A REPORT

ON INDUSTRIAL TRAINING
AT

TML INDUSTRIES LIMITED

PILUDRA UNIT

Submitted By:-

Krushuik Tailor
B.E. Chemical Engineering
Dipartment Of Chemical Engineering
OM ENGINEERING COLLEGE

Mentor:-
Mr.Mulrajshih sindha
Chief Engineer(Production)
TML IND.
 CERTIFICATE

This is to certify that Mr. KRUSHIK TAIOLR , EN No. 191023105042, 7th

semester B.E. (Chemical Engineering) from Om engineering, Junaghadh has
successfully completed his summer training at TML INDUSTRIES LTD., Piludra
during the period of May 24,2021 to June 07, 2021 and has submitted a training
report titled “REPORT ON SUMMER TRAINING AT TML INDUSTRIES LTD.

Date: 15/06/2021
Place: Piludra, Gujarat.

Under the Guidance of: Head of Department:

PROF.Y.P CHAPADIY
PROF. C.N.PARMAR
CERTIFICATE
 ACKNOWLEDGEMENT

I owe many thanks to a great many people who helped and supported me during
the training.

I would also like to thank Training Centre, TML INDUSTRIES LTD.for providing
an opportunity to undergo training. It was indeed an opportunity for us to visit the
different section of Piludra Unit . During my visit to the company for preparing
this Project Report, I learnt many interesting things about the company.

I express my thanks to the Mentor Mr. Mulrajshih sindha for extending his
support.

I would also thank TML and their employees without whom this project would
have been a distant reality.
SR DATE PLANT VISITED
No.
1 24/05/2021 GROUP GATHERING STATION
2 25/05/2021 GROUP GATHERING STATION
3. 25/05/2021 CENTRAL TANK FARM (CTF) PILUDRA
1. PRODUCT
2. HCL TANK
GROUP GATHERING STATION PILUDRA
4. 26/05/2021 PRODUCT RESIVING STATION
PUMP HOUSE (MPH)
5. 28/05/2021 WORKSHOP
6. 28/05/2021 1. MECHINE SHOP
2. REPAIR SHOP
3. ELECTRICAL SHOP
EXPERT LECTURES
7. 29/05/2021 1. ARTIFICIAL LIFT
2. LABORATORY TESTING
VISITING PLANT
8. 01/06/2021 REACTOR SECTION
9. 02/06/2021 TC AND LF RECOVERY SECTION
10. 03/06/2021 WATER TREATMENT PLANT (WTP)
03/06/2021 DISTILLATION SECTION
11. 04/06/2021 1. MAIN RESIVER SECTION (MRS)
2. SCRUBBING AREA
3. SO2 PLANT
4. PROCESS & QUALITY CONTROL LABORATORY
5. GAS IJECTOR UNIT (GIU)
6. EFFLUENT TREATMENT PLANT (ETP)
12 07/06/2021 ORDER LETTER
 Introduction of TML
 TML – Transmetal ltd.
 Commends and business of 1993.
 Suresh dayal is chairman of tml ind.


 Part of Excel group of companies. Shroffs, Tushar Dayal and family have been major Promoters of the
group. Shroffs have business interests exceeding over 7 decades.
 Associate of Excel Industries Ltd, Excel Crop Care Ltd, Transpek, Agrocel, Hyderabad Chemicals Ltd,
Punjab Chemicals Ltd. Leading names in Agrochemicals, Pharmaceutical Intermediates and
Penultimate Chemical Products.

TML IND. in Vadodara :

1. Piludra
2. Karakhdi
Located at two sites. Both the sites, are approx. 50 kms from Vadodara.
 Piludra Plant

 Infrastructure
 Adequate water , power and utilities.
 Covered go downs, tank farms and material handling systems.
 Air emission - Scrubbing systems & Solid / liquid Effluent treatment systems.
 Both the Manufacturing sites located adjacent to the waste water carrier,45km long Liquid
Effluent Channel Project - one of the first of its kind in the world

 All major Raw Materials available proximate to manufacturing site, in the State of Gujarat.

 Use eligibility for river water for all industrial applications.

 Fire Hydrant capability for all risk exposed operations.
 State of art Spray Dryer for treatment of complex effluent
Manager : MULRAJ SINDHA

Year of Commission : 1979

Plant Introduction given by : M.S TAILOR

Production Status :

Total tanks - 6

Total reactors - 5

Total Production - 50m3/day

Raw material : TPA & CATALYST, TC

Product : TPC

VESSELS:

DISTILLATION : Working temperature : 120 – 133c

SCUBBER : Working temperature : 40-45c

EJECTOR : Working Pressure : 730- 750mmhg

TANKS :

Storage Tanks - 4 (Volume - 400 m3)

PUMPS : slurry transfer pump

Equipments :

 Reactors : 5 (vertical) (working temperature : R1-70C, R2 – 80C, R3- 90C, R4- 110C, R5- 130C)
 TC Removal Section : 1 (vertical) (Working temperature : top- 50-100c, bottom- 130-155c)
 LF Removal section : 1 (vertical) (Working temperature : 155c)
 Distillation section : 1 (vertical) (Working temperature : 120 – 133c)
 Ejector : 3 (horizontal) (Working Pressure : 730- 750mmhg)
 Scrubber : 4 (Vertical) (Working temperature : 40-45c)
 MFG. OF Terephthaloyl chloride(TPC):

 INTODUCTION:
 Terephthaloyl chloride is the acid chloride of terephthalic acid and is one of two monomers used to
make Kevlar (Synthetic fiber), the other being p-phenylenediamine.

IUPAC ID benzene-1,4-dicarbonyl chloride

MOLAR MASS 203.0222 g/mol
FORMULA C8H4Cl2O2
BOILING POINT 265 °C
MELTING POINT 81.5 to 83 °C
DENSITY 1.34 g/cm³

 APPLICATION:
 Dyes and Polymer
 As a intermediate for Poly(m-phenyleneisophthamide); Polyether ketone ether ketone ketone; Vat
yellow13; Vat yellow 11.
 RAW MATERIAL DISCRIPTION:
1. TEREPHELIC ACID(TPA) AND CATALYST
Terephthalic acid is an organic compound. This white solid is a commodity chemical, used principally
as a precursor to the polyester PET, used to make clothing and plastic bottles. Several million tonnes
are produced annually.

FORMULA C8H6O4
MOLAR MASS 166.13 g/mol
DENSITY 1.52 g/cm³
SOLUBILITY IN WATER 0.0015 g/100 mL at 20 °C
SOLUBILITY polar organic solvents aqueous base
BOILING POINT Decomposes

2. THIONYL CHLORIDE
Thionyl chloride is an inorganic compound. It is a moderately volatile colourless liquid with an
unpleasant acrid odour. Thionyl chloride is primarily used as a chlorinating reagent

FORMULA SOCl2
DENSITY 1.64 g/cm³
MOLAR MASS 118.97 g/mol
BOILING POINT 74.6 °C
CLASSIFICATION Inorganic compound
HANDALING AND SAFETY PRECUTION OF RAW MATERIAL:
1) TPA AND CATALYST
 Store department should inform the plant incharge and QC lab of receipt of raw material.
 TPA unloading from truck to storage area.
 In presence of QC lab chemist and plant supervisor, operate of plant should draw the sample.
 Then QC chemist will give analysis report to plant supervisor.
Material is stored as per its status according to tested okay, rejected or under testing in its
respective defined storage area.
 Raw material which is passed as per QC is bought from Raw material go down to plant.

2) TC
 Approved TC transferred from TC plant to TCP plant TC storage tank, through TC transfer pump.
 For reaction TC transferred from TC storage tank to TC feed tank.

 SAFETY PRECAUTION :
 During handling / transfer of chemical listed above always use PPEs like safety shoes, goggles,
helmet, and PVC hand gloves.
 Use BA set / canister mask / air line respirator if necessary in case of high spillage or leakage.
 While using hoist do not load the material beyond the capacity of hoist.
 If any abnormality is observed during hoist operation (Noise, vibration, etc.) stop hoist and inform
supervisor.
 Keep the door close while operation of hoist.
 Never enter in the hoist way or stand bellow the hoist.

 CHEMICAL REACTION

C8H6O4 + SOCl2 CATALYST C8H4Cl2O2 + 2HCL + 2SO2

(TPA) (TC) (TPC)

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

 REACTION SECTION
 First of all TPA taking in TPA tank and TC is coming in TC plant.
 TPA and TC are mix well in slurry mix drum.
 Before starting slurry feeding in 1st reactor(R1) check all the inlet and outlet valve of each reactor are
smooth in operation.
 Crude tank line up check
 Ensure the vent valve of each reactors (R1 to R6) are open and route to scrubbing section through Heat
exchanger.
 In HE must be use cooling water , chilling water, and brine water.
 Ensure all inlet and outlet valve of cooling water, chilling water. Ensure Brine supply pressure is 1
kg/cm2
 Ensure that all inlet and outlet valve of low pressure steam supply and condensate return of each
reactor.
 Now open the bottom valve of slurry feed vessel and start feeding through XV-S001.The valve is work
on time base so it will open for 3 sec. and off for 9 sec.
 Once start the feeding in 1st reactor (R1) . simultaneously start agitator.
 Maintain the temperature inside the reactor (R1) at 70c through temperature indicator(TE-003). And
record log sheet.
 Reaction mass from reactor (R1) overflows to 2nd reactor(R2).
 Start the agitator when the level is 2nd reactor (R2) increase up to overflow level.
 Maintain the temperature inside reactor (R2) at 80c through TE-009
 Reaction mass from reactor R2 overflows to 3rd reactor R3.
 Start the agitator when the level in the 3rd reactor (R3) increase upto overflow level.
 Maintain the temperature inside reactor (R3) at 90c through TE-015
 Reaction mass from reactor(R3) overflows to 4th reactor (R4)
 Start the agitator when the level in the 4th reactor (R4) increase up to overflow level.
 Maintain the temperature inside reactor(R4) at 110c through TE-021
 Reaction mass from reactor(R4) overflows to 5th reactor (R5)
 Start the agitator when the level in the 5th reactor (R5) increase up to overflow level.
 Maintain the temperature inside reactor (R5) at 130c
 Overflow of TPC crude mass is collected in crude holdup tank (V-01)
 Maintain the pressure in reactors (R1, R2, R3, R4, R5) below 0.122 kg/cm2 and monitor by PT.
control the feed if pressure is increased more then 0.122 kg/cm2.
 Flush all overflow line and pressure balance line with TC as and when required.
 Facility to drain each reactors mass to crude holdup vessel.
 Non condensable vent gas HCL and SO2 is send to HCL scrubbing section through vent buffer vessel.
 TC which is escaped with HCL and SO2 gases. This is recovered TC is collected in TC recovery tank
by condenser.
 Measure the quantity of recovered TC by Load cell by Level indicator. Transfer the mass of TC to TC
day collection tank.

 EMERGENCY CASE NO.01

 If pressure will increase in any of reactors (R1 TO R5) respective Rupture disc. Will be operated at 0.6
kg/cm2 set point.

 TC REMOVAL / LF REMOVAL SECTION

TC RECOVERY
 Ensure that all utility supply and return valve of TC condenser are open.
 Ensure TC / LF recovery vessel is empty.
 Ensure that inlet valve of recovered TC day tank open and outlet valve is closed.
 Take a partial vacuum in TC/LF recovery vessel and maintain in range of 300-720 mm hg
 When approximately 20% crude mass is resaved in TC / LF recovery vessel, start hot oil supply and
stirrer of vessel. Stop the transfer of crude mass when level in TC / LF recovery vessel be come 80-
90% of its total volume.
 Maintain top temperature At 50 – 100 c and bottom temperature at 130 – 155 c by hot oil.
 After TC recovery is completed relive partial vacuum from vessel.
 LF RECOVERY
 Ensure that utility supply and return vessel of LF condenser is open.
 Take a vacuum in TC / LF recovery vessel and LF receiver in range if 700-740 mm Hg
 Maintain set point in vessel of max. 155 c, bottom temp 140 – 160 c and top temp 50 – 150 c by hot oil
jacket.
 Higher fraction of LF is refluxed to TC / LF recovery vessel and its sample is given for colour
analysis. When colour become < 100 HU, the mass is transferred to distillation feed vessel by transfer
pump. In general practice, colour of the mass is checked by visual inspection and it is transferred to
distillation vessel.
 Lower fraction of LF is collected in LF receiver and it is reused is next batch.]

 DISSTILATION SECTION
 After finish the TPC crude transfer in crude holdup tank, close the discharge valve of TPC crude
transferred pump.
 Check the outlet valve of crude holdup tank.it should be closed at bottom.
 Check utility (LPS) supply for crude holdup tank, reside vessel, product receiver 1 and product
reservoir 2, product main storage tank.
 Check hot oil supply for product distillation vessel, residue vessel.
 Ensure vacuum for distillation vessel is maintained at 730 – 750 mm Hg
 Ensure that all equipment are clean, dry and decontaminated.
 check vapor outlet line is routed from product distillation vessel, to product vacuum buffer through
bero holdup vessel and product product distillation condenser.
 Start cooling water circulation in steam jet ejector condenser. Measure manometer reading . which
should be 730 – 750 mm Hg.
 Now, open bottom valve of crude hold up tank and start the transfer of TPC crude to product
distillation vessel by vacuum.
 Now start the agitator of distillation vessel and maintain the temperature from 120 – 135 c.
simultaneously start ejector system and open the vacuum supply valve of product vacuum buffer.
 Maintain 730 -750 mm Hg vacuum in distillation vessel and bottom temperature 140 – 150 c , top
temperature 120 – 140 c
 TPC will vaporized and reflux from distillation condenser.
 Crude TPC controlled approximately same as product condenser rate, by ejector vacuum system
 Collected product sample for analysis
 When distilled product catches dark colour, drain out residue or after 30 – 60 MTs of distilled TPC.
Residue collected in vessel.

 HCL SCRUBBING SECTION

 Ensure vent line is routed from Bubbler vessel to final scrubber.
 Check utility supply in each cooling water condenser
 Ensure suction and discharge of each HCL circulation pump
 Ensure that inlet and outlet of each cooling water condenser
 Start cooling water circulation in HCL absorber and heat exchanger in HCL scrubbing section.
 Open the gas inlet valve of bubbler vessel. Gas insert by deep pipe. If TC may carry out with HCL and
SO2 gas. It will decomposed in this vessel and gases go to washer tower. Note down the level.
 Ensure the all inlet and outlet valve of all HCL scrubber (A/B/C)
 Ensure all inlet and outlet valve of HCL scrubber heat exchanger are open (HE- A/B/C/D)
 Start circulation of cooling water in all HE
 Simultaneously start HCL circulation pump of HCL scrubber.
 HCL and SO2 will come from vent Buffer to HCL scrubber and only HCL scrubbed.
 When the density in 1st HCL scrubber reaches to 1150 kg/m3. 30% of HCL solution be transferred to
storage tank.

 RAW MATERIAL AND FINAL PRODUCT SAMPLE DATA

RAW MATERIAL
TPA 1200 KG IN SINGLE BATCH
TPP 10.9 KG IN SINGLE BATCH
TC 1950 TO 1995 IN SINGLE BATCH

 TPA RESULT

DESCRIPTION SPECIFICATION RESULTS

APPIARANCE WHITE CRYSTALINE WHITE CRYSTALINE
POWDER POWDER
P TOLUIC ACIC 200 MAX. PPM 150 MAX. PPM
ISOPHALIC ACID 100 MAX PPM NIL
PURITY 99.80 MIN. 99.985
 TPP RESULT

APPIARANCE WHITE CRYSTALINE WHITE CRYSTALINE

POWDER POWDER
MELTING POINT 70 TO 80 C 80 TO 81 C
ASSAY 99 99.8%

 TC RESULT

APPIARANCE COLOURLESS TO PALE COLOURLESS TO PALE

YELLOW CLEAR LIQUID YELLOW CLEAR LIQUID
WITH PUNGENT SMELL WITH PUNGENT SMELL
ASSAY 99.7 MIN 99.8%
SULPHAR CHLORIDE 0.15 MAX. 0.116 MAX
SOCL2 0.20 MAX. 0.068 MAX.
S02 - 0.45

 STEAM CONDENSATE DATA

REACTOR R1 R2 R3 R4
AVG 372 652.2 283.9 49.8
STEAM
/HR.
*(KGS)

 TEMERATURE DATA

REACTORS TEMPERATURE MOC CAPACITY

R1 70 MSGL 2 KL
R2 80 MSGL 3 KL
R3 90 MSGL 6.3 KL
R4 110 MSGL 6.3 KL
R5 130 MSGL 6.3 KL

 LF SECTION TIME SECTION

1. CRUDE LEVELING TIME: 2 TO 3 HRS

2. TC RECOVERY TIME : 12 TO 14 HRS
3. LF CUT REMOVEL TIME: 2 TO 3 HRS
4. LF CRUDE TRANSFER TIME: 2 HR
5. TOTAL TIME : 24 HR REQUIERD FOR 8 MT CRUDE

 BOTTOM TEMPERATURE DATA

1. FOR TC RECOVERY : 100 TO 140 C TEMP.

2. FOR LF REMOVEL : 140 TO 160 C TEMP.

 AFTER LF REMOVAL RESULT OF LOWER SECTION

APPIARANCE YELLOW
ASSAY 99.9%
DIMER 35
TPPO 103.9
LF IMPURITY 417.6 PPM
OTHER 197.8 PPM

 DISTILLATION SECTION

DISTILLATION RATE

 APPROXYMATLY 340 TO 350 KGS PER HRS

 CAPASITY : 8 MT/ DAY

 TEMPERATURE DATA OF DISTILLATION

 BOTTOM TEMPERATURE : 145 TO 160 C
 TOP TEMPERATURE : 130 TO 145 C

 FINAL AVERAGE RESULT OF RESIVER

COLOUR ASSAY TMC DIMER TPPO OTHER

(H.V) (%) (PPM) (PPM) (PPM) (PPM)
40 99.96 550 65 80 320

 SPECIAL EQUIPMENT USED IN ALL AUTOMATION INDUSTRY

 XV : USED FOR ON OFF SERVISE VALVE. CONTRLLED BY DCS

 TE : TEMPERATURE ELEMENT TO MEASURE TEMPERATURE
 LG : LEVEL GUAGE TO MEASURE LEVEL IN ANY VESSEL
 FV : FLOW CONTROL VALVE TO CONTROL THE FLOW OF ANY PROCESS LINE
 RTD: RETRACTABLE THERMOCUPLE
 HU : HAZEN SCALE
 UTILITY AND ETP PLANT

In a TML moistly used in utility

 LP STEAM
 AIR
 INSTRUMENT AIR
 BREATHING AIR
 NITROGEN

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

 FIRE & SAFETY

 Safety is becoming very important with every management as it has come to play a
very vital role in the modern development.
 Before many years, accidents were considered as acts of god and nature. Scientific
minded people have analyzed accidents and developed a separate engineering branch of
accident prevention .
 This analysis was required due to:

 Rising trend of accidents

 Increased use of machinery
 Increased material handling
 Lack of safety standard
 Lack to training
 Better reporting of accident
 SAFETY:

 Safe use of man, material and machine by safe system method of work is to achieve
zero accidents which results in higher productivity.

 ACCIDENT:

 An Accident is unplanned and unexpected events which interfere or interrupts the

planned process of work and results in personal injury.

 ACCIDENT FACTORS
1. A personal accident injury occurs as a result of an accident.
2. An Accident due to unsafe act and/or unsafe condition.
3. Unsafe act/unsafe condition exists due to fault of persons.
4. Fault of persons are due to negligence
Thus, if we can remove fault of persons, we can prevent 98% accidents.

 LIST OF SAFETY EQUIPMENTS:

 Safety Helmet

o White – Employee
o Blue – Visitors

o Yellow – Contractor

 Ear muff and ear plugs

 Goggles

 Hand Gloves

 Aprons

 Safety Shoes
  Safety Harness

 Dust Mask ( Highly hazardous chemical like CL2, BR2, NH3 etc.)

 GOLDEN RULES OF SAFETY:

1. Permit to work.

2. Energy isolation.

3. Ground disturbance.

4. Confined space entry.

5. Working at a height.

6. Lifting operation.

7. Driving safety.

8. Management of change.
 EMERGENCY

 DEFINITION:
 Emergency is defined as any situation which presents a threat to safety of
persons or property.
 Emergency (in industry) can be defined as one or more.

 Affect one or several plants.

 Cause serious injury to the person.

 Results in extensive damage to the property.

 TYPES OF EMERGENCY:

 Fire
 Explosion or blast
 Heavy leakage/spillage of chemical

 EMERGANCY SIREN TONE:

1. FIRE & OTHER EMERGNCY: - 20 sec, cycle wailing (on 20 sec & off 5 sec).
2. GAS LEAK: - Wailing sound for two minutes (60 sec on & 5 min off).
3. ALL CLEAR: - Continuous sound for two minutes.
4. TESTING: - Every Saturday at 11:00 O’clock (Continuous sound for two
minute).
 ASSEMBLY POINTS LOCATION:

1. Car parking near Gate.

2. SCM – Supply, Change & Management department.
3. Salt & Election department.
4. Cement plant main gate.
5. Make up water plant AR- 2 GATE.

 WHAT TO DO WHERE EMERGENCY OCCURS:

 You must know the escape routes.

 Do not run, this tends to cause panic.

 Do not get panicky, move to safe area.

 Play your role in orderly manner for combating the emergency, if you
can.
 Do not loiter unnecessarily.

 If you have no role to play move out of the area and reach to the safer
assembly point by seeing wind direction.
 Do not approach to emergency site as spectators.

 Do not engage communication channels (Phone etc.) unnecessarily.

 Do not approach control center unnecessarily for inquiry unless you

are required.
 Proceed in orderly manner to the safe assembly point when you are
instructed to do so.