ORIENTATION REPORT

HAREESH SASI, 1633

PRODUCTION ENGINEER (TRAINEE)
SÜD CHEMIE INDIA PVT LTD
25/07/2018

Completed joining formalities with Mr. Sreekumar and Mr. Premnath, and received appointment
letter from Mr. Saji V Mathew DGM, HR.

26/07/2018

An orientation programme schedule was prepared by Mr. Anand AS, Assist Manager HR and
Discussed in detail about our company profile.
Safety orientation was given by Mr. Vipin Das, HOD Safety.

27/07/2018 and 28/07/2018

Had personnel discussion and interaction with following people

 Mr. Pious James ,Chief Manager Finance

 Mr. Vijayakumar, Sr Executive Stores
 Mr. Arun Tomy, Executive Purchase
 Mr. P Unnikrishnan, DGM Qa
 Mrs. Sreekala R, GM R & D
 Mr. Manesh George, Sr Manager Purchase

 Mr. Mahesh, Exexutive Despatch

 Mr. Dinil C Mathew, Executine Maintenance

 Mr. Arun Narayanan, Senior Manager Production

I would like to express my sincere gratitude towards Mr. Saji.V.Mathew, DGM HR, Mr Anand
A.S, Asst Manager HR for arranging a detailed orientation schedule for me.
ABOUT SÜD CHEMIE

The company was founded by Sri. Fazal H. Lalljee and Sri. Altaf H. Lalljee and was registered in
1969 as Catalysts and Chemicals India (West Asia) Pvt. Ltd. The name was first changed to United
Catalysts India Ltd. and then to Sud-chemie India Ltd., consequent to change in name of the parent
company. Manufacturing operations at Cochin unit has started in 1970. The Company has also got
marketing offices at Delhi and Bombay. The company has been catering to the Syngas catalyst
requirements of almost all the fertilizer manufacturing companies in India and is market leaders
for Syngas catalysts in India. Refineries and Petrochemical industries are also using their catalysts.
With the introduction of MIDREX catalysts they started meeting the requirements of Sponge Iron
Plants also. Now they have started feeding to the highly competitive automobile sector also with
their Catalytic Converters for two and three wheelers as OEM suppliers.

COCHIN UNIT
This unit was started in 1970. Edayar unit is spread over 22 acres. Almost 25-30% of entire
production of Sud-chemie India is carried out through Cochin unit. This unit is equipped with
sophisticated machineries and a well setup quality assurance laboratory. Cochin unit of Sud-
chemie has a total number of 153 employees. Production process is continuous throughout the
year.

PRODUCTS AND ITS USES

Catalysts reduce the amount of energy needed to activate chemical reactions. Almost every
process in the manufacture of a chemicals, petrochemicals & fertilizers require specific catalysts.
Catalysts vary in composition, structure and shape – according to the chemical reaction in which
they are used.
Sud-chemie India manufactures a wide range of catalysts for varied applications in Fertilizers
Industries, Refineries, Petrochemical plants, Sponge Iron plants and now for emission control in
automobiles and stationery engines. Its products are the result of many years research and
development work. Apart from the regular product lines, it also develops and manufactures
catalysts as per the specific requirements of customers under secrecy agreements. The well-
equipped R & D division and pilot plant at Cochin are capable of taking care of all such.
OPERATIONS DEPARTMENT
GM Operations is the overall in charge. He maintains the operations and its planning and control
from top to bottom. HOD (Production) is in charge of production department. He is working in
liaison with marketing department people at Delhi and Mumbai for planning the production.
According to the requirements and orders received the products are produced and can be
delivered in time. As per the production plan and raw material procurement is planned and given
to purchase department. Manager (Production) deals with the production, statutory and legal
requirements in liaison with HR department.
The main departments that come under this section are
1. Production Department,
2. Maintenance Department
3. Store Department.
4. Q A
PRODUCTION
30/07/2018 to 13/08/2018
C12 (SHIFTMAX 120)
 RAW MATERIALS
1. Ferrous sulphate
2. Sodium bichromate
3. Caustic (NaOH)
4. Copper sulphate
5. Graphite
 PROCESS
COPPERAS SOLUTION PREPARATION
Take 12 KL water in copperas pit tank. Add 25 -30 L H2SO4 to it. Recycle and agitation is kept
on. Add 90 bags (4500 kg) ferrous sulphate. Again recycle for 30 minutes. Check % Fe and %
Free Acid. Spec value is % Fe (6.8-7.2) and % FA (0.5 -1.0)
FILTRATION
Transfer the solution to filter press in order to remove sand particles and other impurities. After
filtration the solution is pumped to Copperas solution tank 1 and 2 which is the hold tank.

CAUSTIC PREPARATION
5000-1000 L water and 2000-3000L caustic (41%) is taken in the dilution tank and recycle for 2
hours. After dilution % caustic must be in the range of (18 – 21) %.
SODIUM BICHROMATE PREPARATION
Take 2500L of water in the bichromate tank. Charge 1000 kg of sodium bichromate through
charging hole. Recycle and agitate for 2 hours. % bichromate should be in the range of (34 – 40)
%.
PREMIX PREPARATION
Required quantity of copperas solution is pumped to the premix tank.
Check % Fe of the premix. Add 0.265 x Fe kg of sodium bichromate to premix. Also add 80 kg of
copper sulphate. Give 15 minutes agitation.
PRECIPITATION
Take 1.6 x Fe kg of dilute caustic in the precipitator. Agitation and recycle should be kept ON.
Pump premix into the precipitator. Check excess caustic. It should be in the range of (0.5 – .75)
%. Heat to 50 – 70 deg. Start air blow. Add required quantity of graphite. After 4 hours transfer to
C12 hold tank.
HOLD TANK
Store the slurry with continuous agitation.
MEMBRANE PRESS
Slurry from the hold tank is fed to membrane press. Filtration, washing and squeezing is done.

Filling time =1 hour 15 minutes.

Washing = 1 hrs. recycle wash
= 3.5 hrs. fresh wash
Squeezing = 45 minutes.
Feed pump discharge pressure = 5 kg/cm2
Wash pump discharge pressure = 8-9 kg/cm2
Squeeze pump discharge pressure =10-14 kg/cm2
Wash water temperature = 50 -700C
LUMP CALCINATION
Membrane cake is fed to rotary calciner 1 and 2 (old and new). First zone temperature is
3500C.Temperature outlet of the calciner is in the range of 180 – 2500C. % sulphur should be <150
ppm. Calcined lump is transferred to silo1 and silo 2.
FEED PREPARATION
1. Sieving
Lump is sieved in the sieving machine. Separate undersize and oversize.
2. Multimilling
Oversize will be multimilled and collected along with sieve under size
3. Water Blending
Above powder is water blended with water to get 10% Loss On Ignition ((LOI).
4. Sieving
Water blended feed is sieved and stored in the containers.
TABLETTING
Feed prepared is tableted in the tableting machine with an off machine crush of average 8 kg/cm2.
The off machine tablet are collected in the containers.

TABLET CALCINATION
Calcination is done in the Band Drier to get an average crush in the range (10-14) kg/cm2. Band
drier fired at the rate of 4000C. Calcination will be done at 3500C.Calcined tablet is collected in
containers and allowed to cool.
SCREENING
Calcined tablets after cooling is screened to finished product drums with liners.
 CHEMICAL REACTIONS TAKING PLACE
By addition of Sodium Bichromate solution and Sulphuric acid to ferrous sulphate solution
corresponding Ferric Sulphate and Chromic Sulphate is formed. With the addition of excess
sodium hydroxide solution corresponding hydroxides of Iron and Chromium is formed. Copper
sulphate is added here for required copper content. On drying corresponding metal oxides is
formed.

 FINISHED PRODUCT SPECIFICATIONS

1. LOI = max 10%
2. Fe2O3= min 85%
3. Cr2O3 = 7 -10 %
4. CuO = 1.5 -2.5 %
5. Cr6+ = < 2%
6. Crush =average 14
7. Bulk density = 1.06 – 1.22
SULFOMAX (C116)
 RAW MATERIALS
1. Ammonium Metavanadate
2. Potassium carbonate
3. Sodium carbonate
4. Cesium carbonate
5. Diatomaceous earth
 PROCESS
PREMIX PREPARATION
Add 62cm more DM water to the initial level in premix tank. Open the steam valve. The
temperature will be automatically controlled by the solenoid. Agitation and recycle should be kept
on. When temperature reaches 900C slowly charge Potassium Carbonate. And maintain
temperature at 900C. Then slowly charge Ammonium Metavanadate. Then charge Sodium
Carbonate. The premix level should be 90cm more than initial level. If any level drop occurs make
up with the DM water. The compositions of the ingredients may vary according to the finished
product needed.
MIX MULLING
Ensure mixmull discharge door is in closed condition. Charge 12 bags of celite and 2 drums of
rework powder and put the mixmull in running condition. Then pump the required premix quantity
to mixmull keeping premix tank in recycle. Ensure level gauge is accurate by draining. After
premix pumping run the mixmull for 10 minutes. After this, charge required quantity of
Concentrated Sulphuric Acid to mixmull. After acid charging, run the mixmull for 45 minutes.
Then add required quantity of wheat flour and run mixmull for 10 minutes. Then charge paraffin
through spray bucket for uniform mixing and charge required quantity of water. Then run the
mixmull for another 10 minutes. After mixing, the mixmull powder is unloaded in containers.
PELLETISATION
The mixmull powder from the container is granulated and sieved in a granulator and it is fed to the
palletiser. Fix the required die in palletiser and fix the rollers. For initial lubrication in die inserts,
put some paraffin mixed with water.The pellets are collected in conveyor and allowed to dry in
band dryer.
DRYING IN BAND DRYER

There are three zones in band dryer having a temperature of 1500C, 4500C and 6000C respectively.
The band dryer belt will be running at very slow speed. SO2 will be generated due to the presence
of Sulphuric Acid. So the vapours generated are passed through a scrubbing system. The SO2
generated will be scrubbed in 3.5 % caustic solution.
SCREENING
The dried pellets are collected in containers and screened in screening machine with required mesh
size and collected in finished product drums.
CRITICAL PARAMETERS
Premix temperature – 900C
% Caustic = 1-2.5 % (for scrubbing)
Mixmull LOI – 40%

 CHEMICAL REACTIONS
1. PREMIX
Ammonium metavanadate, Potassium Carbonate and Sodium Carbonate reacts to form Sodium
Vanadate and Potassium Vanadate.

NH4VO3 + K2CO3 + Na2CO3 = NaVO3 + KVO3 +NH3

2. MIXMULL
Sodium vanadate and potassium vanadate reacts with sulphuric acid to form potassium sulphate,
sodium sulphate and vanadium sulphate.

NaVO3 + KVO3 + H2SO4 = K2SO4 + Na2SO4 +V2(SO4)3

3. CALCINATION
On calcination corresponding oxides are formed.
K2SO4 + Na2SO4 + V2 (SO4)3
On heating at 6000C gives
K2S2O7 + Na2S2O7 + VO (SO4)3
FINISHED PRODUCT SPECIFICATIONS
1. % V2O5 = 6.5-7.5 %
2. % Potassium Oxide = 9.5-11.5 %
3. % Sodium = 0.9-1.5 %
4. Pore volume = 0.4-0.8 %
5. Average crush = 5 kg/cm2

C18 (SHIFTMAX 210)

 RAW MATERIALS
1. Zinc metal cuttings
2. Copper metal granules.
3. Graphite
4. Alumina.
 PROCESS
VENT 3 AND VENT 5
Take solution from concentrated liquor tank of scrubbing system, DM water or from scrubber tank
to vent-3&vent-5. Inject ammonia from ammonia bullet and carbon dioxide from carbon dioxide
bullet. Ammonia should be 10 – 12 % and carbon dioxide should be 8 – 9 %.

ZINC SOLUTION PREPARATION

Charge zinc cuttings to reactor. Charge scrubber solution from either vent 3 or vent 5. Recycle the
solution. Check the metal percentage at intervals & when the percentage becomes 9- 9.5 % transfer
it to zinc solution tank.
COPPER SOLUTION PREPARATION
Charge copper granules to reactors 1 or 2. Charge scrubber solution from either vent 3 or vent 5 to
the reactor. Then recycle the solution .Check the metal percentage at intervals & when the
percentage becomes 2- 3% start air blow in reactor to enrich the metal percentage to 9- 9.5%.
Check the metal percentage at intervals & when the percentage becomes 9-9.5% transfer it to
copper solution tank-1. In copper solution tank-1, start air blow continuously with recycle to
remove the cuprous to cupric oxide. Check at intervals & when the solution cuprous is removed
transfer it to copper solution tank-2.
PREMIX PREPARATION
Take blend from copper solution tank 2 and zinc solution tank on the ratio 1.06 – 1.08 to premix
tank 1. If the ratio is correct then transfer to premix tank 2.
DECOMPOSITION
Take DM water/scrubber or both depending on the level in decomposer 3. Add 350kgs (14bags)
of alumina SCF or arnal alumina to decomposer 3 with agitation & ensure that the manhole is
closed in tight condition. Put decomposer pump on recycle, start vacuum pump no.2 & steam
through coils with C02 at the rate of 250L per hour, ensure vacuum of 1200-1450 mm H2O. Soluble
metal percentage should be 0.3% while pumping premix. After pumping the required quantity of
premix start boiling down to make the soluble metal to 0.01%. When the soluble metal becomes
0.01%, stop CO2 & steam and transfer to decomposer 2.
DECANTING
Take DM water in decomposer-2 up to the required level. After receiving slurry from decomposer
3 it is allowed to settle. When the slurry settles in the bottom allow the clear water to pass through
filter press to pond. Take DM water again to the required level with agitation, put it under settling
& allow the clear water to pass through filter press to pond. After 2 decanting charge 50 kg of
graphite to the slurry with agitation & transfer it to C18 hold tank.
FILTER PRESS FILLING
Pump the filtrate to the filter press. When the filtrate rate get reduced, stop the hold tank pump,
close the valves, and give compressed air to the press to squeeze out the remaining water.
DRYING IN BOX DRIER
Unloaded racks from filter press are to be dried in box drier at 3500C for 3 Hours.
Allow the rack to cool do raking to remove the carbon dioxide, and again dry it for 3 hours to bring
down the LOI to 5%.
DRYING IN ROTARY CALCINER

The cake is dried inside the rotary calciner at a temperature of 3700C. The material should have an
LOI of 8-9% and it is transferred to silo1. From there it is unloaded to the container and taken for
tableting.
ROLL COMPACT OPERATION
The lump from the box drier is transferred to silo 2 through a drag chain system. From silo 2 it is
fed to roll compactor. The roll compacted feed is transferred to machine called granulator.
From the granulator feed will be powdered to fine particles and transferred to the sieving machine.
From the sieving machine fine powder is collected in drums and oversize in separate drums.
TABLETTING
Off machine crush to be maintained at 6-7 kg/cm2 (4.8x3.2mm) & 5-6 kg/cm2 (6.4x3.2, 6x3 mm).
Off machine tablets to be collected in containers & sent to band drier for drying.
DRYING IN BAND DRIER
Ensure that the bed temperature is maintained at 3800C. Feed the off machine tablets having LOI
8 – 9 % to the band drier. After drying the LOI will be less than 5% & crush should be minimum
average 8 kg/cm2.
SCREENING
Calcined tablets after cooling is screened to finished product drums with liners.
 CHEMICAL REACTIONS
SCRUBBER SOLUTION
Ammonia and carbon dioxide dissolve in water to form ammonium hydro carbonate and
ammonium carbonate (carbamine solution).
ZINC REACTOR
Zinc reacts with carbamine to form Zinc amine carbonate
COPPER REACTOR
Copper reacts with carbamine to form copper amine carbonate.
PREMIX
Premix is a mixture of Zinc amine carbonate and copper amine carbonate.
DECOMPOSITION
On decomposition with steam copper hydroxy carbonate and zinc hydroxy carbonate are formed.
Ammonia and carbon dioxide are evolved out and scrubbed for reuse.
DRYING
On drying CO2 will be eliminated and corresponding oxides are formed.
CRIRICAL PARAMETERS
For zinc
NH3 = 9.5 to 10.0 %
CO2 = 6.5 - 7.5 %
Zn - 9.0 - 9.5%
For copper
NH3 = 9.5 to 11.0 %
CO2 = 7.0 - 8.0 %
Cu = 9.0 - 9.5 %.
Premix
Zn: Cu = 1.06 - 1.08
SM should be 0.3 - 0.4 % throughout premix addition.

SM 0.01 % before transfer for slurry washing.

FINISHED PRODUCT SPECIFICATIONS
ZnO = 44-50%
CuO = 40-44%
Al2O3= 7.5-12.5%
Sulphur= upto0.03%
Chloride=up to 100ppm
LOI=Upto10%.
Na<50 ppm
Crush strength= average minimum 8 kg/cm2. No tablet should have crush < 4.5 kg/cm2

C7 ADSORBENT
 RAW MATERIALS
1. Zinc Oxide
2. Rework powder
3. Clay
4. Atta
5. Cement
6. Talcum powder
 PROCESS
MIXMULLING

Ensure mixmull discharge door is in closed condition. Charge 300 kg ZnO, 25 kg rework powder,
10 kg clay, 10 kg Atta, 3 kg cement and 14kg talcum powder. Start mixmull and drymull for 10
minutes. Ensure proper mixing. After 10 minutes add required quantity of water and wetmull for
another 10 minutes. Mixmull LOI should be in the range of 25-30 %.Unload the mixmull in
container.
EXTRUSION
Fix the required die. Ensure cooling water circulation. Feed wet mixmull to the extruder and collect
the extrusions in plastic baskets with shift identification. Then the extrutions are allowed for
drying.
DRYING
Drying can be done in either band dryer or box dryer. Band dryer outlet temperature will be 4000C.
In box dryer the extrusions are dried in racks at a temperature of 3600C for 3 hours. After that it is
allowed to cool.
SCREENING
The dried extrusions after cooling is screened into finished product drums with liners. Collect
undersize and oversize as rework.
CRITICAL PARAMETERS
1. Mixmull LOI =25-30 %
2. Band dryer outlet temperature – 4000C
3. LNG pressure – 600 mm WC
FINISHED PRODUCT SPECIFICATIONS
1. Crush = average 6.8 kg/cm2
2. LOI = min 5 %
3. Surface area = min 25 m2/g
4. Bulk density =1.1 kg/L
5. ZnO = 87-93 %

ActiSorb GP - 105

 RAW MATERIALS
1. Zinc
2. Copper
3. Ammonia
 4. Carbon dioxide
5. Flash calcined alumina
6. Acetic acid
7. Volclay
 PROCESS
Take required quantity DM water & acetic acid up to marked level in dilution preparation tank to
get 2-3% concentration. Confirm analysis.
MIXMULLING

Ensure dust suction blower in operation & mix mull discharge valve in closed position. Charge
required quantity rework, Copper Malachite Lump, Zinc Hydrotalcite Lump, Volclay, FCA in mix
mull. Start mix mull & dry mull for 10 minute for proper mixing. Add required quantity dilute
acetic acid solution in to mix mull slowly to get 30-35% LOI. Wet mulling to be done for 45
minute. Inspect mix mull and unload material into container for extrusion.

EXTRUSION
Fix required extruder die. Ensure cooling water circulation & pellet cutter position. Initially low crush
pellet, if any formed to be re extruded. Collect wet pellets in plastic baskets with shift identification.
Consume all rework generated during extrusions in the next mix mull batch.
DRYING
Hot air from HAG is given to 3rd zone to get bed temperature 165 - 175°. As the burner burns LNG &
produce flame, the FD fan will give cold air from outside and which will get heated up. This hot air is being
carried to the drier bed.Open gas train inlet valve slowly, check slam shut off valve position. If it is in up
position & green band is visible, there will be gas flow. If there is any abnormal / sudden pressure difference
slam shut off valve will get closed automatically. If slam shut off valve is in closed condition it shows red
band, then close gas inlet valve, open safety vent valve to depressurized gas & pull up the slam shut off
valve top knob.
Drier is provided with two ID fans. One is for first zone and the second is for second and third zone. Hot
gas enters through the side of third zone and leaves through the top of third zone. This is directed to the
second zone. Same to that of third zone, hot air enters through the side ducts and leaves through the top
ducts. These exit ducts are connected to ID fan. Draft balance for the drier is maintained by this ID fan.
SCREENING
The dried pellets after cooling is screened into finished product 200 L drums with liners. Collect
screen under size material in identified drums & milled for using in all mix mull batches as rework.
CRITICAL PARAMETERS
Crush : Avg ˃ 5kg/cm2
LOI : 20 - 30 % (540°C)
BD : 1 -1.2 Kg/L
Copper Oxide: 44.0 ± 3.0 %
Zn Oxide : 38.0 ± 5.0 %
Alumina : Balance %

G1-MH
 RAW MATERIALS
1. ZnO
2. C18 Lump
3. Graphite
4. Cement
5. Water
 PROCESS
MIXMULLING
Ensure mixmull discharge door is in closed condition. Charge 125 kg ZnO, 180 kg C18 Lump, 2.5
kg graphite, 5 kg cement. Start mixmull and drymull for 10 minutes. Ensure proper mixing. After
that add 60-70 liters of water and start wet mulling. Wet mulling is continued till granules are
formed. When granules are formed, unload it in containers.
DRYING
The mixmull is taken into racks from the container for drying in box dryer. It is dried for 1 hour
30 minutes at 3500C.After drying it is allowed to cool.

GRANULATION
The dried mixmull is granulated in the granulator and separate undersize and oversize. The
granulated powder is collected in containers.
TABLETING
The containers are taken for tableting.6x3 mm tablets are tableted in the machine. The off machine
crushed will be around 6 kg/cm2. The tablets are loaded in racks and allowed for 24 hour
atmospheric cooling.
DRYING
The tablets are dried in the box dryer at 3500C for 3 hours. After drying the tablets are allowed for
cooling.
SCREENING
The dried tablets after cooling is screened into finished product drums with liners. Collect
undersize and oversize as rework.

CRITICAL PARAMETERS
1. Mixmull drying time =1 hour 30 minutes
2. Mixmull drying temperature = 350 0C
3. Tablet drying time = 3 hours
4. Tablet drying temperature = 350 0C

FINISHED PRODUCT SPECIFICATIONS

1. LOI @ 540 0C – max 6
2. ZnO – min 60 %
3. Average crush – min 10 kg/cm2
4. Bulk density – 1.45 + / - 0.1 kg/L
RESEARCH AND DEVELOPMENT
29/08/2018 to 05/09/2018

GP ADSORBENTS
GP adsorbents are used to remove the sulphur impurities from natural gas. They are also used to
remove mercury, arsenic and other wide range of impurities.

Once H2S reacts with metal oxide present in adsorbent, it is chemically reacts with the adsorbent.
Even when the adsorbent is fully saturated it will not desorb H2S or sulphur. It is then shifted to a
smelting plant that can remove the sulphur before metals are extracted.

Raw materials:

 Malachite lump
 Zn Hydrotalcite/ZnO
 Volclay
 Flash calcined Alumina(FCA)
 Acetic acid

GP product compositions
% ZnO = (33- 43) %
% CuO = (41- 47) %
Copper hydroxy carbonate (malachite) is the active phase here.
CuO + H2S  CuS + H2O

Operation Conditions
Operate at a temperature of 30-150C for sulphur removal. No feed stock loses are there, only
impurities are reacted and adsorbed.

Advantages of GP Adsorbents
1. High pick up capacity, lowers operation cost.
2. High crush strength.
3. Active metal and promoters do not leach into downstream equipment
4. Low capital cost
5. Impurity removed to very low levels
6. Longer life span
Types of GP Adsorbents

1. GP 105

2. GP 108

3. GP 107

4. GP 110

5. GP 112

6. GP 405 S

G92–C Adsorbent
G92–C adsorbent is used to remove the chloride impurities from hydrocarbon feed. Chloride is
considered as a poison. Naphtha feed contains chloride compounds.

G92–C is Na2O (7 – 11) % on alumina spheres with 3 – 4 mm size. Manufactured by incipient

wetness impregnation of alumina balls with caustic solution. After that it is dried and calcined at
2700C.

Effects of chlorides
1. Equipment corrosion
2. Impurity problems in downstream processing
Features of the catalyst
1. Low dust
2. Low attrition
3. High crush strength
4. High adsorption capacity.

Chloride pick-up test for G92 – C

 10cc catalyst is loaded in glass reactor. Pass N2 gas (50 – 55 LPH) through hydrochloric
acid, concentrated sulphuric acid and finally through catalyst bed for 3 days. Scrub outlet
of the reactor in silver nitrate solution. Unload catalyst after 3 days and analyse chloride
pickup using volumetric analysis.
  The same experiment is carried out in an SS reactor where the catalyst is loaded along with
inactive alumina in an SS tube and loaded in reactor. N2 and Cl2 gases are passed through
the bed. The outlet is bubbled through Silver nitrate solution which turns white when Cl 2
slips from the reactor.

SULFOMAX (C 116)
Sulfomax catalyst is used for the production of sulphuric acid. Contact process is the method used
for the production of sulphuric acid.
Platinum catalysts were used earlier, but it reacts with the impurities in sulphur feed stock.
Vanadium pentoxide is now preferred.

The reactions occurring in contact process are:

S + O2 SO2

SO2 + ½ O2 SO3

SO3+ H2O H2SO4

In the presence of vanadium pentoxide catalyst 95 % conversion is possible.

Catalyst action takes place in 2 steps
a) Oxidation of SO2 to SO3 by V5+

2SO2 + 4V5++ 2O 2SO3 + 4V4+

b) Oxidation of V4+ back to V5+

4V4++ O2 4V5+ + 2O

SO2 enter into the catalytic convertor and get converted to SO3 at first stage of conversion. The
exit gas from this stage of conversion contains both SO2 and SO3 which are passed through
absorption towers where sulphuric acid is used. SO3 reacts with acid increasing sulphuric acid
concentration. The stream of SO2 is passed through the catalytic convertor bed again achieving
99.8 % conversion of SO2 to SO3.
PRODUCTION PROCESS AND CHEMICAL REACTIONS
1. Premix
Ammonium metavanadate, potassium carbonate and sodium carbonate reacts to form sodium
vanadate and potassium vanadate.
NH4VO3 + K2CO3 + Na2CO3 NaVO3 + KVO3 +NH3
NH3 will be liberated and scrubbed for reuse.

2. Mixmull
Sodium vanadate and potassium vanadate reacts with sulphuric acid to form potassium sulphate,
sodium sulphate and vanadium sulphate.
NaVO3 + KVO3 + H2SO4 K2SO4 + Na2SO4 +V2 (SO4)3
3. Calcination
On calcination corresponding oxides are formed.
K2SO4 + Na2SO4 + V2 (SO4)3 6000C K2S2O7 + Na2S2O7 + VO (SO4)3

Activity test for sulfomax catalyst

200cc catalyst is loaded in the reactor. SO2 and air are used to analyse the activity. Inlet SO2 will
be 8 – 8.5 %. Test is conducted at a temperature range of 360 – 4200C. The flow of inlet gases is
controlled by MFC. Steam is provided using heater. SO2 will be converted to SO3 in the presence
of catalyst. % SO2 is analysed at the inlet and outlet.

Purpose of the catalyst

1. To reduce emissions
2. To increase productivity
3. To maximise energy
4. To decrease pressure drop

Different types of sulfomax

1. Sulfomax RR
Its structure is a ribbed ring form providing overall integration.
Properties
 High mechanical strength
 High activity due to high surface area
 Better gas distribution.
2. Sulfomax Cs/Cv
Cesium promoted variants of sulfomax improves conversion because of its low temperature
activation. Activation temperature is around 3800C.
Properties
 Reduce stack emissions
 High steam generation possible
 Activation at lower temperature

INSTRUMENT LAB
1. X-ray Powder Diffraction (XRD) Machine:
It is a rapid analytical technique primarily used for phase identification of a crystalline material
and can provide information on unit cell dimensions. The analyzed material is finely ground,
homogenized, and average bulk composition is determined.
2. Micromeritics AutoPore IV:
It characterizes a material's porosity by applying various levels of pressure to a sample
immersed in mercury. The pressure required to intrude mercury into the sample's pores is
inversely proportional to the size of the pores. This is called mercury porosimetry, or often,
"mercury intrusion."
3. Mastersizer 3000- particle size analyzer:
The Mastersizer 3000 laser diffraction particle size analyzer delivers rapid, accurate particle
size distributions for both wet and dry dispersions with the minimum of effort. Measuring
over the nanometre to millimetre particle size ranges, it packs exceptional performance into
the smallest of footprints, bringing operator-independent measurements that every user can
rely on.

4. Tristar-Surface Area & Porosity Analyzer:

It provides high-quality surface area and porosity measurements on solid materials by using
the technique of gas adsorption. It is a three-station analyzer capable of increasing the speed
and efficiency of quality control analyses, with the accuracy, resolution, and data reduction to
meet most research requirements. This easy-to-operate, tabletop instrument is designed to
analyze up to three samples simultaneously for optimum throughput. Its speed and accuracy
make it an ideal instrument for a wide variety of applications that include pharmaceuticals,
catalysts, carbon, cosmetics, paints, pigments, geoscience, fuel cells, high-tech ceramics and
much more.
5. TA Instrument SDT 600- Thermogravimetric Analyzer

This Thermogravimetric Analyzer (TGA) & Differential Scanning Calorimeter (DSC)

provides simultaneous measurement of weight change (TGA) and true differential heat flow
(DSC) on the same sample from ambient to 1300˚C.

6. Thermo fisher scientific- PFPD Gas Chromatograph:

It is dedicated to routine analysis of Sulphur in the gas samples.

7. MITSUBISHI Chemical Analytech- Nitrogen, Sulphur and Chlorine measurement NSX-

2100:

Four different detectors can be connected to one furnace depending on the requirement.

Advantages:

 High end performance

 Robustness
 Reliability
 Stability
 High productivity
 low running cost
 Easy daily maintenance
8. AUTOCHEM II - chemisorption analyzer:

It is a fully automated chemisorption analyzer that can provide the ability to conduct a
comprehensive array of highly precise studies of chemical adsorption and temperature-
programmed reactions. With this single instrument, we can acquire valuable information about the
physical properties of the catalyst, catalyst support, or other materials. It can determine catalytic
properties such as percent of metal dispersion, active metal surface area, acid strength, surface
acidity, distribution of strength of active sites, BET surface area, and more. It performs pulse
chemisorption, temperature-programmed reduction (TPR), desorption (TPD), oxidation (TPO),
and reaction analyses and does it automatically.
C7 ADSORBENT
Zinc oxide is the active phase in C7 adsorbent. It is used for removing sulphur impurities in natural
gas. It will react with the H2S gas and zinc sulphide (ZnS) is formed.
ZnO + H2S ZnS + H2O
C7 adsorbent works in temperature range of around 3000C. GP works only in room temperature.
Adsorption capacity of C7 is less compared to GP adsorbent.

ActiSorb G-1
ActiSorb G1 is a brilliant dual function HDS cum Sulfur Guard catalyst.
Function-1: Hydrogenation of organic sulfur in the presence of H2 (Similar to CoMo / NiMo HDS
catalysts)
Function-2: Absorption of H2S & COS

Raw materials:

 Zinc Oxide
 Cement Graphite
 C18 Lump
 Ammonium HeptaMolybdate
 Dilute Caustic soda
 Calal cement ( 4 -7%)
 DM water

Catalyst Properties:

CuO 1.5%

MoO3 3.5%

ZnO Balance

Bulk Density 1.2 - 1.3 kg/l

These unique characteristics unlock possibilities for several new process flow schemes for
purification section.
Unique attributes of G1

 Ideal for Natural Gas with low Sulfur: < 20 ppm

• Sulfur pick-up as high as with Zinc Oxide
• Maintains Hydrogenation activity even without Sulfur
• No pre-sulphiding required & can start up without H2
• Highly recommended for fine polishing with COS in feed
• Drop-in replacement in ZnO beds, absolutely no other changes required

LOW TEMPERATURE SHIFT CATALYST (C18)

C18 catalyst is used for the production of hydrogen gas. In the water gas shift reaction, carbon
monoxide reacts with water to form carbon dioxide and hydrogen gas in the presence of catalyst.
CO + H2O CO2 + H2 (water gas shift reaction)

TESTING OF C18 ACTIVITY

Two test units Test unit 1 and test unit 2 are available in R & D lab for testing the activity of C18
catalyst. CO, CO2, H2 is given to the reactor from their respective cylinders. The flow rate of the
gases is controlled by a mass flow controller (MFC).A gas flow meter is used to measure the flow
rate. As per spec CO =2.5 – 2.8 %, CO2 =10 – 11 % and balance will be H2. These gases react with
steam in the presence of the catalyst inside the reactor. Steam is produced by using an electric
heater. Usually 10 cc catalyst will be loaded in the reactor bed. Back pressure regulator is used to
control the pressure inside the reactor. Activity of the catalyst is checked based on %CO at inlet
and outlet. It is analysed using gas chromatography. A chromatograph will be plotted showing %
CO, %CO2, %H2 at inlets and outlets. Analysing this activity of the catalyst is determined.

CATALYST PREPARATION & CHEMICAL REACTIONS:

SCRUBBER SOLUTION
Ammonia and carbon dioxide dissolved in water to form ammonium hydro carbonate and
ammonium carbonate.
ZINC REACTOR
Zinc reacts with ammonia, carbon dioxide and water to form Zinc amine carbonate
COPPER REACTOR
Copper reacts with ammonia, carbon dioxide and water to form copper amine carbonate.
PREMIX
Premix is a mixture of Zinc amine carbonate and copper amine carbonate.
DECOMPOSITION
On decomposition with steam copper hydroxy carbonate and zinc hydoxy carbonate are formed.
Ammonia and carbon dioxide are evolved out and scrubbed for reuse.
DRYING
On drying CO2 will be eliminated and corresponding oxides are formed.
COMPOSITION
CuO = 32 – 33 %
ZnO = 34 – 53 %
Al2O3 = 15 – 33 %
Active catalyst part is CuO. Function of ZnO is to provide structural support as well as prevent
poisoning of copper by sulphur.Al2O3 prevents dispersion.
LTS works under a temperature range of 200 – 2500C.
PROPERTIES OF LTS
1. Good and stable catalyst.
2. Maximum conversion from CO to CO2.
3. High conversion favourable at lower temperature.
Factors affecting the activity of catalyst
1. Surface area
2. Pore volume
3. Temperature.
4. Space velocity
HIGH TEMPERATURE SHIFT CATALYST (C12)
1. Sodium bichromate addition
Sodium bichromate reacts with ferrous sulphate solution and sulphuric acid to form ferric sulphate,
chromium sulphate and sodium sulphate.
75 % Fe2+ is converted to Fe3+.
2. Precipitator
Excess sodium hydroxide solution is added to the premix in the precipitator to get corresponding
hydroxides. Copper sulphate is added here for the required copper content.
Slurry is filtered and washed there by Sodium sulphate is removed and the cake is dried.
3. Drying
On drying corresponding metal oxides are formed.
2Cr(OH)3 Cr2O3 + 3H2O
2Fe(OH)3 Fe2O3 + 3H2O
Cu2CO3(OH)2 2CuO + CO2 + H2O
Operational conditions of HTS catalyst
% CO (inlet) =8 – 15 %
% CO (outlet) = 2 - 4 %
CO conversions will be greater than 75 %.
Impurities affecting the catalytic action
1. Cr6+
2. Sulphur content.
Cr6+ is water soluble and decreases the catalytic strength.
During initial catalyst reduction H2S will be liberated which is a poison for LTS catalyst.
COMPOSITION
1. % Fe2O3 =85 – 87 %
2. % Cr2O3 =9-11 %
3. CuO =1.5 – 2.5 %
4. Graphite = 3 %
Active phase of the catalyst is Fe3O4.In absence of chromium oxide Fe3O4 loses activity due to
reduction in surface area. Copper is acting as an activity enhancer.
ACTIVITY TEST
Bottom layer of the reactor is filled with 20cc Alumina. Middle layer is filled with 10cc catalyst +
20cc silicon carbide. Top layer is filled with 50cc silicon carbide. Initially leak test is done by
applying nitrogen @ 25kg pressure. Ensuring there is no leak drain the pressure to 3 kg. Increase
the reactor temperature to 3700C. Then start pumping water to the reactor @ 55 – 58 cc/hr. Raise
the pressure to 25 kg by nitrogen and introduce process gas CO, CO2, H2. Inlet CO concentration
is 11 – 13 %. Outlet analysis is taken after 3 hours of reduction. Reduction will be continued for
72 hours and monitored.
Chemical reaction taking place in HCF
As per the customer requirement Cr6+ is reduced to Cr3+ in R & C plant. Reduction is done by
addition of hydrogen. Chemical reaction taking place is:
2CrO3 + 3H2 = Cr2O3 + 3H2O
Hydrogen is given by ammonia cracking.

COPPER CHROMITE
Copper chromite is used in the unit process of organic synthesis such as hydrogenation,
dehydrogenation, hydrogenolysis etc. It is also used in the production of H2 as an energy carrier
and also for the conversion of alcohols. Manganese and barium are the commonly used promoters.
Process steps in Cu.Cr Catalyst production
1. Chromic acid solution preparation
Chromic acid flakes is diluted in water to form chromic acid solution (17 % concentration)
2. Copper nitrate solution preparation
Copper nitrate solution is prepared by making % Cu =15- 20.
3. Premix
In premix tank chromic acid solution, copper nitrate solution and manganese nitrate is mixed.
Cu/Cr ratio is 1.04.
4. Precipitation
Ammonia is then passed to premix tank using control valve to maintain the pH as 5.6 to 8. pH is
the critical parameter here. Copper nitrate, manganese nitrate, chromic acid and ammonia react to
form copper hydroxy ammonium carbonate.
5. Drying
Drying is done in the box drier at a temperature of 4100C. Copper chromate is formed by liberating
nitrogen gas and water.
QA
06/09/2018 to 08/09/2018
ISO CERTIFICATES
1. ISO 14001(2015) – Environment management system.
It deals with environmental aspects and impacts. Environmental aspects are the problems causing
while handling equipment, chemicals etc. And impact is how it is affecting the environment.
He also explained about the areas where we have to concentrate while we are on process.
2. ISO 18001 – Safety management system (OSHAS)
It deals with HIRA-Hazard identification and risk assessment. It is the study of various factors or
malpractices which can cause serious hazards. Also a risk assessment is also done there. Will find
out whether it is significant or not significant. If it is significant we will check into the root cause
and will find the corrective action for the same. If a hazard is happened the procedure will be
1. Initial correction
2. Root cause analysis
3. Finding out corrective action.
3. ISO 9001(2015) – Quality management system
It deals with the various parameters of the production process. As per the SOP a process will be
done under certain critical parameters.
We should follow the parameters to meet the quality.
Following are the specifications of different products and components:

C12 (SHIFTMAX120)
 FERROUS SULPHATE
1. % purity =98% min
Titanium is an impurity (should be0.1%max)
2. % ferric = 0.5% max
Fe3+ will precipitate in copperas tank. So Fe3+ is not needed.
3. Acid insoluble= 0.5% max
To check whether sand or dust particles is present.
 SODIUM BICHROMATE
1. Moisture@1500C = 13%
It denotes the moisture content in the solution
2. % purity = 99% min
 NAOH SOLUTION
1. % Caustic = 40% w/w min
It denotes the percentage of caustic in the solution.
 COPPER SULPHATE
1. % Copper = min 25%
It denotes the percentage of copper in the copper sulphate crystal.
2. pH of 5% solution= min 3.5
Copper sulphate is introduced to avoid the ammoniacal nitrogen
 GRAPHITE
1. % Purity= 98% min

It can be found out by heating at 9000C

2. Impurities
Sulphur, Sodium, Chloride are the impurities which are poisonous to the catalyst function.
Spec values are Sulphur (0.1% maximum), Sodium (0.15%maximum), Chloride (0.01% max)
3. Passing through 200 mesh =90% min
Particle size must be low.
INTERMEDIATE PROCESS
 COPPERAS PIT TANK AND COPPERAS SOLUTION TANK
1. % Fe (iron content in the solution) =6.5-7.5%
2. %FA (free acid) = 0.5-1%
 PREMIX TANK
1. % Fe = 6.5-7.5%
2. %FA =0.5-1%
 SODIUM BICHROMATE SOLUTION TANK
1. Sodium bichromate solution =30-35%
 DILUTE TANK 3
1. % Caustic =15-17%
 PRECIPITATOR 3
1. Conversion Test =95%min
It denotes how much ferrous is converted to ferric.
 MEMBRANE 1, 2, 3 &4
1. % Sulphur =0.015% max
Sulphur is poisonous to catalyst. So it is washed away.
2. %CuO=1.5-2.5%
 ROTARY CALCINER
1. LOI @ 5400C =4-9%
LOI indicate the moisture content.
 FEED PREPARATION
1. LOI @ 5400C=12-15 %.
 TABLETTING
1. Crush =14 kg/cm2
 CALCINATION
1. Crush =14 kg/cm2 average
2. Bulk density= 1.06-1.22
3. LOI= 7% max
 SCREENING
1. Visual Inspection
Visually check the tablet size, structure and whether it is contaminated by foreign particles.
 FINISHED PRODUCT
The spec values for the finished products are given below.
1. LOI =7% max
2. Fe2O3=85% min
3. Cr2O3 =7-10 %
4. CuO =1.5-2.5%
5. Cr6+ =<2%
6. Sulphur=<0.015%
7. Crush =average 14 kg/cm2
8. BD =1.06-1.22
HCF (HEXAVALENT CHROMIUM FREE)
Process taking place
1. Catalyst Loading
2. Pressure Test
3. Ammonia Cracking
4. Reduction Process
5. Screening
6. Auto weighment
Chemical reaction Happening
Ammonia cracking is done at a temperature of about 8750C and 7 kg/cm2.Ammonia crack into
75% hydrogen and 25% nitrogen.
Hydrogen is a reducing agent. It reduces CrO3 to Cr2O3.
That is Cr6+ to Cr3+.Nitrogen is an inert gas which is recollected further.
When the hydrogen liberated is fully consumed the process is stopped.
TESTS UNDERGOING
Finished product Shiftmax120 (C12) is the raw material.
Tests under gone for HCF finished products and their specifications are
1. LOI =7% max
2. Fe2O3 =85% min

3. Cr2O3 =7-10 %
4. CuO =1.5-2.5 %
5. Cr6+ =<50ppm
6. Sulphur =<0.015%
7. Crush =average 14 kg/cm2
8. BD =1.06-1.22
VISUAL INSPECTION
In visual inspection the physical structure of the final product is being analyzed. Checks for any
broken pieces, size variations, dust contaminations etc. If the inspecting officer approves the visual
inspection then only the final product is taken for further QA analysis.
C18 (SHIFTMAX 210)
1. Zinc metal
Usually for zinc metal test are not undergoing because supplier is providing with 99.9% purity.
2. Copper metal granules= 99.9% purity
3. Graphite= 98% min purity
Purity is found out by heating at around 9000C.
Impurities in graphite are sulphur, chloride and sodium
Quantities of these impurities are also tested.
Spec value are % sulphur =<1000 ppm
%chloride =<100 ppm, %sodium =<1500ppm
Passing through 200 mesh =Min 90%
4. Alumina
LOI =30% max
Impurities are also tested
Spec value are % sulphur =<200 ppm
%chloride =<200 ppm, %sodium =<200ppm
Passing through 200 mesh= max98%
%Al2O3 =min 70%

INTERMEDIATE PROCESS
1. Copper solution tank-2
% copper metal= 8.5-10.5%
2. Zinc solution tank
% zinc metal= 8.5-10.5%
Premix tank 1
. The zinc to copper ratio =1.06-1.09
4. Decomposer 3
Zinc to copper ratio =1.06-1.09
Soluble metal percentage =0.01% max.
5. Rotary calciner
% LOI=max 5%
%CO2=max 3%
6. Feed
%LOI = 0-14%
%CO2 = max 3%
7. Tableting
Off machine tablets
%LOI= max 10%
Crush= min 6 kg/cm2
Calcined tablets
%LOI= max 10%

Average crush-8 kg/cm2

Bulk density =1.2-1.36

FINISHED PRODUCT
Specifications for C18 finished product
1. % ZnO =44-50 %
2. %CuO=40-44 %
3. LOI=max 10%
4. Al2O3=7.5-12.5 %
5. Crush =Min. average crush> 8 kg/cm2
6. Bulk density=1.28+ – 0.08
7. Sodium =max 300 ppm
8. Chloride=max 300 ppm
9. Sulphur=max 300 ppm.
VISUAL INSPECTION
In visual inspection the physical structure of the final product is being analyzed. Checks for any
broken pieces, size variations, dust contaminations etc. If the inspecting officer approves the visual
inspection then only the final product is taken for further QA analysis.
BRIEF DESCRIPTION ABOUT C18 FINAL PRODUCT ANALYSIS
1. LOI
LOI is done at 5400C in muffle furnace for 30 minutes.
Also LOI is tested by heating at 900 0C muffle furnace for 1 hour.
Graphite will be burnt out.
The weight loss determines the LOI.
2. % Zinc and % Copper
0.5 gram sample is taken and per chloric acid will be poured into it for dissolving. It is then allowed
to boil. After boiling it is allowed to cool. Xylenol orange indicator and ammonia is added. Add
1:1 H2SO4 drop wise. To mask alumina add sodium fluoride. To mask Copper add ascorbic acid
and thiourea. Then titrate with EDTA and we will get the endpoint as yellow. To de mask copper
add hydrogen peroxide. Then again add sodium acetate and xylenol indicator. Titrate using EDTA.
End point is light green. Then calculations are done to find % zinc and % copper.
3. Ion Chromatograph for chloride detection
A graph will be plotted according to the values which are compared with the result of an already
tested standard solution.
4. Flame photometer for sodium detection
It is found out by comparing the flame intensity produced.

C116 (SULFOMAX)
1. Ammonium Metavanadate
 % V2O5 = 75% min
 % chloride = 0.1% max
2. Potassium carbonate
 % purity = min 98%
3. Sodium carbonate (soda ash)
 % purity = min 95%

4.Caesium carbonate
 % purity =min99%
5. Diatomaceous earth (Celaton)
1. % silica =min 88%
2. % LOI @ 540 0C =max 7%
3. %Fe2O3 = max 1.5%
4. % Al2O3 = max 3.6%
5. % CaO = max 0.6%
6. % MgO =max 0.5%
7. BD =0.1-0.2
8. Passing through 325 mesh = min 99.5 %
INTERMEDIATE PROCESS
PREMIX
1. % Vanadium =13-15.
2. % Sodium =1.5-2.5
3. % Potassium =20-23
4. Molar ratio (K/V) = 2.5-3.4
5. % Caesium =13-15
FINISHED PRODUCT
1. % V2O5 = 6.5-7.5 %
2. % potassium oxide =9.5-11.5 %
3. % sodium =0.9-1.5 %
4. Pore volume =0.4-0.8 %
5. Average crush = 5kg/cm2
6. Activity =9*3 – minimum 80%
=12*4 – minimum 75%
7. % caesium = 3-4 %
SULFOMAX HV,CV
1. % V2O5 = 7.5-8.5 %
2. % potassium oxide =9.5-12.5 %
3. % sodium =0.9-1.3 %
4. Pore volume =0.4-0.8 %
5. Average crush = 5 g/cm2
6. % caesium =5-7 %

SULFOMAX WRR (RIBBED RINGS)

1. % V2O5 =12-13 %
2. % K2O =22-24 %
3. Sodium =3.5-4 %
4. Molar ratio =3.3 – 3.8
SULFOMAX WCs (RIBBED RINGS)
1. % V2O5 =14
2. % K2O = 29.5
3. %Na =2.6
4. %Cs2O = 8.2
VISUAL INSPECTION
In visual inspection the physical structure of the final product is being analyzed. Checks for any
broken pieces, size variations, dust contaminations etc. If the inspecting officer approves the visual
inspection then only the final product is taken for further QA analysis.
Analysis on Sulfomax finished product
1. % Vanadium
Take 1 gram sample and add approximately 10gram NaOH pellets. Boil at 5400C for 25 minutes
in muffle furnace. Add 1:1 H2SO4, excess KMnO4 for complete oxidation. It is titrated against
0.1N ferrous ammonium sulphate. Excess KMnO4 is titrated using FAS. Then add
orthophosphoric acid and BDS indicator (5-6) drops. End point is light green in colour.
2. % sodium, % potassium, % caesium
Take sample of around 0.3-0.4 grams. Initially make it wet and pore hydrochloric acid and place
it in bunser burner. It should become completely dry (approximately 1 hour).After that add HNO3
and allowed to cool for a while. After that make up 1 litre conical flask using distilled water. 10
ml is pippeted out from it and make up to 100 ml. Then 0.6 grams of KCl is added.
% sodium and % potassium is found out by flame photometer. It is found out based on the flame
intensity. % caesium is found out by atomic absorption spectrometer.
In AAS we use C2H2 and air as fuel. Concentration is compared with 1M, 3M, and 6M standard
solutions respectively.

ACTISORB S2 (C7)
% NaOH = above 40
Zinc oxide
1. % purity =min 95%
2. % LOI =max 5 %
3. % sulphur = max 1500 ppm.
4. % sodium = max 6000 ppm.
5. % chloride =max 300 ppm.
6. Compact BD =0.5 – 0.65
7. Surface area =min 40 m2/gram.
8. % CO2 = max 1.5
INTERMEDIATE PROCESS
1. Mix mulling
% LOI =25-30 %
% ZnO =87-93 %

2. Extrusion
% LOI =max 5
% ZnO =87-93 %
BD =1 – 1.2
Average crush = 6.8 kg/cm2
Surface area – 25 m2/g
FINISHED PRODUCT
1. Average Crush = 6.8 kg/cm2
2. LOI = min5%
3. Surface area =min 25m2/gram
4. Bulk density =1 - 1.2
5. Zinc Oxide =87 – 93 %
6. Chloride =max 0.04 %
7. Sulphur = max 0.15 %

ACTISORB (G1)
Test undergoing are
1. % Zinc oxide =min 99 %
2. % MoO3= min80 %
3. % caustic =min 40 %
FINISHED PRODUCT ANALYSIS
1. % Zinc oxide =80 – 90 %
2. % molybdenum =3.1 – 3.9%

3. % CuO =1.3 – 2.1 %

4 LOI @ 5400C =max 5
5. Average crush =10 kg/cm2
6. Bulk density =1.1 – 1.3

GP 105
1. %Zinc =99.9%
Usually zinc metal test are not done because supplier is providing with 99.9%purity.

2. Copper %=99.9%
3. Alumina
LOI = 30% max
%sulphur =<200 ppm
%chloride =<200 ppm
%sodium =<200ppm
Passing through 200 mesh= max 98%
%Al2O3 =min 70%

G 92-C
1. % NaOH =25-26
2. Activated alumina balls
LOI =< 10
Surface area =min200 m2/gram.
Average crush =9 kg/cm2

FINISHED PRODUCT ANALYSIS

1. LOI @ 5400C= <10%
2. Average crush =20 kg/cm2
3. Surface area = >95 m2/gram
4. Bulk density = 0.85 – 0.9
5. % Na2O =7 – 11 %

TEST DONE ON ETP

ETP is used for the treatment of effluent produced in plant.
Ammoniakel nitrogen
Take 50 ml sample. Add ISA. ISA – (53.6gram magnesium acetate+28.7 ml glacial acetic acid)
Electrode will be dipped in the solution sample and reading in ppm will be shown in the
ammoniakel nitrogen meter.
pH
Take 50 ml sample. Add ISA. ISA – (53.6gram magnesium acetate+28.7 ml glacial acetic acid)
Electrode will be dipped in the solution sample and reading in ppm will be shown in the pH meter.
Cr6+
Around 10ml sample is taken. Add 1:1 H2SO4 and diphenyl carbizyde indicator. If it becomes
maroon then there is chromium content. It is colourless then there is no Cr6+.

CONCLUSION

A detailed study on different products, their production processes, applications, properties,

analysis and researches happening have been completed.