INTERNSHIP REPORT

IN

AMOLI ORGANICS PVT LTD. VADODARA

BY

SOLANKI DARSHAN, PADHIYAR GAURAV

AND

LIMBACHIYA SANDIP

UNDER THE GUIDANCE OF

MR. ABHISEK JANI

(AGM-TECHNOLLOGY TRANSFER AMOLI
ORGANICS PVT LTD VADODARA)

SUBMITED IN PARTIAL FULFILLMENT OF

REQUIREMENT OF FOR THE SECOND YEAR
DIPLOMA IN CHEMICAL ENGINEERING

SHRI KJ POLYTECHICH,BHARUCH
 ACKNOWLEDGEMENT

I would like to thank all the people who gave their

valuable time, guidance and help for the completion of my
project work. It gives me immense pleasure and
sanctification to express my deep gratitude to my guide at
AMOLI Mr. Abhisek Jani and Mr. Amit Bawane for my
project knowledge and being with me and helping me
always when I needed help. I am sure this knowledge will
help me gain the power to my contributions to the world
as a CHEMCAL ENGINEER and as a human being.
I would also thank AMOLI ORGANICS PVT LTD. For
providing me this wonderful opportunity. AMOLI
ORGANICS PVT LTD. For their valuable guidance and
providing opportunity for in plant training. My special
thanks to Technology Transfer Team for their valuable
guidance of respective area.
I would like to thank Dhaval Yadav Sir for their
valuable suggestions’ constant encouragement and
generous help and also for giving me the opportunity to
begin my training at AMOLI ORGANICS PVT LTD,
Vadodara.
I greatly appreciate the concern and involvement
of employees at AMOLI ORGANICS PVT LTD. Especially
department staff and operators at the plant for being
friendly and helping me in every manner. Nevertheless, I
would like to thank all the charge hands, senior and junior
operators without whom my training and also this report
would have not been possible
 Introduction
Comment [xyz1]:

“Amoli Group’s philosophy is honesty integrity and transparency in

business”

Amoli is the vision and perseverance of its founder Mr. Umed

Doshi a widely respected entrepreneur amoli has a successful track
record in the pharmaceutical and allied industry making a beginning
as a manufacturer of API’s and intermediates ; /it made successful
forays in the field of ‘Contract’ research and ‘custom synthesis’ Amoli
has been working collaboratively with some of the leading global
healthcare players.

Strength :-
 1100 strong dedicated work force.

 2 state of theart manufacturing sites.

 Sites are CGMP and SHE compliant.

 Well equipped R & D sector.

 Presence in USA, EUROPE, JAPAN, RUSSIA, SOUTH EAST and
LATAM.

 Fast growing well integrated health care group.

Chemistry Lab :-
 Situated at Baroda’ Gujrat’ India’AMoli Research center is
spread over 12000 sq.Ft

 Well equipped GMp compliant 2 synthetic labs and a pilot plant

with ss and Gl reactors.

 Has a talented pool of 80 scientists including organics/analytical

chemists.

 R & D center is engaged in developing process technology for

API’s.

Analytical Lab :-
 Our an assist the regulatory affairs to prepare high quality
ethical packaged and drug master files analytical lab provide
support to our R & D through documentation and validation of
test results as per ICH guidelines.

R & D Capabillites :-
 Polymorph Development

 Impurity Profiling

 Generaion of Intrllectual property

 Chirac Separations

 Sterco selective synthesis

 Cryogenic reactions

 Particle sizing capabilities.

Company Location :-

1. Baroda Comprises of 7 manufacturing facilities.

2. VAPI Comprises of 3 manufacturing facilities.
 Types Of Reactor
1. Batch Reactor
A batch reactor is a closed vessel in which reactions happen
and it is a non-continuous type of reactor. The reactants are
fed in to the reactor all at once initially. The vessel contains
an agitator. The purpose of the agitator is to mix the
reactants thoroughly so that the contact makes them react
together efficiently and produce products.

Fig.1-Batch Reactor

The batch reactor is a non-steady, transient reactor. It means

the extent of conversion within the reactor depends on time.
Due to agitator the batch reactor is highly uniform in nature.
It means the extent of conversion does not depend on
location within the reactor. At a given time the extent of
reaction at any location of the volume of the reactor will be
equal to each other.

Advantage
The greatest advantage of operating a batch reactor is its
versatility. Same batch reactor can be used to chemically
react quite different variety of reactants. Batch reactors are
especially used in cases where the reaction produces lots of
products. Batch reactors are often used in labs to study
kinetics of the liquid phase reaction systems.

Disadvantage
The disadvantage of batch reactor is that it requires lots of
labour force to constantly charge reactants, discharge
products and then to clean the reactor for the next batch

2. Continuous Stirred Tank Reactor (C.S.T.R)

A continuous stirred tank reactor (C.S.T.R) is also often called
a mixed flow reactor (M.F.R). In this reactor also the reaction
occurs in a closed tank. The tank also has agitator in order to
mix the reactants thoroughly.
 Fig.2-Continuous Stirred Tank Reactor

It is different from batch reactor in the sense thay the name

itself indicates it is continuous type of equipment. The
reactants enter the reactor at a certain mass flow rate, the
react inside the vessel for sometime
dictated by the space time of the
reactor and then they form products. The products flow out
of the reactor at the same mass flow rate. One space time is
the time required to process one reactor volume.
The C.S.T.R is steady sate equipment. It means the extent of
conversion does not depend on the time. The agitator makes
the concentration uniform throughout the reactor. It means
the extent of conversion does not depend on the location
also. The extent of conversion depends on the volume of the
reactor.

Advantage
The biggest advantage of using a C.S.T.R in industries is that it
can produce a large amount of products and being a
continuous steady state reactor the reactor can keep on
operating hours on end.

Disadvantage
The disadvantage is that a C.S.T.R cannot be used for
reactions which have very slow kinetics because it will
require a reactor of very large volume. The fabrication and
operational cost of the reactor may make it infeasible. Batch
reactor is used in this case.

3. Plug Flow Reactor (P.F.R) flow reactor (P.F.R) is also

sometime called a continuous tubular reactor (C.T.R). In an
idealised model, the profile A plug of the reaction mixture
can be considered to be made up of a number of plugs and
each plug having a uniform concentration.

Fig.3-Plug Flow Reactor(P.F.R.)

Advantage
The advantage of P.F.R over C.S.T.R is that for same space
time and same level of conversion, the volume of the P.F.R is
relatively smaller than a C.S.T.R, It means a smaller space is
needed for the reactor also for same volume of reactor the
level of conversion is higher in P.F.R than in C.S.T.R. Often the
P.F.R are used to study kinetics of gas phase catalytic
reactions.

Disadvantage
The disadvantage is that if we carry out an exothermic
reaction in a P.F.R then the temperature gradients are
difficult to control. The operational and maintenance cost of
a P.F.R are also greater than a C.S.T.R.
4. Semi-Batch Reactor
A semi-batch reactor is a semi-flow reactor. It is a
modification of batch reactor. It is also a closed vessel which
contains agitator for the purpose of mixing the reactants
thoroughly. The difference is that one of the reactants is
charged completely
initially in the reactor and
the other reactant is
charged continuously in
the reactor as the time
progresse

Advantage
The advantage of using a
semi-batch reactor is that

Fig.4-Semi batch Reactor

if we are carrying out multiple reactions then we have a

greater control over yield or selectivity of the products. This
reactor is extremely useful when we are carrying out an
exothermic reaction as the continuous flow of the other
reactant can be varied to better control the exothermic
reaction.
Disadvantage
If we want to scale up the semi-batch process then
disadvantage over the continuous process reactors (C.S.T.R
and P.F.R) is that capital costs per unit scales up relatively a
lot. Greater man power is required to charge and discharge
the contents of the reactor, to clean blades, to clean reactors
etc.
 PARTS OF REACTOR
Major components of chemical reactor :-
1. Reaction vessel
2. Various incoming and outgoing lines
3. Jackets
4. Agitator
5. Baffles
6. Pressure relief valve and rupture disc.
7. Steam trap

Lines coming in/Going out in chemical reactor :-

 These are basically used for transferring material n the
reactors.
 MOC is decided based on the material being handled.
 Line sie decided on flow rate needed.

Reactor Jacket ;-

 Basically Reactions are carried out in reactors and the

specific conditions need to be achieved.
  Jacket is provided in which utility flows and we maintain
desired conditions.

Agitator And Baffles :-

 Basically used for better mixing improve heat and
mass transfer.
 Baffles are basically used to stop vortex formation.

Steam Trap :-
 Installed in condensate line to allow condensate to go
out not live steam.

Pressure Relief :-
 Used as a safety for reactor in case a ay reaction
that can go out of control.

Rupture Disc :-
 First layer of safety has a thin disc which bursts
when pressure n creses et value.
 BOD [Biochemical Oxygen Demand]
BOD – Biochemical Oxygen Demand is applied to determine
the aerobic destructibility of organic substances.
BOD is the biological method used for the measurement of
the total amount of dissolved oxygen (DO) used by microbes
in the biological process of metabolizing organic molecules
present in water.
The total amount of oxygen gas present in the water is called
dissolved oxygen (DO). The non-compound oxygen present
in water may either be a by-product of the photosynthesis of
the aquatic plants or the dissolved atmospheric oxygen gas.
In some water bodies, organic matter is a great source of
BOD. These organic matters include sewage and other
pollutants present in the water bodies. The greater the BOD,
the lower is the dissolved oxygen available for aerobic
animals such as fishes and other aquatic organisms.
The BOD is accordingly a reliable measure of the organic
pollution of water bodies. The main reason for treating
wastewater prior to its discharge into a water resource is to
reduce its BOD level (the demand for oxygen).

Importance of BOD :-
1. BOD measures the amount of oxygen consumed by
microorganisms for the process of decomposition of the
organic matters in the water bodies.
2. It indicates the amount of organic pollution present in
an aquatic ecosystem.
3. BOD is calculated in sewage treatment or wastewater
treatment to find the destruction of organic wastes by
aerobic microbes
4. It determines the amount of organic matter present in
soils, sewages, sediment, garbage, sludge, etc.
5. The biochemical oxygen demand also determines the
rate of respiration in living beings.
6. BOD is also used in the medicinal & pharmaceutical
industries to test the oxygen consumption of cell
cultures.
 Chemical oxygen demand [COD]
Chemical oxygen demand, or COD, is the measure of the
capacity of water to consume oxygen during the
decomposition of organic matter in the water. In other
words, it’s the amount of oxygen that’s needed to oxidise the
organic matter present in a quantity of water.
COD analysis is used as an indirect measure of pollutants
(organics) in a water sample. It is an important parameter
in water quality analysis, helping to reduce risk to humans
and the environment.
COD is an excellent way of monitoring the efficiency
of water treatment plants. If water is left untreated, or
partially treated, discharged water contains effluent organics
that can compete with downstream organisms for
oxygen. This oxygen demand can kill or inhibit life
downstream of the discharge area. It should be clear,
therefore, that anything that can help gather accurate
information about water quality, such as COD, has a key role
to play in reducing the likelihood of pollutants causing any
environmental damage.
Chemical Oxygen Demand important [COD] :-
Modern societies have a high demand for water to meet a
wide range of personal, health, and commercial purposes. At
the same time, our industrial society produces a wide range
of pollutants and environmental challenges, all of which can
produce serious health and biodiversity outcomes if left
untreated. Pollutants can overwhelm natural processes of
recovery.
In addition to products arising from the decomposition of
natural substances (e.g. proteins, greases, carbohydrates)
there is a build-up of other, potentially harmful, additives
such as pesticides, effluents and garbage, which contaminate
drinking water supplies with their toxic or hormonal effects.
They may also consume such large quantities of oxygen
that water resources become fouled.
High organic contamination in water discharged to tributaries
and streams can have a range of impacts. These include:
 Toxicity of organic compounds: health effects on plants
and wildlife
 Decreasing dissolved oxygen and eutrophication
 Impact on fish populations
 FIRE AND SAFETY
The fire triangle, or combustion triangle, is the three
components needed to ignite and sustain a fire. The three
ingredients of a fire triangle are; heat, fuel and oxygen.

Fig.5-Fire Triangle

1. Heat
A source of heat is required in order for ignition to occur, and
different materials have different ‘flash points’ e.g. the
lowest temperature at which they ignite.
Unfortunately, combustion reactions also produce heat as
they burn, further increasing the temperature of the fuel. For
some types of fire, the heat can be cooled with the
application of water.
2. Fuel
A fire cannot begin if there is no material to burn. Homes and
businesses are full of flammable materials, such as paper, oil,
wood and fabrics. Any of these can serve as a fuel for a fire.
Some materials burn more easily than others. Fuels are
probably the most difficult ‘side’ of the fire triangle to
remove, so it’s wise to store them appropriately to prevent
them becoming a fire hazard.
3. Oxygen
To sustain the combustion reaction, oxygen (or an oxidising
agent) is needed, as it reacts with the burning fuel to release
heat and CO2. Earth’s atmosphere consists of 21% oxygen, so
there is plenty available to trigger a fire if the other two
components are present.
Different types of fire extinguishers and their uses:

Fig.6-Types Of Fire Extinguishers

 Water jet: Operates by spraying water at the burning

flames and avoiding the re-ignition. It is dangerous to
use this type of electrical equipment.
 Water spray: Operates by spraying water droplets at the
burning flames. The concept is that the water droplet is
surrounded by non-conductive air.
 Water extinguishers with additives: Adding foaming
chemicals to the water makes the fire extinguisher
operate much more effectively. Another benefit; using
chemicals means that a smaller fire extinguisher can
carry the same water volume.
 Water mist or fog: This type absorbs heat energy faster,
extinguishing fires in the form of mist or fog, which have
smaller droplets than water. This type is safe to use in
case of any fire class except Class D.
 SEPARATION METHOD
Need of Separation
The mixtures are separated into their components for various
purposes, such as;
1. To remove an undesirable component
2. To remove a harmful component
3. To obtain the pure sample of a substance
4. To obtain a useful component
Distillation
The changing of water into water vapour on heating is called
evaporation. And the changing back of hot water vapour into
liquid water on cooling is called condensation. Thus,
distillation involves two processes: evaporation followed by
condensation.
 Fig.7-Distillation Process

AGITATED NUTSCHE FILTER (ANF) :-

Agitated Nutsche Filters are used widely in the
Production Processes of Pharmaceutical, Chemical and
laboratory industries, among others. They are
manufactured as agitated Nutsche filter dryers
(ANFD'S) for the filtration and drying in the same unit
of active pharmaceutical ingredients (API) and chemical
compounds.

Agitated Nutsche filter (ANF) is a filtration technique

used in applications such as dye, paint, and
pharmaceutical production and waste water
treatment.

Safety requirements and environmental concerns due

to solvent evaporation led to the development of this
type of filter wherein filtration under vacuum or
pressure can be carried out in closed vessels and solids
can be discharged straightaway into a drier.

Fig.8- AGITATED NUTSCHE FILTER (ANF)

MATERIALS OF CONSTRUCTION:-

 like Hastelloy C-276, C-22, stainless steel, mild steel, and
mild steel with rubber lining as per service
requirements.
 Recently, Agitated Nutsche Filters have been fabricated
out of polypropylene fiber-reinforced plastic (PPFRP).

Sparkler Filter
The Sparkle Filter has wide usage in pharmaceutical and
cosmetic industry for filtering out the foreign and unwanted
elements from liquid. The filter is manufactured with two
options viz. deep plate for high percentage of cake holding
capacity & shallow plate for small percentage of cake
capacity.

The filters constructed with excellent filter media ensure

complete recover of product.+
Applications :-
 Pharmaceutical industry
 Cosmetic industry
 Chemical industry
 Edible oil
 Food & beverage

Fig.9- Sparkle Filter