STUDY OF DELTA PLANT

AT GODREJ INDUSTRIES LTD. VALIA

A PROJECT REPORT

Submitted by

RAJKUMAR PRAMODBHAI PATEL

180990105040

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

in

Chemical Engineering

Shroff S. R. Rotary Institute of Chemical Technology, Vataria, Bharuch

Gujarat Technological University, Ahmedabad

May, 2022
 Shroff S.R. Rotary Institute of Chemical Technology

Block No: 402, Ankleshwar-valia Road, Vataria, Bharuch Gujarat

393135

CERTIFICATE

This is to certify that the project report submitted along with the project

entitled Study of Delta Plant at Godrej Industries Ltd. Valia has been

carried out by Rajkumar Pramodbhai Patel under my guidance in partial

fulfillment for the degree of Bachelor of Engineering in Chemical

Engineering, 8th semester of Gujarat Technological University, Ahmadabad

during the academic year 2021-22.

Mr. Hemant Balsora Dr. Alok Gautam

Internal Guide Head of the Department
 Shroff S.R. Rotary Institute of Chemical Technology

Block No: 402, Ankleshwar-valia Road, Vataria, Bharuch Gujarat 393135

DECLARATION

We hereby declare that the Internship report submitted along with the

Internship entitled Study of Delta Plant at Godrej Industries Ltd. Valia

submitted in partial fulfillment for the degree of Bachelor of Engineering in

Chemical Engineering to Gujarat Technological University, Ahmedabad, is a

bonafide record of original project work carried out by me at Godrej

Industries Limited under the supervision of Mr. Hemant Balsora and that no

part of this report has been directly copied from any students’ reports or

taken from any other source, without providing due reference.

Name of the Student Sign of Student

Rajkumar Pramodbhai Patel
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ACKNOWLEDGEMENT

I feel obliged that a prestigious organization like GODREJ INDUSTRIES LTD. gave

me a chance to get a valuable technical exposure of the industry through the internship

training program. The training period from 1st January, 2022 to 30th April, 2022 has given

me a lot of knowledge regarding the practical application of the theoretical knowledge

that is taught in the engineering institutes and This practical exposure is must in the

academics of every engineering student.

During the training period, I have been guided by numbers of GODREJ INDUSTRIES

LTD. Personnel and without their active and enthusiastic support this training would

not have been possible. First of all, I would like to thank general manager MR. S B

Pandey for accepting me for availing the benefit of the training program.

I am highly indebted to Mr. Vaibhav Kamble (Executive-production), Mr. Ronak Gandhi

(Executive-production), Mr. Ravindra singh (senior production engineer), Mr. Nandlal

Tandel (Pannel Operator), Mr. Nikunj Patel (Production engineer), Mr. Krutagna Desai

(Graduate Apprentice Trainee), Mr. Jayant Yadav (Graduate Engineer Trainee),

Mr.Jaydeep Dobariya (Production engineer) Mr. Harsh Patel (Apprentice) for their

excellent guidance and support.

I am heartily thankful for guidance and support of Dr. Alok Gautam (HOD - Chemical

Engineering Department).

I am sincerely thankful to Mr. Hemant Balsora (Assistant Professor) for his guidance

and help in needs during this period of training.

I also would like to thank all operators, employees of multiple production plant for their
wonderful co-operation and guidance throughout my training period.

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ABSTRACT

The main purpose of the internship is to learn the processing and designed
of equipment used in plants. The other things are to learn discipline and
industrial management. Theory of any subject is important but without its
practical knowledge it becomes useless for the technical students.

A technical student cannot be a perfect engineer or technologist without

practical understanding of the actual scenario of the branch in particular
industries. Hence this training provides a golden opportunity for all the
students to enhance their knowledge in the world of technical industries.

The principle objective of the training report is to get details about the
operations, processes & general aspect of all technical details which are
carried out in the industries and more about the equipment, instruments and
other plant accessories used in the chemical industries.

This report is totally based on my training experiences during entire 4

months. This report includes the brief introduction about the GODREJ. In
short in the plant training gives the students is clear about the industrial
behavior, which is our actual future field. Hence always we listen that,

According to GODREJ INDUSTRIES LTD.

“Knowledge not shared, Is energy wasted.”

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LIST OF FIGURES

FIGURE 2.1 OLEO-CHEMICAL PRODUCTION .......................................................... 6

FIGURE 3.1 OVERALL PROCESS FLOW DIAGRAM................................................. 9
FIGURE 4.1 FLOW DIAGRAM OF FAT SPLITTING ................................................. 16
FIGURE 4.2 FLOW DIAGRAM OF SWEET WATER TREATMENT ........................ 19
FIGURE 4.3 FLOW DIAGRAM OF SWEET WATER EVAPORATION.................... 20
FIGURE 4.4 FLOW DIAGRAM OF GLYCERIN DISTILLATION ............................. 22
FIGURE 4.5 DRIER AND PREHEATER OF CRUDE GLYCERIN ............................ 23
FIGURE 4.6 DISTILLATION OF GLYCERIN ............................................................. 23
FIGURE 4.7 POST DISTILLATION OF GLYCERIN RESIDUE ................................ 24
FIGURE 4.8 FEED & DISTILLATE OF GLYCERIN ................................................... 25
FIGURE 5.1 PFD OF EURCIC ACID FRACTIONATION ........................................... 32
FIGURE 5.2 BFD OF PALMITIC ACID PRODUCTION ............................................. 36
FIGURE 6.1 BLOCK DIAGRAM OF SPLITTING COLUMN ..................................... 38
FIGURE 6.2 BLOCK DIAGRAM OF PRE-CONCENTRATOR .................................. 40
FIGURE 7.1 BLOCK DIAGRAM OF SPLITTING COLUMN ..................................... 43
FIGURE 8.1 WATER TREATMENT............................................................................. 48
FIGURE 8.2 BOILER ...................................................................................................... 50
FIGURE 8.3 TYPES OF COOLING TOWER................................................................ 53
FIGURE 10.1 MULTI EFFECT EVAPORATION......................................................... 58
FIGURE 11.1 GRAPH OF JH VS RE .............................................................................. 69
FIGURE 11.2 GRAPH OF NRE, BAFFLE CUT & JH ................................................... 71
FIGURE 11.3 GRAPH OF JF VS NRE (TUBE SIDE) ..................................................... 72
FIGURE 11.4 GRAPH OF JF VS NRE (SHELL SIDE) ................................................... 73
FIGURE 14.1 PLANT LAYOUT .................................................................................... 96

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LIST OF TABLES

TABLE 1.1 CAPACITY OF PLANTS ............................................................................. 3

TABLE 4.1 OILS WITH THEIR PROPERTIES ............................................................ 13
TABLE 4.2 EXPECTED QUALITY PARAMETER OF CFA AND SW PRODUCED16
TABLE 4.3 PHYSICAL PROPERTIES OF GLYCERIN .............................................. 21
TABLE 4.4 SPECIFICATION OF CRUDE GLYCERIN .............................................. 25
TABLE 4.5 PRODUCT SPECIFICATION-REFINED GLYCERIN ............................. 26
TABLE 5.1 CARBON CHAIN DISTRIBUTION OF FATS/OILS ............................... 29
TABLE 5.2 PHYSICAL PROPERTIES OF FATTY ACIDS......................................... 30
TABLE 5.3 D2 COLUMN PARAMETERS ................................................................... 33
TABLE 5.4 D3 COLUMN PARAMETERS ................................................................... 33
TABLE 5.5 PHYSICAL & CHEMICAL PROPERTIES OF PALMITIC ACID ........... 34
TABLE 6.1 MASS BALANCE OVER SPLITTING COLUMN ................................... 40
TABLE 7.1 HEAT CAPACITIES OF RAW MATERIAL AND PRODUCT ............... 43
TABLE 7.2 ENERGY BALANCE OVER SPLITTING COLUMN .............................. 45
TABLE 10.1 OPTIMIZATION OF STEAM ECONOMY ............................................. 59
TABLE 11.1 DATA FOR CENTRIFUGAL PUMP DESIGN ....................................... 63
TABLE 11.2 DATA FOR HEAT EXCHANGER DESIGN ........................................... 65
TABLE 15.1 PURCHASE EQUIPMENT COST ......................................................... 100
TABLE 15.2 TOTAL PURCHASED EQUIPMENT COST ........................................ 100
TABLE 15.3 TOTAL CAPITAL COST ....................................................................... 100
TABLE 15.4 COST REQUIRED FOR PRODUCTION............................................... 102
TABLE 15.5 PROFITABILITY ANALYSIS ................................................................ 103
TABLE 16.1 MSDS OF PFAD ..................................................................................... 106
TABLE 16.2 MSDS OF GLYCERIN ........................................................................... 108
TABLE 16.3 MSDS OF ERUCIC ACID ...................................................................... 110

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LIST OF ABBREVIATIONS

PFAD Palm Fatty Acid Distillate

RBD Refined Bleached Deodorized Distillate
RSO Rap-Seed Oil
PKFAD Palm Kernel Fatty Acid Distillate
CNFAD Coconut Fatty Acid Distillate
CFA Crude Fatty Acid
SW Sweet Water
GLY Glycerin
HPS High Pressure Steam
LPS Low Pressure Steam
AV Acid Value
SV Saponification Value
M/C Moisture
MOC Material Of Construction
MS Mild Steel
SS Stainless Steel
CS Carbon Steel
LMTD Log Mean Temperature Difference
NPSH Net Positive Suction Head
PPEs Personal Protective Equipments
STHE Shell & Tube Heat Exchanger
PHE Plate type Heat Exchanger
N/A Not Available
MSDS Material Safety Data Sheet
SHE Safety Health Environment
ITCS Impact Tested Carbon Steel
LTCS Low Temperature service Carbon Steel
CPR Cardiopulmonary Resuscitation
BA Breathing Apparatus
ISO International Organization for Standardization
AOS Alpha Olefin Sulphonate

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SLS Sodium Laurryl Sulphate

SLES Sodium Lauryl Ether Sulphate
PAC Poly Aluminum Chloride
DCP Dry Chemical Powder
MONG Matter Organic Non-Glycerol
DM De Mineralize
DMF Dual Media Filter
SAC Strong Acid Cation
FRP Fiber Reinforced Plastic
MCB Miniature Circuit Breakers
FCI Fixed Capital Investment
WCI Working Capital Investment
INR Indian Rupees
TCI Total Capital Investment
ROR Rate Of Return
PFD Process Flow Diagram
BFD Block Flow Diagram

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LIST OF SYMBOLS & UNITS

Symbol Property Unit

Cp Specific heat capacity KJ/Kg K
λ Latent heat of vaporization KJ/Kg
G Mass flow rate Kg/hr
Q Heat load KJ
MW Molecular weight g/gmol
D Diameter m
A Area m2
P Pressure KPa
μ Viscosity Poise
T Temperature K
t Thickness mm
CA Corrosion allowance mm
ρ Density Kg/m3
N Rotation per minute Rad/s
W Wind velocity m/s
V Volume m3
η Efficiency -
Np Power number -
NRe Reynolds number -
J Joint efficiency factor -
Jh Heat transfer factor -
Jf Tube side friction factor -

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LIST OF CONTENTS

ACKNOWLEDGEMENT ......................................................................................................... i

ABSTRACT .............................................................................................................................. ii

LIST OF FIGURES ................................................................................................................. iii

LIST OF TABLES ................................................................................................................... iv

LIST OF ABBREVIATIONS ................................................................................................... v

LIST OF SYMBOLS & UNITS ............................................................................................. vii

LIST OF CONTENTS ........................................................................................................... viii

1.0 INTRODUCTION ......................................................................................................... 1

1.1 HISTORY.............................................................................................................. 2
1.2 DIFFERENT PRODUCTS ................................................................................... 2
1.3 CAPACITY OF PLANTS ..................................................................................... 3
2.0 OLEO-CHEMICALS .................................................................................................... 4

2.1 INTRODUCTION ................................................................................................. 5

2.2 TRENDS IN THE OLEOCHEMICAL INDUSTRY............................................ 6
3.0 DELTA PHASE ............................................................................................................. 7

3.1 WHAT IS DELTA PHASE? ................................................................................. 8

3.2 PRODUCT NAME ............................................................................................... 8
3.3 PRODUCTION CAPACITY ................................................................................ 8
3.4 RAW MATERIALS .............................................................................................. 8
3.5 GODREJ CONSUMERS ...................................................................................... 8
3.6 GODREJ COMPETITORS ................................................................................... 9
3.7 TECHNOLOGY PROVIDER............................................................................... 9
3.8 OVERALL PROCESS FLOW DIAGRAM ......................................................... 9
4.0 PRODUCTION OF GLYCERIN ................................................................................ 11

4.1 PHYSICAL AND CHEMICAL PROPERTIES OF RAW MATERIAL ........... 12

4.2 OIL/FATS CHEMISTRY ................................................................................... 12
4.3 FATTY ACID FROM FATS OR OILS .............................................................. 13
4.4 PRINCIPLE OF FAT SPLITTING ..................................................................... 13
4.5 TYPES OF REACTION ..................................................................................... 14

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4.6 CHEMICAL REACTION ................................................................................... 14

4.7 FAT SPLITTING PLANT .................................................................................. 15
4.7.1 Section 1 Fat Splitting.................................................................................. 15
4.7.2 Section 2 Sweet Water Treatment................................................................ 17
4.7.3 Section 3 Sweet Water Evaporation ............................................................ 19
4.7.4 Section 4 Glycerin Distillation..................................................................... 20
5.0 FATTY ACID DISTILLATION & FRACTIONATION ............................................ 27

5.1 INTRODUCTION............................................................................................... 28
5.2 PHYSICAL PROPERTIES OF FATTY ACIDS ................................................ 30
5.3 ERUCIC ACID FRACTIONATION .................................................................. 31
5.3.1 Product ......................................................................................................... 31
5.3.2 Production Capacity ..................................................................................... 31
5.3.3 Raw materials............................................................................................... 31
5.3.4 Consumers.................................................................................................... 31
5.3.5 Process Flow Diagram ................................................................................. 32
5.3.6 Process Description ...................................................................................... 32
5.3.7 Column Parameters ...................................................................................... 33
5.4 PRODUCTION OF PALMITIC ACID .............................................................. 33
5.4.1 Product Name............................................................................................... 33
5.4.2 Capacity: ...................................................................................................... 33
5.4.3 Raw Material ................................................................................................ 34
5.4.4 Application ................................................................................................... 34
5.4.5 Physical And Chemical Properties............................................................... 34
5.4.6 Process Description ...................................................................................... 35
6.0 MATERIAL BALANCE ............................................................................................. 37

6.1 SPLITTING COLUMN ...................................................................................... 38

6.2 PRE-CONCENTRATOR .................................................................................... 40
7.0 ENERGY BALANCE ................................................................................................. 42

7.1 FOR SPLITTING COLUMN.............................................................................. 43

8.0 PLANT UTILITY ........................................................................................................ 46

8.1 ELECTRICITY SUPPLY ................................................................................... 47

8.2 WATER TREATMENT PLANT........................................................................ 47

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8.2.1 D.M. Water .................................................................................................. 48

8.2.2 Treatment Process in Industry ..................................................................... 48
8.3 STEAM GENERATION PLANT ....................................................................... 49
8.3.1 Components of A Boiler System ................................................................. 51
8.4 COOLING WATER SUPPLY ............................................................................ 53
9.0 Detail Description of Equipment ................................................................................. 54

9.1 STORAGE TANK .............................................................................................. 55

9.2 SPLITTING COLUMN ...................................................................................... 55
9.3 DRYER ............................................................................................................... 55
9.4 PRE-HEATER .................................................................................................... 55
10.0 ACTIVITIES................................................................................................................ 56

10.1 POWER CALCULATION OF PUMP ............................................................... 57

10.2 STEAM ECONOMY .......................................................................................... 58
10.3 OPTIMIZATION ................................................................................................ 59
11.0 EQUIPMENT DESIGN ............................................................................................... 60

11.1 STORAGE TANK .............................................................................................. 61

11.2 CENTRIFUGAL PUMP ..................................................................................... 63
11.3 HEAT EXCHANGER......................................................................................... 65
12.0 PUMPS, PIPING, FITTING AND CONTROL VALVE ............................................ 75

12.1 INTRODUCTION ............................................................................................... 76

12.2 VARIES TYPES OF PUMPS ............................................................................. 76
12.2.1 Reciprocating Pump: .................................................................................... 76
12.2.2 Centrifugal Pump: ........................................................................................ 77
12.3 PIPE & FITTINGS .............................................................................................. 77
12.3.1 Elbow ........................................................................................................... 78
12.3.2 Coupling....................................................................................................... 79
12.3.3 Reducer ........................................................................................................ 79
12.3.4 Owlets .......................................................................................................... 79
12.3.5 Tee................................................................................................................ 79
12.3.6 Cross ............................................................................................................ 80
12.3.7 Cap ............................................................................................................... 80
12.3.8 Plug .............................................................................................................. 80

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12.3.9 Valves .......................................................................................................... 80

12.4 CONTROLS VALVES ....................................................................................... 81
13.0 SAFETY, HEALTH AND ENVIRONMENT ............................................................ 82

13.1 INTRODUCTION ............................................................................................... 83

13.2 GENERAL SAFETY AWARENESS................................................................. 83
13.3 USE OF PPE ....................................................................................................... 83
13.3.1 Respiratory PPEs ......................................................................................... 83
13.3.2 Non Respiratory PPEs.................................................................................. 84
13.4 FIRE ENGINEERING AND CONTROL .......................................................... 84
13.5 GAS LEAKAGE ................................................................................................. 85
13.6 CHEMICAL SPILLAGE .................................................................................... 85
13.7 EMERGENCY PREPARADNESS .................................................................... 85
13.8 SAFETY WORK PERMIT SYSTEM ................................................................ 85
13.9 ACCIDENT OCCURANCE REPORTING SYSTEM ....................................... 86
13.10 FIRST AID ...................................................................................................... 86
13.11 PROCESS SAFETY ........................................................................................ 87
13.12 PREVENTIVE MAINTAINANCE ................................................................ 87
13.13 RUNAWAY REACTION (THERMAL EXPANSION) ................................ 88
13.14 FIRST AID MEASURES ................................................................................ 89
14.0 PLANT LOCATION AND LAYOUT ........................................................................ 91

14.1 PLANT LOCATION........................................................................................... 92

14.2 PLANT LAYOUT............................................................................................... 94
15.0 COST ESTIMATION .................................................................................................. 97

15.1 Introduction ......................................................................................................... 98

15.2 Total Capital Investment ..................................................................................... 98
16.0 ANNEXURE.............................................................................................................. 105

16.1 MSDS OF PFAD ............................................................................................... 106

16.2 MSDS OF GLYCERIN ..................................................................................... 108
16.3 MSDS OF ERUCIC ACID ............................................................................... 110
17.0 CONCLUSION .......................................................................................................... 116

18.0 REFERENCES .......................................................................................................... 117

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1.0 INTRODUCTION

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CHAPTER 1: INTRODUCTION

1.1 HISTORY

In 1990, Godrej set up flagship manufacturing facility at Valia in Gujarat. Spread across
140 acres, this integrated manufacturing plant has a production capacity of over 1,94,700
metric tons per annum. It has a Fatty Alcohol unit to enable customization of products
according to the needs of customers. All plants have a Distributed Control System, which
enables good process control and ensures product quality.

Valia plant is ISO 9001:2015, ISO 14001:2015, ISO 45001:2018 certified and all
products made at this facility are Kosher certified. The plant is also ISO 50001:2018
certified. They have also won several industry awards and accolades for their Green
initiatives at Valia, including being the first oleo chemicals manufacturer to receive a
"Gold" Green Co rating by the CII - Sohrabji Godrej Green Business Centre.

1.2 DIFFERENT PRODUCTS

In Godrej Industries Ltd. following products are manufactured as per customer demand:

Glycerin

Fatty acids
o Stearic acid
o Behenic acid
o Erucic acid
o Palmitic acid
o Puroleic acid
Fatty alcohols
o Lauryl alcohol
o Cetostearyl alcohol
o Cetyl alcohol
o Stearyl alcohol
o Behenyl alcohol
Surfactants
o Alpha olefin sulphonate(AOS)
o Sodium lauryl sulphate(SLS)
o Sodium lauryl ether sulphate(SLES)

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1.3 CAPACITY OF PLANTS

Capacities of the main plants are as follows:

Table 1.1 Capacity of plants

Production Plant Capacity (MT/Day)

Fat splitting 250

Fatty acid distillation 165
Sweet water evaporation 100
Refined glycerin 16
Hydrogen gas generation (Nm3/day) 36000
Crude alcohol 120
Fatty acid Fractionation 110
Fatty alcohol flaking 80
Fatty alcohol pastillator 60
Hydrogenation 75
Stearic acid flaker 50
Sulphonation plant 45
Spray drier 4

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2.0 OLEO-CHEMICALS

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CHAPTER 2: OLEO-CHEMICALS

2.1 INTRODUCTION

Oleo-chemicals are chemical compounds derived from sustainable resources that are
majorly oils and fats of vegetables that can be used as raw materials in a variety of
industries. These resources are widely available or can be easily cultivated (virgin
vegetable oils) or cheaply sources (waste vegetable oils) in virtually all parts of the world.
These Ecological and economic advantages are responsible for the growing importance of
oleo-chemicals as energy resources and intermediate manufacturing of industrial
chemicals. Oleo-chemicals can be used as a substitute for petrochemicals-based products
known as petrochemicals.

Manufacturers began switching from petrochemicals to oleo-chemicals in the late 1970

due to the rise in prices of crude oil and the affordability of plant-based lauric oil
produced from palm kernels. Fatty acid, the largest application for oleo-chemicals and
other basic oleo-chemicals substances are produced by various chemical and enzymatic
reactions.

Oleo-chemicals are produced using chemical processes such as water-based hydrolysis,

alcohol-based alcoholysis and hydrogenation. Basic oleo-chemicals include fatty acid,
methyl esters, fatty alcohols of these fatty acids and glycerol as well as fatty amines.

Oleo-chemicals are used in a wide range of industries including:

 Personal care

 Cosmetics

 Coating, adhesives, elastomers and sealants

 Household and industrial cleaning

 Lubricants, grease and metalworking

 Food

 Pharmaceuticals

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Figure 2.1 Oleo-Chemical Production

2.2 TRENDS IN THE OLEOCHEMICAL INDUSTRY

As non-renewable resources become depleted and environment regulations become

stricter, oleo-chemicals are on the rise as sustainable substitutes. The growth of the oleo-
chemicals market is driven by number of factors, such as:
 Availability of raw materials

 High demand from consumers

 Growth of the green chemicals market

The demand for oleo-chemicals is expected to increase in applications such as personal
care, detergents and foods and beverages. Glycerol is expected to see the highest amount
of growth over the next few years due to its increasing preference in applications such as
personal care and food and beverage products.

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3.0 DELTA PHASE

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CHAPTER 3: DELTA PHASE

3.1 WHAT IS DELTA PHASE?

In GODREJ, there are many plants like hydrogenation, hydrogen gas generation, crude
alcohol, fatty acid fractionation, fatty alcohol flaking, sulphonation plant, stearic acid
flaker, fat splitting, fatty acid distillation, sweet water evaporation, refined glycerin, fatty
acid fractionation, etc.

In our Internship period, many other students from different colleges were also doing
internship so students were divided in different plants of company. We were placed in
Delta Phase. It includes fat splitting plant, sweet water treatment plant, sweet water
evaporation plant and glycerin distillation plant.

In Delta Phase, the products are glycerin and crude fatty acid. In fat splitting plant feed
oil is feeding from bottom and water is feeding from top. And from splitting column the
top product is crude fatty acid and bottom product is glycerin water (sweet water). In this
phase main processing for sweet water to get purified glycerin from it and crude fatty acid
is stored in tank.

3.2 PRODUCT NAME

 Crude fatty acid (main product)

 Glycerin (by product)

3.3 PRODUCTION CAPACITY

 Plant capacity 250 MT/day

3.4 RAW MATERIALS

 PFAD (Palm fatty acid distillate)

 RBD (Refined bleached deodorized oil)
 RSO (rapeseed oil)

3.5 GODREJ CONSUMERS

 Dabur India
 Colgate - Palmolive
 Emami
 P & G (Procter & Gamble)
 Hindustan foods

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3.6 GODREJ COMPETITORS

 Nirma chemicals
 Virava chemicals
 Trivene chemicals
 Adani
 Galaxy

3.7 TECHNOLOGY PROVIDER

 Honeywell
 Sierra

3.8 OVERALL PROCESS FLOW DIAGRAM

Figure 3.1 Overall Process Flow Diagram

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This is main process flow diagram of GODREJ production. In fat splitting oil is splitted

into sweet water and crude fatty acid. Sweet water is further treated for getting pure

glycerin. Sweet water treatment, sweet water evaporation and glycerin distillation is

treatment of sweet water to getting higher percentage of glycerin from sweet water. The

split crude fatty acid is treated further in fatty acid distillation to get desire fatty alcohol of

carbon chain. Fatty acid fractionation, fatty alcohol synthesis and fatty acid distillation are

treatment for crude fatty acid. In hydrogen generation plant, hydrogen is produce from

natural gas.

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4.0 PRODUCTION OF GLYCERIN

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CHAPTER 4: PRODUCTION OF GLYCERIN

4.1 PHYSICAL AND CHEMICAL PROPERTIES OF RAW

MATERIAL
Form: Semi Solid at Ambient.
Color: Orange in color
Odor: Gentle fruity smell
pH: N/A
Boiling point: > 200℃
Solidification point: 10℃-50℃ approx.
Flash point: 200℃ approx.
Auto ignition temperature: 350℃ approx.
Explosive/Oxidizing properties: not to be expected
Vapor pressure (20℃): < 1mbar
Density (55℃): 887 kg/m3 approx.
Solubility: insoluble in water (20℃)
Viscosity (55℃): 30 cSt approx.

4.2 OIL/FATS CHEMISTRY

Oil/fats are a compound of carbon, hydrogen and oxygen. An oil molecule is called as
Triglyceride.

Oil/Fats contain triglycerides, di-glycerides, mono-glycerides and free fatty acid. It also
contains gums, color bodies, sterols, moisture and hydrocarbons as minor components.

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Major oils process in Godrej is as tabulated below along with their properties.

Table 4.1 Oils With Their Properties

RBD Crude Palm RSO/

PKFAD/
Palm Palm PFAD Kernel Mustard
CNFAD
stearin stearin oil oil
Acid value 0.1-1.0 5-80 Min. 175 2-10 200-205 0.5-1.0
Saponification
195-205 195-210 200-210 235-245 240-253 166-175
value
Iodine value 30-40 35-45 45-55 15-20 16-20 100-105
%moisture Max. 1.0 Max. 1.5 Max. 1.0 Max. 0.5 Max. 1.5 Max. 0.5
%unsap matter Max. 1.0 Max. 1.0 Max. 1.0 Max. 1.0 Max. 2.0 Max. 1.0

4.3 FATTY ACID FROM FATS OR OILS

A fatty acid is a carboxylic acid with a long aliphatic chain, which is either saturated or
unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even
number of carbon atoms, from 4 to 28. Fatty acids are usually not found in organisms, but
instead as three main classes of esters: triglycerides, phospholipids, and cholesteryl esters.

High pressure processes uses water alone or water aided by a basic catalyst usually zinc
oxide – higher temperatures and / or longer times are needed when no catalyst is
employed, but processes without catalyst avoid the expense of the catalyst and of
removing it from the hydrolysis products. When zinc oxide catalyst is used, it reaches the
distillation still residue. Commercially high pressure fat splitting with steam/water
without catalyst is well established with high degree of split.

4.4 PRINCIPLE OF FAT SPLITTING

Process of fat/oil splitting is termed as hydrolysis. The triglycerides of fatty acids as

present in natural oils and fats are split hydrolytically with process water into free fatty
acids and glycerin at a temperature of 225 - 255℃ and pressure between 50 - 55 kg/cm2.

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4.5 TYPES OF REACTION

There are two types of reaction scheme by which we can achieve the fat splitting reaction.
They are as follows:
 High pressure High temperature

 Enzymatic reaction
In the high temperature high pressure process the reaction is carried out at 54 bar pressure
and 250 to 255℃ of temperature in case of PFAD type of feed. This is known as
hydrolysis reaction and it is reversible type of reaction so high pressure and high
temperature is necessary.

In Enzymatic type of reaction enzyme named lipase is used which helps to convert fat
into fatty acids. This process is not generally used in industries because it would be costly
to separate enzyme after the reaction as it would need to set up a different plant.

4.6 CHEMICAL REACTION

Chemical reaction occurs as follows:

1 fat + 3 H2O → 3 fatty acid + 1 glycerin

Above reaction of the hydrolysis of fat takes place in stages and the reactions are
reversible,
C3H5(OOCR)3 + H2O → C3H5(OH)(OOCR)2 + R – COOH

Triglyceride Water Di-glyceride Fatty Acid

C3H5(OH)(OOCR)2 + H2O → C3H5(OH)2(OOCR) + R – COOH

Di-glyceride Water Mono-glyceride Fatty Acid

C3H5(OH)2(OOCR) + H2O → C3H5(OH)3 + R – COOH

Mono-glyceride Water Glycerol Fatty acid

It can be observed from this that degree of split can be increased by removal of glycerol
as soon as it forms. However, the concentration of glycerol in sweet water is to be
optimized with maximum degree of split to be achieved.

The solubility of water in fatty acids and fats increase with rise in temperature.

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4.7 FAT SPLITTING PLANT

4.7.1 Section 1 Fat Splitting

Oil/Fat and process water are passed continuously in counter-current manner (water from
top and oil from bottom) through the splitting column. The process water preferably DM
water or steam condensate which is collected from Sweet Water Evaporation Plant is fed
from top of the column by means of high pressure feed water pump. The top section of
column is incorporates heat exchanger which bring about a heat exchange between hot
leaving fatty acids and entering process water having comparatively low temperature.
Final heating of process water is conducted by admission of high pressure live steam
supplied by HP Steam boiler. The water heated to the temperature of reaction is
distributed uniformly over the cross sectional area of the column and subject to its higher
density sinks down passing through the fat phase which is slowly and steadily flowing
upward direction.

Similarly, oil/fat is passed through heat exchanger and steam pre-heater is fed at the
bottom of the column by means of high pressure feed pump. In splitting column oil/fat
first run dispersed into small droplets through a zone filled with sweet water (having low
glycerin concentration) where it cools the sweet water and adopts its heat. Subsequently,
oil/fat is brought to the temperature of reaction again by admission of HP live steam. The
oil mixed with the fatty acid which is already presplit and forms a uniform phase with it.
This phase were sweet water and fatty acid is separate is called Interface which is
maintained at a constant level to keep the operating condition at equilibrium.

Splitting is conducted in this way and the temperature and the desired pressure of the
column is maintained high enough to allow sufficient quantity of water remains dissolve
in the fat phase. Hot crude fatty acid and liberated glycerin in sweet water is continuously
removed from top and bottom respectively after flashing through flash vessel and
subsequently cools down in heat exchangers and sent to storage tank by means product
pump for further processing.

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Expected quality parameter of crude fatty acid and sweet water produced are as follows,

Table 4.2 Expected Quality Parameter of CFA And SW Produced

RBD Palm Palm

PFAD PKFAD RSO/ Mustard oil
Stearin Kernel Oil
CFA SW CFA SW CFA SW CFA SW CFA SW
200- 190- 240- 240-
AV - - - - 158-174 -
209 206 260 260
201- 195- 241- 241-
SV - - - - 170-176 -
210 208 265 265
Max. Max. Max. Max.
%M/C - - - - Max. 2.0 -
2.0 3.0 3.0 3.0
10- 10-
%GLY - - 2-6 - - 4-8 - 10-12
20 12

Figure 4.1 Flow Diagram of Fat Splitting

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Typical Operating Parameters,

Column Temperature – 225 to 255 ℃

Column Pressure – 50 to 55 Bar g

Water to oil/fat ratio – 55 to 65%

4.7.2 Section 2 Sweet Water Treatment

The glycerin water (Sweet Water) obtained from high pressure fat splitting needs
chemical treatment in order to produce high quality glycerin. This treatment removes
fatty matters such as free fats, fatty acids and soap, as well as, gums and other organic
impurities. Sweet Water will be treated with Acid to remove fatty matter. The acidulated
glycerin water is further treated with Chemicals such as Lime /Caustic etc. & Filtered.
The resulting product is treated Sweet Water.

To produce good quality glycerin this treatment is very important. Extra care must be
taken other this will lead to high scale formation in evaporator’s and thus reducing its
efficiency with high steam consumption for no reason. Improper treatment will also lead
to have high fatty acid & ester, objectionable odour and taste in refined glycerin.

Treatment procedure followed in plant involves two stages as follows;

 Primary treatment:

Sweet water collected in 102 F01 is to be heated to 90°C (±2°C) and oil to be removed
from top layer. Maintain this temperature throughout the treatment. Note that air agitation
must be stopped during this settling operation.

After removing oil add 10-12 liters of HCl acid slowly in tank under treatment. Check the
pH it should be around 3-4. The color of sweet also changes from whitish emulsion type
to light yellow clear liquid. If haziness is still observed then add some more HCl acid and
continue air agitation and ensure that the emulsion is broken. After agitating for 25 min
skim off the top layer such that no oil remains in the tank.

Now after removing oil from the top add 80 gm of EAUCHEM and continue air agitation
for 20 min. After 20 min stop the air agitation completely (use valve key for valve

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tightening) and allow the batch to settle. Layer oil will get separated on the surface of
water remove it. D. Now transfer this material from 102F03 to 102F04.

 Secondary treatment:

Maintain temp around 90°C. Add slowly caustic lye around 45 liters in the batch. Check
pH it should be around 10-10.5. If this is not the case add some more caustic to it. Carry
out air agitation for 30 minutes. This is very important step of the treatment air agitation
should be given its proper time. The remaining fatty acid will react with caustic to form
sodium soap which remains in dissolved condition.

RCOOH + NaOH → RCOONa + OH-

After 30 minutes add around 4 kg of lime and continue air agitation for another 20
minutes. The dissolved sodium soap will react with lime (CaCO3) to form calcium soap
which precipitates and forms a layer on water. Stop the air agitation completely. Skim of
this layer completely.

RCOONa + Ca(OH)2 → RCOOCa↓ + NaOH

After removing the calcium soap add 13 kg of soda ash (Na2CO3). Start air agitation for
25 min. This will cause excess Calcium to react and form Calcium carbonate. Stop the air
agitation and allow it to settle for 20 minutes. Skim off any layer on the top.

Ca2+ + Na2CO3 → CaCO3 +2Na+

After this check the sample for Hardness, alkalinity, pH and fatty acid & ester. After the
analysis transfer the material to tank. Hardness should be around 50 ppm, pH ≥ 10,
alkalinity between 0.018 – 0.022 and fatty acid and ester ≤ 0.006.

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Figure 4.2 Flow Diagram of Sweet Water Treatment

4.7.3 Section 3 Sweet Water Evaporation

The Evaporation is an important operation in which vaporization of water from sweet

water/glycerin water takes place with aid of heat input by means of steam. Chemically
pre-purified glycerin water is evaporated in 3-effect evaporation system to a final
concentration of 88%. Climbing film evaporators connected in series are used for
evaporation of the water. The resulting product is Crude Glycerin (with a glycerol
concentration of about 88%).

In sweet water evaporation section is of the four effect type, allowing a steam energy
saving. The water vapors distilling from the first effect being used for the sweet water
concentration in the second effect then from the second to the third and from the third to
the fourth.

The treated sweet waters are fed, after been collected in storage tank in tank farm, to the
steam heated first effect vaporization chamber, where some of the water is removed. Most
of the steam, due to the evaporated water, heats up the internal tube bundle of the second
effect vaporization chamber.

The partly concentrated sweet water, leaving the first effect vaporization chamber, will
pass directly into the second effect chamber. The sweet water flow then to the third effect

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vaporization chamber that is maintained under vacuum by the condensers and vacuum
pump. The water vapors produced by the evaporation in the chambers, automatically go
to heat the following evaporation chambers in sequence.

The crude glycerin inside the third evaporation chamber, under temperature control is
sent to storage tank by means of pump. The condensate coming from the evaporation
chambers flows into condensate vessel under level control. This condensate is further
used in splitting process as process water for splitting reaction. The plant is equipped with
a thermo-compressor which allows utilizing again, for heating up the first effect, some
quantity of the steam produced in the same effect due to the evaporation of the water from
the pre-concentrated sweet water.

Figure 4.3 Flow Diagram of Sweet Water Evaporation

4.7.4 Section 4 Glycerin Distillation

Crude glycerin obtained from sweet evaporation plant is needed to be further purified to
get pure glycerin. Purification process involves two steps,

 Crude glycerin is subjected to vacuum distillation wherein water content and low
volatile odoriferous & colouring substances removed from top of distillation column
through vacuum system. Salt content and high boiling impurities along with some
polymerized glycerol removed from bottom as glycerin foot. Distilled glycerin
collected from middle of distillation column.

 Second step involve refining of distilled glycerin. Distilled glycerin passes though the
carbon beds. To get good quality glycerin, it needs to be pass through two beds of
carbon operating in series.

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Boiling point of glycerin is 290℃ at atmospheric pressure. At this temperature, it may get
decompose and polymerized resulting poor quality of glycerin. To avoid this distillation
takes place under vacuum. Glycerin distillation plants typically operate at 4–6 mmHg
absolute pressure and at about 165℃.
Table 4.3 Physical Properties of Glycerin

Property Value
Molecular weight 92.09
Melting point 18.17℃
Boiling point(760mm Hg) 290℃
Density(20℃) 1.261 g/cm3
0.0025mm Hg at 50℃
0.195mm Hg at 100℃
Vapor pressure
4.3mm Hg at 150℃
46mm Hg at 200℃
Refraction index 1.474
Surface tension 63.4 dyne/cm at 20℃(100% glycerol)
Compressibility(28.5℃) 2.1x10 MPa
Viscosity 1499 c.p. at 20℃ (100% glycerol)
Specific heat 0.5779 cal/gm at 26℃(99.94% glycerol)
21060 cal/mole at 55℃
Heat of vaporization
18170 cal/mole at 195℃
Heat of formation 159.6 Kcal/gm mole
Heat of combustion 1662 KJ/mole
Heat of fusion 18.3 KJ/mole
Thermal conductivity 0.29w/K
Flash point 177℃
Fire point 204℃

The plant serves for the continuous distillation of Saponification / Soap Lye crude
glycerin containing Min 80% gly. Evaporation of the glycerin takes place under vacuum
of 4-6 bar and in the presence of live steam to reduce the boiling temperature and partial
pressure of glycerin respectively and to ensure sufficient circulation in the heating

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system. Apart from the main distillate which is bleached by means of activated carbon a
smaller portion of approx. 5-10% is produced as distillate 2 which represents a lower
quality (95% pure). To increase the glycerin yield the main still is succeed by a residual
or post distillation which operates batch wise.

The crude glycerin is continuously fed by feed pump through product heat exchanger and
steam header into the drier/degasser. In drier, residual water contained in feed evaporated.
Circulation of crude glycerin is carried out continuously through drier by means of
circulation pump.

A part stream is supplied to the first two stages of the distillation still. Main distillation
still is subdivided at the liquid side in 4 chambers which are connected in series. In the
main distillation an adequate quantity of MP steam is supplied to evaporate the glycerol
to produce distillate and reflux.

The rectified glycerin will leave the fractionation zone with a temperature of 145-150°C
on the top of the fractionation part of the column for final condensation. In this process
we get 95 to 99.9% pure glycerin as demand of market & it is main byproduct of Delta
Plant.

Figure 4.4 Flow Diagram of Glycerin Distillation

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Figure 4.5 Drier and Preheater of Crude Glycerin

The crude glycerin is continuously fed through heat exchanger and into the drier. In drier,
residual water contained in feed evaporated. Circulation of crude glycerin is carried out
by means of circulation pump.

Figure 4.6 Distillation of Glycerin

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Crude glycerin from drier fed to the distillation column D02 through the reboiler. In
reboiler MP steam is used as a heating medium. From distillation column reflux is
provided and we get glycerin distillate as a middle product, gly residue as a bottom
product and vapour from the top.

Figure 4.7 Post Distillation of Glycerin Residue

Glycerin residue from D02 column goes to the post distillation where glycerin residue is
further distillate and vapour of glycerin distillate from the top of the post distillate fed to
the degasser through the heat exchanger (condenser).

Vapour from the D02 top is condensed in heat exchanger and collect in a distillate
receiver. And then store in tank farm.

Distillate glycerin is store in distillate receiver F01. Temperature of glycerin distillate

from the middle of the D02 column is about 150-155℃ so we cannot store it at this
temperature in tank farm so we use this distillate glycerin as a pre-heating medium for the
crude glycerin which is feeding to the D01 column. After the pre-heating it is cooling in
heat exchanger with the help of cooling water then store to the tank farm.

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Figure 4.8 Feed & Distillate of Glycerin

Specification of crude glycerin,

Table 4.4 Specification of Crude Glycerin

Saponification Crude
Soap lye Crude Glycerin
Glycerin

Glycerol % 80-88 % 78-82 %

Chloride % 2.5 (Max.) 8 (Max.)

Fatty acid and ester % 0.05 (Max.) 0.03 (Max.)

MONG % 4 (Max.) 4 (Max.)

Alkalinity % 0.1-0.2 0.1-0.2

Moisture % 9-20 % 12 (Max.)

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Product specification- refined glycerin,

Table 4.5 Product Specification-Refined Glycerin

Dynamite
Parameter CP grade IW grade 99.5% pure
grade

Chloride
10 Max. 60 Max. 10 Max. 30 Max.
(ppm)

Fatty acid &

0.03 Max. - 0.031 Max. 0.05 Max.
ester % w/w

Glycerol % 98.0 Min. 98.0 Min. 99.5 Min. 98.0 Min.

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5.0 FATTY ACID DISTILLATION & FRACTIONATION

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CHAPTER 5: FATTY ACID DISTILLATION &

FREACTIONATION

5.1 INTRODUCTION

Crude fatty acids generated during fat splitting process, are generally purified by
distillation to separate the fatty acids into groups according to their chain lengths.
Depending on the distribution of fatty acids and their intended uses, the distillation
consists of a series of distillation columns that are designed to create specific cuts of fatty
acids at a specific purity level. With such a wide range of boiling points for various fatty
acids and the impurities (usually mono-glycerides) in the feedstock, the process is usually
tailored to remove a heavy cut (pitch) that contains very little fatty acid.

The rest is often separated into a narrow range of fatty acids depends upon end use or
requirement in downstream conversion process.

Distillation removes both the low and high boiling impurities as well as odorous/coloring
substances. Distillation of fatty acids may be either batch or continuous process under
reduced pressure.

It may be simple distillation involving purification of mixed fatty acids or fractional

distillation consisting of both purification and separation of fatty acids according to chain
length. Because of the inherent sensitivity of fatty acids toward heat, the distillation
methods employed should be conducted at as low a temperature as practically and
economically feasible while maintaining the shortest residence time of the fatty acid in
the distillation unit.

As mentioned, fatty acids are sensitive to thermal degradation, so care is used to limit the
amount of time spent at high temperatures. The distillation is done under vacuum to
achieve a reasonable boiling point for the fatty acid cuts.

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Typical carbon chain distribution of fats/oils,

Table 5.1 Carbon Chain Distribution of Fats/Oils

Composition Fat/Oil
Molecular
(carbon RBD
weight Rapeseed Crude
chain) palm PFAD PKFAD CNFAD
oil palm oil
stearin
6:0 116 0.1 0.2
8:0 144 0.1 2.9 4.61 0.02
10:0 172 0.1 3 5.06 0.02
12:0 200 0.4 50.1 47.67 0.2
14:0 228 0.1 1.5 1.2 16.6 20.36 1.22
16:0 256 2 55 48 10.3 10.57 56.72
18:0 284 1.1 7 4.3 1.7 10.33 6.7
18:1 282 11.3 30 36.2 12.9 28.5
18:2 280 14 6.5 8.9 2.1 6.3
18:3 278 10.9 0.4 0.3
20:0 312 0.9 0.3 0.1 0.1 0.11
20:1 310 6.8
20:2 308 8
22:0 340 1.2 0.08
22:1 338 46.6
22:2 336 1.4
24:0 368 0.7
24:2 366 2.2

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5.2 PHYSICAL PROPERTIES OF FATTY ACIDS

Table 5.2 Physical Properties of Fatty Acids

Boiling Point
Carbon Systematic Common Molecular Melting
(℃ At 10mm
no. Name Name Weight Point (℃)
Hg)
Hexanoic Caproic 205.8
C6 116 -3.4
Acid Acid (@760 mmHg)
239.7
C8 Octanoic Caprylic 144 16.7
(@760 mmHg)
C10 Decanoic Capric 172 31 150
C12 Dodecanoic Lauric 200 44.8 173
C14 Tetradecanoic Myristic 228 54.4 193

C16 Hexadecanoic Palmitic 256 62.9 212

9- Palmitolei
C16:1 254 0.5 180
Hexadecanoic c
C18 Octadecanoic Stearic 284 70.1 227

9-
C18:1 Oleic 282 16.3 223
Octadecanoic
9,12-
C18:2 Linoleic 280 -6.5 224
Octadecanoic
9,12,15-
C18:3 Linolenic 278 -12.8 225
Octadecanoic
C20 Eicosanoic Arachidic 312 76.1 248

C20:1 9-Eicosanoic Gadoliec 310 23 170

C22 Docosanoic Behenic 340 80 263

13-
C22:1 Erucic 338 33.5 255
Docosanoic
C24 Tetracosanoic Lignoceric 368 84.2 -

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5.3 ERUCIC ACID FRACTIONATION

5.3.1 Product

 Erucic acid (main Product)

 Lubolic-20

5.3.2 Production Capacity

 60 MT/day

5.3.3 Raw materials

 Split RSO

 Split PFAD

 Split RBD

5.3.4 Consumers

 Fine organics

 Pathwel

 PMC biogenix

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5.3.5 Process Flow Diagram

Figure 5.1 PFD of Eurcic Acid Fractionation

5.3.6 Process Description

Crude fatty acid has multiple carbon chain distribution as mention earlier. This material is
distilled to get desired product in continuous distillation column under vacuum.

Crude fatty acid feed to the dryer through pre-heater. After preheating the temperature is
raised to 100-110℃ by means of low pressure steam. In dryer, moisture present in the
fatty acid will be removed. Thus dried and degassed fatty acid feed to D2 column. But
before it, feed is heated to desired temperature of 205-210℃ so feed is feeding to D2
column through the pre-heater. In this pre-heater heat transfer taking place between the
feed and hot oil. After pre-heating the temperature of feed is raised to its desired
temperature so it feed to D2 column.

D2 column is equipped with reboiler and over-head condenser. It is packed with

structured packing in three beds. Hot thermic fluid is used in reboiler. Operating
temperature of D2 column is 210-245℃ so fatty acid whose boiling point is less that the
operating pressure will remove from the top of the D2 column. Now low volatile fatty

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acid from bottom of the D2 column will send to the D3 column. D3 column is also same
equipped as D2 column.

Operating temperature of D3 column is 210-260℃ so material whose boiling point is

high that this will be remains unaffected and collects from the bottom of the D3 column
as residue. And from the middle of the D3 column we will get our main product Euricic
acid. And store it in the tank farm.

5.3.7 Column Parameters

Table 5.3 D2 Column Parameters

Process Parameter Unit Range

Feed Temperature ℃ 200-210
Column Top ℃ 200-205
Temperature Bottom ℃ 245-250
Column Top mbar 2.2-3
Vacuum Bottom mbar 6-10

Table 5.4 D3 Column Parameters

Process Parameter Unit Range

Feed Temperature ℃ 240-255
Column Top ℃ 205-215
Temperature Bottom ℃ 250-260
Column Top mbar 0.1-1
Vacuum Bottom mbar 3-5

5.4 PRODUCTION OF PALMITIC ACID

5.4.1 Product Name

Palmitic acid

5.4.2 Capacity:

Plant capacity: 150 Mt/day

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5.4.3 Raw Material

PFAD
RBD
RSO
5.4.4 Application

Palmitic acid is used to produce soaps, cosmetics, and industrial mold release agents.
These applications use sodium palmitate, which is commonly obtained by saponification
of palm oil. To this end, palm oil, rendered from palm tree (species Elaeis guineensis), is
treated with sodium hydroxide (in the form of caustic soda or lye), which causes
hydrolysis of the ester groups, yielding glycerol and sodium palmitate. Because it is
inexpensive and adds texture and "mouth feel" to processed foods (convenience food),
palmitic acid and its sodium salt find wide use in foodstuffs. Sodium palmitate is
permitted as a natural additive in organic products. Thaluminium salt is used as a
thickening agent of napalm used in military actions.

5.4.5 Physical And Chemical Properties

Table 5.5 Physical & Chemical Properties of Palmitic Acid

Chemical formula C16H32O2

Molar mass 256.430 g·mol−1
Appearance white crystals
0.852 g/cm3 (25 °C)
Density
0.8527 g/cm3 (62 °C)
Melting point 62.9 °C (145.2 °F; 336.0 K)
351–352 °C (664–666 °F; 624–625 K)
Boiling point 271.5 °C (520.7 °F; 544.6 K) at 100 mmHg
215 °C (419 °F; 488 K) at 15 mmHg
0.46 mg/L (0 °C)
0.719 mg/L (20 °C)
Solubility in water 0.826 mg/L (30 °C)
0.99 mg/L (45 °C)
1.18 mg/L (60 °C)
Solubility soluble in amyl acetate, alcohol, CCl4

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C6H6 ,very soluble in CHCl3

0.051 mPa (25 °C)
Vapor pressure 1.08 kPa (200 °C)
28.06 kPa (300 °C)
Acidity 4.75
Magnetic susceptibility -198.6·10−6 cm3/mol
Refractive index 1.43 (70 °C)
viscosity 7.8 cP (70 °C)

5.4.6 Process Description

Crude fatty acids generated during fat splitting process, are generally purified by
distillation to separate the fatty acids into groups according to their chain lengths.
Depending on the distribution of fatty acids and their intended uses, the distillation
consists of a series of distillation columns that are designed to create specific cuts of fatty
acids at a specific purity level. With such a wide range of boiling points for various fatty
acids and the impurities (usually mono-glycerides) in the feedstock, the process is usually
tailored to remove a heavy cut (pitch) that contains very little fatty acid. The rest is often
separated into a narrow range of fatty acids depends upon end use or requirement in
downstream conversion process. Distillation removes both the low and high boiling
impurities as well as odorous/coloring substances. Distillation of fatty acids may be either
batch or continuous process under reduced pressure.

It may be simple distillation involving purification of mixed fatty acids or fractional

distillation consisting of both purification and separation of fatty acids according to chain
length. Because of the inherent sensitivity of fatty acids toward heat, the distillation
methods employed should be conducted at as low a temperature as practically and
economically feasible while maintaining the shortest residence time of the fatty acid in
the distillation unit As mentioned, fatty acids are sensitive to thermal degradation, so care
is used to limit the amount of time spent at high temperatures. The distillation is done
under vacuum to achieve a reasonable boiling point for the fatty acid cuts.

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Figure 5.2 BFD of Palmitic Acid Production

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6.0 MATERIAL BALANCE

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CHAPTER 6: MATERIAL BALANCE

6.1 SPLITTING COLUMN

Reaction:

1 fat + 3 H2O → 3 fatty acid + 1 glycerin

Above reaction of the hydrolysis of fat takes place in stages and the reactions are
reversible

C3H5(OOCR)3 + H2O → C3H5(OH)(OOCR)2 + R – COOH

Triglyceride Water Di-glyceride Fatty Acid

C3H5(OH)(OOCR)2 + H2O → C3H5(OH)2(OOCR) + R – COOH

Di-glyceride Water Mono-glyceride Fatty Acid

C3H5(OH)2(OOCR) + H2O → C3H5(OH)3 + R – COOH

Mono-glyceride Water Glycerol Fatty acid

Figure 6.1 Block Diagram of Splitting Column

Fats and Oils contain a mix of different triglycerides species, the average MW can be
calculated according to the following relation:

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(6.1.1)

Saponification value of PFAD = 205

MW of PFAD oil = 821 Kg/mole

MW of glycerin = 92 Kg/mole

MW of water = 18 Kg/mole

Let taking basis of 1 mole PFAD oil

1 PFAD oil + 3 H2O → 3 fatty acid + 1 glycerin

1 mole 3 mole 3 mole 1 mole

821 kg (3x18) kg (3xY) kg 92 kg

Now applying material balance,

( )

Y = 261 kg

MW of fatty acid = 261 kg

Feed = 250 MT/day

Conversion = 98.5%

Water used = 65% of feed =162.5 MT/day

821 kg PFAD → (3*261=783) kg fatty acid

So, 250000 kg of PFAD → 238428.745 kg fatty acid

821 kg PFAD require 54 kg water

So, 250000 kg PFAD requires 16443.36 kg water

But the water is use in excess amount to dissolve glycerin.

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Similarly,

821 kg PFAD require 92 kg glycerin

So, 250000 kg PFAD require 28014.62 kg glycerin

Table 6.1 Mass Balance over Splitting Column

Input Output
Compound
Mass (kg) MW Mass (kg) MW

PFAD 250000 821 - 821

H2 O 162500 18 146056.635 18

Fatty acid - 261 238428.745 261

Glycerin - 92 28014.62 92

Total 412500 412500

6.2 PRE-CONCENTRATOR

Figure 6.2 Block Diagram of Pre-Concentrator

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Data:

Feed = 173849 kg/day of 16.09 % of glycerin

Steam = 37365 kg/day

Bottom = x kg

173849 = 37365 + (28014.62 + y)

y = 108469.38 kg of water with glycerin

x = 136484 kg of bottom

For % of glycerin in bottom

(0.1609*173849) = (z*136484)

z = 0.20495 = 20.495 %

So after pre-concentrator % of glycerin = 20.495

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7.0 ENERGY BALANCE

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CHAPTER 7: ENERGY BALANCE

7.1 FOR SPLITTING COLUMN

Figure 7.1 Block Diagram of Splitting Column

The reaction between PFAD and water is endothermic in nature. The heat must be added
using steam at high temperature and pressure.

PFAD mass flow rate = 10373 kg/hr.

Water mass flow rate = 5580 kg/hr.
Fatty acid mass flow rate = 10451 kg/hr.
Glycerol mass flow rate = 1204 kg/hr.
Water in outlet mass flow rate = 4298 kg/hr

Table 7.1 Heat Capacities of Raw Material and Product

Component Heat capacity (KJ/mol K)

PFAD 1.0425
Water 4.184
Fatty acid 1.1716
Glycerin 2.056

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PFAD molar flow rate = 12.634 mol/hr.

Water in molar flow rate = 310 mol/hr.
Water out molar flow rate = 238.78 mol/hr.
Glycerol molar flow rate = 13.09 mol/hr.
Fatty acid molar flow rate = 40.04 mol/hr.
Reference temperature = 25℃

For heat of reaction,

Heat of formation for PFAD ∆Hf = -2468 kJ/mol

Heat of formation for Fatty acid ∆Hf = -892 kJ/mol
Heat of formation for glycerin ∆Hf = -903.53 kJ/mol
Heat of formation for H2O ∆Hf = -285.82 kJ/mol

∑ ( ) ∑ ( ) (7.1.1)

= [3(-892) + (-903.53)] – [(-2468.7) + 3(-285.82)]

∆HR = -253.37 kJ/mol

Basic EB equation is given as below:

Heat Input = Heat Output

Heat content Q = mCp (Tf – Tr) (7.1.2)

Heat content of PFAD = mCp (Tf – Tr)

= 12.634 x 1.0425 x (115-25)
= 1185.39 kJ/hr

Similarly,

Heat content of water = mCp (Tf – Tr)

= 310 x 4.184 x (85-25)
= 77822.4 kJ/hr

Heat added using steam at 250℃ and 55 bar (from steam table)
= 2789.21 kJ/kg x 58.312 kg/hr
= 162644.4135 kJ/hr

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And, Heat content of leaving water = mCp (Tf – Tr)

= 238.78 x 4.184 x (250-25)
= 224787.492 kJ/hr

Heat removed by fatty acid = mCp (Tf – Tr)

= 40.04 x 1.1716 x (250-25)
= 10554.94 kJ/hr

Heat removed by glycerin = mCp (Tf – Tr)

= 13.09 x 2.056 x (250-25)
= 6055.434 kJ/hr

Table 7.2 Energy Balance over Splitting Column

Input (kJ/hr) Output (kJ/hr)

PFAD 1185.39 Fatty Acid 10554.94

Water 77822.4 Glycerin 6055.434

Water 224787.492
Steam 162644.4135
Heat of Reaction 253.37

Total 241652.2032 Total 241651.236

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8.0 PLANT UTILITY

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CHAPTER 8: PLANT UTILITY

8.1 ELECTRICITY SUPPLY

 Usually power is taken from G.E.B.

 But in case of emergency or power cut off, required power is obtained from
generators sets.
 There are three phase 15A supply of power.
 In normal operational day power consumption is 130KW per day.

8.2 WATER TREATMENT PLANT

The raw water reservoirs contain impurities of dissolved, suspended and microbial nature.
The pre-treatment plants treat raw water to remove suspended & microbial impurities.
The water pumped to the stilling chamber of clarifiers is mixed with chlorine. For an ideal
treatment, the residual chlorine in stilling chamber is controlled around 2 to 3 ppm. Pre-
chlorinated raw water is allowed to two clarifloculators through their individual. Flumes
indicate the flow of water.

Raw water is monitored continuously for its turbidity. Based on the turbidity & flow of
raw water, the alum does is regulated so as to get a PH of 7 and turbidity of 1 NTU. The
dose of alum is very-very important because lack of alum will cause slippage of colloidal
& suspended particles; on other hand high dose of alum puts extra load on resins of D.M
plant but also spoils Human health when used as potable water.

The turbidity & free chlorine in clarifier outlet is continuously monitored and recorded.
About 50 to 80 MT of alum and 5 to 6 MT of chlorine are used per month for water
purification. The filtered water pumped by drinking water pump is further chlorinated
called post filter chlorination to make it 100% free from bacteria and to ensure its
suitability for human consumption.

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Figure 8.1 Water Treatment

8.2.1 D.M. Water

All-natural sources of water contain impurities as well as dissolved gasses. The amount of
these impurities depends on type of water source and location. Raw water coming from
different sources contains dissolved salts and un-dissolved or suspended impurities. It is
necessary to remove harmful salts dissolved into the water before feeding it to the any
processes.

 The deposition of dissolved salts and suspended impurities will form a scale on the
inside wall of different heatexchangers and thus there will create excessive pressure
and thermal stress (due to uneven heat exchange across the wall of heat-exchanger)
inside the heat-exchangers, which may lead to the explosion and serious hazards for
boilers.

 The harmful dissolved salts may react with various parts of boiler through which it
flows, thereby corrode the surfaces.

 Corrosion damage may occur to turbine blades.

Hence, boiler feed water treatment is very much required to remove such dissolved and
suspended impurities from water before feeding it to boiler.

8.2.2 Treatment Process in Industry

Dual Media Filter: Capacity - 18 m3/hr, working gauge pressure- 6.0 bar. There are two
beds of sand and gravels. Dual media filter is a one type of sand filter. Raw water from
the process water storage sump (800 m3 capacity) at 5800 kg/hr flow transfer to DMF.
Process water passes to DMF to remove suspended solids and turbidity. Back washing of
the filter beds has to be carried out periodically more frequently if pressure drop across
the bed exceeds 0.7 bars and this indicates the accumulation of the dust in the bed.

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Backwash is taken once in a week. There is a pressure control valve to maintain DMF
inlet pressure at 6.0 bar g. The pressure control valve is operated on pressure transmitter,
which is located on DMF inlet line.

Activated carbon filter: Capacity: 18 m3/hr, Filter-activated charcoal, the outlet water
from dual media filter comes in activated carbon filter. Activated carbon filters is used to
remove oil and free chlorine.

Strong acid cation: Capacity- 12 m3/hr, MOC- MS rubber lined, Resin-Tulsan T-42 (760
litre), Working pressure4.0 bar g. Quantity of resin-660 m3, HCL required- 39.6 kg on
100 % base. Output between regeneration- 220 m3, in a cation exchange cation like ca+2,
mg+2, Na+2 are replaced by hydrogen ion H+

2HR + CaCl2 → CaR2 + 2 HCl

2HR + MgCl2 → MgR2 + 2 HCl

2HR + MgSO4 → MgR2 + H2SO4

2HR + CaSO4 → CaR2 + H2SO4

Periodically we check the quality of the SAC outlet water during their service cycle. The
quality of the SAC outlet water is as per bellow. pH 3.0. Sodium<300ppb. Free mineral
acid-30 ppm. If any of the one parameter gets disturbed we have to do regeneration
generally within 18 hrs.

Degasser tower: Top portion filled with poly propylene rings. Bottom portion storage
tank (1600*1800) MOC MS Size 500*2500 Degasser air blower capacity-212 m3/hr
Degasser pump- 12 m3/hr Water coming from strong acid cation enters in the top portion
of the degasser tower. Air is blown from the bottom of the tower. Temporary hardness is
removed by blowing air through packing. Air will decompose bicarbonate and CO2 will
liberate which will be removed from the top portion of the tower.

8.3 STEAM GENERATION PLANT

There are mainly two types of boilers. They are fire tube boiler and water tube boiler.

Fire tube boiler consists of numbers of tubes through which hot gasses are passed. These
hot gas tubes are immersed into water, in a closed vessel. In this boiler one closed vessel

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or shell contains water, through which hot gas tubes are passed. These hot gas tubes heat
up the water and convert the water into steam and the steam remains in same vessel. Fire
tube boilers are generally used for relatively small steam capacities and low to medium
steam pressures. These boilers are compact, of packaged construction and cheaper.

Water tube boiler is a kind of boiler where the water is heated inside tubes and the hot
gasses surround them. This is just opposite of fire tube boiler. In this boiler, boiler feed
water flows through the tubes and enters the boiler drum. The circulated water is heated
by the combustion gases and converted into steam at the vapor space in the drum. This
boiler is used when the steam demand as well as steam pressure requirements are high as
in the case of boiler needed to meet the steam requirements for industrial processes as
well as for power generation. The features of water tube boilers include forced, induced
and balanced draft provisions helping to improve combustion efficiency lesser tolerance
for water quality hence necessity for water treatment plant, and higher thermal efficiency
levels.

Figure 8.2 Boiler

Broadly a boiler system consists of a feed water system, steam system and fuel system.
The feed water system provides treated water to the boiler and regulates it automatically
to meet the steam demand. The steam system collects and controls the steam produced in
the boiler. Steam is directed through a piping system to the point of use. The fuel system
includes all equipment used to provide fuel to generate the necessary heat. The equipment
needed depends on the type of the fuel used.

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8.3.1 Components of A Boiler System

Feed water system: Feed water is the water supplied to the boiler which is converted into
steam. The two sources of the feed water are condensate or condensed steam returned
from the process and the makeup water which is the treated water from the water
treatment plant.

Feed water heater: Boiler efficiency is improved by the extraction of waste heat from the
spent steam to preheat the boiler feed water. Heaters are shell and tube type heat
exchangers with the feed water on the tube side and steam on the shell side. The
condensate is returned to the condensate storage tank or condensate hot well.

Deaerators: Feed water often has oxygen dissolved in it at objectionable levels, which
comes from air in-leakages from the condenser, pumps seals, or from the condensate
itself. The oxygen is removed mechanically in a deaerator. Deaerator works on the
principle that oxygen is decreasingly soluble as the temperature is raised. This is done by
passing steam through the feed water.

Economizers: Economizers are the last stage of the feed water system. They are designed
to extract heat value from exhaust gases to heat the steam and improve the efficiency of
the boiler. They are simple finned tube heat exchangers. A feed water economizer reduces
fuel requirements by transferring heat from the flue gas to the incoming water.

Steam system: Steam system consists of steam and mud drums, boiler tubes, super
heaters, attemperators, and condensate systems.

Steam and mud drums: Steam drum is the upper drum of a water tube boiler where the
separation of water and steam occurs. Steam drum contains internal elements for feed
water entry, chemical injection, blow down removal, level control, and steam water
separation. Feed water enters the steam drum from the economizer. Steam flows out from
the top of the drum through steam separators. The steam outlet normally takes off from
this drum to a lower drum by a set of riser and down comer tubes. The lower drum which
is called the mud drum is a tank at the bottom of the boiler that equalizes distribution of
water to the generating tubes and collects solids such as salts formed from hardness and
silica.

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Boiler tubes: Boiler tubes are fabricated from high strength carbon steel. Tubes are
welded to form a continuous wall of tube. Usually more than one bank of tubes is used.
Tubes are the most susceptible to failure due to flow problems or corrosion deposition
problems.

Superheater: Steam when it leaves the boiler is saturated since it is in equilibrium with
water at the boiler pressure and temperature. The purpose of superheater is to remove all
moisture content from the steam by raising the temperature of the steam above its
saturation point. Superheater adds energy to the exit steam of the boiler. The added
energy raises the temperature and heat content of the steam above saturation point. Super-
heated steam has a larger specific volume.

Attemperators: Attemperators control the degree of superheat. Attemperator is the process

of partial DE superheating of steam by control injection of water into the superheated
steam flow. Usually boiler feed water is used for attemperator.

Condensate systems: Condensate from various heat exchanger systems are returned to the
boiler as part of the feed water. However, condensates are to be closely monitored for pH
and oxygen ingress and proper condensate treatment is to be applied.

Fuel system: Fuel feed systems play a critical role in the performance of boilers. Their
primary functions include transfer of the fuel into the boiler and distributing the fuel
within the boiler to promote uniform and complete combustion. The type of fuel
influences the operational features of a fuel system. The fuel feed system forms the most
significant component of a boiler system. Fuels are to be prepared for combustion and
transported to the boiler. The combustion system is to ensure stability of flame over a
wide range of flow rates by creating a favorable condition for fuel ignition and
establishing aero dynamic conditions that ensure good mixing between the primary
combustion air and the fuel. Burners are the central elements for an effective combustion
system.

Steam boiler efficiency: In steam boiler some energy losses take place which include
incomplete combustion, radiation loss occurring from steam boiler surrounding wall, heat
carried by exhaust gases etc. The efficiency of steam boiler gives indication of these
losses. Steam boiler efficiency is the percentage of total heat exported by outlet steam out
of the total heat supplied by the fuel as given below.

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Boiler steam efficiency: Steam boiler efficiency includes thermal efficiency, combustion
efficiency & fuel to steam efficiency. Steam boiler efficiency depends upon many factors
which include the size of boiler, type of the boiler, design of the boiler etc.

8.4 COOLING WATER SUPPLY

Cooling water in the company is utilized for the cooling of the various streams and it is
obtained from the cooling tower erected in the plant itself. There is a Forced Draft of
cooling in the plant. Water is cooled using air.

Figure 8.3 Types of Cooling Tower

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9.0 Detail Description of Equipment

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 203849 Detail Description of Equipment

CHAPTER 9: DETAIL DESCRIPTION OF EQUIPMENT

9.1 STORAGE TANK

Storage tank of RBD

MOC: CS
Capacity: 1000 m3
Height: 14 M
Safe filling: 13.5 M

9.2 SPLITTING COLUMN

MOC: SS
Design pressure: 60 bar g
Design temperature: 280℃
Operating pressure: 50.55 bar g
Operating temperature: 255℃
Capacity: 74.80 m3

9.3 DRYER

Design pressure: 6 bar g

Design temperature: 152℃
Operating pressure: 0.11 bar g
Operating temperature: 100℃
Capacity: 1.52 m3

9.4 PRE-HEATER

Shell and tube type

Design pressure: 6 bar g
Design temperature: 150℃
Operating pressure: 3.5 bar g
Operating temperature: 139℃
Bundle weight: 200 kg
Surface area: 6.15 m2

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10.0 ACTIVITIES

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CHAPTER 10: ACTIVITIES

10.1 POWER CALCULATION OF PUMP

Power calculation for pump 101G02,

Data:

Density ρ = 997 kg/hr

Volumetric Flow Rate qv = 6.3 m3/hr
Efficiency η = 0.75
Suction Pressure, Ps = 5.46 bar g
Discharge pressure, Pd = 52.48 bar g
Assuming no friction losses.

hs = hss - hfs
= hss

=( )

= 66.185 m

hd = hds - hfd
= hds

=( )

= 593 m

H = hd - hs
= 526.815 m

Power ,

= 12.88 kW

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10.2 STEAM ECONOMY

Figure 10.1 Multi Effect Evaporation

Data:

Feed: % Glycerin = 21.81

Product: % Glycerin = 79.8
Feed rate: 3.01 m3/hr
Steam pressure: 1.42 bar g
Steam rate: 576.50 kg/hr
Product rate: 1701.4 kg/hr
Vapour: X kg/hr
ρ = 1056.706 kg/hr

feed rate =

= 3180.69 kg/hr

Overall mas balance

3180.69 + 576.50 = X + 1701.4
X = 2055.79 kg/hr

= 3.57

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10.3 OPTIMIZATION

We find the steam economy first now our plant head gave us a task to optimization of
steam economy by varying the feed flow rate, glycerin % in feed, glycerin % in product
and steam.
In beginning, we collected data which are required and how they are varying by time.
Data
Glycerin% in feed – 20-30%
Glycerin% in product – 75-80%
Feed rate – 2.5-3.3 m3/hr
Steam – 500-700 kg/hr
For optimization, We find economy according to the different data. Then we use solver
for get maximum value of economy by Glycerin% in feed, Glycerin% in product, Feed
rate and Steam rate.
In table optimizing value is indicating in green.

Table 10.1 Optimization of Steam Economy

Gly % Feed
Gly% in Feed Steam Product Vapour
in Rate Economy
Product (kg/hr) (kg/hr) (kg/hr) (kg/hr)
Feed (m3/hr)

20 80 2.5 2630 576.5 1701.4 1505.1 2.610755

20 80 2.6 2735.2 500 1500 1735.2 3.4704

20 80 2.7 2840.4 600 2000 1440.4 2.400667

20 80 2.8 2945.6 550 1600 1895.6 3.446545

20 80 2.9 3050.8 650 1800 1900.8 2.924308

20 80 3 3156 700 1900 1956 2.794286

30 80 3.3 3557.4 500 1900 2157.4 4.3148

22 80 3.01 3182.172 500 1900 1782.172 3.564344

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11.0 EQUIPMENT DESIGN

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CHAPTER 11: EQUIPMENT DESIGN

11.1 STORAGE TANK

Tank Dia. = 18 m.
Tank height = 8 m.
Specific gravity of liquid = 0.8.
Material of construction = Carbon steel.
Permissible stress = 130 N/mm2
Modulus of elasticity = 2*105 N/mm2.

Total number of plate in one course

= (3.14*D)-(0.002*N)/L.
= [(3.14*18)-(0.002*1.4)]/6.3= 8.97
=9
N = 9 plates.

X = [ H-(0.002)L]/N.
= [8-(0.002)6.3]/9
=5.71
=6
X = 6 course.

Hence the total number of plates are X*N = 6*9 = 54 plates.

Pressure related thickness Pressure P
= ρ*(H-0.3)*10
= 0.0008(8-0.3)*10
= 0.0616 n/mm2.

Thickness
t = ρ*D/(2*f*j)+c.
= (0.0616*18000)/(2*130*0.85)+c.
=5.02+c = 8.02.

t = 9mm.

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Assume t = 7mm
Hence,
t = (ρ*D)/(2*f*j)+c
P = (t-c)*(2f*j)/D = 0.049 N/mm2.
P = ρ*(H-0.3)*10
0.049=0.0008(H-0.3)*10.
H = 6.43m.
Assume t = 6mm.
t = (P*D)/2f*j)+c.
P = (t-c)*(2f*j)/D.
P = 0.0368 N/mm2.
P = ρ*(H-0.3)*10.
0.0368= 0.0008*(H-0.3)*10.
H = 4.91 m.
Here the width of the plate selected is 1.4m and it is necessary to use 9mm thick plate to
form the lower layer so the height should be 1*1.4 = 1.4m.
The remaining height of the tank is = 8 - 1.4 =6.6.
Assume t = 7mm (second last layer)
Height = 2*1.4 = 2.8m.
The remaining height of the tank = 8-2.8 = 5.2 m.
Assume the remaining four layers will be of 6mm thickness.
Height of the fourth layer = 4*1.4 = 5.6m.
Total height of the tank = 6*1.4 = 8.4m.
Tank height in the data = 8m.
Excess height = 8.4-8 =0.4m.
Overlap per joint = (0.4)/(6-1)*100 = 8cm.
Bottom Dia. Db = [Di+2ts+(2*65/1000)]=[18+(2*0.009)+(2*65/1000)].
Db = 18.148 m.
Assume roof plate thickness as 12 mm.
Weight per unit area (roof plate) = Thickness*density.
= 0.012*8.6*104 = 1032 n/m2.
Total pressure on the roof = Superimposed load + Weight of the roof plate.
=1250+1030. =2282N/m2.
Assume roof plate thickness of 15mm.

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Weight per unit area (roof plate) = Thickness*density. =0.015*8.6*104.

=1290 N/m2.
Total pressure on the roof = Superimposed load + weight of the roof plate.
= 1250+1290
= 2520 N/m2

11.2 CENTRIFUGAL PUMP

Table 11.1 Data for Centrifugal Pump Design

Liquid handle Hydrochloric acid

Liquid temperature 30 ℃

Capacity 25 m3 /hour

Suction pressure 0.72 kg/cm2*sec

Discharge pressure 2.3 kg/cm2 *sec

Viscosity 0.00128 kg/m*sec

Specific gravity 1.9

MOC CS

Efficiency 85%

Seal type Mechanical seal

Length of pipe 30 m

Diameter of pipe 10 cm (outlet) and 6 cm (inlet)

Calculation at input
Area, A = π (d²/4)
= 0.00785 m2

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Velocity, V = Capacity / Area

= 25/.00785*3600
V = 0.8846 m/sec

Reynolds No.,
Nre = 1900*.8846*.1/.00128
= 131314.1366

Calculation at Output
Area A = π (d²/4)
= 0.002826 m2

Velocity
V = 25/0.00286 x 3600
= 2.457 m/sec

Reynolds no.,
Nre =1900*2.457*.06/.00128
=218856.89
Friction losses
Fs = 0.085*Re-0.25
= 0.036

Head Losses = 4 * Frictional losses * Length *Velocity2/Dia. * g

= 4*0.036*30*2.457*2.457/0.06*9.81
= 44.396 m

Calculation of Head
Head = Head losses + pressure drop + differential head + velocity compound
= head losses + Pb/ρ + gZb + Vb2/2g - Pa/ρ (from Bernoulli‟s Equation)
= head losses + (Pb- Pa)/ρ + g*Zb + Vb2/2g (Zb = 2.5 m suction height from pump
base)
= 44.396 + ((2.3-0.72)*98066.5/1900*9.8) + 2.5 + (2.452/2*9.81)
= 78.016 m

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Calculation of pump Power required

Power Requied = Head * Density * Capacity/Effi.* 3.67 *105
= 78.01*1900*25*9.8/.85*3600
= 11.88 KW

Calculation of NPSH
Vapour pressure (Pv) at 32℃ = 400 N/m2
The net positive head available is given by the following equation

NPSH = (Ps-Pv)/(ρg) +(V2/(2g))

Where,
Ps = suction pressure
Pv = the vapour pressure of the liquid at the pump suction, N/m2
NPSH = [(0.72-0.04)*98066.5/(1900*9.81)] + [2.452/(2*9.81)]
= 3.885 m

11.3 HEAT EXCHANGER

Table 11.2 Data for Heat Exchanger Design

In 95 35
Temp (℃)
Out 45 45

Pressure (kgf/cm2 g) 0.5 2.5

Density (kg/m3) 851 1000

Viscosity (cp) 0.017 0.8

Sp. Heat (KJ/Kg K) 2.1 1.87

Thermal cond. (W/mK) 0.14 0.611

MOC Impervious Graphite SS41 Hard rubber lining

Gasket Teflon -

Corrosivity Yes -

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Heat Load :-

Q = MCpΔT (fat)
= 6735 * 2.1 *(95-45) /3600
= 196.43 W

Q = MCpΔT (fat) = MCpΔT (Water)

M (Water) = 196.43 / (1.87 * ( 95-45))

= 2.18 Kg/Sec
= 7865.61 Kg/Hr

NO. of Passes,

Shell Side = 1

Tube Side = 1

LMTD

Tm= {(95 – 45)-(45 -35)}/ ln(( 95 – 45 )/( 45 – 35 ))

= 21.73℃

The correction factor is a function of shell &tube side temperature & the no. of tube
&shell passes &is co-related as a function of &dimension less temperature

ΔTlm = 0.99 * 21.73

= 21.51℃

Overall Heat Transfer Coefficient U = 254 kcal/hr m2 ℃

0.29533 kJ/m2 sec ℃

295.33 W/m2 ℃

Q = UAΔTm

196.43*1000 = 295.33 *A*(21.73)

A = 30.60 m2

Length Of Tube = 2500mm = 2.5m

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O.D. = 25.4mm
Thickness of tube = 1.5mm

I.D. = O.D. – (2*t)

=25.4 - (2*1.5)
=22.4 mm

Area Of 1 Tube = п * D * L
= 3.14*25.4*2.5/1000
=0.19939 m2

Total No. Of Tubes = Total Area /Area of 1 Tube

= 30.60 / 0.19939
= 115.51
=116

Pitch = 1.5 O.D.

= 1.5 *25.4
= 31.75
=32 mm

Bundle Diameter

Db = d0(Nt/K1)1/nl

Where,

Nt = No. of tubes
Do = Tube outside dia, mm
We have triangular pitch with 1 pass on tube side
K1= 0.319, n1=2.142

Db = 25.4*(116/0.319)(1/2.142)
= 392.10 mm
= 0.392 m

Shell Diameter = 392.10 + 1009.88 mm

= 1.4019 m

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Tube Side Coefficient:-

Mean Water Temp.= ( 110 + 90 ) / 2 = 100℃

= 3.14 *22.4*22.4/4
= 393.88 mm2

Tubes Per Pass = 116/1 = 116

Total Flow Area = Tubes Per Pass * Tubes C/S Area

= 116 * 393.88/(10^6)
= 0.0456 m2

Water Mass Velocity = Kg/Sec Of Water /Total Flow Area

= 31.28/0.0456
= 685.96 kg/sec m2

Density Of Water = 996 kg/m3

Water Linear Velocity = water mass velocity /Density of water

= 685.96 / 996
= 0.6887 m/sec

Using Eagle & Ferguson equation we have ,

hi = 4200 (1.35 +0.02 t) Ut0.8 /Di0.2

hi = Inside heat transfer coefficient for water , W/m2℃

t = Water temp., ℃

Ut = Water velocity, m/sec

Di = Tube inside dia, mm

hi = 4200 [1.35 + 0.02 *28.5] *2.7550.8 /22.40.2

= 9740.88 W/m2 ℃

Re = ρv Di/µ

= 996 * 0.6887 * 22.4*10-3 / (0.8681*10-3)

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=17699.77

Pr = µCp/K

= 0.8681*1.8713*1000/ (0.611*1000)

= 2.659

L/Di = 2.5*1000/22.4

= 111.61

From fig of heat transfer factor Jh vs Reynolds no. (Re) Jh =1.9*10(-3)

Now, hi di /k = Jh Re Pr 0.33 (µ/µw)0.14

(Assuming the last term as 1)

Hi = 1.9*(10(-3)) * 17699.77 * (2.6590.33) *0.611/(22.4*10-3)

= 1266.70 W/m2 K

Hi = 1266.70 W/m2 K

Figure 11.1 Graph of Jh Vs Re

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Shell Side Coefficient:-

Baffle Spacing = Ds/5 = Shell Dia /5
= 1446/5
= 289.2 = 290mm

Cross Flow Area,

As = (Pt-Do)Ds Lb /Pt
Pt = Tube Pitch
Do= Tube Outside Dia
Ds = Shell Dia
Lb = Baffle Spacing

As = (32-25.4)*290 *1.446/(32*1000)
= 0.0865 m

Mass Velocity Gs = Kg/sec of Fat /Cross Flow Area

= 0.6368 / 0.0865
=7.362 kg/secm2

Equivalent Diameter
= 1.1 * ( 32*32 -0.917 * 25.4 *25.4 ) / 25.4
=18.73 mm

Mean Shell Side Temp. = (45+95) /2 = 70 ℃

Density Of Fat = 851 Kg/m3

Re = Gs De /µ = 7.362 * 18.73 * 1000 / (0.017 * 1000)

= 8111.19
Pr = Cpµ/K = 0.31 * 1000 * 0.017 *1000 / ( 0.39*1000)
=13.51
Here, We Have 25% Baffle Cut .From Fig of Heat Transfer Factor Jh vs Re
Jh =1.97/100

NOW,
HsDe /K = Jh Re Pr1/3 (µ/µw)0.14
Hs = 1.97 * 8111.19 * ( 13.51)1/3 * 0.39 *1000/(18.73*1000*100)
= 79.24 W/m2 K

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Figure 11.2 Graph of NRe, Baffle Cut & Jh

( ⁄ )

U = 71.65 W/m2 ℃

Now,

Q = UAΔTm
196.43*1000 = 71.65 *A*(21.73)

A = 90.39 m2 > 30.60 m2

Hence, assumed U is suitable for the design.

Pressure Drop

Tube Side Re =17699.77

From Graph of Friction Factor Jf Vs Re Jf = 0.005

Now,
ΔPt = Np [8 Jf (L/Di)(µ/µw)(-m)+2.5] *ρUt2 /2

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Figure 11.3 Graph of Jf vs NRe (Tube Side)

ΔPt = tube side pressure drop ,N/m2

Np= no. of tube side passes
Ut = tube side velocity ,m/sec
L = length of 1 tube
Neglecting the viscosity correction term.

ΔPt = 4[ 8*5.2*1000*2.5/(22.4*1000)+2.5] *996*2.755*2.755/2

= 107995.2N/m2 =1.1012 Kgf/cm2

Shell Side
Linear Velocity = Gs/ρ
= 7.362 / (1.31*1000) = 0.00562 m/sec

Re =8111.90

From fig. 11.4 friction factor Vs Re,

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Figure 11.4 Graph of Jf Vs NRe (shell side)

Jf = 0.032

ΔPs = 8 *Jf *(Ds/De)*(L/Lb)*ρUs2/2 *(µ/µw)(-.14)

= 8*3.2*(10(-2))*(1.446*1000/18.73)*(2.5*1000/290)*1310*0.062*0.062/2
= 428.98 N/m2
= 0.004383 kgf/cm2

Mechanical Design of Heat Exchanger

Dished End (Torispherical Head)

Pi = 5.5 kg/cm2
J = 0.85
F = 966.72 kg/cm2
T=90℃ =194 F

Rc = 1.446m =144.6cm

Rk = 0.1Rc =14.46 cm

Cs =1/4 *[3 + (Rc/Rk)(1/2)]

= 1.541

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t = (Pi*Rc*Cs)/[2fJ+Pi(Cs-0.2)]
= 0.7424cm
= 7.424mm
= 8mm

Thickness of Shell

t = PiDi/(2fJ-Pi)
= 5.5*144.6/(2*966.72*0.85 -5.5)
= 0.4856cm
= 4.856 +3 mm
= 7.856mm
= 10mm

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 203849 Pumps, Piping, Fitting and Control Valve

12.0 PUMPS, PIPING, FITTING AND CONTROL VALVE

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 203849 Pumps, Piping, Fitting and Control Valve

CHAPTER 12: PUMPS, PIPPING, FITTING AND

CONTROL VALVE
12.1 INTRODUCTION

In an industry, the equipment’s are needed to be connected for transportation of fluid or

chemicals. Therefore, pipelines are required to connect these equipment’s. Also, the
chemicals are required to flow through specific rate to maintain the flow rate through this
equipment’s. Hence, pumps are used for this purpose.

12.2 VARIES TYPES OF PUMPS

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by

mechanical action. Pumps can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps,
reciprocating pumps and Centrifugal pumps. There are two types of pumps used in the
company and are very common in almost every industry.
 Reciprocating pump
 Centrifugal pump

12.2.1 Reciprocating Pump:

A reciprocating pump is a class of positive-displacement pumps which includes the piston

pump, plunger pump and diaphragm pump. It is often used where a relatively small
quantity of liquid is to be handled and where delivery pressure is quite large. In
reciprocating pumps, the chamber in which the liquid is trapped, is a stationary cylinder
that contains the piston or plunger.
 Uses of reciprocating pump:
There are various uses of the reciprocating pump and they are as following:
1. The lubricating pump is a reciprocating pump and it supplies the lubrication oil to
the main engine.
2. Main bilge suction pump is also a reciprocating pump.

3. For ballast they are sometimes used.

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12.2.2 Centrifugal Pump:

Centrifugal pumps are a sub-class of dynamic axis symmetric work-absorbing turbo

machinery. Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow.

 Advantages of centrifugal pump:

 As there is no drive seal so there is no leakage in pump.
 It can pump hazardous liquids.
 There are very less frictional losses.
 There in almost no noise.
 Pump has almost had 100% efficiency.
 Centrifugal pump have minimum wear with respect to others.
 There is a gap between pump chamber and motor, so there is no heat transfer
between.
 Because of the gap between pump chamber and motor, water cannot enter into
motor.
 Centrifugal pump use magnetic coupling which breakup on high load eliminating
the Risk of damaging the motor.

 Disadvantages of centrifugal pump:

o Because of the magnetic resistance there are some energy losses.
o Unexpected heavy load may cause the coupling to slip.

12.3 PIPE & FITTINGS

A fitting is used in pipe systems to connect straight pipe or tubing sections, to adapt to
different sizes or shapes, and for other purposes, such as regulating or measuring fluid
flow. The term plumbing is generally used to describe conveyance of water, gas, or liquid
waste in ordinary domestic or commercial environments, whereas piping is often used to
describe high-performance (e.g. high pressure, high flow, high temperature, hazardous
materials) conveyance of fluids in specialized applications. The term tubing is sometimes
used for lighter-weight piping, especially types that are flexible enough to be supplied in
coiled form. Fittings (especially uncommon types) require money, time, materials, and
tools to install, so they are a non-trivial part of piping and plumbing systems.

 Carbon Steel (CS), also galvanized

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 Impact Tested Carbon Steel (ITCS)

 Low Temperature Service Carbon Steel (LTCS)
 Stainless Steel (SS)
 Malleable iron (malleable iron)
 Non-Ferrous Metals (Copper, Inconel, Incoloy, Cupro-nickel etc.)
 Non-Metallic (ABS, Fiber-reinforced plastic (FRP), PVC, HDPE, tempered glass,
etc.)
 Chrome-molybdenum steel (Alloy steel) — generally used for high temperature
service

 Common fittings for both piping and plumbing,

a. Elbow
b. Coupling
c. Union
d. Reducer
e. Owlets
f. Tee
12.3.1 Elbow

An elbow is a pipe fitting installed between two lengths of pipe or tubing to allow a
change of direction, usually a 90° or 45° angle, though 22.5° elbows are also made. The
ends may be machined for butt welding, threaded (usually female), or socketed, etc.
When the two ends differ in size, the fitting is called a reducing elbow or reducer elbow.
Elbows are categorized based on various design features as below:

 Long Radius (LR) Elbows - radius is 1.5 times the pipe diameter.
 Short Radius (SR) Elbows - radius is 1.0 times the pipe diameter.
 90 Degree Elbow - where change in direction required is 90°.
 60 Degree Elbow - where change in direction required is 60°.
 45 Degree Elbow - where change in direction required is 45°.
A 90 degree elbow is also called a "90 bend" or "90 elbows". It is a fitting which is bent
in such a way to produce 90 degree change in the direction of flow in the pipe. It is used
to change the direction in piping and is also sometimes called a "quarter bend". A 90
degree elbow attaches readily to plastic, copper, cast iron, steel and lead. It can also attach

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 203849 Pumps, Piping, Fitting and Control Valve

to rubber with stainless steel Clamps. It is available in many materials like silicone,
rubber compounds, galvanized steel, etc. The main application of an elbow (90 degree) is
to connect hoses to valves, water pressure pumps, and deck drains. These elbows can be
made from tough nylon material or NPT thread.

12.3.2 Coupling

A coupling connects two pipes to each other. If the size of the pipe is not the same, the
fitting may be called a reducing coupling or reducer, or an adapter. By convention, the
term "expander" is not generally used for a coupler that increases pipe size; instead the
term "reducer" is used. There are two different types of couplings: slip and regular
couplings.

12.3.3 Reducer

A reducer allows for a change in pipe size to meet hydraulic flow requirements of the
system, or to adapt to existing piping of a different size. Reducers are usually concentric
but eccentric reducers are used when required to maintain the same top- or bottom-of-
pipe level.

12.3.4 Owlets

Whenever branch connections are required in size where reducing tees are not available
and/or when the branch connections are of smaller size as compared to header size,
owlets are generally used.
 The following are few configurations of owlet connections:
 Flanged Owlet
 Socket-Weld & Threaded Owlet
 Lateral & Elbow Owlets
 Nipple Owlet
12.3.5 Tee

A tee is the most common pipe fitting. It is available with all female thread sockets, all
solvent weld sockets, or with opposed solvent weld sockets and a side outlet with female
Threads. It is used to either combine or split a fluid flow. It is a type of pipe fitting which
is T-shaped having two outlets, at 90° to the connection to the main line. It is a short
piece of pipe with a lateral outlet. A tee is used for connecting pipes of different

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diameters or for changing the direction of Pipe runs. They are made of various materials
and available in various sizes and finishes. They are extensively used in pipeline networks
to transport two-phase fluid mixtures.

They are categorized as:

 Equal
 Unequal
12.3.6 Cross

Cross fittings are also called 4-way fittings. If a branch line passes completely through a
tee, the fitting becomes a cross. A cross has one inlet and three outlets, or vice versa.
They often have solvent welded socket ends or female threaded ends.

12.3.7 Cap

If a solvent weld cap is used to provide for a future connection point, several inches of
pipe must be left before the cap. This is because when the cap is cut off for the future
connection, enough pipes must remain to allow a new fitting to be glued onto it.

12.3.8 Plug

A plug closes off the end of a pipe. It is similar to a cap but it fits inside the fitting it is
mated to. In a threaded iron pipe plumbing system, plugs have male threads.
 Some of the popular types of plugs are:

 Mechanical pipe plug

 Pneumatic disk pipe plug
 Single size pneumatic all rubber pipe plug

12.3.9 Valves

Valves are equipment designed to stop or regulate flow of any fluid (liquid, gas,
condensate, stem, slurry, etc.) in its path. Valves are categorized depending on their
applications like isolation, throttling, and non-return.

 Various types of valves are available depending upon the type of construction as
follows:
 Gate valve - used for isolation only
 Plug valve - used for isolation only

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 Globe valve - used for throttling

 Butterfly valve - used for isolation as well as throttling
 Check valve - used for preventing reverse flow (non-return)

12.4 CONTROLS VALVES

As the whole plant is DCS operated, there are more than 250 control valves. All control
valves used are Pneumatic Control Valves.

 These valves are classified in two major types,

a) Air to open
b) Air to close

a) Air to open:
These valves are used to control feeding to reactor. As the supply of operating air fails the
valve remains 0% open and feed supply to reactor stops.

b) Air to close:
These valves are mostly used to control the flow of coolant in the jacket of reactor or any
other supporting fluid in downstream equipment.

Although operating air supply fails the flow of coolant remains continuous & safety
aspects are maintained.

Most of the control valves cost Rs. 17000/-

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13.0 SAFETY, HEALTH AND ENVIRONMENT

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CHAPTER 13: SAFETY, HEALTH AND ENVIRONMENT

13.1 INTRODUCTION

Safety is essentially meant for protecting human life and property. Elimination of unsafe
condition in all the operating area and prevention of unsafe practices are given prime
importance by the top management.

 Goals in respect of safety, health and environment (S.H.E.) are:

 To prevent injuries and personnel illness.
 To maintain work place and surrounding area safe and healthy.
 To eliminate any predictable occupational and environmental hazard that may
result in fire and damage to property.

13.2 GENERAL SAFETY AWARENESS

 Smoking and consumption of tobacco is strictly prohibited.

 Don not run or jump on ladder. Wash hands and rinse mouth properly before
eating. Take bath before going home.
 Do not eat anywhere in the plant except in canteen.
 All employees should wear helmet and shoes in the plant.
 Do not spill any oily substance on the floor.
 Use safety belts while working on high altitudes.
 Do not repair any machine/equipment when it is in operating condition.
 Use flameproof lamp near M.C.B., Benzene, Ammonia and methanol.

13.3 USE OF PPE

There are two types of PPE.

13.3.1 Respiratory PPEs

 Breathing Apparatus (B.A.) set: Used while handling gas leakages

 Canister Mask (Organic/ Inorganic / Acids / Ammonia): Used while cleaning vessels
or reactors internally.
 Air Supply Mask: Used while internal cleaning of vessels.
 Dust Mask: Gives Protection against Dust.

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13.3.2 Non Respiratory PPEs

 Helmet: Protection of head.

 Ear Plug: Protection against noise.
 Face Seal: Protection of face.
 Safety Goggles: Protection of eyes.
 PVC Suit: Protection of body and clothes.
 Hand Gloves: Protection of hands.
 Apron: Protection of clothes.
 Safety Shoes/ Gum Boot: Protection of legs.
 Safety Belts: Used while working on height.

13.4 FIRE ENGINEERING AND CONTROL

 Requirements for fire:

 Heat
 Fuel
 Air/ Oxygen

 Types of fire:
There are five types of fire.

 'A': The cause for this fire is organic combustible solids like paper, plastics,
wood, grass, clothes, etc... The best remedy for this type of fire is cooling by
water.
 ‘B’: The cause for this fire is flammable liquids or solids which can be liquefied
like oil petrol, paint, etc... The best remedy for this type of fire is blanketing.
 'C': The cause for this fire is combustible compressed gases like L.P.G.,
ammonia. This type of fire can be extinguished using D.C.P.
 'D': This includes fire due to metals like aluminum, zinc, potassium, sodium, and
magnesium. The best remedy for this type of fire is D.C.P.
 'E': This includes the fire due to electrical appliances. This fire can be
extinguished using CO2 etc.

 Types of fire extinguishers:

 D.C.P. type

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 CO2
 Foam
 Mechanical foam
 Chemical foam
 Soda ash

The temperature of the flame is at least 450°C. While controlling fire, the fire at lower
levels should be first extinguished.

13.5 GAS LEAKAGE

 Wind direction is observed by seeing wind direction indicator. It is advised to go

into the transverse (90°) or opposite direction and reach the safe assembly point.
 Only trained and persons equipped with B.A. set should go to the place of
emergency.
 If a person inhales gas take him to open place. Loose his clothes. Remove shoe
and helmet. If he becomes unconscious, send him immediately to hospital.

13.6 CHEMICAL SPILLAGE

 If there is contact with face or eyes immediately wash below safety shower for at
least 15 minutes.
 If chemical goes in mouth rinse properly with water.
 Immediately Contact the safety department.

13.7 EMERGENCY PREPARADNESS

 Water should be readily available at every point by means of fire hydrant line.
 Fire extinguishers should be easily accessible in every plant.
 There should be wind direction indicator and siren.

13.8 SAFETY WORK PERMIT SYSTEM

Work permits are given to maintenance workers. There are four types of work permits.
 They are as follows:
 Hot Work Permit required for welding of reactors or vessels.
 Cold Work Permit
 Height Work Permit given for working on height.

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 Vessel Work Permit: Given for working inside the vessel/reactor.

13.9 ACCIDENT OCCURANCE REPORTING SYSTEM

 In case of fire a siren is blown twice at an interval of 15 seconds.

 In case of gas leakage a siren is blown continuously four times for 15 seconds
duration.
 When situation comes under control a siren is blown for 1 minute.

13.10 FIRST AID

 Following are the objectives of first aid:

 To keep the person alive.
 To improve his condition.
 To prevent deterioration in his condition.

 First aid for some common accidents is as follows:

 Burn:
 Pour cold water on the bum portion. Do not apply any ointment.

 Shock:
 Remove the person from the place of danger. If respiration is stopped give
C.P.R.
 Injury or Cut:
 Stop the blood flow. Clean the cut with sterilized cloth. Wash the wound with
water. Apply bandage.

 Suffocation:
 Remove the person from the place of danger. Inspect and clean his respiratory
tract if necessary. If respiration is stopped give C.P.R.

 Eye Injury:
 If there is foreign bodies in the eye try to remove it. If the eye infected with
chemical, wash it with water for 15 minutes. Do not apply ointment or oil. If
the eye is burnt use sterilized bandage after washing with water.

 Poisoning:
 Remove the person from the place of danger. Make the person to lie down.
Remove the infected clothes and wash the infected skin with water.

 Fracture:
 Tie splints on the upper and lower part of the fractured body part. Take the
person to the hospital on a hard frame. In case of neck fracture summon the
doctor on the place of incidence.

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13.11 PROCESS SAFETY

 Inspection and testing of process equipment’s and accessories.

 Important industrial maintenance includes mechanical, electrical and civil

maintenances.

 If the production is properly scheduled but there is improper maintenance of the

machine, it may lead to delay in deliveries and production loss.

 Maintenance of the machine means efforts directed towards the upkeep and repair
of the machine.

 Inspection, testing and maintenance of process equipment is generally done when

it is not in operation.

 Maintenance helps in improving the productivity and keeping the machines in a

state of maximum efficient with economy.

 Inspection and testing are essential function of the preventive maintenance

program

 External inspection means to watch for defects from abnormal sound, vibration,
heat, smoke, etc. When the machine is in operation. Internal inspection means
inspection of internal parts such as gear bushes, bearings tolerances, and lathe
parts, etc. during the period when the machine is under planned shutdown.

 Two maintenance activities are carried out

 Activities that directly contribute to prolonging life of the machine.
 Activities that are carried out to assess the performance of various components
at any particular point of time.

13.12 PREVENTIVE MAINTAINANCE

 Weekly confirmed activities:

 Tentative inspection
 Testing and maintenance plan
 Activity recording control
 Exception reports

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13.13 RUNAWAY REACTION (THERMAL EXPANSION)

It's the consequence of the loss of control of the temperature of a chemical compound or a
reaction mixture in an enclosure.

 Consequence of a runaway reaction:

 It results in the emission of a two-phase mixture of gas and liquid to the
atmosphere giving an aerosol.
 In open air aerosol can ignite due to oxidation of hot gases and droplets with air or
possibly to the Occurrence of electric sparks.
 The emission of reaction mixture in a housing area can cause serious problems.

 Causes of Runaway Reaction:

 Any deviation from process condition.
 Lack of experimental information necessary for risk assessment, choice of safe
choices.
 Lack of consequences of runaway reactions.

 Types of thermal explosions:

 Homogeneous thermal explosion:
It includes,
 Reactors under heating conditions.
 Reactors under cooling conditions.
 Reactors under heating conditions with high heat flux applied.
 Other initiating agents.

 Heterogeneous thermal explosion:

It includes,
 Storage vessel hazards.
 Process deviation parameters.
 Fast propagating reactions.

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13.14 FIRST AID MEASURES

 Eye contact:
 Immediately flush eyes thoroughly with water for at least 15 minutes. Hold the
eyelids open and away from the eyeballs to ensure all surfaces are flushed
thoroughly. See a physician, preferably an ophthalmologist, immediately.

 Skin contact:
 For exposure to liquid, immediately warm frostbite area with warm water not
to exceed 105 F (41 C). In case of massive exposure, remove contaminated
clothing while showering with warm water. Call a physician.

 Ingestion:
 An unlikely route of exposure; this product is gas at normal temperature and
Pressure.

 Inhalation:
 Immediately remove to fresh air. If not breathing, give artificial respiration. If
breathing is difficult, qualified personnel may give oxygen. Call a physician.

 Fire-Fighting Measures:
 Suitable extinguishing media:
 Argon cannot catch fire. Use media appropriate for surrounding fire.

 Specific hazards:
 Heat of fire can build pressure in cylinder and cause it to rupture. No part of
cylinder should be subjected to a temperature higher than 125 F (52 ℃).
Liquid argon cylinders are equipped with a pressure relief device. (Exceptions
may exist where authorized by DOT). Venting vapors may obscure visibility.
Liquid causes severe frostbite, a burn-like injury.

 Firefighting:
 WARNING! Extremely cold liquid and gas under pressure. Evacuate all
personnel from danger area. Immediately deluge cylinders with water from
maim distance until cool, taking care not to direct spray onto vents on top of
container. Do not discharge sprays into liquid argon. Liquid argon will freeze
water rapidly. When containers have cooled, move them away from fire area if

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without risk. Self-contained breathing apparatus may be required by rescue

workers. On-site fire fighters must comply with OSHS 29 CFR 1910.156.

 Accidental Release Measures

 Personal precautions:
 Argon is an asphyxiant. Lack of oxygen can kill. Evacuate all personnel from
danger area. Use self-contained breathing apparatus when needed. Extremely
cold liquid and gas. Avoid contact with spilled liquid and allow it to
evaporate. Liquid causes severe frostbite, a burn-like injury. Shut off leak if
without risk. Ventilate area of leak or move container to a well-ventilated area.
Test for sufficient oxygen, especially in confined spaces, before allowing
reentry.

 Environmental precautions:
 Prevent waste from contaminating the surrounding environment. Keep
personnel away. Discard any product, residue, disposable container, or liner in
an environmentally acceptable manner, in full compliance with federal, state
and local regulations. If necessary, call your local suppliers for assistance.

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 203849 Plant Location and Layout

14.0 PLANT LOCATION AND LAYOUT

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 203849 Plant Location and Layout

CHAPTER 14: PLANT LOCATION AND LAYOUT

14.1 PLANT LOCATION

Plant location is however one of the most important part of final planning. Selection of
suitable location of the plant is very important because success of the plant is based on
this point.

An approximate idea as to the plant location should be obtained before a design project
reaches the detailed-estimate stage, and a firm location should be established upon
completion of the detailed-estimate design.

The choice of the final site should first be based on a complete survey of the advantages
and disadvantages of various geographical area and, ultimately, on the advantages and
disadvantages of available real estate.

The following factors should be considered in choosing a plant site:

 Raw materials
 Markets
 Power and fuel
 Climate
 Transportation facilities
 Water supply
 Waste disposal
 Labor supply
 Taxation and legal restrictions
 Site characteristics
 Flood and fire protection
 Community factors

The factors that must be evaluated in a plant-location study indicate the need for a vast
amount of information, both quantitative (statistical) and qualitative.

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 Raw Materials
 The source of raw materials is one of the most important factors influencing the
selection of a plant site. This is particularly true if large volumes of raw materials
are consumed, because location near the raw-materials source permits
considerable reduction in transportation and storage charges. Attention should be
given to the purchased price of the raw materials, distance from the source of
supply, freight or transportation expenses, reliability of supply, purity of the
available raw materials, and storage requirements.

 Market
 The location of markets or intermediate distribution centers affects the cost of
product distribution and the time required for shipping. Proximity to the major
markets is an important consideration in the selection of a plant site, because the
buyer usually finds it advantageous to purchase from nearby sources. It should be
noted that markets are needed for byproducts as well as for the major final
products.

 Power And Fuel

 Power and steam requirements are high in most industrial plants, and fuel is
ordinarily required to supply these utilities. Consequently, power and fuel can be
combined as one major factor in the choice of a plant using electrolytic processes
are often located near large hydroelectric installations. If the plant requires large
quantities of coal or oil, location near a source of fuel supply may be essential for
economic operation. The local cost of power can help determine whether power
should be purchased or self-generated.

 Climate
 If the plant is located in a cold climate, costs may be increase by the necessity for
construction of protective shelters around the process equipment, and special
cooling towers or air-conditioning equipment may be required if the prevailing
temperatures are high. Excessive humidity or extremes of hot or cold weather can
have a serious effect on the economic operation of a plant, and these factors
should be examined when picking a plant site.

 Transportation Facilities
 Water, railroads, and highways are the common means of transportation used by
industrial concerns. The kind and amount of products and raw materials determine
the most suitable type of transportation facilities. In any case, careful attention
should be given to local freight rates and existing railroad lines. The proximity to
railroad centers and possibility of canal, river, lake, or ocean transport must be
considered. If possible, the plant site should have access to all three types of
transportation, and, certainly, at least two types should be available. Effective
transportation facilities for the plant workers are necessary.

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 Water Supply
 The process industries use large quantities of water for cooling, washing, steam
generation, and as a raw material. The plant, therefore, must be located where a
dependable supply of water is available. The temperature, mineral content, silt or
sand content, bacteriological content, and cost for supply and purification
treatment must also be considered when choosing a water supply.

 Waste Disposal
 In recent years, many legal restrictions have been placed on the methods for
disposing of waste materials from the process industries. The site selected for a
plant should have adequate capacity and facilities for correct waste disposal. Even
though a given area has no restrictions on pollution, it should not be assumed that
this condition will continue to exist. Waste disposal can be accomplished by
water, land, or air dispersal. In choosing a plant site, the permissible tolerance
levels for the various methods of waste disposal should be considered, and
attention should be given to potential requirements for additional waste treatment
facilities.

 Labor Supply
 The type and supply of labor available in the vicinity of a proposed plant site must
be examined. Consideration should be given to prevailing pay rates, restrictions
on number of hours worked per week, competing industries that can cause
dissatisfaction or high turnover rates among the workers, racial problems, and
variations in the skill and intelligence of the workers.

 Taxation And Legal Restrictions

 State and local tax rates on property, income, unemployment insurance and
similar items vary from one location to another. Similarly, local regulations on
zoning, building codes, nuisance aspects, and transportation facilities can have a
major influence on the final choice of a plant site.

14.2 PLANT LAYOUT

After the process flow diagrams are completed and before detailed piping, structural,
and electrical design can begin, the layout of the process units in a plant and
equipment within these process units must be planned. This layout can play an
important part in determining construction and manufacturing costs, and thus must be
planned carefully with attention being given to future problems that may arise. Since
each plant differs in many ways and no two plant sites are exactly alike, there is no
one ideal plant layout.

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However, proper layout in each case will include arrangement of processing areas,
storage areas, and handling areas in efficient coordination and with regard to such factors
as:
 New site development or addition to previously developed site
 Type and quantity of products to be produced
 Possible future expansion
 Operational convenience and accessibility
 Type of process and product control
 Economic distribution of utilities and services
 Type of process and product control

 Preparation of The Layout

Scale drawings, complete with elevation indications, can be used for determining the
best location for equipment and facilities.

Elementary layouts are developed first. These show the fundamental relationships
between storage space and operating equipment.

The next step requires consideration of the operational sequence and gives a primary
layout based on flow of materials, unit operations, storage, and future expansion.

Finally, by analyzing all the factors that are involved in plant layout, a detailed
recommendation can be presented, and drawings and elevations, including isometric
drawings of the piping systems, can be prepared.

Three-dimensional models are often made. Errors in a plant layout are easily located
when three-dimensional models are used, since the operations and construction
engineers can immediately see errors which might have escaped notice on two-
dimensional templates or blueprints.

In addition to increasing the efficiency of a plant layout, models are very useful during
plant construction and for instruction and orientation purposes after the plant is
completed.

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Figure 14.1 Plant Layout

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15.0 COST ESTIMATION

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CHAPTER 15: COST ESTIMATION

15.1 Introduction

Cost estimation is done to calculate the total cost of the plant including fixed costs, direct
production costs for raw materials, labor, maintenance, power, and utilities along with
costs for plant and administrative overhead, distribution of the final products, and other
miscellaneous items.

As soon as the final process-design stage is completed, it becomes possible to make

accurate cost estimations because detailed equipment specifications and definite plant-
facility information are available. Direct price quotations based on detailed specifications
can then be obtained from various manufacturers.

15.2 Total Capital Investment

Before an industrial plant can be put into operation, a large sum of money must be
supplied to purchase and install the necessary machinery and equipment. Land and
service facilities must be obtained, and the plant must be erected complete with all piping,
controls, and services. In addition, it is necessary to have money available for the
payment of expenses involved in the plant operation.

The capital needed to supply the necessary manufacturing and plant facilities is called the
fixed capital investment, while that necessary for the operation of the plant is termed the
working capital. The sum of the fixed-capital investment and the working capital is
known as the total capital investment. The fixed-capital portion may be further
subdivided into manufacturing capital investment and nonmanufacturing capital
investment.

 Fixed Capital Investment:

Manufacturing fixed-capital investment represents the capital necessary for the
installed process equipment with all auxiliaries that are needed for complete process
operation. Fixed capital investment can be finding out by summing direct & indirect
cost.

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 Working Capital:
The working capital for an industrial plant consists of the total amount of money
invested in,
 Raw materials and supplies carried in stock.

 Finished products in stock and semi-finished products in the process of being

manufactured.

 Accounts receivable.

Cost of Reactor:

0.5% mo steel is used

Diameter

Di=3.5m

Do=3.7m

Height=31.5m

Density=7800kg/m3

Volume of reactor = 3.14*((Di2 -Do2) /4 )*h

= 35.69m3

20% more volume

1.2*35.69 = 42.8281m3

Wt of MOC = 7800*42.8281

= 334059.54kg

Total cost = 255rs/kg*334059.54kg

=85185185.18 rs

Cost of auxiliary items = 20% of total cost

=17037037.036 rs

Extra equipment = 0.15% of total cost

= 1451.3031rs

Total equipment cost=115000000 rs.

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Table 15.1 Purchase Equipment Cost

Sr.
Equipment Price Count Total Equipment
No.
1. Reactor 11,50,00,000 1 11,50,00,000
2. Column 3,00,00,000 20 60,00,00,000
3. Fin Fan 3,00,000 30 90,00,000
4. Pump 4,00,000 141 5,64,00,000
5. Heat Exchanger 25,00,000 35 8,75,00,000
6. Coal Heater 2,00,00,000 2 4,00,00,000
7. Separator 1,00,000 10 10,00,000
8. Boiler 1,00,00,000 2 2,00,00,000
9. Reactor 50,00,000 5 2,50,00,000
10. Absorber 1,00,00,000 8 8,00,00,000
11. Rotary Valve 15,00,00,000 1 15,00,00,000
12. Cooling Tower 75,00,000 1 75,00,000
13. Compressor 90,00,000 5 4,50,00,000
14. Utility + Other 40,00,00,000 1 40,00,00,000
Total 1,63,64,00,000

Table 15.2 Total Purchased Equipment Cost

Sr. No. Basis Cost (INR)

1. Total Purchased Equipment Cost 1,63,64,00,000

Table 15.3 Total Capital Cost

1. Fixed Capital Investment

I. Direct Cost
Sr. No. Item % of Equipment Cost Total cost in INR
1. Purchased equipment 100 1,63,64,00,000
cost
2. Installation cost 30 49,09,20,000

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3. Instrument & control 15 24,54,60,000

4. Piping 45 73,63,80,000
5. Electrical installation 20 32,72,80,000
6. Building 30 49,09,20,000
7. Service facilities 40 65,45,60,000
8. Land requirement 4 6,54,56,000
9. Yard improvement 8 13,09,12,000
Total Cost 4,77,82,88,000
II. Indirect Cost
Sr. No. Item % of Equipment Cost Total cost in INR
1. Engineering and 13 21,27,32,000
supervision
2. Construction 10 16,36,40,000
3. Contractor fees 5 8,18,20,000
4. contingency 10 16,36,40,000
Total Cost 62,18,32,000

Fixed Capital Direct Cost + 5,40,01,00,000

Investment Indirect Cost
2. Working Capital Investment
Sr. No. Item Total cost in INR
1. Working Capital 15% of fixed capital 81,00,18,000
investment
Total Capital FCI + WCI 6,21,01,38,000
Investment

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Table 15.4 Cost Required for Production

3. Cost Require For Production

1. Direct Production Cost
Sr. No Total cost in INR
1. Raw Material Cost 40% of fixed capital 2,16,00,48,000
investment
2. Operating Labor Cost 10% of purchased 16,36,40,000
equipment cost
3. Utility Cost 15% of purchased 24,54,60,000
equipment cost
4. Maintenance & Repair 5% of fixed capital 2,70,06,000
Cost investment
5. Operating & Supply 15% of maintenance & 4,05,00,900
Cost repair cost
6. Laboratory and Testing 15% of labor cost 2,45,46,000
Cost
7. Patterns and Royalties 3% of purchased equipment 4,90,92,000
cost
Direct Production Cost Total 29,53,29,200

2. Fixed Charges
Sr. No. Item % of Fixed Capital Cost in INR
Investment
1. Depreciation 10 54,00,12,000
2. Local taxes 2 10,80,02,400
3. insurance 1 5,40,01,200
Total Fixed Charges 70,20,15,600
3. Plant Overhead 50% of Labor & Maintenance 21,68,23,000
Cost Cost
Sr. No.
1. Administrative expense 25% of labor cost 4,09,10,000
2. Distribution & Market 10% of Production cost 29,53,29,290

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expense
3. R & D cost 5% of Fixed capital investment 27,00,06,000
4. Interest 8% of Fixed capital investment 43,20,09,600
Total Production Cost 4,91,03,86,390

Table 15.5 Profitability Analysis

4. Profitability Analysis
1. Total Income
Sr. No. Product Cost per kg Capacity (kg/year)

1 Product 9,62,00,000
Total income in INR 7,50,36,00,000

2. Gross Profit
Total income-total production
2,59,32,13,610
cost

1 Assume 30% tax

Amount of tax 30% of gross profit 77,79,64,083

2 Surcharge on tax 3% of income tax 2,33,38,922.49

3. Net Profit
1 Net profit Gross profit-tax-surcharge 1,79,19,10,604.51

4. Rate of Return
1 Rate of return (%) Gross profit / TCI 20.15894984

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5. ROR after Taxes

1 ROR after taxes (%) Net profit / ( (FC / 2) + WC ) 35.66583434

6. Turnover Ratio
1 Turnover ratio Total income / FCI 1.389524677

7. Payback Period
Payback period
1 FCI / Net profit 3.01
(years)

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16.0 ANNEXURE

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CHAPER 16: Annexure

16.1 MSDS OF PFAD

Table 16.1 MSDS of PFAD

1. IDENTIFICATION OF SUBSTANCE/PREPARATION & COMPANY.

Trade name: Palm Fatty Acid Distillate Classification: Vegetable Fatty acid
Chemical type: Mixed fatty acid and triglycerides
2. COMPOSITION / INFORMATION ON INGREDIENTS.
Definition/Botanical Origin: Elais Guineensis
CAS No : 68440-15-3
3. HAZARDS IDENTIFICATION:
Not considered hazardous under normal use. Observe good housekeeping procedures.
4. FIRST-AID MEASURES:
INHALATION: No vapors present at normal temperatures.
EYE CONTACT: Rinse immediately with plenty of water for at least 15 mins. Contact a
doctor if symptoms persist.
SKIN CONTACT: Wash thoroughly with soap & water. None irritating.
INGESTION: Not considered dangerous. Edible quality.
5. FIRE FIGHTING MEASURES:
EXTINGUISHING MEDIA: Use CO2, Dry Powder or Foam type Extinguishers,
spraying RECOMMENDED: extinguishing media to base of flames. Do not use direct
water jet on burning material.
SPECIAL MEASURES: Avoid vapor inhalation. Keep away from sources of ignition. Do
not smoke. Wear positive pressure self-contained breathing apparatus & protective
clothing.
EXTINGUISHING PROCEDURES: Closed containers may build up pressure when
exposed to heat and should be cooled with water spray.
6. ACCIDENTAL RELEASE MEASURES:
PERSONAL PRECAUTIONS: Avoid contact with skin eyes and clothes. Note that
spillages may cause slipping hazard. Use individual protective equipment (safety glasses,
waterproof-boots, suitable protective clothing) in case of major spillages.

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ENVIRONMENT PRECAUTIONS: Keep away from drains, soils, surface & ground
waters.
CLEANING UP METHODS: Remove all potential ignition sources. Contain spilled
material.
Cover FOR SPILLAGES: with an inert or non-combustible inorganic absorbent material,
Sweep up and remove to an approved disposal container. Clean with hot water &
detergents. Observe state, federal & local disposal regulations
7. HANDLING & STORAGE.
PRECAUTIONS IN HANDLING: Apply good manufacturing practice & industrial
hygiene practices. Observe good personal hygiene, and do not eat, drink or smoke whilst
handling. Avoid static discharges.
STORAGE CONDITIONS: Store in suitable container, in a cool & dry area away from
heat sources & protected from light. Keep air contact to a minimum.
FIRE PROTECTION: Keep away from ignition sources & naked flames. Take
precautions to avoid static discharges in working area.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION.
RESPIRATORY PROTECTION: No special measures under normal conditions.
HAND PROTECTION: No special measures under normal conditions.
EYE PROTECTION: Use safety glasses if there is a risk of splashing.
WORK/HYGIENE PRACTICES: Wash hands with soap & water after handling.
9. PHYSICAL & CHEMICAL PROPERTIES.
Melting point (ºC) : 40 min Appearance : Brown solid
Density : 0.85 - 0.93 Odor : faint fat odor
Solubility: Insoluble in water, soluble in hydrocarbons.
10. STABILITY & REACTIVITY.
STABILITY: Generally stable
REACTIVITY: It presents no significant reactivity hazards, by itself or in contact with
water. Avoid contact with strong acids, alkali or oxidizing agents.
11. TOXICOLOGICAL INFORMATION.
Not tested on animals.
12. ECOLOGICAL INFORMATION.
BIODEGRADABILITY: Readily biodegradable
PRECAUTIONS: Prevent surface contamination of soil, ground & surface water.

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13. DISPOSAL CONSIDERATIONS.

Avoid disposing to drainage systems and into the environment. Observe local authority
regulations.
14. TRANSPORT REGULATIONS.
Road (ADR/RID): n/a SEA (IMDG): n/a AIR (IATA): n/a
15. REGULATORY INFORMATION.
HAZARDS: n/a SYMBOLS: n/a
RISK PHRASES: n/a SAFETY PHRASES: n/a
16. OTHER INFORMATION.
Product type/uses: Deodorized Distillate

16.2 MSDS OF GLYCERIN

Table 16.2 MSDS of Glycerin

1. Chemical product and company identification

Trade Name Glycerin
GODREJ INDUSTRIES LIMITED Plot no.3,
Manufacture’s Name and address Village-Kanerao, Taluka-Valia, District-Bharuch,
Gujarat, India Pin: 393135
telephone 91-2643-70756 / 57 / 58 / 59 / 60
2. Composition / ingredients
CAS No 56-81-5
EC No 200-289-5
GLYCERIN , GLYCERINE, 1,2,3-
Synonym PROPANETRIOL TRIHYDROXYPROPANE,
1,2,3TRIHYDROXYPROPANE
3. Hazard identification(reference:4)
Irritating to eyes and skin
In case of contact with eyes, rinse with plenty of
Irritant
water and call a doctor
Wear suitable protective clothing
4. First-aid measures
Wash the affected person's mouth with plenty of
Swallowing
water, provided he is conscious. Call a doctor.

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Remove contaminated clothing and wash

Skin exposed area with plenty of water followed by
soap and water
Eye Irrigate the eyes with plenty of water
Inhalation Take person into fresh air and allow to rest
5. Fire hazard and fire-fighting measures
Wear self-contained breathing apparatus and
Special fire-fighting procedures fully protective clothing to prevent contact with
skin and eyes.
Use Water spray, Carbon Dioxide, Dry
Means of extinction Chemical, or Alcohol Foam. Use Water to keep
fire exposed container cool
Flash point 189℃
6. Accidental release
Wear respirator, chemical safety goggles, rubber boots and heavy rubber gloves.
Absorb on sand and place in a close container for disposal.
Ventilate area and wash spill site after material pickup is complete.
7. Handling and storage
Handle with good hygiene and safety procedures.
Wear respirator, chemical safety goggles, rubber
boots and heavy rubber gloves. Do not breathe
Handling
vapour, and avoid contact with eyes, skin and
clothing. Avoid prolonged or repeated exposure,
and wash thoroughly after handling.
Keep container closed and store in a cool, dry
Storage condition of containers place. Suitable storage material: SS tank / laquor-
lined MS drums / HDPE drums.
8. Exposure controls and personal protection measures
Ventilation of area ,Chemical safety goggles, Compatible chemical resistant gloves,
Safety shower and eye bath, NIOSH / MSHA approved respirator, Do not breathe vapour
9. Physical and chemical properties (reference: 1, 4, 5)
Physical appearance Clear liquid
Boiling point 290℃

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Melting point 20℃

Vapour pressure 0.1 mm at 20℃
Vapour density 3.1
Flash point 160℃
10. Reactivity data
Chemical stability Product is stable
Incompatibility with substances Strong bases, strong oxidizing agents
Hazardous combustion Carbon monoxide and carbon dioxide
11.Toxicological properties
Irritating to skin, may be harmful if absorbed
Actual effects
through the skin.
Behaviour (headache)
Gastrointestinal (nausea or vomiting)
Kidney, ureter, bladder (changes in tubules )
Target organ data
Kidney, ureter, bladder (other changes in urinary
compositions)
Paternal effects (Spermatogenesis)
12. Waste disposal
Dissolve or mix the material with a suitable solvent and burn in a chemical incinerator
13. Transport recommendations
Material should be transported in a closed container to protect it from direct source of
heat and to avoid exposure to highly humid atmosphere.

16.3 MSDS OF ERUCIC ACID

Table 16.3 MSDS of Erucic Acid

1 Identification
Trade name: ERUCIC ACID
CAS Number: 112-86-7
EC number: 204-011-3
Application of the substance / the mixture
• Used as lubricant additive; chemical intermediate for eurcamide, stearyleurcamide &
dibasic acids; polyethylene film additive; water resistant nylon additive.

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• Used in paints, lacquers and varnishes industry, polymer industry, textile processing
industry.
• Used as cooling agents for metal processing.
• Used as cutting fluids.
Details of the supplier of the safety data sheet
Manufacturer/Supplier:
Godrej Industries Limited,
Eastern Express Highway,
Vikhroli (east), Mumbai,
India. Pin - 400 079
Information department:
Telephone:91-22-25188010/20/30
2 Hazard(s) identification
Classification of the substance or mixture
Skin Irrit. 2 H315 Causes skin irritation.
Eye Irrit. 2A H319 Causes serious eye irritation.
Signal word Warning
Hazard statements
Causes skin irritation.
Causes serious eye irritation.
Precautionary statements
Wear protective gloves.
Wear eye protection / face protection.
Wash thoroughly after handling.
If in eyes: Rinse cautiously with water for several minutes. Remove contact lenses, if
present and easy to do. Continue rinsing. Specific treatment (see on this label).
If skin irritation occurs: Get medical advice/attention. If eye irritation persists: Get
medical advice/attention. If on skin: Wash with plenty of water. Take off contaminated
clothing and wash it before reuse.
3 Composition/information on ingredients
Chemical characterization: Substances
CAS No. Description
112-86-7 (Z)-docos-13-enoic acid

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Identification number(s)
EC number: 204-011-3
Additional information:
Synonyms: Prifac 2990, cis-13-Docosenoic acid
Molecular Formula: C22H42O2
Molecular weight: 338,57 g/mol
4 First-aid measures
Description of first aid measures
General information:
Consult a physician. Show this safety data sheet to the doctor in attendance.
After inhalation: If breathed in, move person into fresh air. If not breathing, give artificial
respiration. Consult a physician.
After skin contact: Wash off with soap and plenty of water. Consult a physician.
After eye contact: Rinse thoroughly with plenty of water for at least 15 minutes and
consult a physician.
After swallowing: Never give anything by mouth to an unconscious person. Rinse mouth
with water. Consult a physician.
Information for doctor: Treat symptomatically.
Most important symptoms and effects, both acute and delayed No further relevant
information available.
5 Fire-fighting measures
Extinguishing media
Suitable extinguishing agents:
Use water spray, Carbon Dioxide, Dry Chemical or Alcohol Foam.
For safety reasons unsuitable extinguishing agents: None.
Special hazards arising from the substance or mixture Carbon oxides
Advice for firefighters Wear self-contained breathing apparatus for firefighting if
necessary.
6 Accidental release measures
Personal precautions, protective equipment and emergency procedures
Use personal protective equipment.
Avoid breathing vapours, mist or gas.
Ensure adequate ventilation.

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Evacuate personnel to safe areas.

Environmental precautions: Do not allow to enter sewers/ surface or ground water.
Methods and material for containment and cleaning up: Sweep up and shovel. Keep in
suitable, closed containers for disposal.
7 Handling and storage
Handling:
Precautions for safe handling Avoid contact with skin and eyes. Provide appropriate
exhaust ventilation.
Information about protection against explosions and fires: No special measures required.
Conditions for safe storage, including any incompatibilities Not specific measures
required
Storage:
Requirements to be met by storerooms and receptacles: Keep container tightly closed in a
dry and well-ventilated place.
Information about storage in one common storage facility: Store away from
incompatibles.
8 Exposure controls/personal protections
Control parameters
Components with limit values that require monitoring at the workplace:
The substance does not have critical values that have to be monitored at the workplace.
General protective and hygienic measures:
The usual precautionary measures for handling chemicals should be followed.
Body protection:
Impervious clothing, The type of protective equipment must be selected according to the
concentration and amount of the dangerous substance at the specific workplace.
9 Physical and chemical properties
Information on basic physical and chemical properties
General Information
Appearance: Liquid
Form: Liquid at temp. > 35 C
Color: Pale Yellow
Odor: Slight characteristic Odour
pH-value: Not available

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Change in condition
Melting point/Melting range: 30 - 33 °C (86 - 91 °F)
Boiling point/Boiling range: 281 °C (538 °F) (at 30 mm)
Flash point: > 200 °C (> 392 °F)
Flammability (solid, gaseous): Product is not flammable.
Auto igniting: Product is not self-igniting.
Danger of explosion: Product does not present an explosion hazard.
Vapor pressure at 30 °C (86 °F): < 1 mm
Density at 70 °C (158 °F): 0.8532 g/cm³ (7.12 lbs/gal)
Vapour density >1 g/cm³ (>8.345 lbs/gal)
Solubility in / Miscibility with Water: Insoluble.
Partition coefficient (n-octanol/water): 9.69 log KOW
Viscosity: Dynamic: Not available
Other information No further relevant information available.
10 Stability and reactivity
Reactivity No further relevant information available.
Chemical stability Product is very stable under the prescribed storage conditions.
Thermal decomposition / conditions to be avoided: No decomposition if used according
to specifications.
Possibility of hazardous reactions No dangerous reactions known.
Conditions to avoid No further relevant information available.
Incompatible materials: Strong Oxidizing agents.
Hazardous decomposition products: Acrid smoke and irritating fumes of Carbon Oxides
when heated BP.
Additional information: Not available
11 Toxicological information
On the eye: Species: rabbit Exposure period: 72 hours Summary of the symptoms:
Material produced mild conjunctivitis clearing completely in 72 hours
Result: slightly irritating.
12 Ecological information
General notes: Generally not hazardous for water Do not allow undiluted product or large
quantities of it to reach ground water, water course or sewage system.
Persistence and degradability Biodegradation in water:

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Half-life =15 days (Predicted) Result: Readily biodegradable

Other information: The product is easily biodegradable.
13 Disposal considerations
Waste treatment methods Offer surplus and non-recyclable solutions to a licensed
disposal company. Dissolve or mix the material with a combustible solvent and burn in a
chemical incinerator equipped with an afterburner and scrubber.
Recommendation: Sweep up and store in closed container.
Waste disposal key: Waste must be disposed of in accordance with federal, state and local
environmental control regulations.
Uncleaned packaging: · Recommendation: Disposal must be made according to official
regulations.
Recommended cleansing agent: Not available

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17.0 CONCLUSION

At the end of this project report, I have concluded that things present in the industry are
entirely different and more complicated than the things I have learned in the books.
During my project work I came across many things like Utilities section, many big-big
instruments like Rotary Valve, distillation column and much other equipment’s. The
Material Balance and Energy Balance are the most beautiful things I have done by
collecting data. Which is enhanced my knowledge to a different level. With the help of
the material balance I learned, at what rate it is transporting/moving from one equipment
to another and in what extent it is reacting and what amount of materials required for the
production of the particular amount of product.

With the help of this project work I came to know about many safety rules and use of
several safety equipment’s. And most importantly according to my conclusion this plant
contains a very high rate of return and it has good payback period of less than 4 years.

So, based on my working experience on this project work I can say, it is the best thing for
the enhancement of the knowledge of the chemical engineer.

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18.0 REFERENCES

1. B. I. Bhatt and S.B. Thakore (2010) ‘Stoichiometry’, Fifth Edition, McGraw Hill
Education.
2. Donald R. Coughanowr and Steven E. Leblanc (2009) ‘Process system analysis and
control’, 3rd edition McGraw Hill
3. D. Q. Kern (1950) ‘Process Heat Transfer’ McGraw Hill
4. K. V. Narayan (2013) ‘Chemical Engineering thermodynamics’ , PHI Learning
5. Max S. Peters, Klaus D. Timmerhaus (1991) ‘Plant Design and Economics For
Chemical Engineers’ Fourth Edition, McGraw Hill International Editions
6. McCabe and Smith (1985), Unit Operation of Chemical Engineering, Fourth
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industry/

Gujarat Technological University 117 SRICT