Name of Project (Intenship)

S ubm itte d b y

P a d h iy ar b rija l.(2 2 T 1 3 0 0 9 )

S em e ster V,

D iplo m a Ch em ica l E ng ine ering

U n d er G u id a n c e o f

“ A n ja i b h a tt ”

DEPARTMENT OF CHEMICAL
ENGINEERING ITM (SLS) BARODA
UNIVERSITY
VADODARA-3915102023
 ABSTRACT

The m a in o b je c t is to s tu d y of C h em ic a l en g in e e rin g
p e rs p e c t iv e.
T h e in v e n tio n b e lo n g s to th e fie ld o fo rg a n ic c h e m ic a ls yn th e s is a n d
in p a rtic u la rre la tes t o a p re p a ra t io n m e th o d o fV in ylS u lp h o n e .T h e
p re p a ra tio n m e th o d h a s th eb e n e fic ia leffe c ts t h a tt h e p rep a ra tio n
m et h o d h a s th e a d v a n ta g e s o f e a s ily o b ta in e d ra w m a t eria l,
lo w c os t ,e a s in e s s , in t a il g a s trea tm e n t , a n d t h e lik e a n d is
s u it a b le fo r in d u s tria lp ro d u c tion .
 ACKNOWLEDGEMENT

I o w e m a n y t h e n s to a g re a t m a n y p eo p le w h o h e lp e d a n d s u p p o rte d m e
d u rin g th e tra in in g .

I w o u ld a ls o lik e t o th a n k T ra in in g C e n tre , T M L IN D U S T R IE S L T D .fo r p ro v id in g

a n o p p o rtu n ity t o u n d erg o tra in in g . It w a s in d e e d a n o p p o rt u n ity fo r u s to v is it
th e d iffe re n t s e c t io n o f P ilu d ra U n it . D u rin g m y v is it to th e c o m p a n y fo r
p re p a rin g th is P ro jec t R ep o rt, I le a rn t m a n y in t ere s tin g th in g s a b o u t th e
c o m p a n y.

I w o u ld a ls o th a n k T M L a n d th eir em p loy e es w ith o u t w h o m th is p ro je c t w o u ld

a v e b ee n a d is t a n t re a lit y.
SR PLANT VISITED
No.
1 G R O U P G A T H E R IN G S T A T IO N
2 G R O U P G A T H E R IN G S T A T IO N
3. C E N T R A L T A N K F A R M ( C T F ) P ILU D R A
1. P R ODU CT
2 . H C L TA N K
3 .G R O U P G A T H E R IN G S T A T IO N P ILU D R A
4. P R O D U C T R E S IV IN G S T A T IO N
1 .P U M P H O U S E (M P H )
5. W OR KSHO P
6. 1 . M E C H IN E S H O P
2. R E P A IR S H O P
3 . E LE C T R IC A L S H O P
E X P E R T L E C TU R E S
7. 1 . A R T IF IC IA L L IF T
2 . L A B O R A T O R Y T E S T IN G
V IS IT IN G P LA N T
8. R E A C TO R S E C T IO N
9. T C A N D L F R E C O V E R Y S E C T IO N
1 0. W A T E R T R E A T M E N T P L A N T ( W T P)
D IS TILL A T IO N S E C T IO N
1 1. 1. M A IN R E S IVE R S E C T IO N ( M R S )
2 . S C R U B B IN G A R E A
3 . S O 2 PL A N T
4 . P R O C E S S & Q U A LIT Y C O N T R O L L A B O R A T O R Y
5 . G A S IJ E C T O R U N IT (G IU )
6 . E F F LU E N T T R E A T M E N T PL A N T (E T P )
12 O R DE R LETTE R
 Piludra Plant

▶ Infrastructure

A d eq u a te w a ter , p o w e r a n d u tilitie s .

C o ve re d g o d o w n s , ta n k fa rm s a n d m a te ria l h a n d lin g s ys tem s .

A ir e m is s io n - S c ru b b in g s ys te m s & S o lid / liq u id E fflu e n t tre a tm e nt s ys tem s .

B o th th e M a n u fa c tu rin g s ite s lo c a ted a d ja c e n t to th e w a s te w a te r c a rrier,4 5 k m lo n g Liq u id

E fflu en t C h a n n el P ro je c t - o n e o f th e firs t o f its k in d in th e w o rld

A ll m a jo r R a w M ate ria ls a va ila b le p ro xim ate to m a n u fa c tu rin g s ite , in th e S ta te o f G u ja ra t.

U s e e lig ib ility fo r riv er w a te r fo r a ll in d u s tria l a p p lic a tio n s .

F ire H yd ra n t c a p a b ility fo r a ll ris k e xp o s e d o p era tio n s .

S ta te o f a rt Sp ra y D ryer fo r trea tm en t o f c o m p lex eff lu e n t

 Year of Commission : 1979

Plant Introduction given by : M . S T A ILO R

Production Status :

T o ta l ta n k s - 6

T o ta l rea c to rs - 5

T o ta l Pro d u c tio n - 5 0 m 3/d a y

R a w m a te ria l : T P A & C A T A LY S T, TC

P ro d u c t :

T P C ( T ere phth a lo ylchlo rid e )

DISTILLATION : W o rk in g te m p e ra tu re : 1 2 0 – 1 3 3 c

SCUBBER : W o rk in g tem p e ra tu re : 4 0 -4 5 c

EJE CTO R : W o rk in g P res s u re : 7 3 0 - 7 5 0 m m h g

TANKS : Storage Tanks - 4 (Volume - 400 m 3)

PUMPS : s lu rry tra n s fe r p u m p

Equipments :

● R e a c to rs : 5 (ve rtic a l) (w o rk in g te m p era tu re : R 1 -7 0 C , R 2 – 8 0 C , R 3 - 9 0 C , R 4 - 1 1 0 C , R 5 - 1 3 0 C )

● T C R e m o va l S ec tio n : 1 (ve rtic a l) (W o rk in g tem p e ra tu re : to p - 5 0 -1 0 0 c , b o tto m - 1 3 0 -1 5 5 c )
● LF R em o v a l s ec tio n : 1 (v ertic a l) ( W o rk in g te m p era ture : 1 5 5 c )
● D is tilla tio n s ec tio n : 1 (v ertic a l) ( W o rk ing te m p era ture : 1 2 0 – 1 3 3 c )
● E jec to r : 3 (h o riz o n ta l) (W o rk in g P res s u re : 7 3 0 - 7 5 0 m m h g )
● S c ru b b er : 4 (V e rtic a l) (W o rk in g tem p e ra tu re : 4 0 -4 5 c )
 MFG. OF Terephthaloyl chloride(TPC):

▶ INTODUCTION:
● T ere p h th a lo yl c h lo rid e is th e a c id c h lo rid e o f tere p h th a lic a c id a n d is o n e o f tw o m o n o m e rs

u s e d to m a k e K ev la r (S yn th etic fib e r), th e o th e r b e in g p -p h en ylen e d ia m in e .

IUPAC ID b e nze ne-1,4 -d ica rb o nyl chlo rid e

MOLAR MASS 2 0 3.02 2 2 g/ m ol
FORMULA C 8 H 4 C l2 O 2
BOILING POINT 265 ° C
MELTING POINT 8 1 .5 to 83 ° C
DENSITY 1 .3 4 g /c m ³

▶ APPLICATION:
● D ye s a n d P o lym er
● A s a in te rm e d ia te fo r P o ly(m -p h e n ylen e is o p h th a m id e); P o lye th e r k e to n e e th e r k e to n e

k e to n e; V a ty ello w 1 3 ; V a t yello w 1 1 .
▶ RAW MATERIAL DISCRIPTION:

1. TEREPHELIC ACID(TPA) AND CATALYST

T e re p h th a lic a c id is a n o rg a n ic c o m p o u n d . T h is w h ite s o lid is a c o m m o d ity c h em ic a l, u s ed

p rin c ip a lly a s a p re c u rs o r to th e p o lyes te r P E T , u s e d to m a k e c lo th in g a n d p la s tic b o ttle s .

S e ve ra l m illio n to n n es a re p ro d u c ed a n n u a lly .

FORMULA C 8H 6O 4
MOLAR MASS 1 6 6.13 g /m o l
DENSITY 1 .5 2 g /c m ³
SOLUBILITY IN WATER 0 .0 0 15 g /1 0 0 m L a t 20 ° C
SOLUBILITY p o la r org a nic solve nts a qu eo us b a se
BOILING POINT D e co m p ose s

2. THIONYL CHLORIDE
T h io n yl c h lo rid e is a n in o rg a n ic c o m p o u n d . It is a m o d era tely v o la tile c o lo u rles s liq u id

w ith a n u n p le a s a n t a c rid o d o u r. T h io n yl c h lo rid e is p rim a rily u s ed a s a c h lo rin a tin g rea g en t

FORMULA S O C l2
DENSITY 1 .6 4 g /c m ³
MOLAR MASS 1 1 8.97 g /m o l
BOILING POINT 7 4 .6 ° C
CLASSIFICATION Inorg a nic c om p o und
HANDALING AND SAFETY PRECUTION OF RAW MATERIAL:
TPA AND CATALYST

● S to re d e p a rtm e n t s h o u ld in fo rm th e p la n t in c h a rg e a n d Q C la b o f re c e ip t o f ra w m a te ria l.
● T P A u n lo a d in g fro m tru c k to s to ra g e a rea .
● In p re s en c e o f Q C la b c h em is t a n d p la n t s u p ervis o r, o p e ra te o f p lan t s h o u ld d ra w th e s a m p le.
● T h en Q C c h em is t w ill g iv e a n a lys is re p o rt to p la n t s u p ervis o r.
M a teria l is s to red a s p e r its s ta tu s a c c o rd in g to te s ted o k a y, rejec te d o r u n d er tes tin g in its

re s p e c tive d efin ed s to ra g e a rea .

● R aw m ate ria l w h ic h is p a s s ed a s p er Q C is b o u g h t fro m R a w m a teria l g o d o w n to p la n t.

TC

● A p p ro v ed TC tra n s ferred fro m T C p la n t to T C P p la n t T C s to ra g e ta nk , th ro u g h T C tra n s fer

p um p .

● F o r re a c tio n T C tra n s fe rred fro m T C s to ra g e ta n k to TC f ee d ta n k .

 SAFETY PRECAUTION :
● D u rin g h a n d lin g / tra n s fe r o f c h e m ic a l lis ted a b o v e a lw a ys u s e P P E s lik e s a fe ty s h o es ,

g o g g les ,h e lm e t, a n d PV C h a n d g lo v es .

● U s e B A s e t / c a n is te r m a s k / a ir lin e re s p ira to r if n ec es s a ry in c a s e o f h ig h s p illa g e o r lea k a g e.

● W h ile u s in g h o is t d o n o t lo ad th e m a teria l b eyo nd th e c a p a c ity o f h o is t.
● If a n y a b n o rm a lity is o b s e rv ed d u rin g h o is t o p era tio n (N o is e, v ib ra tio n , etc .) s to p h o is t

a n d in fo rm s u p e rv is o r.

● K ee p th e d o o r c lo s e w h ile o p era tio n o f h o is t.

● N ev er en ter in th e h o is t w a y o r s ta n d b ello w th e h o is t.

 CHEMICAL REACTION
C8H 6O4 + SOCl2 CATALYST C8H 4Cl2O 2 + 2HCL + 2SO2

(TPA) (TC) (TPC)

 PROCESS FLOW DIAGRAM
 PROCESS DISCRIPTION OF TPC PLANT AND STARTUP PROCEDURE:

● REACTION SECTION
● F irs t o f a ll T P A ta k in g in T P A tan k a n d T C is c o m in g in T C p la nt.
● T P A a n d T C a re m ix w e ll in s lu rry m ix d ru m .
● B ef o re s ta rtin g s lu rry fe ed in g in 1 st re a c to r(R 1 ) c he c k a ll th e in le t a n d o u tle t va lve o f ea c h

rea c to r a re s m o o th in o p era tio n .

● C ru d e ta n k lin e u p c h ec k
● E n s u re th e v en t va lv e o f e a c h rea c to rs (R 1 to R 6 ) a re o p e n a n d ro u te to s c ru b b in g s ec tio n

th ro u g h H ea te xc h a n g er.

● In H E m u s t b e u s e c o o lin g w a ter , c h illin g w ate r, a n d b rin e w a ter.

● E n s u re a ll in let a n d o u tle t va lv e o f c o o lin g w a te r, c h illin g w a ter. E n s u re B rin e s u p p ly p res s u re

is 1 k g / c m 2

● E n s u re th a t a ll in let a n d o u tlet va lv e o f lo w p res s u re s tea m s u p p ly a n d c o n d en s a te retu rn

o f ea c h re a c to r.

● N o w o p en th e b o tto m v a lv e o f s lu rry fe ed ve s s el a n d s ta rt fe ed in g th ro ug h - X V S 0 01 .T h e v a lve is

w o rk o n tim e b a s e s o it w ill o p e n fo r 3 s e c . a n d o ff fo r 9 s e c .

● O n c e s ta rt th e f eed in g in 1 st rea c to r ( R 1 ) . s im u lta n eo u s ly s ta rt a g ita to r.

● M a in ta in th e tem p e ra tu re in s id e th e re a c to r (R 1 ) a t 7 0 c th ro u g h te m p era tu re

in d ic ato r(T E -0 0 3 ) . A n d re c o rd lo g s h ee t.

● R e a c tio n m a s s fro m re a c to r (R 1 ) o ve rf lo w s to 2 nd rea c to r(R 2 ).

● S ta rt th e a g ita to r w h e n th e lev el is 2 nd rea c to r (R 2 ) in c rea s e u p to o ve rflo w le ve l.

● M a in ta in th e tem p e ra tu re in s id e re a c to r (R 2 ) a t 8 0 c th ro u g h TE-00 9

● R e a c tio n m a s s fro m re a c to r R 2 o ve rf lo w s to 3 rd rea c to r R 3 .

● S ta rt th e a g ita to r w h e n th e lev el in th e 3 rd rea c to r (R 3 ) in c rea s e u p to o v erflo w le ve l.

● M a in ta in th e tem p e ra tu re in s id e re a c to r (R 3 ) a t 9 0 c th ro u g h TE-01 5

● R e a c tio n m a s s fro m re a c to r(R 3 ) o v erflo w s to 4 th re a c to r (R 4 )

● S ta rt th e a g ita to r w h e n th e lev el in th e 4 th re a c to r (R 4 ) in c re a s e u p to o v erflo w lev el.

● M a in ta in th e tem p e ra tu re in s id e rea c to r(R 4 ) a t 11 0 c th ro u g h T E -0 2 1

● R e a c tio n m a s s fro m re a c to r(R 4 ) o v erflo w s to 5 th re a c to r (R 5 )

● S ta rt th e a g ita to r w h e n th e lev el in th e 5 th re a c to r (R 5 ) in c re a s e u p to o v erflo w lev el.

● M a in ta in th e tem p e ratu re in s id e rea c to r (R 5 ) a t 1 3 0c

● O v erflo w o f T P C c ru d e m a s s is c o llec ted in c ru d e h o ld u p ta n k ( V -0 1 )
● M a in ta in the p re s s u re in rea c to rs (R 1 , R 2 , R 3 , R 4 , R 5 ) b elo w 0.12 2 kg /c m 2 a n d m o n ito r b y

P T .c o n tro l th e fee d if p res s u re is in c re a s ed m o re th en 0 .1 2 2 k g /c m 2 .

● F lu s h a ll o ve rflo w lin e a n d p re s s u re b a la n c e lin e w ith T C a s a n d w h en req u ire d .

● F a c ility to d ra in ea c h re a c to rs m a s s to c ru d e h o ld u p v es s e l.
● N o n c o n d e n s a b le ve n t g a s H C L a n d S O 2 is s e n d to H C L s c ru b b in g s e c tio n th ro u g h ve n t b u ffer
v es s el.

● T C w h ic h is es c a p e d w ith H C L a n d S O 2 g a s es . T h is is rec o v ered T C is c o lle c ted in TC re c o v ery

ta n k b y c o n d en s e r.

● M ea s u re th e q u a n tity o f re c o v ere d T C b y Lo a d c ell b y Le ve l in d ic a to r. T ra n s fe r th e m a s s o f T C

to T C d a y c o lle c tio n ta n k .

● EMERGENCY CASE NO.01

● If p re s s u re w ill in c rea s e in a n y o f re ac to rs (R 1 T O R 5 ) res p ec tiv e R u p tu re d is c . W ill b e o p e ra te d

a t 0 . 6 k g /c m 2 s e t p o in t.

● TC REMOVAL / LF REMOVAL SECTIONTC

RECOVERY

● E n s u re th a t a ll u tility s u p p ly a n d re tu rn va lve o f T C c o n d e n s er a re o p e n.
● E n s u re T C / L F re c o ve ry ve s s el is e m p ty.
● E n s u re th a t in let va lve o f rec o ve red T C d a y ta n k o p e n an d o u tle t v a lve is c lo s e d .
● T a k e a p a rtia l v a c u u m in T C /L F re c o ve ry ve s s el a n d m a in ta in in ra n g e o f 3 0 0 -7 2 0 m m h g

● W h e n a p p ro x im a tely 2 0 % c ru d e m a s s is re s a ve d in T C / LF rec o ve ry v es s e l , sta rt ho t oil s u p p ly

a n d s tirrer o f ve s s el. Sto p th e tra n s fe r o f c ru d e m a s s w h e n lev el in T C / L F rec o v ery v es s e l b e

c o m e 8 0 - 9 0 % o f its to ta l v o lu m e.

● M a inta in top tem p e ra ture A t 50 – 1 0 0 c a nd b otto m tem p e ra ture a t 1 30 – 1 5 5 c

b y h ot o il.

● A f te r T C rec o ve ry is c o m p le te d relive p a rtia l v a c u u m fro m v es s e l.

 LF RECOVERY

● E nsure tha t utility sup p ly a nd re turn v esse l o f LF co nd en ser is o pe n.

● Ta ke a va cuum in T C / L F rec o ve ry ve ssel a nd L F rec eive r in ra ng e if 7 00 -7 4 0 m m
Hg
M a inta in set p oint in ve ssel of m a x . 15 5 c , b o ttom tem p 14 0 – 16 0 c a n d top
te m p 5 0 – 1 50 c b y ho t o il ja c ket.
● H ig he r fra ction o f L F is re flux ed to TC / LF rec o ve ry ve ssel a nd its sa m ple is giv en
for c olo ur a na lysis. W h en c olo ur be c om e < 10 0 H U , the m a ss is tra n sfe rred to

d istilla tio n fe e d ve sse l b y tra nsfe r p um p . In g ene ra l p ra c tic e , c o lo ur of the m a ss is

c hec ked b y v isua l insp ec tio n a nd it is tra nsfe rre d to d istilla tio n ve ssel.

● L ow e r fra ctio n o f L F is co llec ted in L F re ce ive r a nd it is re used is ne xt ba tc h.]

▶ DISSTILATION SECTION
● A f te r fin is h th e TP C c ru d e tra n s fer in c ru d e h o ld u p ta n k , c lo s e th e d is c h a rg e va lv e o f T P C c ru d e

tra n s f erre d p u m p .

● C h e c k th e o u tlet v a lve o f c ru d e h o ld u p ta n k .it s h o u ld b e c lo s ed a t b o tto m .

● C h e c k u tility ( LP S ) s u p p ly fo r c ru d e h o ld u p ta n k , re s id e v es s e l, p ro d u c t re c e ive r 1 a n d

p ro d u c tres e rvo ir 2 , p ro d u c t m a in s to ra g e ta n k .

● C h e c k h o t o il s u p p ly fo r p ro d u c t d is tilla tio n ve s s el, re s id u e v es s e l.

● E n s u re v a c u u m f o r d is tilla tio n ve s s el is m a in ta in e d a t 73 0 – 7 50 m m H g

● E n s u re th a t a ll e q u ip m en t a re c lea n , d ry a n d d e c o n ta m in a te d .
● c h e c k v a p o r o u tlet lin e is ro u ted fro m p ro d u c t d is tilla tio n v es s e l, to p ro d u c t va c u u m b u f fer

th ro u g h b ero h o ld u p ve s s el a n d p ro d u c t p ro d u c t d is tilla tio n c o n d en s er.

● S ta rt c o o lin g w a te r c irc u la tio n in s tea m je t eje c to r c o nd en s e r. M ea s u re m a n o m e te r re a d in g .

w h ic h s h o u ld b e 7 3 0 – 75 0 m m H g .

● N o w , o p e n b o tto m va lve o f c ru d e h o ld u p ta n k a n d s ta rt th e tra n s fer o f T P C c ru d e to p ro d u c t

d is tilla tio n ve s s el b y v a c u u m .

● N ow sta rt th e a g ita to r of distilla tio n v esse l a nd m a inta in the te m pe ra ture fro m 1 2 0

– 1 35 c. s im u lta n e o u s ly s ta rt ejec to r s ys tem a n d o p en th e va c u u m s u p p ly v a lv e o f p ro d u c t

v a c u u m b u ffe r.
● M a inta in 73 0 -75 0 m m H g v a c u u m in d is tilla tio n v es s el a n d b o ttom te m pe ra ture 1 4 0

– 1 50 c , top te m pe ra ture 1 2 0 – 14 0 c

● T P C w ill va p o riz ed a n d re flux fro m d is tilla tio n c o n d e n s er.

● C ru d e T P C c o n tro lled a p p ro x im a tely s a m e a s p ro d u c t c o n d en s er ra te , b y eje c to r va c u u m s ys tem
● C o lle c ted p ro d u c t s a m p le fo r a n a lys is

● W hen d is tille d p ro d u c t c a tc he s d a rk c o lo r, d ra in o ut res id u e o r a fte r 3 0 – 6 0 M Ts o f

d istilled TP C . R esid ue c o lle cte d in ve ssel.

▶ HCL SCRUBBING SECTION

● E n s u re v en t lin e is ro u te d fro m B ub b le r ve s s el to fin al s c ru b b er.
● C h e c k u tility s u p p ly in e a c h c o o lin g w a te r c o n d e n s er
● E n s u re s u c tio n a n d d is c h a rg e o f e a c h H C L c irc ula tio n p u m p
● E n s u re th a t in let a n d o u tle t o f e a c h c o o lin g w ate r c o n d e n s er
● S ta rt c o o lin g w a ter c irc u la tio n in H C L a b s o rb e r a n d h e a t e xc ha n g er in H C L s c ru b b in g s e c tio n .
● O p en th e g a s in le t va lve o f b u b b le r ve s s el. G a s in s e rt b y d e ep p ip e . If TC m a y c a rry o u t w ith H C L

a n d SO 2 g a s . It w ill d e c o m p o s e d in th is v es s e l a n d g a s es g o to w a s h e r to w er. N o te d o w n th e

lev el.

● E n s u re th e a ll in let a n d o u tle t v a lv e o f a ll H C L s c ru b b er ( A / B / C )
● E n s u re a ll in let a n d o u tle t v a lve o f H C L s c ru b b er h ea t e xc h a n g e r a re o p en (H E - A /B / C / D )
● S ta rt c irc u la tio n o f c o o lin g w a ter in a ll H E
● S im u lta n eo u s ly s ta rt H C L c irc u la tio n p u m p o f H C L s c ru b b e r.
● H C L a n d S O 2 w ill c o m e fro m ve n t B u ffe r to H C L s c ru b b er a n d o n ly H C L s c ru b b ed .
● W h e n th e d e n s ity in 1 st H C L s c ru b b er rea c h es to 1 1 5 0 k g /m 3 . 3 0 % o f H C L s o lu tio n b e

tra n s f erre d to s to ra g e ta nk .

▶ RAW MATERIAL AND FINAL PRODUCT SAMPLE DATA

RAW MATERIAL
TPA 1 2 0 0 K G IN S IN G LE B A T C H
TPP 1 0 . 9 K G IN S IN G L E B A T C H
TC 1 9 5 0 T O 1 9 9 5 IN S IN G LE B A T C H

▶ TPA RESULT

DESCRIPTION SPECIFICATION RESULTS

A P PIA R A N C E W H IT E C R Y S T A L IN E W H IT E C R Y S T A L IN E
POW DER P O W D ER
P T O LU IC A C IC 2 0 0 M A X . PP M 15 0 M AX . P P M
ISO P H A LIC A C ID 10 0 M A X P P M NIL
P U R IT Y 9 9 .8 0 M IN . 9 9 .9 8 5
▶ TPP RESULT

A P PIA R A N C E W H IT E C R Y S T A L IN E W H IT E C R Y S T A L IN E
POW DER P O W D ER
M E L T IN G PO IN T 70 TO 8 0 C 80 TO 8 1 C
A SSAY 99 9 9 .8 %

▶ TC RESULT

A P P IA R A N C E C O L O U R LE S S TO P A LE C O LO U R LE S S TO PA LE
Y E L LO W C LE A R LIQ U ID Y E L LO W C LE A R LIQ U ID
W IT H P U N G E N T SM E LL W IT H P U N G E N T S M E L L
ASSAY 9 9 . 7 M IN 9 9 .8 %
S U LP H A R C H L O R ID E 0 .1 5 M A X . 0 .1 1 6 M A X
SOCL2 0 .2 0 M A X . 0 .0 6 8 M A X .
S02 0 .4 5

▶ STEAM CONDENSATE DATA

REACTOR R1 R2 R3 R4
A VG 3 72 6 5 2 .2 2 8 3 .9 49.8
STEA M
/H R.
*(K G S )

▶ TEMERATURE DATA

REACTORS TEMPERATURE MOC CAPACITY

R1 70 MSG L 2 KL
R2 80 MSG L 3 KL
R3 90 MSG L 6 .3 K L
R4 110 MSG L 6 .3 K L
R5 130 MSG L 6 .3 K L

▶ LF SECTION TIME SECTION

1 . C R U D E LE VE LIN G T IM E : 2 T O 3 H R S
2 . T C R E C O V E R Y T IM E : 12 TO 14 H R S
3 . LF C U T R E M O V E L TIM E : 2 T O 3 H R S
4 . LF C R U D E T R A N S F E R T IM E : 2 H R
5 . T O T A L T IM E : 2 4 H R R E Q U IE R D F O R 8 M T C R U D E

▶ BOTTOM TEMPERATURE DATA

1. FO R TC R EC O V ER Y : 1 00 TO 1 40 C TE M P .
2 . F O R LF R E M O V E L : 1 4 0 T O 1 6 0 C T E M P .

▶ AFTER LF REMOVAL RESULT OF LOWER SECTION

A P PIA R A N C E Y E L LO W
A SSAY 9 9.9%
D IM E R 35
TPPO 1 0 3 .9
L F IM P U R IT Y 4 1 7 .6 P P M
O THE R 1 9 7 .8 P P M

▶ DISTILLATION SECTION

DISTILLATION RATE

● AP P R O X YM AT L Y 340 T O 350 KG S P E R HR S
● C A P A S IT Y : 8 M T / D A Y

▶ TEMPERATURE DATA OF DISTILLATION

● B O T T O M T E M P E R A T U R E : 1 4 5 TO 1 6 0 C
● TO P TEM P ERA TURE : 1 3 0 TO 1 4 5 C

▶ FINAL AVERAGE RESULT OF RESIVER

COLOUR ASSAY TMC DIMER TPPO OTHER

(H.V) (%) (PPM) (PPM) (PPM) (PPM)
40 9 9 .9 6 55 0 65 80 32 0

▶ SPECIAL EQUIPMENT USED IN ALL AUTOMATION INDUSTRY

▶ XV : U S E D F O R O N O F F SE R V IS E V A LV E . C O N T R L LE D B Y D C S
▶ TE : T E M P E R A T U R E E LE M E N T T O M E A S U R E T E M P E R A T U R E
▶ LG : L E V E L G U A G E T O M E A S U R E L E V E L IN A N Y V E S S E L
▶ FV : F L O W C O N T R O L V A L V E T O C O N T R O L T H E F L O W O F A N Y P R O C E S S LIN E
▶ RTD: R E T R A C T A B L E T H E R M O C U P LE
▶ HU : H A Z E N S C A LE
▶ UTILITY AND ETP PLANT

In a TML moistly used in utility

● LP S T E A M
● A IR
● IN S T R U M E N T A IR
● B R E A T H IN G A IR
● N IT R O G E N

▶ In ETP plant Scrubber area is also included and removal of HCL and So2 from TPC.
▶ TC recovered in cooler area.

▶ FIRE & SAFETY

● S a fe ty is b ec o m in g ve ry im p o rta n t w ith e ve ry m a n a g e m e n t a s it h a s c o m e to p la y

a ve ry vita l ro le in the m o d e rn d ev elo p m en t.

● B ef o re m a n y ye a rs , a c c id e n ts w ere c o n s id e re d a s a c ts o f g o d a n d n a tu re.

S c ie n tific m ind ed p eo p le h a ve a n a lyze d a c c id e n ts a n d d e ve lo p e d a s e p a ra te

e n g in ee rin g b ra n c h o fa c c id e n t p re ve ntio n .

● T h is a n a lys is w a s re q u ired d ue to :

● R is in g tre n d o f a c c id e n ts

●In c re a s ed u s e o f m a c h in ery
●In c re a s ed m a te ria l h a n d lin g
●La c k o f s a fe ty s ta n d a rd
●La c k to tra in in g
●B etter re p o rtin g o f a c c id en t
▶ SAFETY:

● S a fe u s e o f m a n , m a teria l a n d m a c h in e b y s af e s ys tem m e th o d o f w o rk is to

a c h ie ve ze ro a c c id en ts w h ic h res u lts in h ig h e r p ro d u c tivity.

▶ ACCIDENT:

● A n A c c id en t is u n p la n n ed a n d u n e xp ec te d ev en ts w h ic h in terfe re o r in terru p ts th e

p la n n e d p ro c es s o f w o rk a n d re s u lts in p ers o n a l in ju ry.

▶ ACCIDENT FACTORS

1 . A p e rs o n a l a c c id en t in ju ry o c c u rs a s a res u lt o f a n a c c id e n t.

2 . A n A c c id en t d u e to u n s a fe a c t a n d / o r u n s a fe c o n d itio n .

3 . U n s a fe a c t/u n s a fe c o n d itio n ex is ts d ue to f a ult o f p e rs o n s .

4 . F a u lt o f p ers o n s a re d u e to n eg lig en c e

T h u s , if w e c a n rem o v e fa u lt o f p e rs o n s , w e c a n p rev en t 9 8 % a c c id en ts .

▶ LIST OF SAFETY EQUIPMENTS:

● S a fe ty H elm et

o W h ite – E m p lo yee

o B lu e – V is ito rs

o Y ello w – C o n tra c to r

● E a r m u f f a n d e a r p lu g s

● G o g g le s

● H a n d G lo ve s

● A p ro n s

● S a fe ty S h o es
 ● S a fe ty H a rn es s

● D u s t M a s k ( H ig h ly h a z a rd o u s c h em ic a l lik e C L 2, B R 2, N H 3 etc .)

● GOLDEN RULES OF SAFETY:

1 . P erm it to w o rk.

2 . E ne rgy iso la tio n.

3 . G ro und d isturba nce .

4 . C o nfine d sp a ce e ntry.

5 . W o rking a t a he ig ht.

6 . L ifting op e ra tio n.

7 . D riving sa fety.

8 . M a n a ge m e nt o f c ha ng e.
 EMERGENCY

▶ DEFINITION:
● E m e rg en c y is d e fin ed a s a n y s itu a tio n w h ic h p re s en ts a th rea t to
s a fe ty o f p ers o n s o r p ro p erty.

● E m e rg en c y (in in d u s try) c a n b e d e fin ed a s o n e o r m o re.

● A f fec t o n e o r s e ve ra l p la n ts .

● C a u s e s e rio u s in jury to th e p e rs o n .

● R e s u lts in e xten s iv e d a m a g e to th e p ro p e rty.

▶ TYPES OF EMERGENCY:

●F ire
●E x p lo s io n o r b la s t
●H ea v y lea k a g e/ s p illa g e o f c h e m ic a l

▶ EMERGANCY SIREN TONE:

1. FIRE & OTHER EMERGNCY: - 2 0 s ec , c yc le w a ilin g (o n 2 0 s e c & o ff 5 s e c ).

2. GAS LEAK: - W a ilin g s o u n d fo r tw o m in u tes (6 0 s ec o n & 5 m in o ff).

3. ALL CLEAR: - C o n tin u o u s s o u n d fo r tw o m in u tes .

4. TESTING: - E v ery S a tu rd a y a t 1 1 :0 0 O ’ c lo c k (C o n tin u o u s s o u n d fo r tw o

m in u te) .
▶ ASSEMBLY POINTS LOCATION:

1. C a r p a rk ing n e a r G a te.

2. S C M – S u p p ly, C h a n g e & M a n a g em e n t d ep a rtm en t.

3. S a lt & E lec tio n d e p a rtm e n t.

4. C e m e n t p la n t m a in g a te .

5. M a k e u p w a te r p la n t A R - 2 G A T E .

▶ WHAT TO DO WHERE EMERGENCY OCCURS:

● Y o u m u s t k n o w th e es c a p e ro u te s .

● D o n o t ru n , th is ten d s to c a u s e p an ic .
● D o n o t g et p a n ic k y, m o v e to s a fe a re a .
● P la y yo u r ro le in o rd erly m a n n er fo r c o m b a tin g th e e m erg e n c y, if

yo u c a n .

● D o n o t lo iter u n n ec es s a rily.
● If yo u h a ve n o ro le to p la y m o v e o u t o f th e a rea a n d rea c h to th e

s a fera s s e m b ly p o in t b y s eein g w in d d irec tio n .

● D o n o t a p p ro a c h to e m e rg en c y s ite a s s p ec tato rs .
● Do no t engage c o m m u n ic a tio n c h a n n els (P h o n e e tc .) u n n ec es s a rily.

● Do n o t a p p ro a c h c o n tro l c e n ter u n n ec es s a rily fo r in q u iry u n le s s

yo u a re req u ired .

● P ro c e ed in o rd e rly m a n n e r to th e s af e a s s e m b ly p o in t w h e n yo u

a rein s tru c te d to d o s o