Industrial Internship On Production In Chemical Engineering

By

Jatin Rajeshbhai Viradiya

Enrollment No.: 2021002170810028

Guided by Vishal Kuril

Assistant Professor Chemical Engineering Department
L J INSTITUTE OF ENGINEERING AND TECHNOLOGY, AHMEDABAD

A Report Submitted To
LJ University in Partial Fulfillment of the Requirements for the Bachelor of Engineering
Degree in Chemical Engineering May, 2025

L J INSTITUTE OF ENGINEERING AND TECHNOLOGY

AHMEDABAD
 Lok Jagruti Kendra University,
Ahmedabad
May, 2025

L J Institute of Engineering and Technology

LJ Campus, LJ College Road,
Off. S.G. Road Ahmedabad-382210

CERTIFICATE
This is to certify that the project report submitted along with the project entitled Industrial Internship

On Production In Chemical Engineering has been carried out by Jatin Rajeshbhai Viradiya under

my guidance in partial fulfillment for the degree of Bachelor of Engineering in Chemical Engineering, 8th

Semester of Lok Jagruti Kendra University, Ahmadabad during the academic year 2024-25.

Pro. Vishal Kuril Mr. Hiren Makwana

Internal Guide Head of the Department

 L J Institute of Engineering and Technology
LJ Campus, LJ College Road,
Off. S.G. Road Ahmedabad-382210

DECLARATION

We hereby declare that the Internship / Project report submitted along with the Internship / Project entitled

Industrial Internship On Production In Chemical Engineering submitted in partial fulfillment for

the degree of Bachelor of Engineering in Chemical Engineering to Lok Jagruti Kendra University,

Ahmedabad, is a Bonafede record of original project work carried out by me / us at UPL LIMITED

under the supervision of Vikas Kumar 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.

Jatin Rajeshbhai Viradiya

Name of the Student Sign of Student

 ACKNOWLEDGEMENT

I wish to express our sincere gratitude to my supervisors Jatin Rajeshbhai Viradiya for
continuously guiding me at the company and answering all my doubts with patience. I would also
like to thank my mentor Vikas Kumar for helping us through our internship by giving us the
necessary suggestions and advices along with their valuable co-ordination in completing this
internship.

We also thank our parents, friends and all the members of the family for their precious support and
encouragement which they had provided in completion of our work. In addition to that, we would
also like to mention the company personal who gave us the permission to use and experience the
valuable resources required for the internship.

Thus, in conclusion to the above said, we once again thank the staff members of UPL LIMITED
for their valuable support in completion of the Internship.

I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with all of
you in the future.

I
 ABSTARCT

Over the course of three month internship at UPL LTD, I delved into the intricate
world of heavy equipment manufacturing and mechanical engineering. Each week
presented unique challenges and learning opportunities. Initially, I familiarized
myself with the company's mission and values, shadowing seasoned professionals to
understand crane production processes. I honed my skills in SolidWorks, mastering
3D modeling and drafting techniques to design essential components like end
carriages, wire rope hoists, and wheel assemblies. Throughout the internship, I
collaborated with industry experts, absorbing insights into best practices and
emerging technologies. From calculating costs to refining design specifications,
each project deepened my understanding of engineering principles and fueled my
passion for the field. In conclusion, this internship equipped me with practical skills
and knowledge essential for a successful career in mechanical engineering and
crane manufacturing.

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 TABLE OF CONTENTS

Title Page i
College Certificate ii
Declaration iii
Acknowledgement iv
Abstract v
Table of Contents vi
List of Abbreviations vii
List of Nomenclature viii
List of Figures ix
List of Tables x
Chapter 1 Introduction 4
Chapter 2 Product Details 7
Chapter 3 Raw material 9
Chapter 4 Tank Farm Details 13
Chapter 5 Colour Code 14
Chapter 6 Utilities 16
Chapter 8 Process Block Diagram 21
Chapter 9 Process Flow Diagram 22
Chapter 10 Process Discription 24
Chapter 11 Material Balance 35
Chapter 12 Energy Balance 38
44
Chapter 13 Equipment Design
54
Chapter 14 modification 55
Chapter 15 Safety Health & Environment 56
Chapter 16 References 67

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 LIST OF ABBREVIATIONS

ISO International Organization for Standardization

IUPAC International Union of Pure and Applied Chemistry
GIDC Gujarat industrial Development Corportion
MW Mega Watt
GDP Gross Domestic Product
OEM Original Equipment Manufacturer
km kilo meter
kg kilo gram
kmol kilo mole
SA Steel Alloy
Gr Grade
MOC Material of Construction
ETP Effluent Treatment Plant
FCI Fixed Capital Investment
PBT Profit Before Tax
PAT Profit After Tax
Rs Rupees
HTC Heat Transfer Coefficient

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 LIST OF NOMENCLATURE

Symbol Term Unit

Cp Specific Heat kJ/mol K

m Mass Flow Rate kg/hr

Q Heat Flow Rate kJ/hr

∆H°f Heat of Formation kJ/mol

∆H°r Heat of Reaction kJ/mol

ρ Density kg/m3

P Pressure kgf/cm2

T Temperature °C or K

Rm Minimum Reflux Ratio

R Reflux Ratio

Hv Latent heat of Condensation kJ/kg

t Thickness of plate mm
L Length m or cm or mm
D Diameter m or cm or mm
H Height m or cm or mm

W weight kg

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 LIST OF FIGURES

Figure Title of Figures

No.
1. Bottle of pendimethalin
2. Other company pendimethalin bottle
3. Refrigeration cycle
4. Induced draft cooling tower
5. PSA
6. Process block diagram
7. Process flow diagram
1. Hydrogination Block diagram
2. DEK Recovery Block diagram
3. Nitration Block diagram
4. Concentration unit Block diagram
9.5.1 CDN Block diagram
9.6.1 FFE EDC Recovery Block diagram
9.7.1 TDN Block diagram
9.8.1 Heptane Dissolution Block diagram
9.9.1 TDN Washing Block diagram
9.10.1 Flaker machine
12.1 Reactor
1. Gas induction type tube stirrer
2. Emergency siren codes & Evacuation
3. Work permit system
4. Fire
5. Class Fire & suitable Fire Extinguisher
6. HAZCHEM CODE
7. PPE
8. SCBA kit
9. ELCB & RCCB
10. LOPA

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 LIST OF TABLES

Table Title of Table

No.
2.1 Physical properties of pendimethalin
4.1 Raw materials
4.2 DEK Physical properties
6.1 Colour codes
10.1.1 Hydrogination Reactant
10.1.2 Hydrogination product
10.2.1 DEK Recovery Reactant
10.2.2 DEK Recovery product
10.3.1 Nitration Reactant
10.3.2 Nitration product
10.4.1 CDN Reactant
10.4.2 CDN product
12.1 Design of reactor shell
12.2 Design of Top & Bottom Head of reactor shell
12.3 Design of plain jacket
12.4 Design of bracket support

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 INDEX

TITLE PAGE I
COLLEGE CERTIFICATE II
INDUSTRY CERTIFICATE III
COMPLETION CERTIFICATE IV
DECLARATION V
INTERNSHIP APPROVAL CERTIFICATE VI
TABLE OF CONTENTS VII
ACKNOWLEDGEMENT IX
ABSTRACT X
LIST OF ABBREVIATIONS XI
LIST OF NOMENCLATURE XII
LIST OF FIGURES XIII
LIST OF TABLES XIV

CHAPTER 1: ABOUT COMPANY ........................................................................................ 4

CHAPTER 2: PRODUCT DETAILS....................................................................................... 7
CHAPTER 3: RAW MATERIALS .......................................................................................... 9
CHAPTER 4: TANK FARM DETAILS................................................................................... 13
CHAPTER 5: COLOUR CODES........................................................................................ 14
CHAPTER 6: UTILITIES ................................................................................................... 16
1. Chilling plant: ........................................................................................................... 16
2. Cooling tower: ......................................................................................................... 18
3. N2 Production by PSA: ............................................................................................. 19
CHAPTER 7: PROCESS BLOCK DIAGRAM ....................................................................... 21
CHAPTER 8: PROCESS FLOW DIAGRAM ......................................................................... 22
CHAPTER 9: PROCESS DISCRIPTION ............................................................................. 24
1. Hydrogenation Reaction:.......................................................................................... 24
2. DEK Recovery: ......................................................................................................... 26
3. Nitration: ................................................................................................................. 27
4. Concentration unit:.................................................................................................. 28
5. Chemical Denitrosation: .......................................................................................... 28
6. FFE EDC Recovery: .................................................................................................. 29
7. Thermal Denitrosation: ............................................................................................ 30
8. Heptane Dissolution: ............................................................................................... 31
9. TDN washing: .......................................................................................................... 32

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9.10 Flaker machine: ..................................................................................................... 33
CHAPTER 10: MATERIAL BALANCE................................................................................. 35
1. HYDROGENATION REACTOR:................................................................................. 35
2. DEK RECOVERY: .................................................................................................... 36
3. NITRATION REACTOR: ............................................................................................ 37
4. CDN REACTOR: ..................................................................................................... 37
CHAPTER 11: ENERGY BALANCE ................................................................................... 38
1. Hydrogenation Energy Balance : ............................................................................. 39
2. Nitration energy balance :....................................................................................... 41
3. CDN (Chemical Dinitrosiation) energy balance :...................................................... 43
CHAPTER 12: EQUIPMENT DESIGN ................................................................................ 44
1. Design of Reactor Shell: ......................................................................................... 46
2. Design of Top C Bottom head of reactor shell: ......................................................... 48
3. Design of plain jacket: ............................................................................................ 50
4. Design of bracket support: ..................................................................................... 53
CHAPTER 13: MODIFICATIONS...................................................................................... 54
CHAPTER 14: SAFETY, HEALTH AND ENVIRONMENT....................................................... 56
15: REFERENCES .......................................................................................................... 67

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 CHAPTER 1: ABOUT COMPANY

UPL Ltd, founded in Mumbai, India, in 1969, is a global producer and distributor of
agrochemicals and specialty chemicals. Over the years, UPL has expanded its global
footprint by setting up subsidiaries and joint ventures in several countries. In 2000, UPL
became a publicly listed company on the Bombay Stock Exchange and the National Stock
Exchange of India. Since then, it has made several acquisitions to strengthen its presence
in different markets. In 2019, UPL completed the acquisition of Arysta LifeScience for
$4.2 billion, making it one of the largest crop protection companies in the world. Today,
UPL operates in over 130 countries and has a diverse portfolio of products ranging from
pesticides and seeds to biostimulants and digital farming solutions. In 2021, UPL changed
its name from United Phosphorus Ltd to UPL Ltd to reflect its expanding business beyond
phosphorus-based products. With its strong global presence and focus on innovation, UPL
is poised to continue its growth in the agrochemical and specialty chemicals industry.

UPL Ltd is a leading global producer and distributor of a diverse range of agrochemicals
and specialty chemicals. UPL's portfolio includes insecticides, herbicides, fungicides,
rodenticides, and plant growth regulators, as well as biostimulants, micronutrients, and
adjuvants. In addition, UPL has a strong presence in the seed business, offering a wide
range of seeds for various crops. UPL's digital farming solutions, such as weather
forecasting and crop management tools, enable farmers to improve crop yield and quality
while reducing input costs. The company's specialty chemicals portfolio includes industrial
chemicals, performance products, and surfactants used in various industries, including

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textiles, personal care, and oil and gas. UPL's focus on innovation and sustainability has
led to the development of several novel products, such as biologicals and biopesticides,
that offer effective and environmentally friendly solutions for crop protection. With such
a diverse and innovative product portfolio, UPL is well-positioned to address the evolving
needs of farmers and industries worldwide.

Some examples of products from UPL's portfolio:

• Insecticides: Atanor, Trivor, Votivo, Ultor

• Herbicides: Adengo, Finesse, Samaritan, Strident
• Fungicides: Unizeb Gold, Unizeb Plus, Unizeb Ultra, Helicop
• Plant growth regulators: Apogee, Concero, Moddus, Regalis
• Biostimulants: Unium, Anther, Biosol Forte, Bioteca
• Micronutrients: Ultrasol, Micromax, Nutriplus, Nutrifeed
• Adjuvants: Sticman, Droplet, Tank Mix, Wetcit
• Seeds: corn, soybean, cotton, rice, sunflower, and vegetables
• Biologicals: BioSpore, Biozyme, Biofert, Bioseed
• Performance products: surfactants, defoamers, emulsifiers, and solvents

UPL Ltd's Unit 5 Jhagadia is a manufacturing plant located in the state of Gujarat, India.
The facility covers an area of 143 acres and has a production capacity of 34,800 metric
tonnes per annum. The plant produces a wide range of agrochemicals, including
insecticides, herbicides, and fungicides, as well as specialty chemicals used in various
industries.

Unit 5 Jhagadia is a state-of-the-art facility that adheres to the highest safety, health, and
environmental standards. The plant is equipped with modern manufacturing technologies,
including continuous processes and automated packaging systems, which ensure high-
quality products and efficient operations.

In addition to manufacturing, Unit 5 Jhagadia is also involved in research and development

activities. The plant has a dedicated R&D center that focuses on the development of new
and innovative products, as well as improving the efficiency and sustainability of existing
products.
Unit 5 Jhagadia is an important part of UPL's global manufacturing network and

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contributes significantly to the company's growth and success. With its focus on
innovation, safety, and sustainability, Unit 5 Jhagadia is well-positioned to continue to
meet the evolving needs of the agrochemical and specialty chemicals industries.

Some examples of chemicals produced at UPL's Unit 5 Jhagadia:

• Pendimethalin: A selective herbicide used for pre-emergent control of grasses

and broadleaf weeds in various crops.
• Triazophos: An insecticide used to control a wide range of pests in crops, including
cotton, rice, and vegetables.
• Azoxystrobin: A fungicide used to control various fungal diseases in crops, such as
rust and powdery mildew.
• Fomesafen: A herbicide used for post-emergent control of broadleaf weeds in crops
such as soybean and peanuts.
• Tebuthiuron: A herbicide used for non-selective control of woody and
herbaceous plants in non-crop areas.

• Glufosinate is another example of a chemical produced at UPL's Unit 5 Jhagadia.

Glufosinate is a non-selective herbicide used to control a broad spectrum of weeds in
various crops, including cereals, oilseeds, and vegetables. It is also used as a desiccant in
certain crops, such as cotton and potatoes, to facilitate harvesting.

• UPL's Unit 5 Jhagadia produces high-quality glufosinate using advanced manufacturing

processes and strict quality control measures. The plant has a robust R&D program focused
on developing new and innovative formulations of glufosinate to meet the evolving needs
of farmers and the agricultural industry.

• UPL is one of the leading global producers of glufosinate, with manufacturing facilities
located around the world, including at UPL's Unit 5 Jhagadia in India. The company
produces glufosinate using advanced manufacturing technologies, including fermentation
and chemical synthesis.

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CHAPTER 2: PRODUCT DETAILS

It is mostly used as preemergent herbicide.

Structure:

Figure 2.1
➢ Formula: C13H19N3O4
➢ Spgr: 1.17
➢ It is an orange-yellow dye and stains hair and vinyl floor coverings. White hair stains
green.
➢ Pendimethalin protects crops like wheat, corn, soybeans, potatoes, cabbage, peas, carrots,
and asparagus. It is used to control annual grasses and certain broadleaf weeds which
interfere with growth, development, yield and quality of agricultural and horticultural
crops by competing on nutrients, water and light.
➢ Product price: 400Rs / Litre
➢ Market competitors:
1. IFFCO
2. Gharda chemical limited
3. Atul industries
4. PI industries
Figure 2.2

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Physical properties of pendimethalin:

Acute toxicity of pendimethalin:

Table 2.1

➢ Odour:
Faint, nutty odour
➢ Melting Point:
56-57 ℃
➢ Boiling Point:
Decomposes on distillation

➢ Solubility:
Soluble in most organic solvents
➢ Vapor Pressure
0.00003 [mmHg]

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CHAPTER 3: RAW MATERIALS
1. RAW MATERIALS

Table 3.1

No. RM MOC Spgr

1 DEK SS304L 0.81
2 EDC CS 1.26
3 NaOH CS 1.32
4 HNO3 SS304L 1.5
5 H2SO4 MS 1.84
6 HCl PVDF-FRP 1.19
7 4-NOX SS316 1.13
8 Mix Acid SS316 1.45
9 HCl + Acetone PP-FRP 1.16
10 1% HCl PP-FRP 1
11 Acetone SS316 0.79
12 Heptane CS 0.68

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2.DEK:
Physical properties:
Table 3.2

Molar Mass 86.13

Density 0.813 g/mL at 25 °C (lit.)

Melting Point -42 °C (lit.)

Boling Point 101.5 °C (lit.)

Flash Point 55°F

Water Solubility 50 g/L (20 ºC)

Solubility water: slightly soluble

Vapor Pressure 20 mm Hg ( 28 °C)

Vapor Density 3 (vs air)

Appearance Liquid

Colour Clear colourless

TLV-TWA 705 mg/m3 (200 ppm)

Exposure Limit
(ACGIH).

Merck 14,3121

BRN 635749

PH 6.2 (50g/l, H2O, 20℃)

Storage
Store below +30°C.
Condition

Stable. Highly flammable. Readily

forms explosive mixtures with air.
Stability Incompatible with strong bases,
reducing agents, strong oxidizing
agents.

Explosive Limit 1.6-7.7%(V)

Refractive Index n20/D 1.392(lit.)

Physical and Character: colourless liquid.

Chemical melting point -42 ℃
Properties boiling point 101.7 ℃
relative density 0.8136

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refractive index 1.3927
soluble in ethanol, ether.

DEK – Risk & Safety

R11 - Highly Flammable

R37 - Irritating to the respiratory system
Risk Codes
R66 - Repeated exposure may cause skin dryness or cracking
R67 - Vapours may cause drowsiness and dizziness

S9 - Keep container in a well-ventilated place.

Safety S16 - Keep away from sources of ignition.
Description S25 - Avoid contact with eyes.
S33 - Take precautionary measures against static discharges.

UN IDs UN 1156 3/PG 2

WGK
1
Germany

RTECS SA8050000

TSCA Yes

HS Code 2914 19 90

Hazard
3
Class

Packing
II
Group

LD50 orally in rats: 2.1 g/kg, Smyth et al., Arch. Ind. Hyg. Occup. M
Toxicity
ed. 10, 61 (1954)

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3.EDC :
Properties:

1) Molecular weight: 98.96g/mol

2) Boiling point: 83.6 °C
3) Melting point: 36 °C
4) Flash point: 13 °C
5) Vapor pressure: 102.47 KPa at 25°C
6) Specific gravity of liquid (water=1): 1.2455 at 20°C
7) Relative vapor density/air: 1 Kg/m3 at 20°C

Uses:
The largest use for Ethylene Dichloride is in the production of Vinyl Chloride Monomer
(VCM). More than half of the total VCM consumption is for construction-related
applications, with pipe being the largest single product. Other products made from PVC
resins include flooring, packaging film and sheet, and bottles.

• SBC:
Properties:
Sodium bicarbonate appears as odourless white crystalline powder or lumps. Slightly
alkaline (bitter) taste. pH (of freshly prepared 0.1 molar aqueous solution): 8.3 at 77 °F.
pH (of saturated solution): 8-9. Non-toxic.

• 10% NaOH:

Properties:
CAS-No.: 1310-73-2
a) Physical state liquid
b) Colour colourless
c) Odour odourless

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CHAPTER 4: TANK FARM DETAILS

4-NOX Storage tank (125 kL)

Molten NOX Storage tank (60.8 kL)
32% NaOH Storage tank (24.5 kL)
98% H2SO4 Storage tank (72 kL)
DEK Storage tank (122 kL)
70% HNO3 Storage tank (72 kL)
EDC Storage tank (37 kL)
UG Water storage tank (12000 kL)

➢ Storage on ground floor:

Hydrogenation effluent tank (5 kl)

DEK + NAX hold tank (15.4 kl)
Nitration spent acid tank (25.3 kl)
Nitration effluent tank (5.8 kl)
Nitrated mass hold tank (5 kl)
CDN spent acid tank (10 kl)
CDN decanter organic vessel (2.5 kl)
Mixer settler tank i,ii,iii (5.7 kl, 7.5 kl, 5.7 kl)
Caustic aqueous tank (4.4 kl)
1% HCl aqueous tank (5 kl)
Water aqueous tank (5 kl)
SBC solution hold tank (7.5 kl)
TDN to feed hold vessel (15.6 kl)
Nitration scrubber tank (5 kl)
CDN scrubber tank (5 kl)
Recovered EDC collection tank (4 kl)
TDN feed hold vessel (20 kl)
Recovered DEK (15 kl)
Washed TDN mass hold tank (5 kl)
Washed TDN (16.8 kl)
Recovered heptane collector tank (14.3 kl)
Weak HNO3 (5 kl)
H2SO4 tank unit (17 kl)
70% H2SO4 day tank (5 kl)
Hot water vessel (10.3 kl)
Flaker feed vessel (3.8 kl)

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CHAPTER 5: COLOUR CODES

Table 5.1
UTILITIES

Sr no. Stream Colour Shade

1 Cooling Sea green 217
water in
2 Cooling Sea green 217
water out
3 Chilled Canary 309
water in yellow
4 Chilled Canary 309
water out yellow
5 Chilled Satin blue 177
brine in
6 Chilled Satin blue 177
brine out
7 Process Satin blue 177
water
8 Hot water Sea green 217

9 Hydrant Fire red 536

water
10 Breathing Satin blue 177
air
11 Instrument Satin blue 177
air
12 Nitrogen Canary 309
yellow
13 HP steam Fire red 536

14 MP steam Phirozzi 176

blue
15 LP steam Dark 412
brown
16 Condensate Black
return

CHEMICALS

1 Hydrogen Canary 309

yellow
2 DEK White

3 4-NOX Crimson 540

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4 EDC Sea green 217

5 H2SO4 Dark 796

violet
6 Nitric acid French 166
blue
7 Spend acid White

8 HCl liquid Dark 796

violet
9 Acetone Dark 632
admiralty
grey
10 Caustic lye Smoke 692
grey
11 Heptane Light 697
admiralty
grey
12 Vacuum Satin blue 177
stream
13 Aq. Waste Black
(org+NaCl)
14 Waste water Black
condensate
15 RO Light 410
permeate brown
16 Treated India 284
sewage green
effluent
17 Mixed Oxford 105
process blue
streams

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CHAPTER 6: UTILITIES

• Utilities are the streams which does not take part into the reaction directly but
indirectly helps for the completion of the reaction.
• They are used in a process plant in various forms and provides the services like
heating, cooling, drying etc.
• As we know that for any reaction to start some amount of activation energy is
required which is supplied by these utilities.
• These utilities are also used to maintain the reaction temperature in case of
exothermic reaction.

• In short, the utilities are very important part of any process plant.
• In my plant the following utilities are used for various purposes like mentioned
above:
1) Child Water
2) Cold Water
3) Hot air
4) Steam
5) Hot oil

6.1Chilling plant:
Figure-6.1 Refrigeration cycle

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Working principle:

• This plant is based on the refrigeration cycle in which ammonia is used as a

refrigerant.

• The chilling plant consists an evaporator, condenser, expansion valve and

compressor.
a) Compressor: The compressor has dual purpose in the refrigeration cycle, first is to
maintain pressure difference in the cycle and the second purpose is to compress the
ammonia vapor and convert it into liquid vapor mixture.
b) Evaporator: It is a heat exchanger in which cold water flows on tube side and the
liquid ammonia flows on the shell side.
c) Expansion valve: It is also called throttled valve in which expansion of the ammonia
vapor-liquid mixture take place.
d) Condenser: It is a shell and tube type heat exchanger in which ammonia flows on
shell side and cold water on tube side.
Working

• First the refrigerant ammonia enters into the evaporator which is a shell and tube type
heat exchanger in which cold water and liquid ammonia exchanges heat with each
other and ammonia gets vaporized by absorbing the heat from the water because of
which chilled water gets produced.
• In next step the vaporized ammonia vapor-liquid mixture enters into compressor
which compresses the vapor liquid mixture of ammonia to high pressure mixture
place which enters into the condenser where its condenser and liquid ammonia gets
formed which enters into the expansion valve in which the high pressure liquid
ammonia gets converted into low pressure liquid ammonia which further enters into
the evaporator and this cycle continues.

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6.2 Cooling tower:

Figure-6.2 Induced draft cooling tower

• Working principle: When warm liquid is brought into contact with unsaturated gas,
part of the liquid evaporates and the liquid temperature drops.
• The cooling tower are used 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-diameter columns with special types of packing which are
designed to give good gas-liquid contact with low pressure drop. The warm water in
the cooling tower is distributed over the packing by spray nozzles or a grid of notched
troughs or pipes. Then the air ispassedsimultaneously 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:
1) Cross flow tower
2) Counter flow tower
• In the company they are using counter flow type cooling tower.
• In the counterflow tower, air enters below the layer of fill and passes upward
countercurrent to the flow of descending water. This is a more efficient arrangement
for heat transfer and permits a closer temperature approach. The counterflow tower
can be used with a forced-draft fan at the base of the tower, but a large space below
the fill is needed for good air distribution.

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• The reduction in water temperature in the cooling tower comes mainly from
evaporation, although when the air temperature is low, there is also some sensible-
heat transfer to the air. However, even when the air is warmer than the water, water
can be cooled by evaporation if the wet-bulb temperature is below that of the water. In
practice, the discharge temperature of the water is 5 to 15°F (3 to 8°C) above the wet-
bulb temperature, and this difference is known as the approach. The change in water
temperature from inlet to exit is known as the range, and the range is generally 10 to
30°F (6 to 17°C).
• The loss of water by evaporation during cooling is small. Since about 1,000 Btu is
required to vaporize 1 lb of water, and 50 lb must be cooled 20°F to provide 1,000 Btu,
a range of 20°F means an evaporation loss of 2 percent. In addition, there are losses
of spray droplets, referred to as drift or windage, but in a well-designed lower these
amount to only about 0.2 percent. The total makeup water supplied must equal the
evaporation and drift losses plus the amount of purge or blowdown needed to limit
the build-up of dissolved salts.
Selection criteria for cooling tower:
• The average and maximum heat duty, the required temperature range, the availability
and quality of makeup water, and the local weather conditions. The tower is often
sized to satisfy all but the most extreme conditions, such as when the wet-bulb
temperature exceeds a certain limit for a few days per year.

6.3 N2 Production by PSA:

• One of the core technologies in many nitrogen gas generators today is Pressure Swing
Adsorption (PSA), using Carbon Molecular Sieve (CMS) adsorbent. In the process of PSA
nitrogen generation, a highly efficient CMS method is used to generate a high purity
nitrogen gas from a compressed air source.

➢ Dry process air production:

Same as N2 PSA but Alumina gel is used in place of CM Sieves.

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Figure -6.3 Working of PSA for N2 production

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CHAPTER 7: PROCESS BLOCK DIAGRAM

Figure - 7.1 process block diagram

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CHAPTER 8: PROCESS FLOW DIAGRAM

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Figure - 8.1 process flow diagram

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CHAPTER 9: PROCESS DISCRIPTION

➢ All Reactions:

• Hydrogenation
• DEK Recovery
• Nitration
• Concentration unit
• Chemical Denitrosation
• FFE EDC recovery
• Thermal Denitrosation
• Heptane dissolution
• TDN washing
• Flaker

9.1 Hydrogenation Reaction:

Overview:

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Figure – 9.1 Hydrogenation

Description:

➢ Hydrogenation is first reaction for making intermediate product NAX for production of
Pendimethalin.
➢ Raw materials required for Hydrogenation are 4NOX, DEK, N2SA promoter, palladium
catalyst & H2 gas.
➢ As shown in flow diagram primary feed is in first reactor is DEK with N2SA. The reason
behind for mixing is N2SA produces lumps if directly added to reactor. Now the mixture
of DEK & N2SA promoter feed to the main hydrogenation reactor(R11001).
➢ some secondary feed of DEK charge through the candle filter (CF11001).
➢ Now add H2 gas and palladium catalyst to the reactor & start the batch at 25Kg/cm2
high pressure. For maintaining the temperature of reaction there is vertical Heat
exchanger (HE11001) place at side of reactor.
➢ After reaction get completed, the product feedback to candle filter for recovery of
catalyst. catalyst trap in outside of candles and also use in next batch for same process.
➢ The solution of NAX, unreacted DEK & water sent to hold vessel. after passes through
sparkler filter the final product sent to Nitration unit.

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9.2 DEK Recovery:

Overview:

Figure – 9.2 DEK Recovery

Description:

➢ The feed of Hydrogenation which includes NAX, unreacted DEK & Water send to tall
vertical Settler(D11101) for separation of water and organic solution by use of density
deference.
➢ First separation of water from bottom after getting solution settle down for 1.5 hr.
➢ The organic solution feed in to the washing reactor(R11009). Where first wash by water
at atmospheric pressure, because DEK is slightly dilute in water. And second wash at
vacuum of 670 mmHg and temperature at 120°C.
➢ The vapour of water and DEK goes up and condense vapour in heat exchanger
(HE11009A), recovered DEK is reuse in hydrogenation.
➢ Pure NAX solution send to nitration process further.

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9.3 Nitration:
Reaction:

Overview:

Figure – 9.3 Nitration

Description:
➢ The nitration process is the first process in the 2nd location in the pendi plant.
➢ Raw material of nitration is NAX which is separated from DEK and H2O in DEK
recovery.
➢ H2O removed by settling and DEK removed by evaporation and washing.
➢ Nitration reaction totally contains 4 reactors the first 2 of them (R11013 & R11014) are
in parallel overflow and after two (R11015 & R11016) are in series.
➢ R 13 & 14 having limpets for chilling and internal coils for cooling. 15 & 16 having
external coil for cooling.
➢ All of reactors rums at an average temperature 40℃.
➢ That reacted nitromass shift to the decanter that settles mix acids to the bottom (which
contains Nitric acid + H2SO4 + H2O) have acid separation in the concentration unit.

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➢ Remaining nitromass goes to the nitration washing column which washes mass that
reduces acidity. By pouring nitromass from the top and hot vapour from the bottom.

9.4 Concentration unit:

Overview:

Figure – 9.4 concentration unit

Description:

➢ After Nitration decanter the settled spent acid is feed in concentration unit. The Vapour
Liquid separation column operates at temperature of 103°C and under vacuum of 670
mmHg.
➢ Where reboiler provided at bottom and preheat the acid mixture solution. because of low
boiling point of nitric acid its start to evaporate and vapours of nitric acid goes up in heat
exchanger as shown in flow diagram.
➢ Plate type condenser cooled the nitric acid so we recovered 13% weak nitric acid and we
get 70% sulphuric acid in bottom of column which reuse in plant as needed.

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9.5 Chemical Denitrosation:

Overview:

Figure – 9.5 CDN

Description:
➢ CDN is 3rd most critical reaction in the plant. After hydrogenation and nitration.
➢ Reaction takes raw materials as washed nitrated mass and HCl Acid + acetone in 96:4
proportion.
➢ There are 3 reactors for chemical denitrosation for recuring nitroso compound (which is
generated in nitration process) in to pendimethalin.
➢ Reaction takes place in R-11020-21-22. They are agitated glass line rectors.
➢ Reaction is endothermic.
➢ We maintain the reaction temperature about 70-75 ℃.
➢ After reaction time material goes in to decanter D-11103. Where HCl acid and crude
pendimethalin get separate, HCl is lighter compound as compare to crude. So, it floats
above.
➢ After separating the Acid, crude pendi has about 2000-3000 ppm impurity.
➢ This impure pendi goes in mixer settler which are located on 3 different floors.
➢ In 1st MS-11101 where it washes by water in 2nd MS-11102 it washes by SBC solution
and in 3rd MS-11103 again it got washed by water.
➢ After washing in mixer settlers pendi stored in bottom vessel.
➢ In further process it goes into FFE for EDC recovery.

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9.6 FFE EDC Recovery:

Overview:

Figure – 9.6 FFE EDC Recovery

Description:

➢ In this stage we have to recover EDC which is inserted during nitration as temperature
controlling compound.
➢ Pendi from washing feed in FFE (Falling Film Evaporator).
➢ Here hot vapours come from bottom of FFE and feed of pendi is done from top. Due to
this heat exchange EDC got in vapour phase.
➢ Afterwards it condenses in a heat exchanger at a top place.
➢ And got collected in storage.

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9.7 Thermal Denitrosation:

Overview:

Figure -9.7 TDN

Description:

➢ After FFE unit crude Pendi send to TDN reactor (R11032-33).

➢ The process is for denitrification of Pendi for getting ~2ppm Pendi.
➢ Denitrosation process is endothermic process and for archive the conversion reactor
should maintain at temperature of 140 ℃.
➢ There is another series reactor for complete the TDN process. The Pendi send to R11034
from R11032 and R11035 from R11033 as shown in flow diagram.
➢ After mixing at temperature of 170-175 ℃ in reactor (R11034-35) , we get the ~2 ppm
Pendi and collect it for sample and testing.

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9.8 Heptane Dissolution:

Overview:

Figure – 9.8 Heptane Dissolution

Description:

➢ After TDN reactor, Pendi with Tar solution (~2ppm) goes to Dissolution reactor
(R11036/37). The feeds for dissolution reactor are Pendi, Heptane,10% NaOH and Hi-
flow.
➢ The ratio of Pendi: Heptane: Caustic = 1 : 1.87 : 0.5
➢ The primary feed of Pendi and Heptane at 55-60 ℃ then add 10% caustic solution at 70-
75 ℃ for 30 min.
➢ Now, stop the agitator and charge 50 kg Hi-flow for a batch.
➢ The product of dissolution is send to Roto filter where Tar removes from the Pendi and
store in vessel (V11328-29).

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9.9 TDN washing:

Overview:

Figure – 9.9 TDN Washing

Description:
➢ From vessel (V11328-29) the Pendi solution feed to Washing reactor (R11040-41). Add
1% HCl solution because Caustic makes product basic in nature.
➢ Then second wash by Water for maintain the PH of Pendimethalin.
➢ The solution separates by reactor use as a Settler and final product of Pendi send to
Flaker machine for packaging.

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9.10 Flaker machine:

Overview:

Figure – 9.10 Flaker machine

Description:

➢ The feed from washing reactor is send to Flaker machine, it makes the solid flakes of
Pendimethalin.
➢ First Pendi falls on rotary drum which provides chilling system inside the drum. Due to
low melting point of Pendi its making a layer outer surface of drum.
➢ A sharp blade placed near the drum surface cut Pendi layer and makes flakes.
➢ In between Blower filter uses in Flaker machine because they are responsible for
removing contaminants and impurities from the air before it enters the flaker machine.
➢ The final Product is packing in 400kg jumbo bag and send it to UPL Unit 3 for
formulation and make it ready to use.
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CHAPTER 10: MATERIAL BALANCE

10.1 HYDROGENATION REACTOR:

4 NOX + 14 H2 → 4 NAX + 3 H2O

Table -10.1.1

No. Compound Kg Kmol x

1 4 NOX 7000 46.3 0.28
2 DEK 9800 113.95 0.71
3 N2SA 100 -
4 H2 GAS 350 175
Total Mass
In 17,250

Table -10.1.2
No. Compound Kg Kmol
1 4 NAX 8852.8 46.3
2 DEK 5800 67.44
3 N2SA 100 -
4 4 NAX 120 0.7938
5 H2O 2362 131.22
Total Mass Out 17,234

Accumulation = 16 Kg

10.2 DEK RECOVERY:

Table -10.2.1
No. Component Kg
1 H2O 500
2 NAX+DEK+H2O 17134

Total Mass In 17,634

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Table -10.2.2

No. Component Kg
1 H2O 2862
2 DEK 5800
3 NAX 8972
Total Mass
Out 17,634

10.3 NITRATION REACTOR:

C13H21N + 2 HNO3 → C13H19N3O4 + 2H2O

C13H21N + 3HNO3 + 1.5 H2 → C13H19N4O5 + 4 H2O

Table -10.3.1

No. Component Kg/hr

1 NAX 630
2 EDC 1260
3 Mixed Acid 1890
Total Mass
In 3780

Table -10.3.2
No. Component Kg/hr
Organic
1 UPH 822
2 Nitroso 100
3 EDC 1254
aq. spent
4 Acid 1588
5 EDC 5.6
Total Mass
Out 3769.6

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Accumulation = 10.4 Kg/hr

10.4 CDN REACTOR:

C13H19N3O4 + C13H19N4O5 + C3H6O + HCl → C13H19N3O4 + C3H5NO2 +

HCl

Table -10.3.1

No. Component Kg/hr

1 Nitro mass 5312
Aceton +
2 HCl 2125
Total Mass
In 7437

Table -10.3.2
No. Component Kg/hr
1 Organic 5258
2 spent Acid 2125
Total Mass
In 7383

Accumulation = 54 Kg/hr

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CHAPTER 11: ENERGY BALANCE

11.1 Hydrogenation Energy Balance :

Hydrogenation maintain - 80 ⸰C temp.
Heat of reaction - 841 kcal/kg 4-Nox
max heat load in first 2.16 hrs. (90% Conversion)

= 𝟓𝟐𝟗𝟖𝟑𝟎𝟎 kcal/hr = (6868166.66 kJ/hr)

𝟏.𝟓∗𝟐.𝟏𝟔

hydrogenation maintain at 25 kgf/cm2

Condenser inlet condition :

Pt= p̅H2 + p 4̅ -nox + p̅DEK

25 = p̅H2 + 0.28*0.0507 + 0.71*0.03512
p̅H2 = 24.96 kgf/cm2
𝒏𝑯𝟐 𝒑𝑯𝟐
𝒏𝒕 = 𝒑𝒕

𝟏𝟕.𝟓 𝟐𝟒.𝟗𝟔
𝒏𝒕 = 𝟐𝟓

nt = 17.52 kg/hr
yDEK* nt = 𝑵𝑽𝑫𝑬𝑲

yDEK = 𝐩̅̅𝐃𝐄𝐊
𝒑𝒕

= 𝟎.𝟎𝟐𝟒𝟗𝟑
𝟐𝟓

yDEK = 0.0009972
𝒏𝑽𝑫𝑬𝑲 = nt *yDEK

𝒏𝑽𝑫𝑬𝑲 = 0.0009972 * 17.52

𝒏𝑽𝑫𝑬𝑲 = 0.01747 kg/hr

yNOX = 𝐩̅̅𝐍𝐎𝐗 = 𝟎.𝟎𝟏𝟒𝟏𝟗𝟔 = 0.000567

𝒑𝒕 𝟐𝟓

yNOX * nt = 𝒏𝑽𝑵𝑶𝑿

𝒏𝑽𝑵𝑶𝑿 = 0.000567 * 17.52

𝒏𝑽𝑵𝑶𝑿 = 0.009933 kg/hr

Condenser outlet condition :

Pt = p̅H2 + p 4̅ -nox + p̅DEK

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25 = p̅H2 + 0 + 0.1325
p̅H2 = 24.8675 kgf/cm2
𝒏𝑯𝟐 𝒑𝑯𝟐
𝒏𝒕 = 𝒑𝒕

𝟏𝟕.𝟓 𝟐𝟒.𝟖𝟔𝟕𝟓
𝒏𝒕 = 𝟐𝟓

nt = 17.5932 kg/hr

yDEK = 𝐩̅̅𝐃𝐄𝐊 = 𝟎.𝟎𝟏𝟗𝟖𝟎 = 0.000792

𝒑𝒕 𝟐𝟓

yNOX = 0
𝒏𝑽𝑫𝑬𝑲 = nt *yDEK

= 17.5932 * 0.000792
= 0.01393 kg/hr
heat load

Q = (𝒎∙λ)DEK + (mλ)NOX + mcp∆T

= (0.01747–0.09393)*(291.2) + (0.009933-0)*(385) + 17.5*14.3*(80-25)
= 13768.60 kJ/hr
Energy balance equation
Heat generated by reaction = (heat removed by over head condenser)
+
(heat to be removed by cooling water circulated through external cooler & jacket)
For Overhead Condenser

Q = mwcp∆T

mw = 𝟏𝟑𝟕𝟔𝟖.𝟔𝟎
𝟒.𝟏𝟖𝟒∗𝟓

mw = 658 kg/hr
Combine rate of cooling water (jacket + internal cooler)
Qheat generated = Qoverhead condenser + mcp∆T
6868166.66 = 13768.60 + mcp∆T
6854398.06 = mcp∆T

m= 𝟔𝟖𝟓𝟒𝟑𝟗𝟖.𝟎𝟔
𝟓∗𝟒.𝟏𝟖𝟓

m = 327569.7 kg/hr

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𝟑
m = 327.569 𝒎
𝒉𝒓

11.2 Nitration energy balance :

Nitration maintain - 40 ⸰C temp.

Heat of reaction - 341 kcal/kg 4-NAX
NAX - 630 kg/hr
EDC - 1260 kg/hr
Mixed Acid - 1890 kg/hr
Energy balance in 1st reactor :-
Heat load in first reactor (55% conversion) = (55*630*341)/100
= 118156.5 kcal/hr
Q = 496257.3 kJ/hr

Energy balance equation :-

Heat generated by reaction = (Amount of heat absorb of cooling water circulated through
out the Jacket)

+ +
(Enthalpy of reactant ) (enthalpy of product)

Cp of NAX = 34.41 kJ/kg.K

Cp of EDC = 19.995 kJ/kg.K
Cp of Mixed acid = 30% HNO3 + 35% H2SO4 + 35% H2O
= 0.3*1.72 + 0.35*1.38 + 0.35*4.184
= 2.4634 kJ/kg.K
Q + (mcp∆T)mixed acid = (mcp∆T)UPH +(mcp∆T)Nitroso + (mcp∆T)EDC + (mcp∆T)Unreacted
NAX + (mcp∆T)cooling Water + (mcp∆T)spent acid

496257.3 + (1890*2.4634*15) = (822*0.267*15) + (100*1.083*15) + (1260*19.995*15)

+ (283.5*34.41*15) + (mcp∆T)cooling Water + (1588*0.483*15)
m*4.184*5 = 25439
m = 1216 kg/hr
Energy balance in 2nd reactor :-
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Heat load in second reactor (25% conversion) = (25*630*341)/100

= 53707.5 kcal/hr
Q = 225571.5 kJ/hr

Heat generated by reaction = (Amount of heat absorb of cooling water circulated through
out the Jacket)

+ +
(Enthalpy of reactant ) (enthalpy of product)

Q+0 = 𝑚∙cp∆T + 0
225571.5
𝑚∙ =
5∗4.184

𝑚∙ = 10782.57 kg/hr
𝑚∙ = 10.78 m3/hr

Energy balance in 3rd reactor :-

Heat load in third reactor (10% conversion) = (10*630*341)/100
= 21483 kcal/hr
Q = 90228.6 kJ/hr
Heat generated by reaction = (Amount of heat absorb of cooling water circulated through
out the Jacket)
+ +
(Enthalpy of reactant ) (enthalpy of product)
Q+0 = 𝑚∙cp∆T + 0
90228.6 = 𝑚∙cp∆T
90228.6
𝑚∙ =
5∗4.184

𝑚∙ = 4313 kg/hr
𝑚∙ = 4.313 m3/hr

11.3 CDN (Chemical Dinitrosiation) energy balance :

Reaction maintain at - 78 ⸰C temp.
Nitro mass - 5312 kg/hr

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Energy balance in 1st reactor :-

Amount of heat required in 1st reactor (45% conversion) =341*2390.4
= 815126.4 kcal/hr
Q = 3424530.88 kJ/hr

Energy balance equation :-

Enthalpy of product = enthalpy of reactant
+ +
(Amount of heat absorb during reaction) (Amount of heat release by steam)

Q + (𝒎∙cp∆T)organic + (𝒎∙cp∆T)spent acid = 𝒎∙λs + (𝒎∙cp∆T)nitro mass

342353.88 + (5258*0.267*38) + (2125*1.381*38) = 𝑚∙λs + 0
𝑚∙λs = 3588394.290

𝑚. = 3588394.290 = 1587.78 kg/hr

2260

Energy balance in 2nd reactor :-

Amount of heat required in 2nd reactor (25% conversion) =341*1328
= 452848 kcal/hr
Q = 1901961.6 kJ/hr
Energy balance equation :-
Enthalpy of product = enthalpy of reactant
+ +
(Amount of heat absorb during reaction) (Amount of heat release by steam)

Q + (𝒎∙cp∆T)organic + (𝒎∙cp∆T)spent acid = 𝒎∙λs + (𝒎∙cp∆T)nitro mass

1901961.6 + 0 + 0 = 𝑚∙λs + 0
𝑚∙λs = 1901961.6

𝑚. = 1901961.6 = 841 kg/hr

2260

Energy balance in 3rd reactor :-

Amount of heat required in 3rd reactor (19% conversion) =341*1009.28
= 344164.48 kcal/hr
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Q = 1445490.816 kJ/hr

Energy balance equation :-

Enthalpy of product = enthalpy of reactant
+ +
(Amount of heat absorb during reaction) (Amount of heat release by steam)

Q + (𝒎∙cp∆T)organic + (𝒎∙cp∆T)spent acid = 𝒎∙λs + (𝒎∙cp∆T)nitro mass

1445490.816 + 0 + 0 = 𝑚∙λs + 0
𝑚∙λs = 1445490.816

𝑚. = 1445490.816 = 639.59 kg/hr

2260

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CHAPTER 12: EQUIPMENT DESIGN

1. REACTOR DESIGN:

Figure 12.1- Reactor

12.1 Design of Reactor Shell:

Table – 12.1

MOC SA - 516 Gr 70

Max. possible operating pressure inside the reactor 1.03

(kgf/cm²)
Min. possible operating pressure inside the reactor 1.03
(kgf/cm²)

Max. possible operating pressure inside the jacket (kgf/cm²) 6.20

Min. possible operating pressure inside the jacket (kgf/cm²) 0.00

Max. possible operating temperature inside the reactor (°C) 90.00

Max. possible operating temperature inside the jacket (°C) 110.00

Design temperature (°C) 160.00

Internal design pressure (kgf/cm²) 1.14

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Thickness of the shell required for internal pressure, (ts)

Max. allowable tensile stress of MOC at design temperature

(160°C) (kgf/cm²) 612.40
Inside radius of the shell (mm) 900.00
Joint efficiency factor (J) 0.85
Corrosion allowance (mm) 1.50
External design pressure (kgf/cm²) 5.68

ts (mm) 4.97
tsa (mm) 6.25

Thickness required for external pressure:

Inside diameter of the shell (mm) 1,800.00

L/D ratio 1.80
Height of the jacket shell (mm) (L) 2,430.00

let tsa (mm) 19.05

t (mm) 16.05
O.D. of corroded shell(mm) (Do) 1,835.10
L/Do 1.324
Do/t 114.34
Poisons ratio 0.3
Modulus of elasticity (E) (kgf/cm²) 1930000

By using graphical method

B (psi) from the graph of L/Do v/s A and A v/s B 10500
B (kgf/cm²) 737.86

Pe (kgf/cm²) 6.45

For tsa = 19.05 mm, the max. allowable external pressure is 6.45 kgf/cm²
which is greater than the external design pressure which is 5.68 kgf/cm².
19.05 mm shell plate of SA - 516 Gr70 can be used.

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let tsa (mm) 19.05

t (mm) 16.05
O.D. of corroded shell(mm) (Do) 1,835.10
L/Do 1.32
t/Do 0.01
Poisons ratio 0.3
Modulus of elasticity (E) (kgf/cm²) 1930000

Analytical method
Pc (kgf/cm²) 27.971126
4*Pe (kgf/cm²) 22.73

For tsa = 19.05 mm Pc > 4*Pe. Hence 19.05 mm plate of SA 516 Gr70
can be selected.

As 19.05 mm > 6.25 mm

ts (mm) 19.05
tsa (mm) 19.05

Weight of the shell (W)

Density of the MOC (kg/m³) 7,830.00
W (kg) 2,760.43

12.2 Design of Top & Bottom head of reactor shell:

Table -12.2
Top head

n pressure of reactor is 1.14kgf/cm² < 15 kgf/cm², torispherical head can be

selected as top head

For Torispherical head

MOC SA - 516 Gr
70

Internal design pressure (kgf/cm²) 1.03

Max. allowable tensile stress of MOC at design
temperature (140°C) (f) (kgf/cm²) 612.40
Inside radius of the shell (mm) 900.00
Joint efficiency factor (J) 0.85
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Corrosion allowance (CA) (mm) 1.50

Crown radius (Rc) (mm) 1,800.00

Knuckle radius (Rk) (mm) 180.00

Stress intensification factor (W) 1.54

Thickness of Torispherical head required subjected to internal

pressure
th' (mm) 4.25

th (mm) 4.51

tha (mm) 6.25

For blank diameter (BD)

OD (mm) 1,812.50
SF (mm) 38.10
BD (mm) 2,051.85
Height of the top head (H)
Depth of dish not including SF
(b) (mm) 348.79
H (mm) 393.14

Volume of the top head (V)

Inside volume of Torispherical
head (V') not including SF (m³) 0.49
Total inside volume of top
head 0.59
(V) (m³)

Weight of the top head (W)

Density of the MOC (kg/m³) 7,830.00
W (kg) 161.74

Bottom head

ign pressure of reactor is 1.14kgf/cm² < 15 kgf/cm², torispherical head can be

selected as bottom head
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For Torispherical head

MOC SA - 516 Gr
70

Internal design pressure (kgf/cm²) 1.14

Max. allowable tensile stress of MOC at design
temperature (160°C) (f) (kgf/cm²) 612.40
Inside radius of the shell (mm) 900.00
Joint efficiency factor (J) 0.85
Corrosion allowance (CA) (mm) 1.50
Stress intensification factor (W) 1.54
Crown radius(Rc)(mm) 1800
Knuckle radius(Rk)(mm) 180

f Torispherical head required subjected to internal pressure

th' (mm) 6.03

Adding 6%
th (mm) 6.39 thinking
allowance
Size of
tha (mm) 6.25 standard plate
available

External design pressure (kgf/cm²) 5.68

Max. allowable tensile stress of MOC at
design temperature (160°C) (f) (kgf/cm²) 612.40
Inside radius of the shell (mm) 900.00
Joint efficiency factor (J) 1.00
Corrosion allowance (CA) (mm) 1.50
Poisons ratio 0.30
Modulus of elasticity (E) (kgf/cm²) 1,930,000.
00
Crown radius (Rc) (mm) 1,800.00 Taking
Rc = Di
Knuckle radius (Rk) (mm) 180.00 10% of
Di
Stress intensification factor (W) 1.54

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Thickness of Torispherical head required subjected to external

pressure
th' (mm) 24.52

th (mm) 25.99
th' (mm) 18.88

th (mm) 20.01

As 25.99 mm > 20.01 mm > 6.25 mm

th (mm) 25.99
tha (mm) 28.00

For blank diameter (BD)

OD (mm) 1,851.97
SF (mm) 77.96
BD (mm) 2,233.05

Height of the bottom head (H)

Depth of dish not including SF (b) (mm) 348.79
H (mm) 454.75

Volume of the bottom head (V)

Inside volume of Torispherical head (V')
not including SF (m³) 0.49
Total inside volume of top head (V) (m³) 0.69

Weight of the bottom head (W)

Density of the MOC (kg/m³) 7,830.00
W (kg) 796.47

12.3 Design of plain jacket:

Table -12.3
MOC SA - 516 Gr 70

Max. possible operating pressure outside the jacket (kgf/cm²) 1.03

Min. possible operating pressure outside the jacket (kgf/cm²) 1.03

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Max. possible operating pressure inside the jacket (kgf/cm²) 6.20

Min. possible operating pressure inside the jacket (kgf/cm²) 0.00

Max. possible operating temperature inside the jacket (°C) 110.00

Design temperature (°C) 160.00

Thickness of the reactor shell (mm) 19.05
Length of the jacket shell (mm) 2,430.00
Inside radius of the shell (mm) 900.00
Internal design pressure of jacket (kgf/cm²) 5.68
External design pressure of jacket (kgf/cm²) 1.14

Thickness of the jacket shell required for internal pressure, (ts)

Max. allowable tensile stress of MOC at design temperature (160°C)

612.40
(kgf/cm²)
Inside radius of the jacket (mm) 1,019.05
Joint efficiency factor (J) 0.85
Corrosion allowance (mm) 1.50

ts (mm) 12.70
tsa (mm) 14.00

Weight of the jacket shell (W)

Density of the MOC (kg/m³) 7,830.00
W (kg) 1,716.42

Jacket Head:
Max. allowable tensile stress of MOC at design
612.40
temperature (160°C) (f) (kgf/cm²)
between jacket ID and shell OD (mm)
100.00
Inside radius of the jacket (mm) 1,019.05
Joint efficiency factor (J) 0.85
Corrosion allowance (CA) (mm) 1.50
Poisons ratio 0.30
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Modulus of elasticity (E) (kgf/cm²) 1,930,000.00

Jacket head
As the internal design pressure < 15kgf/cm², Torispherical head
can be selected as a jacket head
Crown radius (Rc) (mm) 2,038.10
Knuckle radius (Rk) (mm) 203.81
Stress intensification factor (W) 1.54

Thickness of Torispherical head required subjected to internal

pressure

th' (mm) 18.65

th (mm) 19.77

tha (mm) 20.00

Thickness of Torispherical head required subjected to external

pressure
th' (mm) 7.23

th (mm) 7.66

th' (mm) 9.54

th (mm) 10.11

As 20.00 mm > 10.12 mm > 7.66 mm

th (mm) 20.00
tha (mm) 20.00
For blank diameter (BD)
OD (mm) 2,078.10
SF (mm) 60.00
BD (mm) 2,383.45

Height of the jacket head (H)

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Depth of dish not including SF (b) (mm) 394.93

H (mm) 474.93

Volume of the jacket head (V)

Inside volume of Torispherical head (V') not
0.72
including SF (m³)
Total inside volume of top head (V) (m³) 0.91

Weight of the jacket head (W)

Density of the MOC (kg/m³) 7,830.00
W (kg) 698.35

12.4 Design of bracket support:

Table -12.4
Sulphonator bracket support mechanical design
Thickness of the jacket shell (mm) 14.00
OD of the jacket shell (m) 2.07
No. of bracket required 4.00
Height of the vessel (m) 4.17
Clearance from the vessel bottom to foundation (m) 2.00
Maximum weight of the vessel with attachment and 16,476.67
contents (kgf)
Diameter of bolt circle (Db) (m) 2.22
Size of base plate for bracket (mm) 150 X 150
A (mm) 150.00
B (mm) 150.00
Height of I-beam from foundation, l(m) 4.00
Size of I-beam (mm) 177.8 X 33.75
Area of cross section of I-beam (A) (cm²) 28.58
Modulas of section, Z(cm³) 24.58
Radius of gyration, r(cm) 1.98

MOC for support IS - 800

Maximum allowable tensile stress, fmax(kgf/cm²) 1,400.00
Maximum allowable compressive stress, fc 1,233.00
allow(kgf/cm²)
Maximum allowable bending stress, fb 1,575.00
allow(kgf/cm²)
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Maximum compressive load acting on support, P 4,119.17

(kgf)

Base plate thickness for bracket (T1)

Assuming Gusset plate thickness tg (mm) 5.00
Distance between two Gusset plates, a(mm) (assumed) 140.0

Average pressure acting on base plate, Pav (kgf/cm²) 19.62

Thickness of base plate required corresponding to maximum

allowable bending stress, t1(cm) 0.92
t1 (mm) 9.20
Use t1 (mm) 10.00

Gusset plate thickness (T2)

Height of triangular portion of bracket, h(mm) 145.0
Angle made by Gusset plate with vertical direction, (°) 48.00
C (m) 0.08
t2 (cm) 0.42
t2 (mm) 4.18
Use t2 (mm) 5.00

I-beam design
a (constant) 0.000133
Effective length of column, le(m) 2.00
Maximum compressive stress induced in column (kgf/cm²) 339.96

Distance between centreline of column and centre line of shell 0.082

wall (Eccentricity), e(m)
Stress created in column due to eccentric load (kgf/cm²) 1,374.14
So, selected I-beam can be used as column for bracket support

Base plate for column

Size of I-beam (mm) 177.8 X
33.75
d (mm) 177.80
W (mm) 33.75
Taking L1 = L2 (mm) 20.00
B (mm) 78.10
C (mm) 208.91
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Bearing pressure, Pb(kgf/cm²) 25.25

Maximum bending moment in the plate, Mmax (kgf•cm) 50.49

Thickness of bearing plate required to withstand Maximum 0.44

bending stress induced in the plate, tb(cm)
tb (mm) 4.39
Use tb (mm) 6.25

CHAPTER 13: MODIFICATIONS

• In the existing plant they were using old technology, So I have suggested some
modifications. I have suggested one major modifications in the design of reactors and
another on manufacturing process.
• I have suggested modification in the Agitator of the reactor. At present they are using 45
pitch blade turbine agitator .

➢ I suggested Gas induction-type hollow agitator is new innovation for this

hydrogenation reaction :-
• Special type of impeller is attached with hollow shaft. In the upper part of the hollow shaft,
windows are provided for gas suction. Gas enters from these windows and discharges
through the lowest part of the impeller. The agitator operates on the principle of water jet
ejector. The suction so generated blows the stirrer edges during the rotation and hence, gas
enters through windows and discharges from the bottom of impeller to liquid pool. A
specially designed impeller vigorously disperses the gas bubbles and creates a mixture
akin to a boiling liquid.Gas bubbles react with liquid as they rise. Unreacted gas is
reinduced into the liquid through the windows. Recirculation of gas is important because
bubbling of gas only once through the liquid does not use it completely.

Advantages:
1) It provides vigorous gas-liquid mixing.
2) It substantially increases gas-liquid interfacial area of contact and enhances gas-liquid
mass transfer rate.
3) It reduces reaction time considerably for the gas-liquid reaction in which overall reaction
rate is governed by rate of mass transfer.
4) It provides very high vessel side (i.e., inside) coefficient which approaches a boiling
coefficient.
5) It is also the best choice for the gas-liquid reaction with suspended solid catalyst. For
example, hydrogenation in presence of suspended Reiny Ni catalyst.
It is used for hydrogenation, alkylation, ozonisation, oxidation, amination, etc.,
reactions.

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➢ Unreacted hydrogen gas convert into steam by combustion process :-

Unreacted H2 gas mass flow rate = 8 kg /hr
Calorific value of H2 gas = 142000 kJ/kg

𝑚∙λs = 8* 142000

𝑚∙ = 8*142000/2260

𝒎∙ = 502.65 kg/hr

Figure 13.1- Gas induction- type tube stirrer for hydrogenation

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CHAPTER 14: SAFETY, HEALTH AND ENVIRONMENT

Safety is the state of being “safe”, the condition of being protected against physical, social,
spiritual, financial, political, emotional, occupational, psychological, educational or other
types of consequences of failure, damage, error, accidents, harm or any other event which
could be considered non desirable. This can take the form of being protected from the
event or from exposure to something that causes health or economical loss. It can include
protection of people or of possessions. Accidents are analysed and developed a separate
engineering branch of safety and this analysis was required due to:

➢ Rising trend of accidents

➢ Increased use of machinery
➢ Increased material handling
➢ Lack of safety standard
➢ Lack of training
➢ Better reporting of accidents

No industry can afford to neglect the fundamentals of safety in design and operation of its
plant and machinery. It is important that all the people responsible for management and
operation of any industry should have a good knowledge of industrial safety.
“Safe use of man, material and machine by safe systems and method of work so as to
achieve zero accidents which results in higher productivity.”
Accident: An accident is unplanned/ unexpected events which interfere or interrupts with
the planned process of work and results on personal injury.

• SAFETY MEASURES TAKEN BY INDUSTRY:

ground water and surface water quality.

➢ Safety department provides training to all operators and trainees. Accidents & incidents
are investigated & records are maintained. Employees are informed about the cause of
accident. Internal Safety Inspection is done regularly by safety department.
➢ Work Permit is also issued for work like hot work, Cold work, confined space entry, work
at height.

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➢ To ensure safe, healthy and clean environment various health and safety policies like SHE
policies, Quality policy, Energy management policy, Training and development policy are
developed.
➢ Occupational Health Centre is present in plant with working 24 hours under the guidance
of doctor. For emergency purpose they also have ambulance service.
➢ To deal with fire, water lines are provided in entire plant. Fire extinguishers are also
provided at each place in plant for fire safety.

➢ Mock drills are also conducted in plant to ensure working of fire alarm.

➢ Personal protective equipment is also provided to each and every employee and worker to
minimize the accidents.
➢ To avoid fire cause of static charge equipment is grounded. Fire alarm is provided at each
site of plant. To ensure safety of equipment safety interlocks like safety valve, rupture disc,
pressure relief valves are also installed.

➢ The waste generated from process is treated in Effluent Treatment Plant

➢ (ETP). Hazardous waste is sent to TSDF (BEIL) side for disposal purpose In addition,
proper care is taken to prevent any spillage/leakage. Proper storage facility is provided for
raw material and hazardous waste. So, there is no hazardous effect on

➢ Adequate safe assembly point is mentioned in some locations in plant where workers can
gather in case of emergency.

• BASIC SAFETY TRAINING:

An Initiative to ensure proper safety while working in the industry.
Basic rules to be followed:

➢ No smoking
➢ No electronic items allowed in the industry without special permission
➢ Photography is strictly prohibited
➢ Personal protective equipment’s (PPE) are compulsory.
➢ Only walk on the showed footpath.
➢ Watch out for big vehicles in the blind spot convex mirrors. Let them pass and then cross
the road.
➢ Speed limit 10km/hr.
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➢ Do not enter in restricted area.

➢ Don’t touch any equipment’s.
➢ Hold the handrail while climbing on stairs.
➢ If any abnormality takes place in the industry then firstly inform the respective
authorized person of the section.
➢ In cases of emergencies use emergency exit and gather at the assembly point as soon as
you hear panic siren and stay there until clear siren.
➢ Always ensure checking of the siren once in a week.
➢ Take care of gate pass and ID card given to you.
➢ Before you go, inform your host and then leave the plant.

• TYPES OF INCIDENTS:

1. First Aid Case (FAC): person may resume his/her work after taking medicine from health
centre.

2. Medical Treatment Case (MTC): A medical treatment case is any injury sustained on the
job by an employee which requires medical treatment from a professional physician or
qualified paramedic.

3. Restricted Working Day (RWC): In such kind of injuries person should immediately be
taken to the hospital and to be kept there until he/she gets fit for the work.

4. Loss Time Incident (LTI): An LTI is an injury sustained by an employee that leads to loss
of productive work in the form of absenteeism or delays.

5. Dangerous Occurrence (DO): These are incidents with a high potential to cause death or
serious injury, but which happen relatively.

6. Major Process Safety Incident (MPSI): An event that is potentially catastrophic, i.e., an
event involving the release/loss of containment of hazardous materials that can result in
large-scale health and environmental consequences.

• SAFETY MANAGEMENT SYSTEM AT UPL:

1. Process hazard analysis

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2. Pre startup safety review

3. Change management
4. Incident investigation & reporting system
5. Work permit system

Including total 26 system developed by UPL for extra cure in “Safety vision.”

In process safety management there are 14 elements in structure and UPL follows 10
elements. from that element which includes primary content as “Technology, Facilities,
Personal.”

UPL follows MSIHC 1989

(manufacturing storage implement of hazardous chemical)

ERT member [Green helmet]

(Emergency Response Team)
- Training by LCS, India

PSR member [Orange helmet]

(Plant Safety Representative)

→ In case of any incident there are 9 step process of incident investigation process.
→ SWASYA SOLUTION is consultant, hiring by UPL and they gives 6 points to
improve work culture in UPL.

• EMERGENCY SIREN CODES & EVACUATION:

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Figure 14.1 – Emergency siren codes & Evacuation

JSA ( Job Safety Analysis)

Benefits: Legality, Responsibility, EQP. Check, Hazard identify…

LOTO (Lock Out Tag Out)

Use for preventive action from accident during maintenance in plant.
New implement by LOTOTO system (Lock out tag out try out)

• TYPES OF EMERGENCIES:

1. Fire
2. Blast
3. Chemical Leakage
4. Reactor Meltdown

Preventive Equipment’s uses in UPL:

➢ for prevention of Fire, UPL have fire hydrant line and hose line in all over unit and for
safety of reactor, there’re sprinkler system uses in critical reactions.
➢ for prevention of Blast in reactor, UPL uses pressure relief device and rupture disc as a
safety instrument device in reactor.
➢ for prevention in Chemical leakage, UPL uses dyke wall in storage tank or tank farm.
➢ for prevention of Reactor meltdown, UPL uses interlock system for emergency shutdown
the plant and provide suitable utility to reactor.

• UPL uses SAFETY MINT software for registering all data and safety information.
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• LEGATRIX software uses for maintenance of compliance and register check list dates
for expiry of equipment.

• WORK PERMIT SYSTEM:

It’s a permission letter to do non routine activity or activity which have high potential
risk, under guidance and perform by train worker for minimize the accident rate. By type
of work permit company have different color coding for respective permits.
TYPES OF WORK PERMIT:

1. Hot work (pink)

2. Confined space (yellow)
3. Cold work / Excavation (white)
4. Electrical LOTO (green)
5. Temporary electric consent (sky blue)
6. Line braking permit (violet border)
7. Crane operation/Entry permit (orange border)
8. Work at hight (gray border)
9. Fire protection permit

• MSDS (Material Safety Data Sheet):

The MSDS lists the hazardous ingredients of a product, its physical and chemical
characteristics (e.g. flammability, explosive properties), its effect on human health, the
chemicals with which it can adversely react, handling precautions, the types of measures
that can be used to control exposure, emergency and first aid procedures, and methods to
contain a spill.

When new regulatory information, such as exposure limits, or new health effects
information becomes available, the MSDS must be updated to reflect it.

• FIRE:

Fire needs 3 basic substance to ignite.

1. Oxygen
2. Heat
Fuel Figure 14.3 - Fire
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3. Fire produces Smoke, Light & Energy.

Fire ignites only between limit of UEL & LEL.

UEL – Upper Explosive Limit
LEL – Lower Explosive Limit
Methods for control fire:
1. Starvation (cut fuel)
2. Smothering (cut oxygen)
3. Cooling Inhabitation (provide cooling)

Class of Fire & Suitable Fire Extinguisher:

Figure 14.4 - Class of Fire & Suitable Fire Extinguisher

HAZCHEM CODE:

Figure 14.5 – Hazchem code

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The Hazchem code, short for “Hazardous Chemicals”, is a system for identifying and
communicating hazards associated with hazardous chemicals.

PPE (Personal Protective Equipment):

Types:
1. Respiratory
2. Non-Respiratory

Respiratory PPE means its uses in breathing apparatus for human and Non-Respiratory
PPE means its uses for non-breathing apparatus like safety shoes, helmet, goggles,
gloves, apron, face shield, muff, etc.

Figure 14.6 - PPE

For sharp object: KEVLAR gloves

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For use in solvent: NEOPRENE gloves

SCBA (Self Contained Breathing Apparatus)

PAPR (Powered Air Purifying Respirator)

Both are use in IDLH (Immediately Dangerous to Life or Health atmosphere) condition.

Figure 14.7 – SCBA kit

ELCB – Earth Leakage Circuit Bracker

RCCB - Residual Current Circuit Breaker

Figure 14.8 - ELCB & RCCB

Both are use as Electrical Safety instruments.

➢ UPL follows Six Sigma and 5S strategy to improve quality & work yield.

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Six Sigma is a set of methodologies and tools used to improve business processes by
reducing defects and errors, minimizing variation, and increasing quality and efficiency.

The 5S pillars - Sort, Set in Order, Shine,

Standardize and sustain, provide a methodology for organizing, cleaning, developing,
and sustaining a productive work environment.

➢ UPL strictly follows identification of chemical by CAS (Chemical Abstract Service

number).

• PSM (Process Safety Management):

➢ OSHA (Occupational Safety & Health Administration)

➢ CSB (Chemical Labour Organization)
➢ ILO (International Labour Organization)
➢ UNISEF

Are organization for investigation major accident or tragedy happens earlier and
preventing same kind of incident by giving basic guidelines & SOP to industry.

• Layer of protection analysis (LOPA):

LOPA is recognised as one of the methods that may be used to select the Safety Integrity
Level (SIL) for a Safety Integrated System (SIS).

Figure 14.9 – LOPA

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➢ Layers of Protection Analysis (LOPA) is a method used to evaluate high-consequence

scenarios determining if the combination of probability of occurrence and severity of
consequences meets a company’s risk tolerance.
➢ Managing process safety means understanding the many factors that contribute to risk
and establishing appropriate measures for risk mitigation. LOPA addresses the key
questions: “how safe is safe enough?”; “how many independent protection layers are
needed?”; and “how much risk reduction should each layer provide?

➢ The layers of protection are;

i. Process design and control

ii. Critical alarms and operator response
iii. Instrumentation safety (ISS)
iv. Physical protection (pressure relief devices)
v. Plant emergency response
vi. Community emerging response

LOPA can also be used to help make risk judgements involving plant modifications and
procedural changes during routine operations.

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15: REFERENCES

1. https://www.upl-ltd.com/
2. https://en.wikipedia.org/wiki/UPL_(company)
3. https://sustainability.uplonline.com/occupation-health
4. https://www.business/standard.com/company/upl%202461/information/company-
history

Books:

(1) Process Engineering and Design, Thakore S.B. and Bhatt B.I. Stoichiometry, 5 edition
(2) Chemical Process Safety, Daniel A. Crowl and Joseph F. Louvar, 3rd edition
(3) Richardson J.F., Coulson J.M., and Sinnott R.K. Chemical engineering
(4) M.V. Joshi, Mahajan V.V. Process equipment design, McMillan India Ltd. 1999
(5) Robert E. Treybal: Mass Transfer operation, 3rd ed.; McGraw-Hill, Inc.: NewYork, 1981
(6) Octave Levenspiel; Chemical reaction engineering, 3rd ed.; John Wileyand Sons; New
York
(7) Warren L. McCabe; Julian C. Smith.: Unit Operation of ChemicalEngineering, 5th ed.;
McGraw-Hill, Inc.: New York, 1981

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