CHAPTER-1

INTRODUCTION

1.1 ABOUT COMPANY:

BHAGWATI ORGANICS PVT. LTD

A part of Bhagwati group, group founded and laid by Mr. Shailesh Patel since the
year 1988. Main activity centres are located in Vatva, Ahmedabad, Gujarat.
Field of operations: Dyes, Chemical, Pharmaceuticals.
Production Capacity: 300 MTPA in 2006 to 500 MTPA in the year 2007 &
increased to 1000 MTPA by 2012

COMPANY POLICY :

BOPL policies are mainly derived from the ethics of the Bhagwati Group and policies
fully reflect the vision and the mission of the company. Company solely believes in
maintaining the quality of the product.

PRESERVING LIFE :

BOPL has been constantly engaged in the production of dyes intermediates and
pharmaceuticals intermediates. BOPL has more than 1000 trees and plants rooted and
maintained at its premises preserving the charm of the nature and also preserving the
green life on earth. BOPL has been awarded the best plantation award in the year 2011 by
GUJARAT POLLUTION CONTROL BOARD AND THE GREEN ENVIRONMENT
SERVICES CO-OP SOCIETY LTD. The award mark the constant efforts of Mr. Girish
Patel to create the Greener and cleaner earth.

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ENVIRONMENTAL PROTECTION :

BOPL committed to the protection of the environment since the start of the company.
Water, Air, Solid waste has been very well maintained and also disposed in the proper
way so as to make sure that it does not affect the environment stability. BOPL is the
member of GESCL Vatva for the Waste water management (CETP Member) and also a
member of GESCL solid waste site.

REDUCE & RECYCLE:

Reducing and recycling has been most prominent and different policy adopted by the
group and the company which sets us apart from the other companies in our tier. The
company is so committed to the R&R policy that the monitoring is been done on the day
to day working basis also. No Paper waste, No plastic polythene in the premises, etc are
some of the policies which are part of R&R working ethics.

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1.2 PRODUCTS MANUFACTURED IN COMPANY:

1. BIS (2-CHLOROETHYL) AMINE HCl

Molecular Weight : 178.49
Molecular formula : C4 H9 C12 N. HCl
Melting Point : 212-214 C
Boiling Point : 204.2 C
Vapour Pressure : 0.267 mmHg at 25C

2. DIMETHYLAMINO ETHYL CHLORIDE HCl

Molecular Weight : 144
Molecular formula : C4 H10 Cl N. HCl
Melting Point : 201-204C
Water Solubility : 2000g/l

3. 2-CHLOROETHYL AMINE HCl

Molecular Weight : 115.99
Molecular Formula : C2 H7 Cl2 N
Melting Point : 144.0 to 149.0 C
Solubility : transparency

4. HYDRAZOBENZENE
Molecular Weight : 184.24
Molecular Formula : C12 H12 N2
Melting Point : 125C
Solubility : Stable, strong acid

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1.3 INTRODUCTION TO PROBLEM STATEMENT

STATEMENT:

To recover maximum amount of solvent by preventing the losses of the solvent from
heat exchanger/condenser & centrifuge.

EXPLANATION:

Ethylene dichloride is used as a solvent in manufacturing of bis (2-chloroethyl) amine

hydrochloride from the Thionyl chloride and Diethanol amine.

This operation involves two major losses of the solvent as follows:

One of the losses is from the glass condenser whose thermal conductivity is very less. Due to
this very less amount of Ethylene Dichloride (EDC) solvent vapour gets condensed, the
condensate is recycled to reactor & the remaining vapour is passed through scrubber to the
atmosphere.

Another loss is form the centrifuge where the EDC is present in the cake of Bis (2-
chloroethyl) amine hydrochloride. The drying of cake causes the vaporization of the EDC
which is then sent to the atmosphere from the top of the dryer.

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 CHAPTER-2

LITERATURE SURVEY

In the previous decades the equipments used were not so efficient & economic. So
lots of new technologies were invented which have made the process economical & easy.

2.1 LITERATURE SURVEY ON GRAPHITE CONDENSER:

A glass condenser, which is characterized by comprising a

glass shell, a material outlet arranged at the bottom of the glass shell,
and a material inlet arranged at the top of the glass shell, wherein a
coiled glass condenser pipe is arranged in the glass shell.

Previously the glass condenser was used for the

condensation of the solvent vapour but because of the low thermal
conductivity of glass less heat transfer was obtained & the graphite
condenser invented for the same purpose. The object of the present
invention is to solve the prior art and to provide a method for the
chemical industry, corrosion resistance, high temperature graphite
condenser. Graphite condenser of the invention, the structure is
simple, convenient and practical, corrosion resistant, high
temperature, good thermal conductivity, etc., to ensure the gas field
of chemical production quality and material quality condenser itself.

2.2 LITERATURE SURVEY ON ANCHOR AGITATOR:

The simple propeller agitator is used for mixing purpose but it is not so efficient to
serve the purpose of the reaction carried out to produce the product .As the slurry in the
agitator is viscous so by such agitators effective mixing is not possible to achieve. To
overcome this disadvantage the propeller agitator are replaced by the anchor agitators.

5
 An anchor agitator with baffles, which consists of an anchor agitator, an inner baffle,
an outer baffle and stainless steel fastening bolts. The anchor agitator
with the baffles is characterized in that one plastic inner baffle is
installed at the position of a transverse bar at the bottom of the anchor
agitator, a plastic outer baffle is installed at the external part of the
transverse bar, and the inner baffle and the outer baffle are fastened on
the transverse bar at the bottom of the anchor agitator through the
stainless steel fastening bolts. Therefore, the agitation contact area is
increased, the distance between the bottom of a reaction kettle and the
agitator is reduced. The anchor agitator with the baffles has the
beneficial effects that small-volume materials can be fully mixed in the
reaction kettle.
Different types of turbines used in agitators:

2.3 LITERATURE SURVEY ON NUTSCHE FILTRATION UNIT:

Centrifuge is an equipment used for the removal of the solvent

from the cake by compressing the cake of the product to prevent the
losses of the solvent with cake & to maintain the purity of the product.

Nutsche Filters are constructed to perform a multitude of tasks

including filtration, cake washing and thermal drying on a single unit.
As such these are very sophisticated machines with tight process
control on parameters such as pressure, temperature and pH. Nutsche
Filters are well suited for handling flammable, toxic, corrosive and
odour-noxious materials since they are autoclaved and designed for
use in hazardous and ex-proof environments when extremely safe operation is required.

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 CHAPTER - 3

BRIEF DETAILS OF WORK

3.1 PROPERTIES OF MATERIALS INVOLVED IN PRODUCTION

OF BIS (2-CHLOROETHYL) AMINE HCl

1) BIS (2-CHLOROETHYL) AMINE HCl

Molecular Weight : 178.49

Molecular formula : C4 H9 C12 N. HCl
Melting Point : 212-214 C
Boiling Point : 204.2 C
Vapour Pressure : 0.267 mmHg at 25C

2) PROPERTIES OF DIETHANOL AMINE:

Molecular Weight : 105.14
Molecular Formula : C4 H11 O2 N
Boiling Point : 268.8 C
Melting Point : 28C
Flash Point : 152C
Density/Specific Gravity : 1.09664
Vapour Pressure : 2.8 x 10-4 mmHg

3) PROPERTIES OF ETHYLENE DICHLORIDE:

Molecular weight : 98.96
Molecular Formula : C2H4Cl2
Boiling Point : 83.84C
Freezing Point : 83.35 Torr
Density : 1.253 g/ml
Vapour Pressure : 78.9 mmHg
Melting Point : 35.5 C

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4) PROPERTIES OF THIONYL CHLORIDE:
Molecular Weight : 118
Molecular Formula : SOCl2
Melting Point : -105 C
Boiling Point : 79 C
Vapour Pressure : 97 mmHg
Density : 1.64 g/ml
Freezing Point : 105 C

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3.2 FLOW SHEET OF BIS (2-CHLOROETHYL) AMINE HCl

9
3.3 MANUFACTURING PROCESS OF BIS (2-CHLOROETHYL)
AMINE HCl

PROCESS STEPS:
1. Reaction
2. Condensation
3. Scrubbing
4. Centrifugation
5. Drying

PROCESS DESCRIPTION:
At first the Ethylene dichloride solvent is charged in a glass lined reactor at normal
temperature. Then charge Thionyl Chloride in reactor. Take Diethyl Amine in mild steel
receiver. After the Thionyl chloride &Ethylene dichloride is charged start adding Diethyl
amine. Add 30% of DEA at 32oC . After adding 30% DEA allow free stirring for half
hour. During this small amount of HCl gas is liberated. After adding DEA the jacket is
emptied & stirr for 2-3 hours. During this SO2 gas is liberated. After the 2-3 hour stirring
steam is applied in the jacket & heating is started & the temperature is raised to 55-65 oC .
At this time the condenser EDC will be refluxed or recycled in reactor. From the top of
the reactor HCl gas + SO2 & EDC vapour is sent to the condenser to recover the solvent
EDC. One part of this condensed EDC is refluxed to the reactor. Other portion containing
HCl gas + SO2 gas & traces of EDC vapour are scrubbed in the scrubber with solution of
(Na2CO3+water). From the bottom of the scrubbers the Sodium bisulphite is taken out &
the gaseous mixture (HCl+SO2+EDC vapour) is sent to atmosphere. As the temperature
in the reactor reaches 55-65 oC drain some product from the bottom valve & check its
melting point at 60 oC. If it is ok then raise the temperature up to 70oC to 75oC . After that
cooling is provided & lower down the temperature up to 18-19oC. After this the bottom
product from the reactor is centrifuged, the wet cake of Bis(2-chloro) diethyl amine HCl
is separated. The EDC rich mother liquor is recycled back. The wet cake is dried in the
dryer at temperature of 40 to 50oC. Finally the product is weighted & sent for packing.

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APPLICATION:
Used in the Production of the Following Products:
1. Cyclopropylpiperazine (Acetic Acid)
2. (3-Trufluoromethylphenyl) piperazine
3. 4-Cyano-4-Phenylpiperidide Hydrochloride
4. 1-(3-Nitrophenyl)- Piperazine
5. 3-(4-MethylPiperazine-1-yl)Phenylboronic acid
6. 1-(2-Methoxyphenyl) piperazineHydrobromide
7. 1-(3-Methylphenyl) piperazine
8. 1-(2-ethoxyphenyl) piperazine Hydrochloride

11
 CHAPTER - 4
MATERIAL BALANCE
REACTION:
0.997 DEA + 1.12 SOCl2 1.34 DEA-HCl + 0.777 HCl (g)

1.34 DEA-HCl + 1.12 SOCl2 1.69 Bis (2-chloro) ethyl amine HCl + 0.777 SO2 (g)
(Product)
Na2CO3 + SO2 + H2O NaHSO3 + CO2 + NaOH

BASIS: 1000Kg (1 TON) PRODUCTION OF BIS (2-CHLOROETHYL) AMINE HCl

4.1 MATERIAL BALANCE AROUND THE REACTOR :

EDC ( Solvent )

DEA HCl (g)

Reactor
SO2 (g)
(97% Conversion)
SOCl2 EDC(vapour)

Unreacted mass
EDC (Solvent) Bis (2-chloro) ethyl amine HCl

MOLECULAR WEIGHT :
DEA = 105
SOCl2 = 118
EDC = 99
Bis (2-chloro) ethyl amine HCl = 178
HCl(g) = 36.5
SO2(g) = 64
NaOH = 40
DEA-HCl = 141
NaHSO3 = 104

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Na2CO3 = 106
CO2 = 44

ACTUAL REACTED DEA :

M.W of DEA = M.W of 141 Bis (2-chloro) ethyl amine HCl

105 = 178
(?) = 1000
= 1000 * (105/178)
= 589.887 Kg
Here yield is assumed to be 96.70% means 97% based on Bis (2-chloro) ethylamine HCl

Actual charged DEA = 589.887/0.97 = 608 kg 610 kg

Unreacted DEA = 610 589.887 = 20.113 kg

ACTUAL REACTED SOCl2

M.W of SOCl2 = M.W of Bis (2-chloro) ethylamine HCl

2.24*118 = 178
(?) = 1000
= 1000 * 2.24 * (118/178)
= 1484.94 Kg

Here yield is assumed to be 96.70% means 97% based on Bis (2-chloro) ethylamine HCl

Actual charged SOCl2 = 1484.94/.97 = 1530 Kg

Unreacted SOCl2 = 1530 1484.94 = 45.06 Kg

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PRODUCT HCl:

Moles of HCl produced = Moles of DEA reacted

0.777 = 1

(?) = 610

= 610* (0.777/1)

= 474 Kg HCl

PRODUCT SO2 :

Moles of SO2 produced = Moles of DEA reacted

0.777 = 1

(?) = 610

= 610* (0.777/1)

= 474 Kg SO2

PRODUCT BIS (2-CHLOROETHYL) AMINE HCl :

Moles of Bis (2-chloroethyl) amine HCl produced = Moles of DEA reacted

1.6952 = 1

(?) = 610

= 610 * (1.6952/1)

= 1035 Kg ( Theoritical product formed )

Actual product formed = 995 Kg ( Assume )

Product yield = (995/1035) * 100 = 96.13%

In the reactor we add 5.31 times EDC of DEA = 5.31 * 610 = 3240 Kg

We assume 18% of solvent will be loss from reactor in the form of vapour,

EDC vapour formed = 0.18 * 3240 = 583.2 Kg

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Remaining solvent in the reactor = 3240 583.2 = 2656.8 Kg

Un-reacted mass = 192 Kg

TABLE: 4.1 MATERIAL BALANCE FOR REACTOR

COMPONENT MATERIAL IN(Kg) MATERIAL OUT(Kg)

DEA 610 20.113
SOCl2 1530 45.06
HCl(g) - 474
SO2(g) - 474
Bis (2-chloroethyl) amine HCl - 1000
EDC 3240 2656.8
EDC(vapour) - 583.2
Un-reacted mass - 126.82
TOTAL 5380 5379.993 5380

4.2 MATERIAL BALANCE AROUND CENTRIFUGE :

Slurry
(Bis (2-chloro) ethylamine CENTRIFUGE
HCl + EDC) Wet cake

Mother liquor (EDC)

In Centrifuge slurry will be separated in two phase.

1. Wet Cake ( Solid Product )
2. Mother Liquor ( Solvent EDC )
We assume 93.90% Solvent will be separated from slurry.
Amount of Solvent entering in the Centrifuge = 2656.8 Kg
Amount of Mother liquor obtain (EDC solvent) = 2656.8 * 0.9390 = 2494.8 Kg
Amount of Solvent present in Cake = 2656.8 2594.8 = 162 Kg
% Loss of solvent = 2.334

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Thus final weight of wet cake = wt. of product + wt. of solvent in cake
= 1000 + 162
= 1162 Kg

TABLE: 4.2 MATERIAL BALANCE FOR CENTRIFUGE

COMPONENT MATERIAL IN (Kg) MATERIAL OUT (Kg)
Bis (2-chloroethyl) amine 1000 1000
HCl
EDC Solvent 2656.8 2494.8
EDC Solvent in Cake - 162
TOTAL 3656.8 3656.8

4.3 MATERIAL BALANCE AROUND DRYER :

EDC Solvent

Wet Cake DRYER

Bis (2-chloroethyl) amine HCl (90% Solvent removed)
+ Solvent EDC )

Dry Cake ( 10% Solvent )

In drying operation our wet cake will be dry, here we assume 90% of solvent will be remove
from wet cake. Thus, we get dry cake ( Product ) with 10% solvent content.
Amount of solvent EDC in wet cake = 162 Kg
Amount of solvent removed from wet cake = 162 * 0.9 = 145.8 Kg
Amount of solvent present in dry cake = 162 145.8 = 16.2 Kg
Final product weight ( Dry Cake ) = wt. of Bis (2-chloroethyl) amine HCl + wt. of solvent
= 1000 + 16.2 = 1016.2 Kg

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 TABLE 4.3 MATERIAL BALANCE FOR DRYER

COMPONENT MATERIAL IN (Kg) MATERIAL OUT (Kg)

EDC Solvent 162 145.8
Bis (2-chloro) ethylamine 1000 1000
HCl
EDC Solvent in dry cake - 16.2
TOTAL 1162 1162

4.4 MATERIAL BALANCE AROUND CONDENSER :

CONDENSER
HCl (g) HCl (g)
( 11.11% CONDENSATION OF
SO2 (g) SO2 (g)
EDC VAPOUR)
EDC (vapour) EDC

Condensed EDC Vapour

In Condenser 11.11% EDC vapour will be condensed (Assumed )

Amount of EDC Vapour entering from reactor = 583.2 Kg
Amount of EDC Vapour condensed = 0.1111 * 583.2 = 64.8 Kg
Amount of un-condensed EDC Vapour = 583.2 64.8 = 518.40 Kg
% Loss of solvent = 88.88 %

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 TABLE: 4.4 MATERIAL BALANCE FOR CONDENSER
COMPONENT MATERIAL IN (Kg) MATERIAL OUT (Kg)
HCl (g) 474 474
SO2 (g) 474 474
EDC (vapour) 583.2 518.40
Condensed EDC vapour - 64.8
TOTAL 1531.2 1531.2

4.5 MATERIAL BALANCE AROUND SCRUBBER :

Na2CO3 SOLUTION

HCl (g) HCl (g)

SO2 (g) SCRUBBER CO2 (g)

EDC VAPOUR EDC V A EDC VAPOUR

Mixture of NaHSO3 + NaOH

In scrubber all leaving streams will get scrubbed by Na2CO3 solution.

From this mixture of gases only SO2 gas will dissolve in Na2CO3 solution & form mixture of
NaHSO3 & NaOH.
According to Reaction :
Amount of Na2CO3 required = 1600 Kg (Basis)
M.W. of Na2CO3 = M .W. of NaHSO3
106 = 104.06
1600 = (?)
= 1600 * (104.06/106) = 1500 Kg

M.W. of Na2CO3 = M .W. of CO2

106 = 44

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 1600 = (?)
= 1600 * (44/106)
= 664 Kg
M.W. of Na2CO3 = M .W. of NaOH
106 = 40
1600 = (?)
= 1600 * (40/106)
= 604 Kg

TABLE: 4.5 MATERIAL BALANCE FOR SCRUBBER

COMPONENT MATERIAL IN (Kg) MATERIAL OUT (Kg)
HCl (g) 474 474
EDC (Vapour) 518.4 518.4
SO2 (g) 474 -
Na2CO3 2362.32 -
NaHSO3 - 1570
NaOH - 604
CO2 - 664
TOTAL 3828.72 3830.40

Total loss of EDC in entire process = Loss from condenser + Loss from dryer
= 518.40 + 162
= 679.82

% Recovery of EDC = (3240 679.82) / 3240

= 0.79018 * 100
= 79.018 %

Therefore, % loss of EDC = 21%

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CONCLUSION:
Previously company was using glass tube condenser & facing the problem of solvent
recovery as 21% of the total solvent is lost during the operation. The project here aims at
minimizing the loss of solvent from condenser & drying units keeping in account the
economic feasibility. The solvent recovered can be recycled back in the process yielding
profits.
So we have designed graphite block type condenser which will condense upto 88% of solvent
in condenser & will save cost of Rs. 23000 /- approximately.

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REFERANCES:

Industrial reference
Bhagwati Organics Pvt, Ltd.

Books
1.RICHARDSON, J. F. (2001). Coulson & Richardson's Chemical Engineering
2. Process Heat Transfer - Donald Kern
3. Perrys Chemical Engineering Handbook
4. Thakore S.B. and B.I Bhatt Introduction to Process Engineering and Design Tata
McGraw hill Publications Co. Ltd., New York.2005, pg. 215
5. Handbook of Chemical Processing Equipment by N.P.Cheremisinoff
6. Frank D. Kover, United States. Environmental Protection Agency. Office of Toxic
Substance.

Websites
1. http://www.chemicalbook.com/ChemicalProductProperty_EN_CB7675423.htm
2. http://www.sigmaaldrich.com/catalog/product/aldrich/b38503?lang=en&region=IN
3. http://www.graphicarb.com/index.php?option=com_content&view=article&id=8&Itemid=
10
4. http://www.carbonngraphite.com/graphite-condenser.html

5. http://www.nzifst.org.nz/unitoperations/matlenerg2.htm

6. http://en.wikibooks.org/wiki/Introduction_to_Chemical_Engineering_Processes/

Steady_state_energy_balance

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