washing the filters.
8.3.4 Sludge Dewatering
 The sludge dewatering system was provided for dewatering of the excess sludge from the
primary settler unit and secondary settler unit.
 Primary/ chemical sludge shall be taken to the sludge holding tank by primary sludge
transfer pumps (1W+1S).
 A sludge holding tank is provided to collect the separated sludge from the primary tube settler.
 Sludge from sludge holding tank shall be taken to Settler tank to thicken the sludge. The
overflow from the settler tank shall be taken back to leachate water tank.
 The thickened sludge from the settler tank shall be taken to volute press feed tank by screw
pumps from there it will be taken to volute press for dewatering. The filtrate shall be taken
back to equalization tanks from leachate water tank. The sludge from volute press shall be
taken to vacuum dryer to reduce the moisture content of the sludge so the same shall be
collected in bags to dispose to TSDF site. One by pass line has provided on screw pump line
to transfer sludge to sludge drying beds, when the volute press system was under
maintenance.
 Secondary/ biological sludge shall be taken to the sludge drying beds as well as to aeration
tank I & II by sludge recycle pumps (1W+1S). Leachate from the drying beds shall be taken
back to equalization tank through leachate transfer pump.
Figure 8.3.4-1 Sludge Thickener
47
CHAPTER 9: SEWAGE TREATMENT PLANT (STP)
9.1 INTRODUCTION
 Sewage treatment (or domestic wastewater treatment, municipal wastewater treatment) is a

type of wastewater treatment which aims to remove contaminants from sewage to
produce an effluent that is suitable to discharge to the surrounding environment or an
intended reuse application, thereby preventing water pollution from raw sewage discharges.
Sewage contains wastewater from households and businesses and possibly pre-treated
industrial wastewater. There are a high number of sewage treatment processes to choose
from. These can range from decentralized systems (including on-site treatment systems) to
large centralized systems involving a network of pipes and pump stations (called sewerage)
which convey the sewage to a treatment plant.
 A large number of sewage treatment technologies have been developed, mostly using
biological treatment processes. Design engineers and decision makers need to take into
account technical and economic criteria of each alternative when choosing a suitable
technology.
9.2BFD OF SAWAGE TREATMENT PLANT
Sewage Feed 1. Sedimentation & separation

Effluent Collection 2. Anaerobic Treatment
Collection pit Tank 3. MBBR Chamber
4. Sedimentation & disinfectant
Final treated water collection A C F PSF Filter feed Tank
Treated Sewage Effluent reused
Back Wash
Sewage Collection Tube

Figure 9.2.1-1 BFD of Sewage Treatment Plant
48
9.3PROCESS DISCRIPTION
 First of all, collect all the Sewage and treated water from rest rooms and effluent treatment
plant.
 Collect all the sewage in 1KL Sewage collection pit via pumps.
 After that sewage is transfer into feed collection tank.
 The feed is transfer in to treatment chamber where sewage is treated into 4 steps.
 The first step is sedimentation and separation in this the sewage is separated by the help of
gravitational force. And semi dense impurities are settle down at the bottom of the treatment
chamber.
 After sedimentation the water is transferred from the top into anaerobic chamber.
 Anaerobic treatment cycle involves wastewater entering a bioreactor receptacle containing a
thick semi-solid substance called sludge, full of anaerobic bacteria and other microorganisms
which break down the organic contaminants present in the wastewater.
 It use microorganisms to break down organic contaminants in wastewater.
 Anaerobic chamber are working in the absence of oxygen.
 After breaking the organic contaminants further is allowed to sedimentation with disinfectant
phenyl tablets.
 The treated water is filter in the two types of filter.
 First it will be passed from PSF (Pressure sand filter), where al the colloidal impurities are
remove by passing into the sand filter.
 Secondly the water is filtered by ACF (Active charcoal Filter).
 This filter contain charcoal as filter media, which is filter all the dust impurities.
 Finale treated water is collected in treated collection tank.
 Remaining impure sludge are collected as solid waste.
 The treated water are used as sewage effluent reused.
Plant Layout
CHAPTER 10: PLANT LAYOUT
 PLANT LAYOUT
 Layout of a plant can play an important part in determining construction and

manufacturing costs, and thus must be planned carefully with attention being given to
future problems that may arise. Since each plant differs in many ways and no two-plant
sites are exactly alike, there is no one ideal plant layout.
 However, proper layout in each case will include arrangement of processing areas,
storage areas, and handling areas in efficient coordination and with regard to such factors
as:
1) New site development or addition to previously developed site.

2) Type and quantity of products to be produced.
3) Possible future expansion
4) Operational convenience and accessibility
5) Type of process and product control
6) Economic distribution of utilities and services
7) Type of process and product control
8) Economic distribution of utilities and services
9) Health and safety considerations
10) Waste-disposal problems
11) Auxiliary equipment
12) Space available and space required
13) Roads and railroads
 Preparation of the Layout:
 Scale drawings, complete with elevation indications, can be used for determining the best
location for equipment and facilities. Elementary layouts are developed first. These show
the fundamental relationships between storage space and operating equipment. The next
step requires consideration of the operational sequence and gives a primary layout based
on flow of materials, unit operations, storage, and future expansion. Finally, by analyzing
all the factors that are involved in plant layout, a detailed recommendation can be
presented, and drawings and elevations, including isometric drawings of the piping
systems, can be prepared. Three- dimensional models are often made.
50
Plant Layout
 Errors in a plant layout are easily located when three-dimensional models are used, since the
operations and construction engineers can immediately see errors, which might have escaped
notice on two dimensional templates or blueprints. In addition to increasing the efficiency of
a plant layout, models are very useful during plant construction and for instruction and
orientation purposes after the plant is completed.
Figure 10.1.-1 Plant Layout
51
Plant Layout
Figure 10.1-2 BFD of Plant Layout
52
Conclusion
CONCLUSION
After completing this 12-week industrial internship I got the interesting knowledge about
industries and have learned about Polymer industries. PIDILITE INDUSTRIES LIMITED,
DAHEJ is a very good place for me to enhance my knowledge practically.
I have learned about various types of Chemicals and their properties. I also have learned about
various types of reactors, filters, DSC system, Blender, Blowdown, conveying Equipment’s,
storage Equipment’s etc. I also got the knowledge of how the equipment working and their uses.
I have learned about various types of unit process and unit operations. I got the knowledge about
Automation (DCS) in pidilite Industries. I also have learned about polymerization, emulsion
polymerization, Addition polymerization etc. I got knowledge about demineralized water plant
and their operating procedure. I have learned about how to solve different different problem
during handling and production of. I also got the knowledge about how the ETP and STP can be
worked, operating procedure of the ETP & STP plant. I got the knowledge of process safety,
various personal protective Equipment’s (PPEs), work permits, color coding, safety symbols and
material safety data sheet (MSDS) of different chemicals. I have learned about waste handling
and hazardous waste managements. I got the knowledge of process flow diagrams (PFD). I have
learned about how to apply theoretical knowledge we get in our academic period into real life
problems.
Overall, My 12-week industrial training at Pidilite Industries Limited, Dahej was a great
opportunity for me to improve my skills and practical knowledge. I am confident that the
knowledge and experienced gained during my training will be useful in my future carrier.
53
National Institute Of Technology Warangal Telangana
References
REFERENCES
1) Seider, W.D., Lewin, D.R., Seader, J.D., & Widagdo, S. (2017). Product and Process Design
Principles: Synthesis, Analysis, and Evaluation. John Wiley & Sons.
2) Sinnott, R.K. (2005). Chemical Engineering Design: Principles, Practice and Economics of Plant and
Process Design. Elsevier.
3) Turton, R., Bailie, R.C., Whiting, W.B., & Shaeiwitz, J.A. (2018). Analysis, Synthesis, and Design
of Chemical Processes. Pearson Education.
4) Kern, D. Q., & Kern, D.Q. (1950). Process heat Transfer (Vol. 5). New York: McGraw-Hill.
5) Gupta, C.P. (1976). Engineering Heat Transfer (SI Units). Nem Chand & Bros.
6) PIdilite Industries Limited https://pidilite.com/
7) Kreiger, M., & Pearce, J. M. (2013). Environmental life cycle analysis of distributed three-
dimensional printing and conventional manufacturing of polymer products. ACS Sustainable
Chemistry & Engineering, 1(12), 1511-1519.
8) Saleh Alghamdi, S., John, S., Roy Choudhury, N., & Dutta, N. K. (2021). Additive manufacturing of
polymer materials: Progress, promise and challenges. Polymers, 13(5), 753.
9) Wu, C., Xu, F., Wang, H., Liu, H., Yan, F., & Ma, C. (2023). Manufacturing technologies of
polymer composites—A Review. Polymers, 15(3), 712.
10) Budzik, G., Woźniak, J., Paszkiewicz, A., Przeszłowski, Ł., Dziubek, T., & Dębski, M. (2021).
Methodology for the quality control process of additive manufacturing products made of polymer
materials. Materials, 14(9), 2202.
11) Silva, D. C., & Oliveira, N. M. (2007). Model based design of polymer product. In Computer Aided
Chemical Engineering (Vol. 24, pp. 455-460). Elsevier.
12) Bakulin, V. N., Larin, A. A., & Reznichenko, V. I. (2015). Improving the quality of manufacture of
polymer-composite products using computed tomography as a nondestructive-testing method.
Journal of Engineering Physics and Thermophysics, 88(2), 556-
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References
55

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INTERNSHIP AT PIDILITE INDUSTRIES LIMITED,

In partial fulfillment for the award of the degree of

National Institute Of Technology Warangal

Between BKM Science College and Government

Polytechnic, Tithal Road, Valsad-396001.

Prof. A.V. PATEL Prof. N. M. Patel

Internal Guide Head of Department

Gujarat Technological University Warangal ,Telangana

Gujarat Technological University Warangal ,Telangana

Name of Student Sign of Student

RAVAL PRATIK KUMAR JITENDRA KUMAR

Gujarat Technological University Warangal ,Telangana

I express my sincere gratitude to Dr. N. M. Patel, Head of Chemical Engineering Department,

The training aimed to:

Throughout the training period, significant insights were acquired in:

Figure 1.1-1 Company profile...................................................................................................1

Table 1.11-1 List of raw material...............................................................................................3

 List of Abbreviations used at Pidilite industries limited

1.1 Compony Profile:

Core Values and Commitment to Quality

Market Leadership and Brand Trust

Figure 1.1-1 Company Profile

1.3 Research Center:

1.4 Researching Ground Breaking Ideas:

1.5 Sustainable Development:

1.6 Recycling Partners:

 Pidilite is committed to minimize environmental impact through its partner network of

1.7 A Global Presence:

1.8 Global Impact:

 We understand the importance of maintaining global perspectives in a shrinking world. That’s

1.9 Pidilite Company Brands:

1.10 Industrial Products:

 Textile & Paper Chemicals

1.11 LIST OF RAW MATERIAL:

Table 1.11-1 List of Raw Material

1.12 PROPERTIES OF RAW MATERIAL:

i. Chemical & Physical Properties of Styrene: -

Molecular weight 104.15 g/mol

Table 1.12-1 List of chemical & physical Properties of Styrene

ii. Chemical & Physical Properties of Butyl Acrylate: -

Molecular weight 128.17 g/mol

Table 1.12-2 List of chemical & physical Properties of Butyl Acrylate

iii. Chemical & Physical Properties of Ethyl Acrylate: -

Molecular weight 100.12 g/mol

Table 1.12-3 List of chemical & physical Properties of Ethyl Acrylate

Molecular weight 53.06 g/mol

Table 1.12-4 List of chemical & physical Properties of Acrylo Nitrile

v. Chemical & Physical Properties of Methyl Methacrylate: -

Molecular weight 100.12 g/mol

Table 1.12-5 List of chemical & physical Properties of Methyl Methacrylate

vi. Chemical & Physical Properties of Acrylic Acid: -

Molecular weight 72.06 g/mol

Table 1.12-6 List of chemical & physical Properties of Acrylic Acid

vii. Chemical & Physical Properties of Methacrylic Acid: -

Molecular weight 86.09 g/mol

Table 1.12-7 List of chemical & physical Properties of Methacrylic Acid

CHAPTER 2: SAFETY MEASURES AT PLAT SITE

2.1 STATUTORY COMLIANCE FOR SAFETY

 Company is having well-established safety department along with well-qualified safety

1) Various types of work permit systems.

2.2 GENERAL SAFETY GUIDELINES

i) Dematching at main gate.

2.2.1 GENERAL SAFETY GUIDELINES FOLLOWED BY EMPLOYEES

 It is responsibility of employee to play his/her role in team. It is responsibility of