A

Project Report
On
Pyridine-2-Ethanol (Phase I)
And
(Product Name) (Phase II)

Submitted in partial fulfilment toward the

Diploma’s Degree in the field of Chemical
Engineering
Prepared By
HARDIK HEMATBHAI KAMBARIYA
(DC010) (21DCDOG054)

Under the Guidance of

Prof. JAYMIN PATEL

Department of Chemical Engineering

Faculty of Technology, Dharmsinh Desai University
College Road, Nadiad – 387001
April - 2024

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 I

 CERTIFICATE

This is to certify that Hardik Hematbhai Kambariya (DC010) (21DCDOG054) has

duly submitted his Project report on Pyridine-2-Ethanol (Phase I) and product name
(Phase II) as a partial fulfilment toward Diploma’s Degree in Chemical Engineering at
Dharmsinh Desai University, Nadiad in the year 2024.

Prof. Jaymin Patel Dr. M. S. Rao

Assistant Professor Professor & Head

Dept. of Chemical Engg. Dept. of Chemical Engg.
DDU, Nadiad. DDU, Nadiad.

Date:- Date:-

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 II

 PHASE
III
Company Certificate

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 III

 PHASE IV

Company Certifica

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 IV

 DECLARATION
I Hardik Hematbhai Kambariya declare that, the project report on Pyridine-2-Ethanol for phase I
and (Product name for phase II) comprises my original work towards the degree of Diploma in
Chemical Engineering at Dharmsinh Desai University and is not copied from any published or
proprietary source. I further declare that this work is not submitted elsewhere towards degree or
diploma in any university or college. The whole content of this project work is genuine and
distinctive.

Kambariya Hardik

DC010 and 21DCDOG054

Semester VI
Department of Chemical
Engineering Faculty of Technology
Dharmsinh Desai University, Nadiad.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 V

 PREFACE
Industrial training fill gaps between theoretical knowledge from academics and the practical
knowledge. Practical give chance to learn new thing. In other words Practical experience is one of the
best type of experience that one can remember throughout the life. During Five semesters we have
enough learning of all chemical engineering aspect so vocational training in industry give good
learning chance and how to approach in corporate world. The man objective of vocational training is
to develop industrial knowledge and prepare self about industrial environment and HR practices in
the student. It increases the skill, ability and attitude of a student and boost confidence.
The main objective of the training report to get details of plant processes, unit operations,
general practice carried by every industry, technical aspects of equipment and instruments used in
chemical industry. So, every technical person have to gain some kind of training in related filed to
enhance knowledge.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 VI

 ACKNOWLEDGEMENT
I extend my heartfelt appreciation to my college mentor Mr. Jaymin Patel at Dharmshinh
Desai University-Nadiad, for their unwavering support, insightful guidance, and constructive
feedback throughout my internship report on chemical industries. Their expertise has been
instrumental in shaping my understanding of the subject.
I would also like to express my sincere thanks to Dr. M. S. Rao the Head of the Department at
Dharmshinh Desai University-Nadiad, for fostering an enriching academic environment and
providing the necessary resources for my project. Their encouragement has been pivotal in the
successful completion of this endeavour.
Furthermore, my sincere gratitude goes to Mr, Lalan Pandey (Production Manager) and the
dedicated workers at Jubilant Ingrevia Ltd. Their willingness to share their industry knowledge and
experiences has significantly enriched my learning during the internship. I am truly thankful for their
cooperation, which allowed me to gain valuable insights into the practical aspects of the chemical
industry.
Overall, I am deeply grateful to all those who contributed to this learning experience, making it a
truly enriching and fulfilling journey.
.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 VII

 PURPOSE OF INTERNSHIP

An internship in the chemical industry serves as a valuable opportunity for individuals to gain
practical, hands-on experience in a dynamic and critical sector of the economy. This experience
allows interns to bridge the gap between theoretical knowledge acquired in academic settings and the
real-world applications within the chemical industry. During an internship, individuals have the
chance to work alongside seasoned professionals, engaging in tasks that range from laboratory
experiments to process optimization and quality control. The chemical industry plays a pivotal role in
manufacturing a wide array of products, including pharmaceuticals, plastics, and specialty chemicals,
contributing significantly to global innovation and economic growth. Interns in this field not only
acquire technical skills but also develop a deep understanding of safety protocols, environmental
regulations, and the intricacies of efficient production processes. Moreover, the exposure gained
during an internship in the chemical industry provides interns with insights into the diverse career
paths available, fostering personal and professional growth as they contribute to the advancement of
science and technology in this vital sector.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 VII

 Weekly Work Overview

Week 1:
In the first week of my internship at Jubilant Ingrevia Ltd., I successfully completed the onboarding
process at the Admin Office, obtaining a permanent entry Gettpass and ensuring a smooth transition.
I received an introduction to the company, learning about its units and the area it covers. Safety
training covered fundamental principles, and I explored the functioning of emergency sirens. This
week set the foundation for a proactive and safety-conscious approach to my internship.
Week 2:
In my second week at Jubilant Ingrevia Ltd., I focused on safety and operational skills. I learned to
identify wind direction using the plant layout map and gained insights into specific personal
protective equipment. Engaging with Standard Operating Procedures, I studied sampling from the
autoclave and emergency shutdown procedures. Additionally, I delved into distillation,
understanding various columns and heat transfer mechanisms. This week enriched my practical skills
and deepened my comprehension of crucial processes within the company.

Week 3:
During my third week at Jubilant Ingrevia Ltd., I concentrated on waste management and production
understanding. I explored the SOP for hazardous waste disposal, documenting properties for effective
management. I also studied raw materials' properties and the overall production process. In-depth
examinations of Stages 1 and 2 provided insights into early production steps, and a comprehensive
look at Stages 3 and 4 contributed to a deeper understanding of the overall production workflow.
These activities significantly enhanced my knowledge in waste management and production
processes.

Week 4:
In my fourth week at Jubilant Ingrevia Ltd., I focused on process visualization and analysis. I
generated a comprehensive Process Flow Diagram, enhancing understanding of the production
sequence. Conducting Material Balance analysis for Stage 1 provided a quantitative insight into
material flow. I also created detailed Process Flow Diagrams for the Hot Oil utility and Steam
Utilization, offering clear visualizations of system interactions. These activities contributed
significantly to a more comprehensive grasp of intricate processes within the production workflow.

Week 5:
In week 5, I performed Material Balances for Raw Material Recovery (Stage 2) and Purification
(Stage 3). Additionally, I visited the Utilities Department to understand utility types and gained
insights into the Power Pack, which maintains autoclave seal pressure for efficient operations. These
activities enhanced my understanding of material utilization and operational dynamics within the
plant.
Week 6:
I explored the overview and functioning of the steam ejector, understanding its role in the plant's
operations. I delved into the process of generating vacuum in the reactor and studied the various
types of valves and pumps utilized in our plant, contributing to my knowledge of fluid control
systems. Additionally, I visited the cooling tower section to gain insights into its operations and
further enhance my understanding of the plant's infrastructure and processes.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 IX

Week 7:
I visited the ETP (Effluent Treatment Plant) section, gaining insights into waste management
processes. I conducted a study on different types of distillation techniques and obtained an overview
of incinerators, deepening my understanding of waste disposal methods. Additionally, I visited the
Boiler section, expanding my knowledge of the plant's energy systems. These experiences provided
valuable exposure to diverse aspects of the plant's operations and infrastructure.

Week 8:
In my final week of the internship at Jubilant Ingrevia Ltd., I focused on concluding the program by
completing administrative tasks. I collected the internship certificate from the company, marking the
formal acknowledgment of my participation and contributions. Additionally, I dedicated time to
compiling a comprehensive written report summarizing my experiences, learnings, and achievements
throughout the internship. This report serves as a reflective document, capturing the skills acquired,
challenges overcome, and the overall impact of the internship on my professional development. As I
wrapped up the final administrative aspects and documentation, I reflected on the valuable insights
gained and the meaningful contributions made during my time with the company.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 X

 INDEX
CERTIFICATE...........................................................................................................II
DECLARATION…......................................................................................................V
PREFACE....................................................................................................................VI
ACKNOWLEDGEMENT.......................................................................................VII
PURPOSE OF INTERNSHIP................................................................................VIII
WEEKLY WORK OVERVIEW..............................................................................IX
LIST OF TABLE.....................................................................................................XIII
LIST OF FIGURE...................................................................................................XIV
CONTENTS PAGE
NO.
1. Introduction...................................................................................................................................15
1.1. Company Details.....................................................................................................................15
1.2. History of Company................................................................................................................15
1.3. Vision & Mission.....................................................................................................................15
1.4. Core Value...............................................................................................................................15
1.5. Organization Structure.............................................................................................................16
2. About Training Plant....................................................................................................................17
2.1. Company Details.....................................................................................................................17
2.2. Product List and It’s Capacity.................................................................................................19
2.3. Process Selection.....................................................................................................................19
2.4. Market Value...........................................................................................................................19
2.5. Raw Material of Pyridine-2-Ethanol.......................................................................................19
2.6. Properties of Pyridine-2-Ethanol.............................................................................................20
2.7. Stability And Reactivity of Pyridine-2-Ethanol......................................................................20
2.8. Properties of Raw Material......................................................................................................20
3. Process Details...............................................................................................................................24
3.1. Introduction to Process............................................................................................................24
3.2. Raw Material...........................................................................................................................24
3.3. Chemical and Physical Properties of Product..........................................................................24
3.4. Chemical Reacrtion..................................................................................................................25
3.5. Block Diagram of Process.......................................................................................................25
3.6. Process Flow Diagram of Plant...............................................................................................26
3.7. Process Description.................................................................................................................27
3.8. Major Engineering Problem....................................................................................................28
3.9. Advantages and Disadvantages of Pyridine-2-Ethanol...........................................................28
3.10. Application of Pyridine-2-Ethanol................................................................................29
3.11. Handling and Storage....................................................................................................29

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 XI

 3.12. Material Balance...........................................................................................................29
4. Major Equipments and Instrumentation....................................................................................32
4.1. Major Equipment.....................................................................................................................32
4.2. Major Instrument.....................................................................................................................41
5. Process Utilities.............................................................................................................................43
5.1. Introduction to Plant Utilities..................................................................................................43
5.2. Types of Utilities in Plant........................................................................................................43
5.2.1. Cool Water....................................................................................................................43
5.2.2. Steam............................................................................................................................45
5.2.3. Hot Oil..........................................................................................................................47
6. Health, Hazards and Safety.........................................................................................................49
6.1. Introduction to Health, Hazard and Safety..............................................................................49
6.2. Industrial Hazard.....................................................................................................................49
6.3. Personal Protective Equipments..............................................................................................50
6.4. General Dos and Don’ts..........................................................................................................52
6.5. Safety Diamond and Symbols.................................................................................................53
7. Plant Location and Layout..........................................................................................................55
7.1. Plant Location..........................................................................................................................55
7.2. Plant Layout.............................................................................................................................56
8. Environmental Aspect..................................................................................................................58
8.1. Environment, Health & Safety Policy....................................................................................58
8.2. Pollution Prevention Control...................................................................................................58
8.3. Effluent Treatment Plant.........................................................................................................59
9. Conclusion.....................................................................................................................................61
10. References......................................................................................................................................62

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 XI

 List of Table
Table No. Content Page No.

2.1 Company Details 17

2.2 Product List 19
2.3 Raw Material & Its Capacity 19
2.4 Properties of Pyridine-2-Ethanol 20
2.5 Properties of Alpha picoline 21
2.6 Properties of P-Formaldehyde 21
2.7 Properties of Acetic Acid 22
2.8 Properties of Catechol 22
3.1 Properties of Product 24
3.2 Material Balance Stage 1 30
3.3 Material Balance Stage 2 31
3.4 Material Balance Stage 3 31

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 XII

 List of Figures
Figure No. Content Page No.

1.1 Organization Structure 16

2.1 Water Requirement as per Annexure 1 23
3.1 Chemical Reaction 25
3.2 Block Diagram of Process 25
3.3 Process Flow Diagram of Plant 26
4.1 SS and Glass lined Reactor 32
4.2 Vertical Condenser 34
4.3 Packed Distillation Column 35
4.4 Steam Ejector 36
4.5 Centrifugal Pump 37
4.6 Reciprocating Pump 38
4.7 Rotary Pump 38
4.8 Diaphragm Plant 38
4.9 Gate Valve 39
4.10 Ball Valve 39
4.11 Butterfly Valve 40
4.12 Check Valve 40
4.13 Globe Valve 40
4.14 Piston Valve 41
4.15 Temperature Indicator 41
4.16 Pressure Guage 41
4.17 Flow Indicator 42
4.18 Rotameter 42
5.1 Forced Draft Cooling Tower 44
5.2 Water Tube Boiler 46
6.1 Example of PPEs 52
6.2 Safety Diamond 53
6.3 Safety Symbols 54
7.1 Plant Layout 57
8.1 Effluent Treatment Plant 59

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 XI

 CHAPTER 1: INTRODUCTION

CHAPTER 1: INTRODUCTION

1.1 Company Details:

Jubilant Infrastructure Limited has successfully developed a specialized SEZ dedicated to the
chemical industry, covering an expansive 310.66 acres in the Vilayat GIDC Industrial Estate of
Bharuch District, Gujarat. This operational facility marks a significant milestone in Jubilant
Infrastructure Limited's commitment to advancing industrial progress and innovation.
Jubilant Ingrevia offers a comprehensive range of high-quality ingredients, catering to industries
worldwide. With a global presence, the company is a reliable partner for clients seeking excellence in
their products and processes. The versatility of Jubilant Ingrevia's offerings is evident in their
applications across pharmaceuticals, nutrition, agrochemicals, and various other sectors.

1.2 History of Company:

The life sciences segment of the company, now known as Jubilant Ingrevia, has been an integral part
of the business since its inception in 1978. Over the years, Jubilant Ingrevia Ltd (JVL) has evolved
into a prominent player in the field of chemistry, establishing itself as a globally integrated provider
of life science products and innovative solutions.
With a robust presence in over 35 chemical platforms, Jubilant Ingrevia stands as a testament to the
company's extensive expertise in the realm of chemistry. This diverse range of chemical platforms
positions the company among the leaders in the country, showcasing its comprehensive capabilities.

1.3 Vision & Mission:

 Vision:
To be a global leader in creating the safest workplace through excellence in health & safety
practices.
 Mission:
We are committed to sustainable business operations through: Asset integrity, operational
discipline leveraging technology, building new competencies and empowering our employees,
contract workers and business partners.

1.4 Core Value:

 Safety First:
It overrides all other priorities and we are committed to preventing all accidents.
 Empower employees:
All employees and associates are fully empowered to enforce safety at all our facilities.
 Build Competency:
Enable our employees and associates to build safety competency and thereby positively influence
risk perception.
 Zero Tolerance:
Comply to standard operating procedures and defined system.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 15

 CHAPTER 1: INTRODUCTION

1.5 Organization Structure:

PRODUCTION MANAGER

DEPUTY MANAGER

SHIFT IN CHARGE

CHEMIST

LABOUR

FIGURE 1.1 ORGANIZATION STRUCTURE

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 16

 CHAPTER 2: ABOUT TRAINING PLANT

CHAPTER 2: ABOUT TRAINING PLANT

2.1 Company Details:

 Brief Description of the Project Nature, Size, Location of the Project and Its Importance to the
Country, Region.

TABLE 2.1 COMPANY DETAILS

Sn. Particulars Details

1 Name of project & Address  UNIT: 1 (Fine Chemicals)
Jubilant Infrastructure
Limited
Plot No, 5, GIDC Rd, Vilayat,
Aragama Gujarat-392160
2 Products Sr. No. Product Capacity
1. 2-pyridineethanol 540 TPA
3 By-Products -
4 Raw Materials Sr. No. Raw Material Capacity
(Kg/batch)
1. A-picoline 3800
2. P-Foemeldehyde 300
3. Catechol 6
4. Acetic Acid 600

5 Latitude (N) Longitude (E) 21.7829° N, 72.8930° E

6 Water Requirement & Sr. No. Water Requirement Capacity

Source of water (KLD)
1. In Process 400
2. Domestic 200
3. Gardening 50
4. Boiler 350
5. Cooling Tower 2300
6. Water for DM Plant & softener 100
Regeneration
7. Plant Miscellaneous 100
 Total Water Requirement 3500

 Recovered from ETP. 600

 Source: Narmada Rever
7 Wastewater Generation Sr. No. Wastewater Capacity
Details (KLD)
1. Domestic 170
2. Process 430

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 17

 CHAPTER 2: ABOUT TRAINING PLANT

3. Plant Miscellaneous 70
4. Cooling Tower 330
Blow Down

- Total 1000
8 Man power Sr. No. Manpower Qantity

1. During construction 800 Nos.

phase
2. Operation Phase 3000 Nos.
9 List of Utilities 1. Cold Oil
2. Nitrogen
3. Air
4. Water
5. Electricity
6. Steam
7. Hot Oil
10 Air emissions Detail Sr. No. Air emissions
1. Thermic Fluid Heater
2. Emission from Process Vents/Raw
material Storage
3. Hot Oil Boiler
4. Fugitive emission
5. Diesel Generating for Emergency
Backup
11 Hazardous waste Generation Sr. No. Hazardous waste
Details 1. Used spent oil
2. Spent catalyst
3. Spent filter aid
4. Packing material, empty containers
etc
5. Waste containing oil
6. Corrosive plant
7. Waste insulation material
8. Contaminated Solvents
9. Spent solvents
10. Spent carbon
11. Organic contaminate aqu. phase.
12. Organic residue from process,
solvent recovery, etc.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 18

 CHAPTER 2: ABOUT TRAINING PLANT

2.2 Product List and It’s Capacity:

TABLE 2.2 PRODUCT LIST

Sr. Product Name Capacity

No. (TPA)
1. Amino Caustic 720
2. Pyridines & Derivatives 360
3. Cyano Pyridine 18000
4. Niacinamide 15000
5. Amino Methyl Pyridine 360
6. Collidine 720
7. Lutidines 300
8. Di Methyl Piperidines& Derivatives 350
9. Methyl Piperidines& Derivatives 120
10. Amino Methyl Pyridines & Derivatives 261
11. Ethyl Methyl Pyridines & Derivatives 180
12. Piperidines& Derivatives 350
13. Beta Picoline - High Purity 3600
14. Carboxylic Acid Ethyl Esters Derivatives 120
15. Aliphatic /Halogenated Derivatives 35
2.3 Process Selection:
 The choice of the process depends on various factors, such as the availability and cost of the
raw materials, the efficiency and safety of the reaction, the quality and quantity of the
product, and the environmental impact of the process. A comparative analysis of the two
processes can help to select the most suitable one for a specific application.

2.4 Market Value:

 Pyridine-2-ethanol: ₹750/kg

2.5 Raw Material of Pyridine-2-Ethanol:

TABLE 2.3 RAW MATERIAL & IT’S CAPACITY

Sr. Name Capacity

No. Kg/Batch
1. Alpha Picoline 3800
2. P-Formaldehyde 300
3. Acetic Acid (Intermediate) 60
4. Catechol (Catalyst) 6

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 CHAPTER 2: ABOUT TRAINING PLANT

2.6 Properties of Pyridine-2-Ethanol:

TABLE 2.4 PROPERTIES OF PYRIDINE-2-ETHANOL

Sr. Parameter Typical value

No.
1. Appearance Clear brown liquid
2. Odor Not available
3. Melting point -7.8℃
4. Boiling point 225℃
5. Flash point 92℃
6. Vapor pressure 10 mbar @ 105℃
7. Specific gravity 1.091 @ 25℃
8. Solubility Very soluble in alcohol, chloroform; soluble in water,
slightly soluble in ether
9. PH (100g/lit) @ 20℃ 8-9 100 g/L aq. Sol.
10. Auto Ignition Temp. Not available
11. Decomposition temp. 150℃
12. Viscosity 30 mPa 20℃
13. Molecule Weight 123.13
14. Flammable Material No
15. Oxidizer No
16. Corrosive Material No
17. Explosive Material No
18. Molecular formula C7H9NO
19. Chemical Structure

2.7 Stability & Reactivity of Pyridine-2-Ethanol:

 Chemical Stability: Stable at room temperature in closed Containers under normal storage
and Handling conditions. Hygroscopic: absorb moisture from the air.
 Conditions to Avoid: Incompatible materials, light, ignition sources, moisture, excess heat,
strong oxidants.
 Incompatibilities with Other Materials: Strong oxidizing agents, strong acids, strong bases.
 Hazardous Decomposition Products: Carbon monoxide, oxides of nitrogen, irritating and
toxic fumes and gases, carbon dioxide.

2.8 Properties of Raw Material:

2.8.1 Properties of Alpha Picoline:

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 20

 CHAPTER 2: ABOUT TRAINING PLANT

TABLE 2.5 PROPERTIES OF ALPHA PICOLINE

Sr. Parameter Typical Value

No.
1. Molecule formula C6H7N
2. Molecular Weight 93.13
3. Physical state Liquid
4. Color Colorless
5. Odor Strong unpleasant odor
6. Melting point -70℃
7. Boiling point 128-129℃
8. Density 0.950 g/ml
9. Solubility Freely soluble in water; miscible with alcohol
10. Chemical Structure

2.8.2 Properties of P-Formaldehyde:

TABLE 2.6 PROPERTIES OF P-FORMALDEHYDE

Sr. Parameter Typical Value

No.
1. Molecule formula CH2O
2. Molecular Weight 30
3. Physical state Solid
4. Colour White to off-white
5. Odor Odor of Formaldehyde
6. Melting point 120-170℃
7. Boiling Point 107.25℃
8. Density 0.88 g/ml @ 25℃
9. Flash point 158℃
10. Solubility Soluble In Chlorophenol above 70℃; miscible in
water.
11. Chemical Structure

2.8.3 Properties of Acetic Acid:

TABLE 2.7 PROPERTIES OF ACETIC ACID

Sr. Parameter Typical Value

No.

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 21

 CHAPTER 2: ABOUT TRAINING PLANT

1. Molecule formula C2H4O2

2. Molecular Weight 60
3. Physical state Liquid
4. Colour Colourless
5. Odor Pungent
6. Melting point 16.2℃
7. Boiling Point 117-118℃
8. Density 1.049 g/lit
9. Solubility Miscible in water.
10. Flash point 104℉
11. Chemical Structure

2.8.4 Properties of Catechol:

TABLE 2.8 PROPERTIES OF CATECHOL

Sr. Parameter Typical Value

No.
1. Molecule formula C6H6O2
2. Molecular Weight 110.11
3. Physical state Solid
4. Colour White to faintly beige
5. Flash point 279℉
6. Melting point 100-103℃
7. Boiling Point 245℃
8. Density 1371 g/cm3
9. Solubility Soluble in water.
10. Chemical Structure

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 22

 CHAPTER 2: ABOUT TRAINING PLANT

2.9 Water Requirement (Annexure: 1):

FIGURE 2.1 WATER REQUIREMENT AS PER ANNEXURE 1

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 23

 CHAPTER 3: PROCESS DETAIL

CHAPTER 3: PROCESS DETAIL

3.1 Introduction to Process:

First of they are issue raw material from RM store as per batch planning & than they are send
material in QA department for testing and checking quality of materials. After checking they are
issued material from QA department and batch started as per batch process record. And then
final output will go to the next stage.
Finished product will go to in GMP (Good Manufacturing Practice) module. Final shifting,
milling & micro grinding done in GMP module. Then after final product send in to the finished
goods store.

3.2 Raw Material:

 Α-Picoline (Liquid)
 P-Formaldehyde (Solid)
 Catechol (Catalyst)
 Acetic Acid (Intermediate)

3.3 Chemical & Physical Properties of Product:

TABLE 3.1 PROPERTIES OF PRODUCT

Sr. Parameter Typical value

No.
1. Appearance Clear brown liquid
2. Odor Not available
3. Melting point -7.8℃
4. Boiling point 225℃
5. Flash point 92℃
6. Vapor pressure 10 mbar @ 105℃
7. Specific gravity 1.091 @ 25℃
8. Solubility Very soluble in alcohol, chloroform; soluble in water,
slightly soluble in ether
9. PH (100g/lit) @ 20℃ 8-9 100 g/L aq. Sol.
10. Auto Ignition Temp. Not available
11. Decomposition temp. 150℃
12. Viscosity 30 mPa 20℃
13. Molecule Weight 123.13
14. Flammable Material No
15. Oxidizer No
16. Corrosive Material No
17. Explosive Material No
18. Molecular formula C7H9NO
19. Chemical Structure

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 24

 CHAPTER 3: PROCESS DETAIL

3.4 Chemical Reaction:

FIGURE 3.1 CHEMICAL REACTION

3.5 Block Diagram of Process:

FIGURE 3.2 BLOCK DIAGRAM OF PROCESS

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 25

 CHAPTER 3: PROCESS DETAIL

3.6 Process Flow Diagram Of Plant:

FIGURE 3.3 PROCESS FLOW DIAGRAM OF PLANT

HARDIK KAMBARIYA, INTERNSHIP REPORT, 2024 26

 CHAPTER 3: PROCESS DETAIL

3.7 Process Description:

3.7.1 Stage 1 (Slurry preparation):
 Vessel should be clean and dry and valve should be closed.
 Charge Alpha Picoline.
 Charge Para Formaldehyde.
 Start agitator and add Catechol in vessel by hopper.
 Close vent valve and apply vacuum in vessel and add acetic acid at 20-25℃, break vacuum by
N2 Pressure.
 Transfer shear mass to Auto clave.
 Flush vessel with Alpha picoline, transfer Alpha Picoline to Auto Clave.
 Start agitator of Autoclave and add Hot oil in Autoclave.
 Maintain the reaction mass for 60-90 Min. after this start cooling.
 After maintain withdraw the sample from AC & send sample for appearance.
 If result not compile then start heating by hot oil circulation in the jacket temp. 165-167℃.
 Maintain 165-167℃ for 30-60 Min. send sample for Every 1 Hours.
 If result compile cooling with cold oil bellow 55℃.
 Start depressurization Autoclave by control valve and check scrubber level.
 Transfer the reaction mass through vessel by N2 pressure.

3.7.2Stage 2 (Alpha recovery):

Reactor 1 should be clean and dry.
Charge reaction mass of Stage 1 to Reactor 1.
Start agitator and charge catechol in reactor 1.
Apply vacuum 700 mmHg in reactor 1.
Increase slowly temp. in reaction start recovery of unreacted Alpha picoline by maintaining
mass temp. up to 85℃ in vessel 1.
 After recovered A-Picoline about 70-80% recovery further increased the mass temp. of 85-
100℃ and collect the Alpha picoline in vessel 2.
 Meanwhile, send sample of recovered Alpha picoline to IPQC for Appearance
informative moisture content, unload the reactor concentrated mass in vessel 3.
3.7.3 Stage 3 (Pot to Pot Distillation):
 Ensure the reactor 2 should be clean and dry. Bottom valve and transferring valve should be
closed.
 Charge Pyridine-2-Ethanol concentrated mass in Reactor 2 from Vessel 3.
 Start agitator and charge catechol in reactor 2 by charging.
 Take vacuum up to 700mmHg.
 Heat the mass by applying the hot oil circulation and start pre-cut collection up to 120℃, send
sample of precut for related substance, unload in Tank 1.
 Start collection of main cut at 135℃, unload in Tank 2, send sample for Purity check.
 After main cut start post cut at 150℃ and send sample for purity and related substance,
unload In Tank 3.

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3.7.4 Stage 4 (Pure Distillation):

 Charge Pyridine-2-Ethanol crude From Tank 2 to Distillation Colum.
 Take vacuum more than 700 mmHg.
 Start Collecting pure Pyridine-2-Ethanol at 120-130℃.
 Remove residue to the Residue Tank.
 Then residue goes in Incinerator.

3.8 Major Engineering Problem:

 The reaction of alpha picoline and paraformaldehyde requires a catalyst, such as catechol, to
increase the rate and selectivity of the formation of 2-pyridinecarboxaldehyde. However, the
catalyst may also cause side reactions, such as the formation of by-products or the
degradation of the product. Therefore, the choice and amount of the catalyst need to be
optimized to minimize the negative effects.
 The reaction of alpha picoline and paraformaldehyde also requires an alkali, such as sodium
hydroxide, to neutralize the acid generated during the reaction. However, the alkali may also
affect the pH and the solubility of the reactants and the product. Therefore, the type and
concentration of the alkali need to be controlled to maintain the optimal conditions for the
reaction.
 The hydrolysis of 2-pyridinecarboxaldehyde acetate to 2-pyridineethanol requires a base, such
as sodium hydroxide or potassium hydroxide, to cleave the ester bond and form 2-
pyridineethanol and acetic acid. However, the base may also cause the dehydration of 2-
pyridineethanol to 2-vinylpyridine, which is an undesired product. Therefore, the temperature
and time of the hydrolysis need to be regulated to avoid the loss of 2-pyridineethanol.
 The purification of 2-pyridineethanol from the reaction mixture may involve distillation,
extraction, crystallization, or other separation techniques. However, these techniques may
also cause the evaporation, decomposition, or contamination of 2-pyridineethanol. Therefore,
the operating parameters and the quality of the materials need to be monitored to ensure the
purity and yield of 2-pyridineethanol.

3.9 Advantages & Disadvantages of Pyridine-2-Ethanol:

3.9.1 Advantage:
 It is a useful intermediate for the synthesis of various pharmacological agents and insect repellents.
 It can be prepared by different methods, such as the catalytic hydrogenation of 2-
pyridinecarboxaldehyde or the hydrolysis of 2-pyridineethanol acetate.
 It can be purified by various techniques, such as distillation, extraction, crystallization, or other
separation techniques.
 It has a low boiling point and a high density, which makes it easy to handle and store.

3.9.2Disadvantages:
It is combustible and forms explosive mixtures with air on intense heating.
It causes skin irritation, serious eye irritation, and respiratory irritation.
It may undergo side reactions, such as dehydration, degradation, or formation of by-products,
depending on the reaction conditions and the catalysts used.
 It may require complex and costly purification techniques to remove the impurities and the
unreacted materials.

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3.10 Application of Pyridine-2-Ethanol:

 It is a useful intermediate for the synthesis of various pharmacological agents and insect
repellents.
 It is used to prepare mononuclear nickel acetate, which is a catalyst for the hydroformylation
of olefins.
 It is used to synthesize mesoridazine, thioridazine, and betahistine hydrochloride, which are
antipsychotic and antihistamine drugs.

3.11 Handling & Storage of Pyridine-2-Ethanol:

3.11.1 Handling:
 Wear protective gloves/clothing and eye/face protection.
 Do not breathe vapours or spray mist.
 Avoid contact with skin and eyes  Avoid contact with clothing
 Wash thoroughly after handling.
 Ground and secure containers when dispensing or pouring product.
 Avoid contact with incompatible materials.
 When handling, DO NOT eat, drink or smoke.
 Launder contaminated clothing before re-use.
 Keep away from open flames, hot surfaces and sources of ignition.
 If on skin or hair, remove all contaminated clothing and rinse/shower with plenty of water.
 Use in a well-ventilated place/Use protective clothing commensurate with exposure levels.

3.11.2 Storage:
 Keep container tightly closed.
 Store at ambient temperature in dry and well-ventilated place.
 Ensure adequate ventilation during use.
 Keep away from heat and sources of ignition.

3.12 Material Balance:

3.12.1 Stage 1 Reaction section:
 Chemical Reaction: C6H7N + CH2O C7H9NO
 Basis:
A-picoline = 3800 Kg
P-Formaldehyde = 300
Kg Acetic Acid = 60 Kg
Catechol = 6
A-Picoline
Kg
3800 Kg
Pyridine-2-Ethanol 20%
Autoclave

P-Formaldehyde
300 Kg

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 Molecular Weight of Alpha Picoline = 93.

 Molecular Weight of 2-pyridineethanol = 123.
 Concentration of Pyridine-2-Ethanol = 20% = 820 Kg.
 A-picoline = 75% = 3075 Kg
 By Product = 3.5% = 143.5 Kg
 Residue = 127.5 Kg

1 mole of A-picoline ≅ 1 mole of Pyridine-2-Ethanol

123 kg of Pyridine-2-Ethanol ≅ 93 kg of A-picoline
820 kg of Pyridine-2-Ethanol ≅ ?

Required raw material A-picoline = (93*820)/123 = 620 Kg

 Total A-picoline convert 20% = 760 Kg.
 620 kg A-picoline is convert to main product.
 140 kg A-picoline is convert to by product.

TABLE: 3.2 MATERIAL BALANCE STAGE 1

Input Output
A-picoline = 3800 Kg Product = 820 Kg
P-formaldehyde = 300 kg A-picoline = 3075 Kg
Acetic Acid = 60 Kg By Product = 143.5 Kg
Catalyst = 6 Kg Residue = 127.5 Kg
Total = 4166 Kg Total = 4166 Kg

3.12.2 Alpha recovery section:

 Basis: Feed 4100 Kg.

Distillate 3034 Kg
Feed 4100 kg 98% A-picoline
75% A-picoline
A-
picoline
recovery
1066 Kg
 Concentration of A-Picoline = 75% of Crude
 Concentration of A-Picoline =
98% Feed (F) = 4100 Kg
Distillate (D) =3034 Kg
xf = 0.75
xd = 0.98
xw = ?
w=?

F=D+W
4100 = 3034 + W

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W = 1066 Kg

Fxf = Dxd + Wxw

(4100*0.75) = (3034*0.98) + (1066*xw)
xw = 0.095
 Concentration of residue of A-picoline = 9.5

TABLE 3.3 MATERIAL BALANCE STAGE 2

Input Output
Feed = 4100 Kg A-picoline Recovery = 3034 Kg
Product = 1066 Kg

3.12.3 Purification Section:

 Basis: Feed of Pyridine-2-Ethanol crude = 1066 kg
 Distillate
Feed 1066 kg 99% Pyridine-2-Ethanol
70% Pyridine-2-Ethanol
Distillation

 Moles of feed = 8.13008 Moles Residue

 Concentration of Feed = 70 % 2% Pyridine-2-Ethanol
 Pyridine-2-Ethanol Concentration in distillate =
99% F = 1066 Kg
D=?
W=?
xw = 0.02
xd = 0.99
xf = 0.7

F=D+W
1066 = D + W Eq. 1

Fxf = Dxd + Wxw

(0.7*1066) = 0.99D + 0.02W Eq. 2
 By solving Eq. 1 & Eq. 2 we
get, D = 749.298 Kg of Distillate.
W = 316.702 Kg of Residue.

TABLE 3.4 MATERIAL BALANCE STAGE 3

Input Output
Feed = 1066 Kg D = 749.29 Kg
W = 316.70 Kg

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CHAPTER 4: MAJOR EQUIPMENT & INSTRUMENT

4.1 Major Equipments:

 Introduction:
he chemical industry relies on essential equipment such as reactors for chemical reactions,
distillation columns for separation, pumps and compressors for fluid management, heat
exchangers for temperature control, and storage tanks for material storage. Together, these
components form a vital infrastructure that drives the production and refinement of
chemicals. Below Mentioned Equipment use in our Plant:
1. Stainless stell and Glass lined Reactor
2. Vertical Condenser
3. Packed Distillation Column
4. Steam Ejector
5. Types of Pump
6. Types of Valve
4.1.1 Stainless steel and Glass lined Reactor:
 Principle:
The principle of stainless steel and glass lined reactor is to use different materials of
construction (MOC) for the reactor body depending on the type and nature of the reaction
mass. The reactor body is the part of the reactor that is in contact with the reaction mass and
is subjected to various physical and chemical effects.

 Figure:

FIGURE 4.1 SS & GLASSLINED REACTOR

 Construction:

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Stainless steel reactors are made of stainless steel, which is an alloy of iron, chromium,
nickel, and other elements. Stainless steel has high strength, corrosion resistance, and
durability. It can withstand high temperatures, pressures, and mechanical stresses. Stainless
steel reactors are usually cylindrical or spherical in shape, with a jacket or coil for heating or
cooling. They have a lid or a manhole for loading and unloading the reactants and the
product, and various nozzles for connecting pipes, valves, sensors, and other accessories.
Glass lined reactors are made of carbon steel with a thin layer of glass coating on the inner
surface. The glass coating is composed of silicon and other elements that form a dense and
uniform enamel. Glass has high chemical resistance, inertness, and anti-sticking properties. It
can protect the reaction mass from contamination and the reactor body from corrosion. Glass
lined reactors are usually cylindrical in shape, with a jacket or coil for heating or cooling.
They have a lid or a manhole for loading and unloading the reactants and the product, and
various nozzles for connecting pipes, valves, sensors, and other accessories.
 Working:
The working of a stainless steel and glass lined reactor combination is similar to the working
of a stainless-steel reactor or a glass lined reactor, depending on the material of construction
(MOC) of the reactor part. The reactants are placed in the reactor body, which is heated or
cooled by the jacket or coil. The reaction mass is mixed by the stirrer or agitator, and
monitored by the sensors. The product is discharged from the reactor body by opening a valve
or a pipe. The advantage of a stainless steel and glass lined reactor combination is that it
combines the benefits of both materials. Stainless steel has high strength, corrosion resistance,
and durability. It can handle high temperatures, pressures, and mechanical stresses. Glass has
high chemical resistance, inertness, and anti-sticking properties.
4.1.2 Vertical Condenser:
 Principle:
The principle of vertical condenser is to use a high-level jet condenser with a vertical
discharge pipe. In this condenser, the steam enters at the bottom and flows in upward
direction and meets with the down coming cooling water. The heat transfer between the steam
and the water causes the steam to condense and the water to heat up. The mixture of
condensate and water is discharged through the vertical pipe by the action of gravity and
vacuum.
 Figure:

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FIGURE 4.2 VERTICAL CONDENSER

 Construction & Working:

It consists of a cylindrical shell in which a number of tubes are arranged in parallel and held
in place at the ends by tube sheets. The steam enters at the bottom and flows in upward
direction and meets with the down coming cooling water. The heat transfer between the
steam and the water causes the steam to condense and the water to heat up.

4.1.3 Packed Distillation Column:

 Principle:
The principle of packed distillation column is to use a cylindrical vessel filled with packing
materials that enhance continuous mass transfer between two feed fluids (liquid-liquid or
gas- liquid) by effectively increasing the contact surface area. Typically, one of the fluids
preferentially wets the packing, flowing as a film over its surface while the second fluid
flows over the remaining volume of the vessel.

 Figure:

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FIGURE 4.3 PACKED DISTILLATION COLUMN

 Construction:
Packings promote contact between two fluids inside flowing either counter currently or co-
currently. The packings can be made of metal, plastic, or ceramic. They can also either be in
random or structured arrangement.
Spray distribution system spreads the liquid feed evenly across the top of the packing.
Packing support allows the liquid being sprayed to drain away from the packing and acts as
an inlet where the gas can pass through the tower’s section.
Demister prevents entrained liquid droplets from leaving the tower alongside the gas stream.
Vessel or tower holds the rest of the components, usually cylindrical and made of steel.
Depending on the intended use, the vessel can be coated to resist corrosion and other harmful
effects.

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 Working:
the liquid is the wetting fluid while the gas/vapor rises through the column making close
contact with the down coming liquid through the packings’ surface. In distillation set-ups
such as in fractional distillation, the more volatile component of a mixture progressively
transfers to the vapor phase while the less volatile component condenses out into the liquid.
For liquid- liquid extraction, the solute is transferred to the solvent as the fluids come in
contact with each other in the surface of the packings.

4.1.4 Steam Ejector:

 Principle:
A steam ejector operates on the principle of utilizing high-pressure steam to create a vacuum
or lower pressure in a system.
 Figure:

FIGURE 4.4 STEAM EJECTOR

 Construction:
It consists of two or more single-stage ejectors connected in series, with inter-condensers
between each stage. The inter-condensers cool and condense the steam from the previous
stage, reducing the load on the subsequent stage. The multi-stage ejector can achieve higher
vacuum and lower steam consumption than the single-stage ejector.
 Working:
A steam ejector operates by harnessing the kinetic energy generated through the expansion
of high-pressure steam. The process begins as steam enters the ejector through a nozzle,
undergoing rapid expansion and gaining considerable velocity. This high-speed steam jet

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creates a region of low pressure, commonly known as the suction or mixing chamber, due to
the Venturi effect. In this low-pressure zone, gases or vapours from the system to be
evacuated are drawn into the ejector. The high-velocity steam mixes with these gases,
leading to their compression and an increase in velocity. The combined stream then enters a
diffuser section, where it expands, and its velocity decreases. The compressed mixture is
eventually directed to the exhaust, where it is released to the atmosphere or to the next stage
in the process. Notably, steam ejectors are valued for their simplicity, reliability, and absence
of moving parts, making them suitable for applications involving corrosive or abrasive
substances. The efficiency of a steam ejector is influenced by factors such as steam pressure,
nozzle and diffuser design, and the properties of the gases being evacuated. Overall, the
working principle of a steam ejector revolves around the conversion of steam energy into
kinetic energy, creating a vacuum that enables the removal of gases or vapours from a
system.

4.1.5 Types of Pumps:

 Centrifugal Pumps:
Principle: Centrifugal force is used to impart kinetic energy to the fluid, and a rotating
impeller increases the fluid's velocity.
Applications: Commonly used for water supply, wastewater treatment, and in various
industrial processes.
Figure:

FIGURE 4.5 CENTRIFUGAL PUMP

 Reciprocating Pumps:
Principle: Piston or diaphragm moves back and forth to create a pressure difference, causing
fluid to move.
Applications: Often used for high-pressure applications, such as hydraulic systems and some
metering applications.
Figure:

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FIGURE 4.6 RECIPROCATING PUMP

 Rotary Pumps:
Principle: Rotating elements (gear, screw, vane) trap and move the fluid.
Applications: Suitable for high viscosity fluids, used in oil and gas, chemical, and food
industries.
Figure:

FIGURE 4.7 ROTARY PUMP

 Diaphragm Pumps:
Principle: Diaphragm flexes and causes a change in volume, creating suction and discharge
phases.
Applications: Used for metering, chemical dosing, and applications where leakage is a
concern.
Figure:

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FIGURE 4.8 DIAPHRAGM PUMP

4.1.6 Types of Valve:
 Gate Valve:
Design: Has a gate or wedge that moves perpendicular to the flow to open or close the
passage.
Function: Provides a tight seal, suitable for on/off applications.
Figure:

FIGURE4.9 GATE VALVE

 Ball Valve:
Design: Uses a rotating ball with a hole to control flow.
Function: Quick on/off control, often used in applications where tight shut-off is required.
Figure:

FIGURE 4.10 BALL VALVE

 Butterfly Valve:
Design: A disc rotates around a central axis to control flow.
Function: Lightweight, used for large-diameter pipelines, and provides good flow control.
Figure:

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FIGURE 4.11 BUTTERFLY VALVE

 Check Valve:
Design: Allows flow in one direction and prevents backflow.
Function: Ensures fluid flows in one direction, preventing reverse flow.
Figure:

FIGURE 4.12 CHECK VALVE

 Globe Valve:
Design: A movable plug or disc on a stem controls flow.
Function: Offers precise flow control, suitable for throttling applications.
Figure:

FIGURE 4.13 GLOBE VALVE

 Piston Valve:

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Design: Uses a piston to control flow.

Function: Suitable for high-pressure and high-temperature applications.
Figure:

FIGURE 4.14 PISTON VALVE

4.2 Major Instrument:

4.2.1 Temperature Indicator:
The temperature indicator is generally used to indicate the operating temperature on which it
is placed. In a temperature controller, specific value of temperature is set up to which heating
or cooling is done according to the process conditions. Here in industry, Thermocouples are
used to indicate temperature of reactor &some other equipment.

FIGURE 4.15 TEMPERATURE INDICATOR

4.2.2 Pressure Guage:
Pressure Gauge is an instrument for measuring the condition of a fluid that is specified by the
force that the Fluid would exert, when at rest, on a unit area, such as pounds per square inch
or Newton per square centimetre. Pressure gauge is located on the top of the Reactor. In
pressure gauge simple scale is on the round shape plate and by pointer indicates on the value
on the scale. When pressure of the reactor increases to set pressure then safety valve is open
and release pressure from the Reactor.

FIGURE 4.16 PRESSURE GUAGE

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4.2.3 Flow Indicator:

A flow meter is a device that measures how much liquid or gas moves through a pipeline in a
given period of time. By measuring flow rates, flow meters provide crucial visibility into
what's flowing where, within pipes, drainage systems, and other types of infrastructure. Flow
measurement is the process of measuring the flow rate or amount of a fluid or gas that passes
through a pipe. Flow measurement can be used to analyst the output of oil from a well,
domestic gas or water usage in homes or to measure fuel dispensed from pumps for usage in
cars.

FIGURE 4.17 FLOW INDICATOR

4.2.4 Rotameter:
A rotameter is a flow meter that operates on the principle of variable area flow measurement.
It consists of a tapered tube and a float. As the fluid flows upward, the float rises in the
tapered tube, creating a larger annular area for the fluid to pass through. The position of the
float is directly proportional to the flow rate. The higher the flow rate, the higher the float
rises. Reading the scale marked on the tube at the top of the float provides a visual indication
of the flow rate, making rotameters simple yet effective instruments for measuring the flow of
gases or liquids in a wide range of applications.

FIGURE 4.18 ROTAMETER

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 CHAPTER 5: PLANT UTILITIES

CHAPTER 5: PLANT UTILITIES

5.1 Introduction To Plant Utilities:

Plant utility refers to the essential services and infrastructure within an industrial facility that are
vital for supporting various operations and processes. These utilities are critical for ensuring the
reliable and efficient functioning of the plant. They encompass a range of services, including
power supply for operating machinery and equipment, steam generation for heating and
mechanical processes, cooling systems to dissipate heat, compressed air for pneumatic tools,
water supply and treatment for industrial processes, heating systems, instrument air for
pneumatic instruments and control valves, and nitrogen or other gases for specific applications.
Additionally, plant utilities include waste management systems, fire protection measures,
communication systems, backup power systems for emergencies, HVAC systems for maintaining
optimal working conditions, and inert gas systems in certain processes. The effective
management and maintenance of these utilities are paramount for the overall safety, productivity,
and sustainability of industrial operations within the plant.

5.2 Types of utilities in Plant:

 Cool Water
 Hot Oil
 Steam

5.2.1 Cool Water:

For The Cold Water We have to use the equipment which Name is Cooling Tower; Reuses
plant side water & cool it and using Again into procedure that’s how whole cycle runs during
plant is running for the Steam for the Plant, we have to use Boiler & use this in Plant for
heating purpose.
 Types of Cooling Tower:
1. Crossflow Cooling Tower
2. Counterflow Cooling Tower
3. Natural Draft Cooling Tower
4. Mechanical Draft Cooling Tower
5. Induced Draft Cooling Tower
6. Forced Draft Cooling Tower
From above types of cooling tower we use Forced Draft Cooling Tower in Plant.
 Forced Draft Cooling Tower:
 Principle:
The principle of a forced draft cooling tower is to use a fan or a blower to force air through the
cooling tower, where it comes into contact with the hot water from an industrial process. The heat
transfer between the air and the water causes the water to cool down and the air to heat up.
 Figure:

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FIGURE 5.1 FORCED DRAFT COOLING TOWER

 Construction:
Support
Structure:
Begin with the construction of a robust support structure or framework, typically made of
reinforced concrete or steel, to bear the weight of the cooling tower components.
Basin Construction:
Build the water basin at the base of the tower to collect and store the hot water from the industrial
processes. This basin is often made of concrete and lined to prevent leaks.
Fan Deck and Fan Stack:
Construct the fan deck at the top of the tower, providing a platform for the installation of fan
assemblies. The fan stack, which houses the fan blades, is erected above the fan deck.
Fan Assemblies:
Install forced draft fans on the fan deck. These fans draw air through the tower and force it over
the water, promoting the cooling process. Fans are typically driven by electric motors.
Fill Media Installation:
Install fill media within the tower structure. The fill provides a large surface area for the water to
spread into thin films, allowing for effective heat transfer through evaporation.
Drift Eliminators:
Include drift eliminators to minimize water droplet carryover from the tower, ensuring efficient
water conservation and preventing environmental concerns.
Distribution System:
Set up a water distribution system to evenly distribute hot water over the fill media. This system
includes pipes, nozzles, and headers to ensure uniform water distribution for optimal cooling.
Louvres and Air Inlet:
Install louvres or air inlet sections to direct the airflow entering the tower. These components help
control the air distribution and enhance the cooling efficiency.
Access Platforms and Ladders:
Construct access platforms and ladders for maintenance personnel to safely access different
sections of the cooling tower for inspection and repairs.
Drift Collection System:
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Implement a drift collection system to capture any water droplets carried by the airflow. This
collected water is returned to the basin, minimizing water losses.
Casing and Cladding:
Apply casing or cladding around the exterior of the cooling tower for protection against
environmental elements and to enhance aesthetics.
Instrumentation and Control System:
Install instrumentation, sensors, and a control system to monitor and regulate the cooling tower's
performance, ensuring optimal cooling efficiency.
 Working:
The forced draft cooling tower operates on the principle of actively drawing air through the tower
to enhance the heat exchange process. Hot water from industrial processes enters the cooling
tower and is evenly distributed over the fill media, which provides a large surface area for the
water to spread into thin films. Electrically driven forced draft fans, located at the top of the
tower, force ambient air through the fill media in a direction opposite to the water flow. As the air
passes through the fill, it comes into direct contact with the thin films of hot water. Heat is
transferred from the hot water to the cooler air, promoting the evaporation of a portion of the
water and extracting heat from the remaining water. The cooled air, now carrying the absorbed
heat, is discharged into the atmosphere, while cooled water collects in the basin at the base of the
cooling tower. Drift eliminators prevent water droplets from being carried out with the air,
ensuring efficient water conservation. The cooled water can be recirculated back to industrial
processes for further use or treated for reuse within the cooling tower system, making this system
effective for applications requiring precise temperature control and efficient heat dissipation in
various industrial processes.
5.2.2 Steam:
Types of Boiler: Water tube Boiler.
Capacity:28 TPH & 35 TPH.
 Principle:
The principle of water tube boiler is to use a cylindrical vessel filled with water that is heated by
the combustion of fuel inside or outside the vessel. The water flows through tubes that are
surrounded by hot gases from the fire. The heat transfer between the water and the gases causes
the water to boil and generate steam. The steam then rises to the top of the vessel, where it can be
collected and used for various purposes.

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 Figures:

FIGURE 5.2 WATER TUBE BOILER

 Constriction:
Drum Construction: Start by fabricating the steam drum, which is a large cylindrical vessel.
The steam drum serves as a reservoir for the water and steam mixture. It may also house internal
components like tubes and headers.
Header Construction: Fabricate headers, which are large pipes that collect and distribute water
and steam to the various sections of the boiler. Headers are connected to the steam drum and the
water drum.
Tube Installation: Install a large number of water tubes within the boiler. These tubes connect
the steam drum and water drum, creating a path for water circulation and steam generation. The
tubes are arranged in various patterns, such as crossflow, longitudinal, or helical.
Burner Installation: Integrate a burner into the boiler to generate heat. Burners are typically
located at the front or rear of the boiler and are responsible for initiating combustion of the fuel,
producing hot gases.
Combustion Chamber: Design and construct a combustion chamber where the burning of fuel
occurs. The combustion chamber is strategically placed to allow hot gases to pass over the water
tubes, transferring heat for steam generation.
Water Walls: Incorporate water walls, which are refractory-lined surfaces located in the furnace
area. Water walls absorb heat from the hot gases and help in maintaining the temperature of the
water within the tubes.
Superheater and Economizer Installation: Include a superheater to further heat the steam to
higher temperatures and an economizer to preheat the feedwater using waste heat from the flue
gases.
Steam and Water Piping: Install the necessary piping to connect the various components,
including steam piping to carry steam to the point of use and water piping for feedwater supply
and circulation.

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Insulation and Casing: Apply insulation to the boiler components to minimize heat loss. Encase
the entire boiler in a protective casing, often made of steel, to ensure safety and structural
integrity.
 Working:
The water tube boiler operates through a systematic process that begins with the introduction of
untreated feedwater into the boiler through a designated inlet. This feedwater undergoes
preheating in the economizer, a heat exchanger in the flue gas path, enhancing overall efficiency.
The preheated water then enters water walls, a series of tubes lining the furnace walls, where it
absorbs heat from hot gases generated by a burner located at one end of the furnace. The heat
transfer causes the water within the tubes to boil and form steam. The generated steam rises to the
steam drum, a large cylindrical vessel positioned at the boiler's top, serving as a reservoir for the
steam-water mixture. As the steam rises, any remaining water is separated and returned to the
water tubes. This continuous process of heat exchange and steam generation ensures the efficient
production of steam for various industrial applications.

 Advantages:
Higher Efficiency: Water tube boilers generally exhibit higher thermal efficiency compared to
their fire tube counterparts, as they can handle higher operating pressures and temperatures.
Faster Steam Generation: Water tube boilers can produce steam more quickly due to their
design, which allows for a more rapid transfer of heat from the combustion process to the water.
Ease of Maintenance: Water tube boilers often allow for easier inspection, maintenance, and
cleaning due to better access to internal components, facilitating proactive measures to ensure
optimal performance.

5.2.3 Hot Oil:

 Application:
Heat Exchangers:
Hot oil is often circulated through heat exchangers to transfer heat to or from other process streams,
ensuring precise temperature control in chemical reactions.
Reboilers:
Hot oil serves as a heating medium in reboilers, supporting the distillation process by providing the
necessary heat for vaporizing liquid components.
Jacketed Reactors:
Reactors in chemical processes may be jacketed with hot oil to maintain specific reaction
temperatures, optimizing reaction rates and product quality.
Drying Processes:
Hot oil is utilized in industrial dryers to provide the necessary heat for the drying of chemicals or
materials, ensuring efficient moisture removal.
 Advantage:
High Thermal Stability:
Hot oil exhibits excellent thermal stability at elevated temperatures, allowing for reliable and
consistent heat transfer without significant degradation or decomposition.
Wide Operating Temperature Range:
Hot oil has a high boiling point, enabling its use in processes requiring elevated temperatures. It
remains in the liquid phase over a broad temperature range, enhancing its applicability.
Efficient Heat Transfer:

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Hot oil efficiently transfers heat due to its low viscosity and high thermal conductivity. This
property ensures effective heat exchange in a variety of heat transfer equipment.
Precise Temperature Control:
Hot oil systems enable precise temperature control, crucial in chemical processes where
maintaining specific reaction temperatures is essential for product quality and reaction efficiency.
Reduced Corrosion and Fouling:
Hot oil systems, compared to steam systems, often experience reduced corrosion and fouling
issues. This can result in longer equipment lifespan and lower maintenance requirements.
 Disadvantages:
Limited Heat Capacity:
Hot oil systems may have a lower heat capacity compared to some other heat transfer fluids,
limiting their ability to absorb and transfer large amounts of heat.
Potential for Oxidation:
Hot oil systems are susceptible to oxidation at high temperatures, which can lead to the formation
of sludge and degradation of the fluid over time. Regular monitoring and maintenance are
required to address potential oxidation issues.
Thermal Degradation:
Prolonged exposure to high temperatures can result in thermal degradation of the hot oil, leading
to a decrease in its performance and lifespan. Frequent monitoring and preventive measures are
essential to mitigate thermal degradation.
Fire Hazard:
Hot oil poses a fire hazard due to its flammable nature. Adequate safety measures, including
proper equipment design, fire detection systems, and emergency response plans, are crucial to
minimize the risk of fires.
High Initial Cost:
The initial installation cost of hot oil systems, including specialized equipment and materials, can
be higher compared to some alternative heat transfer methods.

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 CHAPTER 6: HEALTH, HAZARD & SAFETY

CHAPTER 6: HEALTH, HAZARD & SAFETY

6.1 Introduction to Health, Hazard and Safety:

Health is most important where we work in plant side because There are many chemicals that may
affect our lives & inner Side body it causes health issues which is harmful for long life, for pretend
that we have to be safe from these hazardous chemicals, waste, corrosive chemicals compounds
which is causing Eyes, mouth, or skin diseases and that will cause health issues or may it convert into
Death if that compound has poisonous nature which affects our health.
Hazards in the industry is too in rare case & it is possible to occurred when somewhere
Unconditional & Unnecessary things happens may be due to lack of focusing on process plant or
specially Boiler house. Hazards causes the environmental & physical damage to peoples around it,
also it’s not good situation for the that soil, that hazards may affect all around land long side in that
circle may affect like small earthquake which may lead distraction on living human.
Safety More than two thousand deaths from a methyl isocyanides chemical leak in Bhopal, India,
drew world attention to serious hazards in the chemical industry. Following that tragedy, the
Occupational Safety and Health Administration (OSHA) developed guidelines to aid employers in
reducing the number of potential hazards in chemical industries. This publication is designed to
encourage chemical industry review and safety precautions to guard against chemical disasters. It
contains guidelines used by OSHA compliance officers to evaluate employer safety programs,
particularly in the areas of disaster prevention and emergency response.

6.2 Industrial Hazard:

6.2.1 What is Industrial Hazard?
Industrial hazard refers to any potential danger, risk, or threat arising from industrial
processes, activities, or materials that has the potential to cause harm to people, property, or
the environment. These hazards may include chemical exposures, equipment failures, fires,
explosions, or other unsafe conditions within industrial settings. Identifying, mitigating, and
managing industrial hazards are critical aspects of ensuring workplace safety and
environmental protection.

6.2.2 Types of Industrial Hazard:

 Chemical Hazards:
Involves exposure to harmful substances such as toxic chemicals, corrosive materials, flammable
liquids, and gases, which can lead to health issues, fires, or explosions.
 Physical Hazards:
Includes dangers related to the physical aspects of the workplace, such as machinery, equipment,
noise, vibration, and ergonomic factors that can cause injuries, accidents, or long-term health
issues.
 Biological Hazards:
Involves exposure to biological agents such as bacteria, viruses, fungi, and parasites, commonly
found in certain industries like healthcare, agriculture, and laboratories, leading to infections or
diseases.
 Radiation Hazards:

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Relates to exposure to ionizing or non-ionizing radiation, commonly found in industries such as

nuclear power, healthcare, and certain manufacturing processes, which can cause radiation burns,
sickness, or long-term health issues.
 Fire and Explosion Hazards:
Encompasses risks associated with the presence of flammable materials, combustible dust, or
gases, posing the potential for fires and explosions, leading to severe damage and injuries.
 Mechanical Hazards:
Involves dangers associated with moving machinery, equipment, and tools, which can cause
injuries, amputations, or fatalities if not properly operated or safeguarded.
 Electrical Hazards:
Includes risks associated with electrical systems, equipment, and installations, which can lead to
electric shocks, burns, or fires if proper safety measures are not followed.
 Noise and Vibration Hazards:
Relates to exposure to excessive noise levels or vibrations, commonly found in industries like
construction and manufacturing, which can cause hearing loss, stress, and other health issues.
6.3 Personal Protective Equipments (PPEs):
6.3.1 What is PPEs?
PPE stands for "Personal Protective Equipment." It refers to specialized gear or clothing worn
by individuals to protect themselves from various workplace hazards, ensuring their safety
and reducing the risk of injury or illness. PPE is designed to create a barrier between the
wearer and potential risks in the environment. Common types of PPE include items such as
safety helmets, gloves, eye protection (safety glasses or goggles), ear protection (earplugs or
earmuffs), respiratory protection, high-visibility clothing, and protective footwear. The
selection of appropriate PPE depends on the specific hazards present in the workplace and the
tasks being performed. Proper training on the use, maintenance, and limitations of PPE is
essential for ensuring its effectiveness.

6.3.2 Need of PPEs:

 Worker Safety:
The primary purpose of PPE is to protect workers from potential hazards and injuries in the
workplace. It serves as a physical barrier between the worker and various sources of harm, such
as chemicals, projectiles, electrical hazards, and more.
 Compliance with Regulations:
Many occupational safety and health regulations and standards mandate the use of specific PPE
in certain industries. Adhering to these regulations ensures that workplaces are in compliance
with legal requirements, avoiding penalties and legal issues.
 Risk Reduction:
PPE helps to reduce the risk of accidents and injuries by providing a layer of protection. It is
particularly crucial in industries where exposure to harmful substances, physical hazards, or
environmental risks is inherent in the work environment.
 Prevention of Exposure to Hazardous Substances:
PPE, such as gloves, masks, and respirators, is vital for preventing exposure to hazardous
substances, including chemicals, dust, and biological agents, which could lead to short-term or
long-term health issues.
 Emergency Response:

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 CHAPTER 6: HEALTH, HAZARD & SAFETY

In emergency situations, such as fires, chemical spills, or other accidents, PPE plays a crucial role
in providing immediate protection to workers and enabling them to respond effectively without
exposing themselves to additional risks.
 Maintenance of Workplace Productivity:
When workers feel safe and protected, they are more likely to perform their tasks efficiently and
confidently. PPE contributes to a positive safety culture, promoting employee morale and overall
workplace productivity.
6.3.3 Types of PPEs:
1. Head Protection:
Hard Hats: Protect the head from falling objects, impact, and electrical hazards in construction,
manufacturing, and other industries.
2. Eye and Face Protection:
Safety Glasses: Shield the eyes from impact, chemical splashes, and airborne particles.
Goggles: Provide a more enclosed eye protection against chemical splashes and dust.
Face Shields: Protect the face from larger airborne particles, chemical splashes, and radiation.
3. Hearing Protection:
Earplugs: Inserted into the ear canal to reduce noise exposure.
Earmuffs: Cover the ears to block or attenuate loud noises.
4. Hand Protection:
Gloves: Different types (e.g., leather, latex, nitrile) offer protection against cuts, chemicals, heat,
cold, and other hazards.
5. Foot Protection:
Safety Shoes or Boots: Include features like reinforced toes and soles to protect against impact,
compression, and punctures.
Chemical-resistant Boots: Guard against exposure to hazardous chemicals.
6. Fall Protection:
Harnesses: Securely attach a person to a structure or anchor point to prevent falls.
Lanyards and Lifelines: Used in conjunction with harnesses for fall arrest or restraint.
7. Heat and Cold Protection:
Thermal Clothing: Protect against extreme temperatures, either to retain body heat in cold
environments or to dissipate heat in hot environments.
8. Biological Hazard Protection:
Masks and Respirators: Guard against airborne biological hazards, such as viruses or bacteria.
9. Radiation Protection:
Lead Aprons: Shield against ionizing radiation, commonly used in medical settings.
10. Electrical Protection:
Insulating Gloves: Protect against electrical shock in electrical work.

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 CHAPTER 6: HEALTH, HAZARD & SAFETY

6.3.4 Examples of PPEs:

FIGURE 6.1 EXAMPLE OF PPES

6.4 General Dos &

Don’ts:
 Safety shoes and helmet are Compulsory while working. Also, use other appropriate PPEs as
per requirement. Follow Safety work permit system for Hot work, Height work, Excavation,
Rigging, Lock Out Tag Out (LOTO) & cold work/hazardous work in the plant.
 Before starting any job activity know about the safe working method, give a thought on the
risk involved in it. Do not start work without appropriate PPEs.
 In case of fire, first try to control it if the fire is at incipient stage with the use of available
fire extinguishers & inform fire crew as well as area in charge.
 In case of emergency, report to the area in charge/fire/ ambulance and assemble at the
Nearest Safe Assembly point in the crosswind direction of the wind.
 Never enter restricted Areas like, Pump House, Electrical substations, Electrical /
Mechanical machinery room, Server Room or any other place with tag “RESTRICTED
ENTRY”
 Share the accident learning’s with others. Inform near miss or any abnormal things to your
superior or EHS dept.
 Keep information of types of emergency & Emergency Response Procedure to be followed
in case of emergency.
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 Keep information of location of fire extinguishers, first aid box, safety shower, fire escape,
safe assembly point, wind socks etc.
 Keep information of emergency contact numbers.
 Keep information of properties of chemicals in the company.
 Drugs, tobacco, smoking or alcohol is not allowed in the company.
 It is mandatory to use ear plugs in the High Noise Areas which are identified by
 display of boards.
 Do not eat or drink anything in the plant area.
 Do not touch any chemical, without knowing its properties and without using PPEs. Any
leaking chemical should be immediately brought into the notice of company supervisor.
 Maintain Discipline in the organization.
 Do not horseplay and do not run in plant.
 Do not move in area other than your work area in the plant.
 Co-operate with the security guards deployed at various locations.
 Do not wear loose cloths / remain away from moving machinery.
 Do not touch any other plant equipment, machinery, valves, cable etc.
 Do not allow to go any chemical / contaminated water on land or in storm water drain.
 Mobile phones, Bluetooth, ear phones, hands free are restricted in our premises.
 Use of tobacco, cigarette and any health related hazards items are restricted in our premises.
6.4 Safety Diamonds & Symbols:
6.4.1 Safety Diamond

FIGURE 6.2 SAFETY DIAMOND

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 CHAPTER 6: HEALTH, HAZARD & SAFETY

6.4.2 Safety Symbols:

FIGURE 6.3 SAFETY SYMBOLS

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 CHAPTER 7: PLANT LOCATION AND LAYOUT

CHAPTER 7: PLANT LOCATION AND LAYOUT

7.1 Plant Location:

 The plant site is located at Vilayat, Dist. BHARUCH, STATE -GUJARAT, INDIA. The choice
of site selection should be based on a complete survey of the advantages and disadvantages of
various geographical areas and ultimately on the advantages and disadvantages of available real
estate.
 From all points of view, Vilayat is a very appropriate place to establish a chemical plant because
it is considered the hub of multinational industries. Hence transportation of raw material and
products become easy.
 Vilayat G.I.D.C. is near Bharuch city and available sources from cities. Being an industrial hub,
there is widespread availability of skilled persons and good engineers required to run the
company effectively.
 Factors affecting the Location of Plant:
1. Cost of land
2. Raw Material supply
3. Transportation
4. Electric Power requirement
5. Water supply
6. Legal Restrictions
7. Labour Resources
8. Waste Disposal
9. The market for product manufacture
10. Other Facilities
1. Cost of land: Vilayat GIDC is situated outside of the city hence land is cheap in that area. So
sufficient amount of land can be purchased and can be used to establish a plant. So separate
ETP plant, Separate Power plant, Storage Department, Locker Room, First Aid Room can be
provided without much consideration of space availability.
2. Raw material supply: In nearer to Vilayat there are so many companies producing raw
materials and other raw materials can be directly transported from Vadodara and Ahmedabad
which are nearby cities.
3. Electric power: Torrent power supply electricity continuously as possible. So, there is no
power problem at the plant. And the plant is in G.I.D.C. so there is no chance of power cut.
4. Transportation: This plant is near to National Highway No 288. So, transportation is very
easy. Bharuch city is just 18 km far from the plant site. The plant is connected to Surat-
Baroda Express Highway with the help of the city Bharuch. The railway station of Bharuch is
just 18 km from the city centre, so transportation by railway is very easy and fast.
5. Climate: Climate change in this region is steady and has some minor variation throughout the
year and the place selected for this plant has the least chance of natural calamity.
6. Water supply: Location of the plant is very helpful to get the benefit of G.I.D.C. so that
clean water is available from GIDC.
7. Legal restrictions: Plant location is under the GIDC area of Vilayat so that all the facilities of
G.I.D.C. are available. As the plant is not causing too much pollution thus there are no legal
problems faced by the plant. There is no existence of noise or any other kind of pollution.

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8. Labour: Bharuch is a big city; many people are coming from other cities and villages for
work. so that good labour is available at a lower reasonable cost and efficient engineers are
available from Bharuch city.
9. Waste disposal: For wastewater and Other liquid wastes plant is equipped with ETP
(Effluent Treatment Plant), which is highly efficient & the neutral wastewater from the plant
is finally sent to Centre Effluent Treatment Plant (CETP). Thus, Plant does not produce water
pollution.
10. Market for product manufacturing: As Plant is in Vilayat nearer to Bharuch which is
linked with National Highway No 288. Express Highway Baroda-Surat-Bombay. So,
transportation is fast providing a big market.
11. Site characteristics: Plant is located at G.I.D.C. Estate which is an industrial zone so, there
are no ecologically sensitive areas such as tropical forests, biosphere reserves, and important
lakes or coastal areas rich in coral formation which can be an affected by the plant.
12. Location advantage: Being located in the GIDC Estate along with other similar industries
like same has the advantage of the availability of the facilities offered by G.I.D.C., like water,
roads for transportation, electricity, etc.

7.2 Plant Layout:

1. Storage layout:
Storage facilities for raw material & finished products may be located in isolated areas or
adjoining areas. Arranging materials to facilities or storage simply handling is also a point to
be considered in the design.
2. Equipment layout:
Ample space should be assigned to each piece of equipment. Accessibility is an important
factor for maintenance. If possible gravity ow from one equipment to another is arranged. To
get sound product all equipment.
3. Plant expansion:
Plant expansion must be kept in mind.
4. Floor Space:
The floor space may or not be a major factor in the design of a particular plant. Space to
permit working on parts of equipment that need frequent servicing and safety and comfort of
the operators.
5. Building:
It should be fundamental in chemical engineering industries that the buildings should be built
around the instead of process being made to t building of process conventional design.
Consideration is given to disposal of water liquor fumes dust and gases ventilation fume
elimination and drainage require the installation of extra equipment.

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 CHAPTER 7: PLANT LOCATION AND LAYOUT

FIGURE 7.1 PLANT LAYOUT

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 CHAPTER 8: ENVIROMENTAL ASPECT

CHAPTER 8: ENVIROMENTAL ASPECT

8.1 Environment, Health & Safety Policy

 Environment, health and safety are an integral part of all our activities. Continual
improvement in performance of Environment, Health and Safety is achieved through:
 Sharing the responsibility of maintaining safe & healthy work environment by all
stakeholders. Maintaining a vigilant, responsible & accountable team by imparting
appropriate training.
 Organizing awareness programs for surrounding community.
 Periodical review of EHS practices.
 Complying with all legal & other requirements

8.2 Pollution Prevention & Control

 Here are key pollution prevention and control factors:
1. Source Reduction:
Focus on minimizing the generation of pollutants at the source by improving processes,
technologies, and materials to reduce the overall production of waste and emissions.
2. Cleaner Production Techniques:
Implementing cleaner and more sustainable production methods that reduce the use of
hazardous materials, energy consumption, and waste generation.
3. Waste Minimization:
Developing strategies to minimize the generation of waste, including the reuse and recycling
of materials, and proper disposal methods for unavoidable waste.
4. Energy Efficiency:
Improving energy efficiency in industrial processes and operations to reduce overall energy
consumption, which can, in turn, lower emissions and environmental impact.
5. Technological Upgrades:
Investing in and adopting advanced technologies and equipment that are more environmentally
friendly and produce fewer pollutants.
6. Emission Control Systems:
Installing and maintaining effective emission control systems such as scrubbers, filters, and
catalytic converters to reduce the release of pollutants into the air.
7. Water Conservation:
Implementing water conservation measures to reduce water usage, prevent water pollution, and
ensure responsible water management.
8. Land Use Planning:
Incorporating sustainable land use practices that prevent soil erosion, minimize habitat
disruption, and protect natural ecosystems.
9. Environmental Monitoring:
Regularly monitoring air, water, and soil quality to identify pollution sources, assess the
effectiveness of pollution control measures, and ensure compliance with regulations.
10. Compliance with Regulations:
Adhering to local, regional, and national environmental regulations and standards to ensure that
industrial activities are in compliance and do not pose harm to the environment.

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11. Employee Training:

Providing comprehensive training programs for employees to raise awareness of
environmental issues, promote responsible practices, and ensure compliance with pollution
prevention measures.

8.3 Effluent Treatment Plant:

FIGURE 8.1 EFFLUENT TREATMENT PLANT

An Effluent Treatment Plant (ETP) is a crucial component of industrial infrastructure designed to
treat and manage wastewater generated during various industrial processes. Its primary objective is to
remove contaminants and pollutants from the effluent before it is discharged into the environment or
municipal sewage systems. Here is a detailed description of an ETP:

 Collection and Inlet Section:

Wastewater generated from industrial processes is collected and directed to the inlet section of
the ETP.
The initial step involves screening to remove large debris and solid particles. This helps protect
pumps and other downstream equipment.

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 CHAPTER 8: ENVIROMENTAL ASPECT

 Primary Treatment:
In this phase, physical processes such as sedimentation and flotation are employed to separate
suspended solids and heavy particles from the wastewater.
Primary treatment helps in reducing the organic load and improves the overall efficiency of the
subsequent treatment processes.
 Secondary Treatment:
Biological treatment is a key component of the secondary treatment stage. Microorganisms,
often in the form of activated sludge, are introduced to the wastewater to break down and digest
organic pollutants.
Aeration tanks provide an oxygen-rich environment to support the growth and activity of
microorganisms, promoting the biological degradation of pollutants.
 Tertiary Treatment:
Tertiary treatment involves advanced processes to further polish the effluent and meet stringent
discharge standards.
Filtration, chemical coagulation, and advanced oxidation processes are common techniques used
to remove remaining contaminants and enhance the quality of the treated water.
 Sludge Management:
Solid sludge generated during the treatment processes is separated and often subjected to further
treatment for reduction in volume and stabilization.
Common methods for sludge management include sludge dewatering, drying, and, in some cases,
the utilization of the treated sludge as a resource.
 Discharge or Reuse:
The final treated effluent, now meeting regulatory standards, can be discharged into water bodies
or municipal sewer systems.
In some cases, treated water can be reused within the industrial facility for non-potable purposes
like cooling or irrigation, contributing to sustainable water management.
 Monitoring and Compliance:
Continuous monitoring of the effluent quality is crucial to ensure compliance with environmental
regulations. Effluent quality parameters, such as chemical oxygen demand (COD), biological
oxygen demand (BOD), pH, and others, are regularly monitored to verify that the discharged
water meets the prescribed standards.
An efficiently designed and well-operated ETP is essential for industries to minimize their
environmental impact, comply with regulatory standards, and contribute to sustainable water
management practices.

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 CHAPTER 9: CONCLUSION

CHAPTER 9: CONCLUSION

My 8-week internship in the chemical industry has been a transformative experience that
significantly enriched my understanding of the field. Engaging in hands-on tasks and collaborating
with industry professionals allowed me to apply theoretical knowledge. Exposure to various facets of
the industry, from production processes to safety protocols, broadened my perspective and deepened
my commitment to environmental sustainability. I developed problem-solving strategies, honed
interpersonal skills through teamwork, and established valuable connections for future career growth.
This internship has not only solidified my passion for the chemical industry but has also equipped me
with the practical skills and insights necessary for future endeavours in this dynamic field. I am
grateful for the opportunities and experiences gained during this period, and I look forward to
leveraging them as I progress in my academic and professional journey.

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 CHAPTER 10: REFERENCE

CHAPTER 10: REFERENCE

1. Unit Operation in Chemical Engg. – MaCabe & Smith

2. Introduction to Chem. Engg. – Badger & Banchero
3. Plant Utilites – Ghawane
4. Chemical Engineering Plant Design - F.C.Vilbrandt and C.E.Dryden.
5. Stoichiometry - Bhatt & Vora.
6. Mass Transfer Operations - Robert E. Treybal, Mc-Graw Hill Publications.
7. Industrial instrumentation - Donald P Eckman

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