IN-PLANT TRAINING
AT
GHARDA CHEMICAL LTD. LOTE- PARASHURAM
Mr. Vaibhav V. Pandere Roll No. 49
Training Details
Company Name & address: Gharada Chemicals Limited. D-1/2, Lote MIDC, Lote-Parshuram, Tal: Khed, Dist: Ratnagiri, Maharashtra.
Duration of Training: 6 Weeks [From 16th May, 2011 to 30th June, 2011]
Plant Explored: Plant-2
Product Studied: Cypermethrin
About Company
Established in 1967 Among top ranking chemical companies in India, with world class products and annual sales of Rs. 8948 million (2009-10) including exports worth Rs. 4325 million. Only Indian company to receive U.S. Registration (EPA Approval) for the sale of Chlorpyrifos (Insecticide) and Dicamba (Herbicide) in the U.S.A. Awarded the prestigious "Chemexcil Trishul Award" for outstanding exports among large-scale chemical manufacturers for 1995 1996
Major Products
Insecticides Fiproles Fipronil Neonicotinoid Acetamiprid Organophosphorus Chlorpyrifos Quinalphos Temephos Triazophos Oxadiazine Indoxacarb Synthetic Pyrethroids Alphacypermethrin Cypermethrin Deltamethrin Fenvalerate Permethrin Herbicides Anilofos Clodinafop-propargyl Dicamba Isoproturon Metamitron Napropamide Sulfosulfuron Triclopyr Butoxy Ethyl Ester Fungicides Carbendazim Plant Growth Regulator Mepiquat chloride
CYPERMETHRIN
DELTAMETHRIN
ALPHAMETHRIN
PLANT 2 PRODUCTS
INDOXACARB
METAMITRON
About Cypermethrin
Cypermethrin is a highly active synthetic pyrethroid insecticide. It controls a wide range of insect pests on a variety of crops by stomach and contact action. Structure:
Chemical Name :
cyano(3phenoxyphenyl)methyl 3(2,2-dichloroethenyl)-2,2dimethylcyclopropanecarboxylate CAS number: 52315-07-8 Molecular Weight: 416.30 g/mol Density: 1.23 g/cc at 20oC Solubility in Water: <9g/L at 20oC Vapor Pressure: 5.1 x 10-7 Pa @ 70oC
Chemistry of The Process
Production of cypermethrin
PTC CMAC(l) + MPB(l) + NaCN(aq) CMN(l) + NaCl(aq) Two phase reaction Reaction conditions- 680-720 mm of Hg pressure 15-40oC temperature pH- between 9-9.5
Cyanide destruction
2NaCN(aq) + 5NaOCl(aq) + 2NaOH(aq) N2(g) + 5NaCl(aq) +2Na2CO3(aq) + H2O(l)
Reaction in scrubber
2HCN(g) + 5NaOCl(aq) + 4NaOH(aq) N2(g)+ 5NaCl(aq)+2Na2CO3(aq)+3H2O(aq)
Steps in Standard Operating Procedure (SOP)
Preparation of Cyanide Solution in R-2103 MPB Sucking in T-2921 CMAC Sucking in T-2922 Water and Hexane Receiving in R-2921 Cyanide Receiving in R-2921 PTC Sucking in R-2921 NaOH Charging Simultaneous Feeding of CMAC and MPB Maintaining Sampling Phase Separation NaOCl Wash Water Wash Concentration of Cypermethrin
Block Diagram
T-2923 NaOCl T-2909 Water T-2931 NaCN condenser X2921
Scrubber
T-2920 NaOH
T-2921 MPB
T-2922 CMAC
Vent
T-2924 Hexane
R-2921
condenser
R-2936
To ETP R-2923 T730 To Plant-3 T2507
HEAT EXCHANGERS
Sr.
no. 1 2 Ground 1st
Floor
Shell
& Tube 3 1
Graphite
Block 0 0
Plate
3 0
3
4 5 6 Total
2nd
3rd 4th Terrace
10
4 1 23 42
5
1 0 2 8
0
0 3 0 6
Total=56
PUMPS
Sr.
no.
Floor
Vacuum
Blowers
Reciprocating
Centrifugal
Ground
49
2
3 4 5 6 Total
1st
2nd 3rd 4th Terrace
0
0 0 1 3 5
0
0 0 0 3 3
0
0 1 6 0 7
8
21 8 6 10 102
Total=117
PLANT UTILITY
Boiler House
Consists of 2 boilers with total capacity of 8 tons per hour Coal is used as a fuel Pressure generated is around 9.8 Kg/cm2 Temperature is about 180 oC.
Cogen Plant
Used for production of electricity High pressured steam is sent through the nozzles of the turbine The steam coming out from the turbine is divided into 3 types with the help of a PRV i. High pressure steam ii. Medium pressure steam iii. Low pressure steam
STANDARDS AND COMPLIANCES
ISO 9001-2000 (QMS) ISO 14001-2004 (EMS) OHSAS 18001-1999 (OHSMS)
EFFLUENT TREATMENT PLANT
Steps In ETP
Oil Separator Neutralisation Tank Filter Press Clariflocculator Bioreactor Clarifier
Water processed from ETP is sent to
Common ETP Neighbouring water bodies
TROUBLESHOOTING
Some of the problems commonly encountered in Plant 2 during operations include: Vacuum Problem Flooding Chocking in line-up. Reactor leakage Phase Separation
