SUMMER INTERNSHIP PROJECT REPORT

JUNE– JULY 2018

“Cost optimization of Product”
BY
Krishan pal
3rd Year, Chemical Engg. Integrated MBA

DEPARTMENT OF CHEMICAL ENGG. AND TECHNOLOGY

PANJAB UNIVERSITY, CHANDIGARH-160014

Mentored by: Place of Internship:

Mr. Lalan Pandey Jubilant Infrastructure Limited
Manager of FC Plant Vilayat, Bharuch

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 Certificate
This is to certify that Mr. Krishan pal, 3rd year Undergraduate from
Department of Chemical Engg. And Technology in the Chemical engineering
integrated MBA has successfully completed his summer training from
Jubilant Infrastructure Limited, Vilayat, under the mentorship of Mr. Lalan
Pandey, Manager of FC Plant.
The duration of this training / internship was from 04/06/2018 to
12/07/2018.
As part of this internship, he was assigned a project, titled “cost optimization
Of product”, and he has successfully completed this project and submitted
the report to the concerned department.

Mentor: DGM:

Mr. Lalan Pandey Mr. Kashyap Mapara

Manager of FC Plant Deputy General Manager
Jubilant Infrastructure limited Jubilant Infrastructure limited

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 Acknowledgement
The project would not have been possible without the help and support of
the following key people.
I am deeply grateful to Mr. Chirag Shah (GM Safety Department) for
providing me with this wonderful learning opportunity at Jubilant
Infrastructure Limited, Villayat. And also thanks to Mr. Rajkumar (HR) and
Mr. Tosif (HR) for providing FC plant for training.
I am deeply indebted to Mr. Rabi Mohanty (Deputy Manager) for being an
extremely helpful, deeply insightful and generously supportive mentor. His
guidance during the various stages of my training and internship at Jubilant
Infrastructure Limited and I believe that I have learnt a lot of invaluable
lessons from his able mentorship.
My thanks are due to Mr. Vishvas Pandya (Assistant Manager) for the help
they provided at various stages of the internship at Jubilant Infrastructure
Limited, Villayat.
Last but not the least; I thank all the co-trainees, executives, technicians,
plant in- charges, DCS operators, and mess & housekeeping staff for all the
direct and indirect help they provided me with. Again thank to all plant
member for teaching me and helping me to complete my training safely.
Summer Training / Internship (June- July 2018)
Jubilant Infrastructure Limited, Villayat

3rd Year UG,

Chemical Engineering, UICET

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 INDEX
Sr. No Topic Page no
1 Jubilant Overview 6
1.1 About FI plant 6
2 Process Overview 7
2.1 Raw materials 7
2.2 utilities used 7
2.3 Crude preparation 7A
2.4 Distillation process 8
3 Cost optimization of Product 9
4 Major Equipments 17
4.1 Pumps 17
4.2 Heat exchanger: 21
4.2.1 Shell and Tube Heat Exchanger 21
4.2.2 Plate heat Exchanger 23
4.3 Reactor: Autoclave 25
4.4 Distillation column: Packed tower 26
4.5 Decanter 28
4.6 Ejector 29
4.7 Rotameter 31
4.8 Types of valves 32
5 Utilities 39
5.1 Natural gas 39
5.2 Thermic fluid heater(hot oil) 39
5.2.1 Air Preheater 40
5.2.2 Steam 40
5.3 Chillers 41
5.3.1 Brine 41
5.3.2 Refrigerants 41
5.3.3 Accumulator 41
5.3.4 Economizer 42
5.3.5 Compressor 42
5.4 Cooling water 43
5.4.1 Cooling tower 43
5.5 Instrument Air 46
5 Calibration Of Tank / Vessel 47
6 Safety 48
6.1 Plant safety 48
6.2 MSDS: (material safety data sheet) 48
6.3 Personal protecting equipment(PPEs) 49
6.4 Work permit system 49
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7 Conclusion 50
8 Refrences 51

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 Brief Overview Of The Factory Premises
Jubilant Life Science Limited is an integrated pharmaceutical & Life Science
Company. As Indian’s largest custom research and manufacturing services
(CRAMS) player and leading Drug Discovery and Development Solution
provider out of India, it is constantly engaged in delivering value to its global
customers through innovative technologies, products and services.
The company’s focus is to innovate, collaborate and accelerate the process
of delivering products to the market for its customer. Today it is well
recognized as a ‘Partner of Choice’ by leading global pharm and Life Science
Companies. The company through its presence in India, Canada, Europe, and
China constantly serves its customers in over 65 countries across the globe.

Objective Of The Plant

FI Plant is called as FINE INGREDIENT Plant. It is also called Multi Product
Plant.
The emergency Response plan defines the organization for the co-ordinate
response necessary in the event of a major disaster. The organization plant
shows the structure of the organization and a brief overview the tasks of
personnel in the key roles. Role descriptions are provided for all key
personnel.
First and foremost objective of Employee Management is to maintain healthy
Employee Management relation and meticulously planned and execute all
emergency situation.
The Emergency Response Plan was written to provide response procedure
to protect people and property during an emergency or disaster situation.
This plan identifies and assigns personnel to various emergency tasks and
responsibilities, thus cresting the Site Emergency Team. This plan provides
coordination between the Site Emergency Team response and governmental
authorities to ensure an effective response.

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 2.PROCESS OVERVIEW
2.1 Raw Material : A, B, CATALYST(C)

2.2 Utilities: Hot oil, Cooling Water, Instrument Air, Nitrogen

Product: X

FLOW CHART
Catalyst

Raw Material A Slurry Preparation Water circulation

Raw Material A

High Pressure Gas cooler &

Raw Material B scrubber set
Reaction in Reactor

Catalyst for reuse

Reaction Mass Effluent to ETP

Cooling Catalyst Aq layer recycled
Separation

Recovered RM for use

Distillation and
Product Purification Solvent Residue in incinerator

Pure Product

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2.4 DISTILLATION PROCESS: The final product obtained is X.

The different products obtained at different temperatures are:

1. LBS cut: 95- 130 degree Celsius.

2. 1st Intermediate cut: 130- 169 degree Celsius.
3. 1st Pure cut: 169- 171 degree Celsius.
4. X Intermediate cut: 171- 183 degree Celsius.
5. X Pure cut: 183- 185 degree Celsius.
6. HBS cut: 185+ degree Celsius.
7. Residue.
The X product obtained should be of concentration 99% and has 2%
moisture.

The process flow diagram is also been shown. The abbreviations used
means:

LCV- Level control valve

FCV- Flow control valve

HWS- Hot water supply

CWS- Cold water supply

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3.COST OPTIMIZATION OF PRODUCT
Cost optimization refers to the optimum use of resources in efficient and
effective manner to optimize the cost of production. The cost of production
should be minimum in order to achieve the maximum profit.

C = f (K, L)

WHERE C= INPUT COST

K=FIXED COST

L=VARIABLE COST

 FIXED COST Includes land taxes, man power, transportation charges

which remain fixed for a short run.
 VARIABLE COST includes the cost of raw material and utilities which
include cost of Natural gas and power.

Hence for the optimization of production cost, we have to optimize our

variable cost which includes:

 Cost optimization of raw material

 Cost optimization of power
 Cost optimization of natural gas

COST ASSUMPTION:
FIXED COST= Rs. 50000

RAW MATERIAL A= Rs. 10 per kg

RAW MATERIAL B= Rs. 5 per kg

POWER= Rs. 7 per KWH

NATURAL GAS= Rs. 28 per sm^3.

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THEORTICAL COST OF BATCH:
RAW MATERIAL A:
1 mol of A gives 1 mol of X

116 kg of A gives 123 kg of X

1 kg of X be produced by= 116/123 kg of A

= 0.943 kg of A
Input cost of A for 1 kg of X= 0.943*10

= Rs 9.43

Input cost of A for one batch of X which yields 1,650 kg of X= Rs 9.43*1,650

= Rs 15,559.50

RAW MATERIAL B:
1 mol of B gives 1 mol of X

32 kg of B gives 123 kg of X

1 kg of X be produced by= 32/123 kg of B

= 0.260 kg of B
Input cost of B for 1 kg of X= 0.260*5

= Rs 1.3

Input cost of B for one batch of X which yields 1,650 kg of X= Rs 1.3*1,650

= Rs 2,145

Total input cost of raw material= Rs 17,704.5

POWER: It includes the power needed for driving the pumps needed in slurry
preparation, distillation process and utility.

BATCH DISTILLATION TIME = 10 DAYS =240 HRS.

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SLURRY BATCH TIME= 24 HRS.

FEED PUMP IN BATCH DISTILLATION TIME= 5 HRS.

FEED PUMP IN SLURRY BTACH TIME= 1/6 HRS.

TOTAL POWER IN UTILITY BATCH:

(TFH PUMP + AIR BLOWER PUMP + COOLING TOWER PUMP) *
TIME*EFFICIENCY

= (55+9.3+45) *240*0.8

=20,985.6 KWH.

SLURRY PREPARATION POWER:

(R.M A PUMP+ R.M B PUMP)*TIME + (SLURRY BATCH
POWER)*TIME*EFFICIENCY

= 4.4*1/6 + 33 * 24 *0.8

=633.6 KWH.

BATCH DISTILLATION POWER:

(BATCH FEED PUMP) *TIME + ( REFLUX PUMP+ RESIDUAL PUMP)*
TIME*EFFICIENCY

=5.9*5 + 5.2 * 240*0.8

=1,152.4 KWH.

TOTAL INPUT POWER= 20,985.6+ 633.6 +1,152.4

= 22,771.6 KWH.

TOTAL COST OF INPUT POWER= 22,771.6*7

= Rs. 1,59,401.

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NATURAL GAS : In TFH system, the hot oil is been heated by natural gas.it is
purchased per sm^3.

Q= mc∆T
=30*1000*0.79*1000*0.5*(180-60)
= 1422000 KJ

1KJ= 0.239 KILO CALORIE

1422000 KJ= 0.239*1422000 KILO CALORIE

= 3,39,858 KILO CALORIE

1SM^3 = 9500 KILO CALORIE

3,39,858 KILO CALORIE= 35.77 SM^3

TOTAL COST OF NATURAL GAS= 35.77*28

= Rs 1,001.5

TOTAL THEORTICAL INPUT COST= FIXED COST+ COST OF R.M + COST

OF POWER+ NATURAL GAS COST

= Rs. 50,000+ 17,704.5 + 1,59,401 + 1,001.5

= Rs 2,28,107.

ACTUAL COST OF BATCH: One batch has feed of 3,000 kg of A and 1,212
kg of B and product X has quantity of 1,650 kg.

INPUT COST OF RAW MATERIAL A= Rs 3,000 *10

= Rs 30,000.

INPUT COST OF RAW MATERIAL B= Rs 1,212 * 5 = Rs 6,060.

TOTAL INPUT COST OF RAW MATERIAL : Rs 30,000 +6,060= Rs. 36,060

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ACTUAL POWER: It includes the power needed for driving the pumps
needed in slurry preparation, distillation process and utility.

TOTAL POWER IN UTILITY BATCH:

(TFH PUMP + AIR BLOWER PUMP + COOLING TOWER PUMP) * TIME*

= (25+5.8+47.20) *240

=18,720 KWH.

SLURRY PREPARATION POWER:

(R.M A PUMP+ R.M B PUMP)*TIME + (SLURRY BATCH POWER)*TIME

= 3.8*1/6 + 30.25 * 24

=726.63 KWH.

BATCH DISTILLATION POWER:

(BATCH FEED PUMP) *TIME + ( REFLUX PUMP+ RESIDUAL PUMP)* TIME

=3.9*5 + 4.8 * 240

=1,172 KWH.

CONTROL PANEL POWER:

INPUT POWER= 3*240

= 720 KWH

TOTAL INPUT POWER= 18,720+ 726.63 +1,172+720

= 21,338 KWH.

TOTAL COST OF INPUT POWER= 22,338*7

= Rs. 1,49,370.

NATURAL GAS: ACTUAL CONSUMPTION= 60 SM^3

COST OF NATURAL GAS: Rs. 60*28 = Rs. 1,680

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TOTAL ACTUAL INPUT COST= FIXED COST+ COST OF R.M + COST

OF POWER+ NATURAL GAS COST

= Rs. 50,000+ 36,060 + 1,49,370 + 1,680

= Rs 2,37,110.

OPTIMIZE COST= ACTUAL COST – THEORTICAL COST

= Rs. 2,37,110 – 2,28,107

= Rs. 9003.

WE CAN OPTIMIZE THE COST IN THE FOLLOWING WAYS:

 AUTOMATION OF NATURAL GAS: Innovations in automations can bring

the quantam leaps in production performance. Advanced engineering
tools like those found in Siemens TIA Portal , can cut engineering time
and costs upto 30 percent.

 Minimizing The Seven Wastes of Lean Manufacturing and Their

Impacts on the Environment
 Lean manufacturing, a management philosophy primarily derived from
the Toyota Production System, focuses on eliminating waste—called
“Muda”— within a manufacturing system. It takes into account many
kinds of waste, including the waste of excessive human motion, and
aims to integrate each step of production into a holistic, efficient process
that reduces cost and improves overall revenue. Under the lean
manufacturing system, seven wastes are identified: overproduction,
inventory, motion, defects, over-processing, waiting, and transport.
 Overproduction
 The most serious of the wastes, overproduction can cause all other types
of wastes and results in excess inventory. Stocking too much of a
product that goes unused has obvious costs: storage, wasted materials,
and excessive capital tied up in useless inventory.
 Depending, of course, on the product in question, overproduction can
have very serious environmental effects. More raw materials than
necessary are consumed; the product may spoil or become obsolete,
which requires that it be tossed; and, if the product involves hazardous
materials, more hazardous materials than necessary are wasted,
resulting in extra emissions, extra costs of waste disposal, possible

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 worker exposure, and potential environmental problems resulting from
the waste itself.
 Inventory
 Inventory waste refers to the waste produced by unprocessed inventory.
This includes the waste of storage, the waste of capital tied up in
unprocessed inventory, the waste of transporting the inventory, the
containers used to hold inventory, the lighting of the storage space, etc.
Moreover, having excess inventory can hide the original wastes of
producing said inventory.
 The environmental impacts of inventory waste are packaging,
deterioration or damage to work-in-process, additional materials to
replace damaged or obsolete inventory, and the energy to light—as well
as either heat or cool—inventory space.
 Motion
 Wasteful motion is all of the motion, whether by a person or a machine,
that could be minimized. If excess motion is used to add value that could
have been added by less, than that margin of motion is wasted. Motion
could refer to anything from a worker bending over to pick something
up on the factory floor to additional wear and tear on machines,
resulting in capital depreciation that must be replaced.
 There are many environmental costs from excess motion. One obvious
one is the needless waste of materials used to replace worn machines;
another one could be the health resources for overburdened employees,
who might not have needed them if motion had been minimized.
 Defects
 Defects refer to a product deviating from the standards of its design or
from the customer’s expectation. Defective products must be replaced;
they require paperwork and human labor to process it; they might
potentially lose customers; the resources put into the defective product
are wasted because the product is not used. Moreover, a defective
product implies waste at other levels that may have led to the defect to
begin with; making a more efficient production system reduces defects
and increases the resources needed to address them in the first place.
 Environmental costs of defects are the raw materials consumed, the
defective parts of the product requiring disposal or recycling (which
wastes other resources involved in repurposing it), and the extra space
required and increased energy use involved in dealing with the defects.
 Over-processing
 Over-processing refers to any component of the process of manufacture
that is unnecessary. Painting an area that will never be seen or adding

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 features that will not be used are examples of over-processing.
Essentially, it refers to adding more value than the customer requires.
 The environmental impact involves the excess of parts, labor, and raw
materials consumed in production. Time, energy, and emissions are
wasted when they are used to produce something that is unnecessary in
a product; simplification and efficiency reduce these wastes and benefit
the company and the environment.
 Waiting
 Waiting refers to wasted time because of slowed or halted production in
one step of the production chain while a previous step is completed. To
take the classic example, the production line, if one task along the chain
takes longer than another, than any time the employee in charge of the
next task spends waiting is wasted. The task that takes more time must
be made more efficient, other employees must be hired to help, or the
workflow must be better coordinated or scheduled in order to make up
for this wasted time.
 The environmental impact comes from the wasted labor and energy
from lighting, heating, or cooling during the waiting period. Additionally,
material can be spoiled, and components could be damaged because of
an inefficient workflow.
 Transport
 Transport is moving materials from one position to another. The
transport itself adds no value to the product, so minimizing these costs is
essential. This means having one plant closer to another in the
production chain, or minimizing the costs of transportation using more
efficient methods. Resources and time are used in handling material,
employing staff to operate transportation, training, implement safety
precautions, and using extra space. Transport can also cause the waste
of waiting, as one part of the production chain must wait for material to
arrive.
 Environmental costs to waiting include gas emissions, transportation
packaging used, possible damage to the product en route, as well as a
whole host of other wastes involving transporting hazardous materials.

This will reduce the batch time consumption and also the power
consumption. Hence, these are the factors from which we can optimize
our cost of production.

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 4.MAJOR EQUIPMENTS
4.1 PUMPS
A pump is a device that moves fluids (liquids or gases), or sometimes slurries,
by mechanical action. Pumps can be classified into three major groups
according to the method they use to move the fluid: direct lift, displacement,
and gravity pumps.[1]
Pumps operate by some mechanism (typically reciprocating or rotary), and
consume energy to perform mechanical work for moving the fluid. Pumps
operate via many energy sources, including manual
operation, electricity, engines, or wind power, come in many sizes, from
microscopic for use in medical applications to large industrial pumps.
Mechanical pumps serve in a wide range of applications such as pumping
water from wells, aquarium filtering, pond filtering and aeration, in the car
industry for water-cooling and fuel injection, in the energy
industry for pumping oil and natural gas or for operating cooling towers. In
the medical industry, pumps are used for biochemical processes in developing
and manufacturing medicine, and as artificial replacements for body parts, in
particular the artificial heart and penile prosthesis.
When a casing contains only one revolving impeller, it is called a single stage
pump. When a casing contains two or more revolving impellers, it is called a
double or multi-stage pump.

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4.1.1 RECIPROCATING PUMP (PISTON)
Piston pumps, Plunger pumps, and Diaphragm are examples of reciprocating
pumps. In a Piston pump, liquid is drawn into check valve into the cylinder by
withdrawal of piston and then is forced out through a discharge check valve on
the return stroke. Most piston pumps are double- acting with liquid admitted
alternately on each side of the piston so that one part of the cylinder is being
filled while the other is being emptied. Often two or more cylinders are used in
parallel with common suction and discharge headers , and the configurations
of the pistons is adjusted to minimize the fluctuations in the discharge rate.
The piston may be motor driven through reducing gears, or steam cylinder may
be used to drive the piston rod directly. The maximum discharge pumps
pressure for commercial piston pumps is about 50 ATM.

The mechanical efficiency of reciprocating piston pumps varies from 40 to 50

percent for small pumps to 70 to 90 percent for large ones. It is nearly
independent of speed within normal operating limits and decreases slightly
with an increase in discharge pressure because of added friction and leakage.

CHANGE OVER OF PUMP

In industry , for a operation there are 2 pumps : one in standby mode, other in
operation mode. during an operation if one pump is malfunctioning then
change over of pumps is done as pump1 is closed, then discharge of pump1 is
closed. Discharge of pump2 is open and then pump 2 is open.

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4.1.2 GEAR PUMP
A wide variety of rotary displacement pumps are available. They bear such
names as gear pumps, lobe pumps, vane pumps. Unlike reciprocating pumps ,
these have no check valves. Close tolerances between the moving and
stationary parts minimizing leakage from the discharge space back to suction
space; they also limit the operating speed. Gear pumps operate best on clean ,
moderately viscous fluids, such as light lubricating oil. Discharge pressure upto
200 atm or more can be attained.

In gear pumps intermeshing gears rotate with close clearance inside the casing.
Liquid entering the suction , line at the bottom of casing is caught in spaces
between the teeth and the casing and is carried out to the top of the casing
and forced out the discharge. Liquid cannot short circuit back to the suction
because of the close meshing of gears in the center of pump.

CHANGE OVER OF PUMP

It is same as the reciprocating piston pump.

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4.1.3 CENTRIFUGAL PUMPS
Centrifugal pumps are a sub-class of dynamic axisymmetric work-
absorbing turbomachinery. Centrifugal pumps are used to transport fluids by
the conversion of rotational kinetic energy to the hydrodynamic energy of the
fluid flow. The rotational energy typically comes from an engine or electric
motor. The fluid enters the pump impeller along or near to the rotating axis
and is accelerated by the impeller, flowing radially outward into a diffuser
or volute chamber (casing), from where it exits.
Common uses include water, sewage, petroleum and petrochemical pumping;
a centrifugal fan is commonly used to implement a vacuum cleaner. The
reverse function of the centrifugal pump is a water turbine converting
potential energy of water pressure into mechanical rotational energy.
Like most pumps, a centrifugal pump converts rotational energy, often from a
motor, to energy in a moving fluid. A portion of the energy goes into kinetic
energy of the fluid. Fluid enters axially through eye of the casing, is caught up
in the impeller blades, and is whirled tangentially and radially outward until it
leaves through all circumferential parts of the impeller into the diffuser part of
the casing. The fluid gains both velocity and pressure while passing through the
impeller. The doughnut-shaped diffuser, or scroll, section of the casing
decelerates the flow and further increases the pressure.
CHANGE OVER OF PUMP
In industry , for a operation there are 2 pumps : one in standby mode, other in
operation mode. during an operation if one pump is malfunctioning then
change over of pumps is done as discharge of pump1 is closed, then pump1 is
closed, then suction of pump2 is opened. Suction of pump1 is close and then
pump 2 is open and finally the discharge of pump2 is opened.

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4.2 HEAT EXCHANGER
A heat exchanger is a device used to transfer heat between a solid object and
a fluid, or between two or more fluids. The fluids may be separated by a solid
wall to prevent mixing or they may be in direct contact.[1] They are widely used
in space heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing,
and sewage treatment. The classic example of a heat exchanger is found in
an internal combustion engine in which a circulating fluid known as engine
coolant flows through radiator coils and air flows past the coils, which cools
the coolant and heats the incoming air. Another example is the heat sink,
which is a passive heat exchanger that transfers the heat generated by an
electronic or a mechanical device to a fluid medium, often air or a liquid
coolant.

4.2.1 SHELL AND TUBE HEAT EXCHANGER

Shell and tube heat exchangers consist of series of tubes. One set of these
tubes contains the fluid that must be either heated or cooled. The second fluid
runs over the tubes that are being heated or cooled so that it can either
provide the heat or absorb the heat required. A set of tubes is called the tube
bundle and can be made up of several types of tubes: plain, longitudinally
finned, etc. Shell and tube heat exchangers are typically used for high-pressure
applications (with pressures greater than 30 bar and temperatures greater
than 260 °C). This is because the shell and tube heat exchangers are robust due
to their shape.
Several thermal design features must be considered when designing the tubes
in the shell and tube heat exchangers: There can be many variations on the
shell and tube design. Typically, the ends of each tube are connected to
plenums (sometimes called water boxes) through holes in tubesheets. The
tubes may be straight or bent in the shape of a U, called U-tubes.

 Tube diameter: Using a small tube diameter makes the heat exchanger
both economical and compact. However, it is more likely for the heat
exchanger to foul up faster and the small size makes mechanical cleaning of
the fouling difficult. To prevail over the fouling and cleaning problems,
larger tube diameters can be used. Thus to determine the tube diameter,
the available space, cost and fouling nature of the fluids must be
considered.
 Tube thickness: The thickness of the wall of the tubes is usually determined
to ensure:

21
  There is enough room for corrosion
 That flow-induced vibration has resistance
 Axial strength
 Availability of spare parts
 Hoop strength (to withstand internal tube pressure)
 Buckling strength (to withstand overpressure in the shell)
 Tube length: heat exchangers are usually cheaper when they have a smaller
shell diameter and a long tube length. Thus, typically there is an aim to
make the heat exchanger as long as physically possible whilst not exceeding
production capabilities. However, there are many limitations for this,
including space available at the installation site and the need to ensure
tubes are available in lengths that are twice the required length (so they
can be withdrawn and replaced). Also, long, thin tubes are difficult to take
out and replace.
 Tube pitch: when designing the tubes, it is practical to ensure that the tube
pitch (i.e., the centre-centre distance of adjoining tubes) is not less than
1.25 times the tubes' outside diameter. A larger tube pitch leads to a larger
overall shell diameter, which leads to a more expensive heat exchanger.
 Tube corrugation: this type of tubes, mainly used for the inner tubes,
increases the turbulence of the fluids and the effect is very important in the
heat transfer giving a better performance.
 Tube Layout: refers to how tubes are positioned within the shell. There are
four main types of tube layout, which are, triangular (30°), rotated
triangular (60°), square (90°) and rotated square (45°). The triangular
patterns are employed to give greater heat transfer as they force the fluid
to flow in a more turbulent fashion around the piping. Square patterns are
employed where high fouling is experienced and cleaning is more regular.
 Baffle Design: baffles are used in shell and tube heat exchangers to direct
fluid across the tube bundle. They run perpendicularly to the shell and hold
the bundle, preventing the tubes from sagging over a long length. They can
also prevent the tubes from vibrating. The most common type of baffle is
the segmental baffle. The semicircular segmental baffles are oriented at
180 degrees to the adjacent baffles forcing the fluid to flow upward and
downwards between the tube bundle. Baffle spacing is of large
thermodynamic concern when designing shell and tube heat exchangers.
Baffles must be spaced with consideration for the conversion of pressure
drop and heat transfer. For thermo economic optimization it is suggested
that the baffles be spaced no closer than 20% of the shell’s inner diameter.
Having baffles spaced too closely causes a greater pressure drop because of
flow redirection. Consequently, having the baffles spaced too far apart
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 means that there may be cooler spots in the corners between baffles. It is
also important to ensure the baffles are spaced close enough that the tubes
do not sag. The other main type of baffle is the disc and doughnut baffle,
which consists of two concentric baffles. An outer, wider baffle looks like a
doughnut, whilst the inner baffle is shaped like a disk. This type of baffle
forces the fluid to pass around each side of the disk then through the
doughnut baffle generating a different type of fluid flow.

4.2.2 PLATE HEAT EXCHANGER

Another type of heat exchanger is the plate heat exchanger. These exchangers
are composed of many thin, slightly separated plates that have very large
surface areas and small fluid flow passages for heat transfer. Advances
in gasket and brazing technology have made the plate-type heat exchanger
increasingly practical. In HVAC applications, large heat exchangers of this type
are called plate-and-frame; when used in open loops, these heat exchangers
are normally of the gasket type to allow periodic disassembly, cleaning, and
inspection. There are many types of permanently bonded plate heat
exchangers, such as dip-brazed, vacuum-brazed, and welded plate varieties,
and they are often specified for closed-loop applications such as refrigeration.
Plate heat exchangers also differ in the types of plates that are used, and in the
configurations of those plates. Some plates may be stamped with "chevron",

23
dimpled, or other patterns, where others may have machined fins and/or
grooves.
When compared to shell and tube exchangers, the stacked-plate arrangement
typically has lower volume and cost. Another difference between the two is
that plate exchangers typically serve low to medium pressure fluids, compared
to medium and high pressures of shell and tube. A third and important
difference is that plate exchangers employ more countercurrent flow rather
than cross current flow, which allows lower approach temperature differences,
high temperature changes, and increased efficiencies.

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4.3 REACTOR: AUTOCLAVE
In industry , slurry is being prepared in autoclave reactor . These reactors are
used when very high pressures are required or when the feed is a solid or
slurry. The reactors ranging in size from 250 cm3 to 1 liter can be used at
pressures and temperatures up to 5000 psig and 932°F (500°C). The 1-gallon
autoclave is rated to 5100 psig and 950°F (510°C), and the 2-gallon autoclave is
rated to 5500 psig and 650°F (340°C).

The 250-, 500-, and 1000-cm3 reactors are all equipped with magnetically
driven mixing impellers and baffles; diptubes for gas inlet or liquid sampling;
PID (proportional-integral-derivative)-controlled water cooling; headspace
ports for gas venting and liquid addition; thermocouples for monitoring the
heater, liquid, and gas temperatures; condensers; and inline vent traps for
bubbling product gas through liquid scrubbing solutions. The 1-liter reactor is
also equipped with a bottom drain for removing liquid without opening or
lifting the reactor. All gas and liquid feed can be metered into the reactors
manually or by computer control from behind a blast wall. Gas can be
automatically metered into the reactor to maintain a pressure set point when
constant pressure is required in a gas-consuming reaction.

The 1- and 2-gallon reactors are equipped with heaters, gas fill and vent lines,
and a vacuum pump to assist in venting or to run reactions at below
atmospheric pressure. Vent lines run to a water-cooled condenser for
collecting volatile product. The 2-gallon autoclave is heated in four separate
bands to help maintain constant temperature throughout. This reactor is
stirred by a belt-driven water-cooled mixer with two propellers and an impeller
along the shaft length. The 1-gallon autoclave is heated by a single-zone
heater. The 1-gallon reactor can be run with or without a mixer and is
equipped with a bottom drain for liquid removal. Both reactors are equipped
with thermocouples at top and bottom for monitoring the temperature of both
the vapor and liquid phases.

Several systems are available, ranging in volume from 100 mL to 2 gallons, with
pressure ratings to 6000 psi, automated heatup and cooldown, constant

25
hydrogen pressure regulation, and computer control and recording of runs. In
industrial operation, it operate at 55 kg per square cm. pressure and it is
designed for 70 kg per square cm. pressure. It has a operation temperature
range between 255-260 degree Celsius. It has stainless steel as material of
construction. For the safety of Autoclave, it has 3 safety valves in series as
pressure safety valve(PSV) followed by Repture disk(RD) followed again by
another PSV.

4.4 DISTILLATION COLUMN: PACKED

TOWER

Packed columns are used for distillation, gas absorption and liquid-liquid
extraction.

The gas-liquid contact in a packed column is continuous, not stage-wise, as in a

plate column. The liquid flows down in the column over a packing surface and
the vapor (or the gas) moves counter-currently, up the column. The
performance of a packed column is very dependent on the maintenance of

26
good liquid and gas distribution through the packed bed, and this is an
important consideration in packed column design.

There are some advantages and disadvantages for the plate and the packed
columns.

1. Plate columns can be designed to handle a wider range of liquid and gas
flow rates than packed columns.
2. Packed columns are not suitable for very low liquid flow rates.
3. The efficiency of a plate can be predicted more accurately than the
equivalent terms of packings (HETP or HTU).
4. For corrosive liquids a packed column will usually be cheaper than the
equivalent plate column.
5. The liquid hold-up is lower in a packed column than in a plate column. This
can be important when the hold-up of toxic or flammable liquids must be
kept as small as possible for safety reasons.
6. Packed columns are more suitable for handling foaming systems.
The pressure drop can be lower in a packed column than the equivalent plate
column

DESIGN OF PACKED TOWER

PACKING- Structured packing
HEIGHT AND DIAMETER- 42 Meter and 800 MM.

27
4.5 DECANTER
A centrifuge is a device which employs a high rotational speed to separate
components of different densities. This becomes relevant in the majority of
industrial jobs where solids, liquids and gases are merged into a single mixture
and the separation of these different phases is necessary. A decanter
centrifuge separates solid materials from liquids in slurry and therefore plays
an important role in wastewater treatment, chemical, oil and food processing
industries. There are several factors that affect the performance of a decanter
centrifuge and some design heuristics to be followed which are dependent
upon given applications. In oil well drilling fluid process, decanter centrifuge is
the 5th purification equipment in whole mud system.

The operating principle of a decanter centrifuge is based on separation

via buoyancy. Naturally, a component with a higher density would fall to the
bottom of a mixture, while the less dense component would be suspended
above it. A decanter centrifuge increases the rate of settling through the use of
continuous rotation, producing a force equivalent to between 1000 and
4000 G's. This reduces the settling time of the components by a large
magnitude, whereby mixtures previously having to take hours to settle can be
settled in a matter of seconds using a decanter centrifuge. This form of
separation enables more rapid and controllable results.

28
4.6 EJECTOR
 What is Ejector? : An ejector is a device used to suck the gas or
vapour from the desired vessel or system. An ejector is similar to of
vacuum pump or compressor. The major difference between the
ejector and the vacuum pump or compressor is it had no moving parts.
Hence it is relatively low-cost and easy to operate and maintenance
free equipment.

 Principle of Ejector: The operating principle of the ejector is the

pressure energy in the motive fluid is converted to velocity energy by
an adiabatic expansion in the Converging/Diverging Nozzle. Due to the
pressure drop of the motive fluid, it will create a low-pressure zone
before the mixing chamber. Due to the low-pressure zone, the suction
fluid will start to move to toward it and mix with motive fluid in the
mixing chamber. In mixed fluid enter the diverging portion of the
ejector where its velocity energy is converted into Pressure energy.

PARTS OF EJECTOR:
STEAM CHEST. This is the connection through which the high pressure motive
steam supply is introduced.

SUCTION CHAMBER. This provides a plenum chamber with the

appropriate connections for the suction inlet, diffuser and steam nozzle. This
part can sometimes be eliminated by incorporating the diffuser connection

29
and steam nozzle connection in the vessel which is to be evacuated.
Frequently more compact designs and savings in cost can result from such
designs.

STEAM NOZZLE. This is the heart of an ejector since it converts the energy of
pressure to velocity and directs the flow of motive steam into the diffuser.

INLET DIFFUSER. This provides a correctly shaped introductory section and

converging diffuser section to handle the high velocity flow of fluids. It is in
this section that entrainment and mixing of the motive and load fluids is
completed and the energy of supersonic velocity is converted to pressure.

THROAT SECTION. This is the transition piece between the converging

supersonic inlet diffuser and the diverging subsonic outlet diffuser.

OUTLET DIFFUSER. This provides a correctly shaped diverging diffuser section

for completing the conversion of velocity to pressure. After the fluid flow has
passed through the throat of the diffuser, the flow is essentially subsonic. The
outlet diffuser section further reduces the fluid velocity to a reasonable level
so as to convert practically all the velocity energy to pressure energy.

 Benefits of Ejector
o Ejectors can be operated with many different motive fluids:
steam, air, organic vapour and other gases.
o No moving parts, no lubrication, no vibration. Hence low
maintenance cost when to compare with other peer equipment.
o Ejectors can be installed indoors or outdoors without
restriction.
o Can be installed at any orientation. Hence space requirement
will be very low.
o Initial cost is very less and no spares required.
o Easy to handle corrosive and slugging liquids.

30
4.7 ROTAMETER
A rotameter is a device that measures the volumetric flow rate of fluid in a
closed tube.
It belongs to a class of meters called variable area meters, which measure flow
rate by allowing the cross-sectional area the fluid travels through to vary,
causing a measurable effect
A rotameter consists of a tapered tube, typically made of glass with a 'float' (a
shaped weight, made either of anodized aluminum or a ceramic), inside that is
pushed up by the drag force of the flow and pulled down by gravity. The drag
force for a given fluid and float cross section is a function of flow speed
squared only, see drag equation.
A higher volumetric flow rate through a given area increases flow speed and
drag force, so the float will be pushed upwards. However, as the inside of the
rotameter is cone shaped (widens), the area around the float through which
the medium flows increases, the flow speed and drag force decrease until
there is mechanical equilibrium with the float's weight.
Floats are made in many different shapes, with spheres and ellipsoids being
the most common. The float may be diagonally grooved and partially colored
so that it rotates axially as the fluid passes. This shows if the float is stuck since
it will only rotate if it is free. Readings are usually taken at the top of the
widest part of the float; the center for an ellipsoid, or the top for a cylinder.
Some manufacturers use a different standard.
The "float" must not float in the fluid: it has to have a higher density than the
fluid, otherwise it will float to the top even if there is no flow.
The mechanical nature of the measuring principle provides a flow
measurement device that does not require any electrical power. If the tube is
made of metal, the float position is transferred to an external indicator via a
magnetic coupling. This capability has considerably expanded the range of
applications for the variable area flowmeter, since the measurement can
observed remotely from the process or used for automatic control.

31
4.8 VALVES
A valve is a device that regulates, directs or controls the flow of a fluid (gases,
liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing
various passageways. Valves are technically fittings, but are usually discussed
as a separate category. In an open valve, fluid flows in a direction from higher
pressure to lower pressure. The word is derived from the Latin valva, the
moving part of a door, in turn from volvere, to turn, roll.
The simplest, and very ancient, valve is simply a freely hinged flap which drops
to obstruct fluid (gas or liquid) flow in one direction, but is pushed open by
flow in the opposite direction. This is called a check valve, as it prevents or
"checks" the flow in one direction. Modern control valves may
regulate pressureor flow downstream and operate on
sophisticated automation systems.
Valves have many uses, including controlling water for irrigation, industrial
uses for controlling processes, residential uses such as on/off and pressure
control to dish and clothes washers and taps in the home. Even aerosols have a
tiny valve built in. Valves are also used in the military and transport sectors.

TYPES OF VALVES
4.8.1 GATE VALVE: A gate valve, also known as a sluice valve, is
a valve which opens by lifting a round or rectangular gate/wedge out of the
path of the fluid. The distinct feature of a gate valve is the sealing surfaces
between the gate and seats are planar, so gate valves are often used when a
32
straight-line flow of fluid and minimum restriction is desired. The gate faces
can be parallel, but are most commonly wedge-shaped. Gate valves are
primarily used to permit or prevent the flow of liquids, but typical gate valves
shouldn't be used for regulating flow, unless they are specifically designed for
that purpose. Because of their ability to cut through liquids, gate valves are
often used in the petroleum industry. For extremely thick fluids, a specialty
valve often known as a knife gate valve is used to cut through the liquid. On
opening the gate valve, the flow path is enlarged in a highly nonlinear manner
with respect to percent of opening. This means that flow rate does not change
evenly with stem travel. Also, a partially open gate tends to vibrate from the
fluid flow. Most of the flow change occurs near shutoff with a relatively high
fluid velocity causing gate and seat wear and eventual leakage if used to
regulate flow. Typical gate valves are designed to be fully opened or closed.
When fully open, the typical gate valve has no obstruction in the flow path,
resulting in very low friction loss.
Gate valves are actuated by a threaded stem which connects the actuator (e.g.
handwheel or motor) to the gate. They are characterised as having either a
rising or a nonrising stem, depending on which end of the stem is threaded.
Rising stems are fixed to the gate and rise and lower together as the valve is
operated, providing a visual indication of valve position. The actuator takes the
form of a nut which is rotated around the threaded stem to move it. Nonrising
stem valves are fixed to, and rotate with, the actuator, and are threaded into
the gate. They may have a pointer threaded onto the upper end of the stem to
indicate valve position, since the gate's motion is concealed inside the valve.
Non rising stems are used underground or where vertical space is limited.
4.8.2 GLOBE VALVE: A globe valve, different from ball valve, is a type
of valve used for regulating flow in a pipeline, consisting of a movable disk-type
element and a stationary ring seat in a generally spherical body.[1]
Globe valves are named for their spherical body shape with the two halves of
the body being separated by an internal baffle. This has an opening that forms
a seat onto which a movable plug can be screwed in to close (or shut) the
valve. The plug is also called a disc or disk. In globe valves, the plug is
connected to a stem which is operated by screw action using a handwheel in
manual valves. Typically, automated globe valves use smooth stems rather
than threaded and are opened and closed by an actuator assembly.

33
4.8.3 BALL VALVE:
A ball valve is a form of quarter-turn valve which uses a hollow, perforated and
pivoting ball to control flow through it. It is open when the ball's hole is in line
with the flow and closed when it is pivoted 90-degrees by the valve
handle.[1] The handle lies flat in alignment with the flow when open, and is
perpendicular to it when closed, making for easy visual confirmation of the
valve's status.[2]
Ball valves are durable, performing well after many cycles, and reliable, closing
securely even after long periods of disuse. These qualities make them an
excellent choice for shutoff and control applications, where they are often
preferred to gates and globe valves, but they lack their fine control in throttling
applications.
The ball valve's ease of operation, repair, and versatility lend it to extensive
industrial use, supporting pressures up to 1000 bar and temperatures up to
752 °F (400 °C), depending on design and materials used. Sizes typically range
from 0.2 to 48 inches (0.5 cm to 121 cm). Valve bodies are made
of metal, plastic, or metal with a ceramic; floating balls are often chrome
plated for durability. One disadvantage of a ball valve is that they trap water in
the center cavity while in the closed position. In the event of a freeze, the sides
can crack due to expansion of ice forming. Some means of insulation or heat
tape in this situation will usually prevent damage. Another option for cold
climates is the "freeze tolerant ball valve". This style of ball valve incorporates
a freeze plug in the side so in the event of a freeze up, the freeze plug ruptures
(acts as a sacrificial disk), thus making for an easy repair. Now instead of
replacing the whole valve, just screw in a new freeze plug.
In the case that a ball valve is used for cryogenics or product that may expand
inside of the ball, there is a vent drilled into the upstream side of the valve.
This is referred to as a vented ball. Safety is the number one concern when
engineers specify a vented ball.
A ball valve should not be confused with a "ball-check valve", a type of check
valve that uses a solid ball to prevent undesired backflow.

34
4.8.4 CONTROL VALVE: A control valve is a valve used to control fluid
flow by varying the size of the flow passage as directed by a signal from a
controller. This enables the direct control of flow rate and the consequential
control of process quantities such as pressure, temperature,
and liquid level.In automatic control terminology a control valve is termed a
"final control element"
The opening or closing of automatic control valves is usually done
by electrical, hydraulic or pneumatic actuators. Normally with a modulating
valve, which can be set to any position between fully open and fully closed,
valve positioners are used to ensure the valve attains the desired degree of
opening.Air-actuated valves are commonly used because of their simplicity, as
they only require a compressed air supply, whereas electrically-operated
valves require additional cabling and switch gear, and hydraulically-actuated
valves required high pressure supply and return lines for the hydraulic fluid.
The pneumatic control signals are traditionally based on a pressure range of 3-
15psi (0.2-1.0 bar), or more commonly now, an electrical signal of 4-20mA for
industry, or 0-10V for HVAC systems. Electrical control now often includes a
"Smart" communication signal superimposed on the 4-20mA control current,
such that the health and verification of the valve position can be signalled back
to the controller. The HART, Fieldbus Foundation, and Profibus are the most
common protocols.
An automatic control valve consists of three main parts in which each part exist
in several types and designs:

 Valve actuator - which moves the valve's modulating element, such as ball
or butterfly.
 Valve positioner - Which ensures the valve has reached the desired degree
of opening. This overcomes the problems of friction and wear.
 Valve body - in which the modulating element, a plug, globe, ball or
butterfly, is contained.

35
4.8.5 BUTTERFLY VALVE: A butterfly valve is a valve that isolates or
regulates the flow of a fluid. The closing mechanism is a disk that rotates.
Operation is similar to that of a ball valve, which allows for quick shut off.
Butterfly valves are generally favored because they cost less than other valve
design, and are lighter weight so they need less support. The disc is positioned
in the center of the pipe. A rod passes through the disc to an actuator on the
outside of the valve. Rotating the actuator turns the disc either parallel or
perpendicular to the flow. Unlike a ball valve, the disc is always present within
the flow, so it induces a pressuredrop, even when open.
A butterfly valve is from a family of valves called quarter-turn valves. In
operation, the valve is fully open or closed when the disc is rotated a quarter
turn. The "butterfly" is a metal disc mounted on a rod. When the valve is
closed, the disc is turned so that it completely blocks off the passageway.
When the valve is fully open, the disc is rotated a quarter turn so that it allows
an almost unrestricted passage of the fluid. The valve may also be opened
incrementally to throttle flow.
There are different kinds of butterfly valves, each adapted for different
pressures and different usage. The zero-offset butterfly valve, which uses the
flexibility of rubber, has the lowest pressure rating. The high-performance
double offset butterfly valve, used in slightly higher-pressure systems, is offset
from the centre line of the disc seat and body seal (offset one), and the centre
line of the bore (offset two). This creates a cam action during operation to lift
the seat out of the seal resulting in less friction than is created in the zero
offset design and decreases its tendency to wear. The valve best suited for
high-pressure systems is the triple offset butterfly valve. In this valve the disc
seat contact axis is offset, which acts to virtually eliminate sliding contact
between disc and seat. In the case of triple offset valves the seat is made of
metal so that it can be machined such as to achieve a bubble tight shut-off
when in contact with the disc.

36
4.8.6 PRESSURE SAFETY VALVE: A safety valve is a valve that acts as
a fail-safe. An example of safety valve is a pressure relief valve (PRV), which
automatically releases a substance from a boiler, pressure vessel, or
other system, when the pressure or temperature exceeds preset limits. Pilot-
operated relief valves are a specialized type of pressure safety valve. A leak
tight, lower cost, single emergency use option would be a rupture disk.Safety
valves were first developed for use on steam boilers during the Industrial
Revolution. Early boilers operating without them were prone
to explosion unless carefully operated.
Vacuum safety valves (or combined pressure/vacuum safety valves) are used
to prevent a tank from collapsing . In 1856, John Ramsbottom invented a
tamper-proof spring safety valve that became universal on railways. The
Ramsbottom valve consisted of two plug-type valves connected to each other
by a spring-laden pivoting arm, with one valve element on either side of the
pivot. Any adjustment made to one of valves in an attempt to increase its
operating pressure would cause the other valve to be lifted off its seat,
regardless of how the adjustment was attempted. The pivot point on the arm
was not symmetrically between the valves, so any tightening of the spring
would cause one of the valves to lift. Only by removing and diassembling the
entire valve assembly could its operating pressure be adjusted, making
impromptu 'tying down' of the valve by locomotive crews in search of more
power impossible. The pivoting arm was commonly extended into a handle
shape lead back into the locomotive cab, allowing crews to 'rock' both valves
off their seats to confirm they were set and operating correctly.
Safety valves also evolved to protect equipment such as pressure vessels (fired
or not) and heat exchangers. The term safety valve should be limited to
compressible fluid applications (gas, vapor, or steam).

37
4.8.7 CHECK VALVES: A check valve, clack valve, non-return valve, reflux
valve, retention valve or one-way valve is a valve that normally
allows fluid (liquid or gas) to flow through it in only one direction. An
important concept in check valves is the cracking pressure which is the
minimum upstream pressure at which the valve will operate. Typically the
check valve is designed for and can therefore be specified for a specific
cracking pressure.
A ball check valve is a check valve in which the closing member, the movable
part to block the flow, is a ball. In some ball check valves, the ball is spring-
loaded to help keep it shut. For those designs without a spring, reverse flow is
required to move the ball toward the seat and create a seal. The interior
surface of the main seats of ball check valves are more or less conically-
tapered to guide the ball into the seat and form a positive seal when stopping
reverse flow.
Ball check valves are often very small, simple, and cheap. They are commonly
used in liquid or gel minipump dispenser spigots, spray devices, some rubber
bulbs for pumping air, etc., manual air pumps and some other pumps, and
refillable dispensing syringes. Although the balls are most often made of metal,
they can be made of other materials; in some specialized cases out of highly
durable or inert materials, such as sapphire. High pressure HPLC pumps and
similar applications commonly use small inlet and outlet ball check valves with
balls of (artificial) ruby and seats made of sapphire or both ball and seat of
ruby, for both hardness and chemical resistance. After prolonged use, such
check valves can eventually wear out or the seat can develop a crack, requiring
replacement. Therefore, such valves are made to be replaceable, sometimes
placed in a small plastic body tightly-fitted inside a metal fitting which can
withstand high pressure and which is screwed into the pump head.
There are similar check valves where the disc is not a ball, but some other
shape, such as a poppet energized by a spring. Ball check valves should not be
confused with ball valves, which is a different type of valve in which a ball acts
as a controllable rotor to stop or direct flow.

38
5. UTILITIES
Utilities are those things which are used in the day to day lie. In the plant
phenomena the utilities are those things which are used in the plants very
actively but do not take part in the process or reaction directly.
The examples of utilities are natural gas, hot oil, cooling water,
steam, Instrument air, chilled brine.

5.1 NATURAL GAS: Natural gas is a naturally

occurring hydrocarbon gas mixture consisting primarily of methane, but
commonly including varying amounts of other higher alkanes, and sometimes a
small percentage of carbon dioxide, nitrogen, hydrogen sulfide, or helium. It is
formed when layers of decomposing plant and animal matter are exposed to
intense heat and pressure under the surface of the Earth over millions of years.
The energy that the plants originally obtained from the sun is stored in the
form of chemical bonds in the gas. Natural gas can generate temperatures in
excess of 1,100 °C (2,000 °F) making it a powerful heating fuel. Both North
America and Europe are major consumers of natural gas.it also has a high
calorific value of 13 kilo calorie per gram.

5.2 THERMIC FLUID HEATER ( HOT OIL): In process heating, the

hot oil is been used. The hot oil is being supplied at 180 degree Celsius to plant
which is fed at 60 degree Celsius to TFH. This thermic fluid has many
advantages over steam boiler.
1. Thermal Fluid Systems Don’t Need to Be Pressurized: Steam
heating systems require some level of pressure in order to function. With hot
oil heating systems, all of your equipment is non-pressurized. This decreases
the risk of dangerous explosions in your facility and eliminates the necessity of
monitoring and regulating system pressure levels continuously.
2. Hot Oil Does Not Cause Corrosion: Though steam based heating
systems are popular with some facility managers because water is an
affordable heating medium, they are also susceptible to corrosion. hot oil is a
lubricant and can run smoothly through a heating system without causing
corrosion.
3. Thermal Oil Systems Do Not Require Chemical
Regulation:With hot oil systems, you don’t have to worry about chemical
regulation. The thermal heating fluid runs through the system in a loop and
requires no chemical regulation.

39
4. Hot Oil Heating Systems Can Operate at Higher
Temperatures: When it comes to efficient heating, operating temperature
is very important. Since hot oil has a higher boiling point than water, hot oil
heating systems can operate at higher temperatures.
5. Thermal Heating Fluid Will Not Freeze: While water can freeze,
causing boiler system issues and hazards, thermal heating fluid will not freeze.
This eliminates the safety hazards and system operation issues that can be
caused by cold temperatures, another benefit of hot oil heating systems.

6. Hot Oil Heating is Safer Than Steam: Perhaps the most compelling
reason you may want to consider a thermal fluid heating system over a steam
heating system for your facility is safety. Hot oil heating is safer than heating
processes involving steam for a number of reasons. Since the system does not
require pressurization, the risk of a dangerous explosion is eliminated.

7.Hot Oil Heating Systems Require Less Capital Than Steam

Systems:Hot oil heating systems typically require less capital than boiler
systems as they are significantly simpler. Boiler system components include
boilers, blow down tanks, chemical feed tanks, deaerators, condensate tanks,
feed pumps for the boiler, feed pumps for the make-up water, pumps for the
chemical feed, steam traps – the list goes on and on. Hot oil heating systems
require only one pump, a heater and an expansion tank.

5.2.1 AIR PREHEATER: Thermic fluid heater also has Air pre-heater to
recover the heat from boiler flue gas which increases the thermal efficiency of
boiler by reducing the useful heat loss in flue gas. As consequence flue gases
are also conveyed to flue gas stack at low temperature to meet emission
regulations. Air pre heater blows the air at atmoshpheric pressure and it
exchanges heat with hot flue gases. After heat exchanges, hot flue gases at
lower temperature goes in chimney to atmosphere.

5.2.2 STEAM: There are mainly 3 types of steam in plant:

1) Low pressure steam(LPS)- It is mainly used in plant . It has pressure of 5
kg/cm^2.

2) Medium pressure steam(MPS)- It has pressure of 15-18 kg/cm^2.

3) High pressure steam(HPS)- it has pressure more than 18 kg/cm^2.

40
5.3 CHILLERS : In chillers , the brine is being chilled by refrigerant gases for
the supply of chilled brine as a utility in plant.

Its main components are described below:

5.3.1 BRINE: The addition of salt to water lowers the freezing temperature of
solution below the freezing point of water and heat transport efficiency can
easily be greatly enhanced. Such solutions are known as brine solutions. These
are used as secondary refrigerant in large refrigeration installments for the
transport of thermal energy from place to place .Being inexpensive most
common refrigerant brines are based on CaCl2,NaCl and glycols. The lowest
freezing point of NaCl brine is -21.1 degree Celsius at 23.3 wt% NaCl. In
industry, methanol as a brine is used.

5.3.2 REFRIGERANT GASES: The cooling system contains refrigerant

gases inside coils.it absorb heat from solution, and it transitions from low
pressure gas to high pressure liquid. Earlier Hydrochlorofluoro carbons were
used as refrigerant gaes but later chlorine was removed as it cause the ozone
layer depletion. Now hydrofluoro carbons are used as refrigerant gases. R-
410A is the most common refrigerant used in AC.

5.3.3 ACCUMULATOR: It is the device that used to store the energy of

liquid under pressure and make this energy available to hydraulic machines
such as air cranes, lift , press. when liquid at high pressure enters , the ram lift
from its rest position. When ram is at its highest position .the accumulator has
highest stored energy. With the help of weight, it convey the desired energy to
needed equipment.

41
5.3.4 ECONOMIZER: It works as the heat exchanger which increase its
efficiency of exchanging heat.it operatelly internally in system with internal
utilization .
A common form of refrigeration economizer is a "walk-in cooler economizer"
or "outside air refrigeration system". In such a system outside air that is cooler
than the air inside a refrigerated space is brought into that space and the same
amount of warmer inside air is ducted outside. The resulting cooling
supplements or replaces the operation of a compressor-based refrigeration
system. If the air inside a cooled space is only about 5 °F warmer than the
outside air that replaces it (that is, the ∆T>5 °F) this cooling effect is
accomplished more efficiently than the same amount of cooling resulting from
a compressor based system. If the outside air is not cold enough to overcome
the refrigeration load of the space the compressor system will need to also
operate, or the temperature inside the space will rise.

5.3.5 COMPRESSOR: A compressor is a mechanical device that increases

the pressure of a gas by reducing its volume. An air compressor is a specific
type of gas compressor.Compressors are similar to pumps: both increase the
pressure on a fluid and both can transport the fluid through a pipe. As gases
are compressible, the compressor also reduces the volume of a gas. Liquids are
relatively incompressible; while some can be compressed, the main action of a
pump is to pressurize and transport liquids.
Rotary screw compressors use two meshed rotating positive-
displacement helical screws to force the gas into a smaller space. These are
usually used for continuous operation in commercial and industrial
applications and may be either stationary or portable. Their application can be
from 3 horsepower (2.2 kW) to over 1,200 horsepower (890 kW) and from low
pressure to moderately high pressure (>1,200 psi or 8.3 MPa).
The classifications of rotary screw compressors vary based on stages, cooling
methods, and drive types among others. Rotary screw compressors are
commercially produced in Oil Flooded, Water Flooded and Dry type.

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5.4 COOLING WATER: The cooling water is used as utility for condensing
the liquid in the condenser. The hot water is supplied to cooling tower and
cooling water is supplied by cooling tower with the temperature difference of
8 to 10 degree Celsius.
5.4.1 COOLING TOWER: A cooling tower is a heat rejection device that
rejects waste heat to the atmosphere through the cooling of a water stream to
a lower temperature. Cooling towers may either use the evaporation of water
to remove process heat and cool the working fluid to near the wet-bulb air
temperature or, in the case of closed circuit dry cooling towers, rely solely on
air to cool the working fluid to near the dry-bulb air temperature.
Common applications include cooling the circulating water used in oil
refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is based on
the type of air induction into the tower: the main types of cooling towers
are natural draft and induced draft cooling towers.
Cooling towers vary in size from small roof-top units to very large hyperboloid
structures (as in the adjacent image) that can be up to 200 metres (660 ft) tall
and 100 metres (330 ft) in diameter, or rectangular structures that can be over
40 metres (130 ft) tall and 80 metres (260 ft) long. The hyperboloid cooling
towers are often associated with nuclear power plants,[1] although they are
also used in some coal-fired plants and to some extent in some large chemical
and other industrial plants. Although these large towers are very prominent,
the vast majority of cooling towers are much smaller, including many units
installed on or near buildings to discharge heat from air conditioning.
AIR FLOW GENERATION METHODS:
With respect to drawing air through the tower, there are three types of cooling
towers:

 Natural draft — Utilizes buoyancy via a tall chimney. Warm, moist

air naturally rises due to the density differential compared to the dry,
cooler outside air. Warm moist air is less dense than drier air at the same
pressure. This moist air buoyancy produces an upwards current of air
through the tower.
 Mechanical draft — Uses power-driven fan motors to force or draw air
through the tower.
 Induced draft — A mechanical draft tower with a fan at the discharge
(at the top) which pulls air up through the tower. The fan induces hot
moist air out the discharge. This produces low entering and high exiting

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 air velocities, reducing the possibility of recirculation in which
discharged air flows back into the air intake. This fan/fin arrangement is
also known as draw-through.
 Forced draft — A mechanical draft tower with a blower type fan at the
intake. The fan forces air into the tower, creating high entering and low
exiting air velocities. The low exiting velocity is much more susceptible
to recirculation. With the fan on the air intake, the fan is more
susceptible to complications due to freezing conditions. Another
disadvantage is that a forced draft design typically requires more motor
horsepower than an equivalent induced draft design. The benefit of the
forced draft design is its ability to work with high static pressure. Such
setups can be installed in more-confined spaces and even in some
indoor situations. This fan/fin geometry is also known as blow-through.
 Fan assisted natural draft — A hybrid type that appears like a natural draft
setup, though airflow is assisted by a fan.
CATEGORIZATION BY AIR TO WATER FLOW
CROSS FLOW:
Typically lower initial and long-term cost, mostly due to pump requirements.
Crossflow is a design in which the air flow is directed perpendicular to the
water flow (see diagram below). Air flow enters one or more vertical faces of
the cooling tower to meet the fill material. Water flows (perpendicular to the
air) through the fill by gravity. The air continues through the fill and thus past
the water flow into an open plenum volume. Lastly, a fan forces the air out
into the atmosphere.
A distribution or hot water basin consisting of a deep pan with holes
or nozzles in its bottom is located near the top of a crossflow tower. Gravity
distributes the water through the nozzles uniformly across the fill material.
Advantages of the crossflow design:

 Gravity water distribution allows smaller pumps and maintenance while in

use.
 Non-pressurized spray simplifies variable flow.
Disadvantages of the crossflow design:

 More prone to freezing than counterflow designs.

 Variable flow is useless in some conditions.
 More prone to dirt buildup in the fill than counterflow designs, especially in
dusty or sandy areas

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COUNTERFLOW: In a counterflow design, the air flow is directly opposite to the
water flow (see diagram below). Air flow first enters an open area beneath the
fill media, and is then drawn up vertically. The water is sprayed through
pressurized nozzles near the top of the tower, and then flows downward
through the fill, opposite to the air flow.
Advantages of the counterflow design:

 Spray water distribution makes the tower more freeze-resistant.

 Breakup of water in spray makes heat transfer more efficient.
Disadvantages of the counterflow design:

 Typically higher initial and long-term cost, primarily due to pump

requirements.
 Difficult to use variable water flow, as spray characteristics may be
negatively affected.
 Typically noisier, due to the greater water fall height from the bottom of
the fill into the cold water basin
Common aspects of both designs:

 The interactions of the air and water flow allow a partial equalization of
temperature, and evaporation of water.
 The air, now saturated with water vapor, is discharged from the top of the
cooling tower.
 A "collection basin" or "cold water basin" is used to collect and contain the
cooled water after its interaction with the air flow.

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INDUSTRY COOLING TOWER: It has induced cooling tower with 2 cells each
having their own induced fan. It has 2 motors and the operation of fan1 starts
when temperature is greater than 33 degree Celsius and operation of fan2
starts when temperature is greater than 37 degree Celsius. The average speed
of wind in these regions are 10-14 miles per hour.

5.5 INSTRUMENT AIR: Instrument air is used to operate the operating

valves by control system. All valves can by operated by this air.

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6.Calibration Of Tank/Vessel

 Calibration in measurement technology and metrology is the comparison

of measurement values delivered by a device under test with those of
a calibration standard of known accuracy. Such a standard could be
another measurement device of known accuracy, a device generating the
quantity to be measured such as a voltage, or a physical artefact, such as
a metre ruler.

 Calibration may be required for the following reasons:

oA new instrument
oAfter an instrument has been repaired or modified
oWhen a specified time period has elapsed
oWhen a specified usage (operating hours) has elapsed
oBefore and/or after a critical measurement
oAfter an event, for example
 After an instrument has been exposed to a shock, vibration,
or physical damage, which might potentially have
compromised the integrity of its calibration
 Sudden changes in weather
o Whenever observations appear questionable or instrument
indications do not match the output of surrogate instruments
o As specified by a requirement, e.g., customer specification,
instrument manufacturer recommendation.
 How to measure level of Tank in term of Litter?
o First find that in 1 CM how much quantity of liquid is tank.
o Than every tank heaving its Dead Level find that.
o Now tank one example:

 Liquid level in tank is 15 CM and its Dead volume is 1400 Litter and its
LPC is 73.1 Litter. Fine out quantity of liquid.
o Quantity = (15* 73.1) + 1400 = 2496.5 Litter

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6.SAFETY
6.1 PLANT SAFETY: Plant operation should be made as safe as possible by
designing a control system for the process. the control system should be
capable of taking care of all possible foreseeable emergency situations. All the
equipments should be safeguarded against high pressure failure by putting
pressure relief valves vent or flare stake system.

6.2 MSDS: A safety data sheet (SDS), material safety data sheet (MSDS), or
product safety data sheet (PSDS) is an important component of product
stewardship, occupational safety and health, and spill-handling procedures. SDS
formats can vary from source to source within a country depending on national
requirements.

 Some of those chemicals are perfectly safe, some of them may or may not be
safe, and some have known risks. ... A material safety data sheet (or MSDS)
is a document that provides workers with procedures for safely handling or
working with a particular substance.

 The Globally Harmonized System of Classification and Labelling of

Chemicals contains a standard specification for safety data sheets. The SDS
follows a 16 section format which is internationally agreed and for
substances especially, the SDS should be followed with an Annex which
contains the exposure scenarios of this particular substance. The 16 sections
are:

 Chemical product and company identification

 Composition and information on ingredients
 Hazards Identification
 First aid measures
 Fire and explosion data
 Accidental release measures
 Handling and storage
 Exposure control / personal protection
 Physical and chemical properties
 Stability and reactivity data
 Toxicological information
 Ecological information
 Disposal Consideration

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  Transport information
 Other regulatory information
 Other information

6.3 PERSONAL PROTECTIVE EQUIPMENT:

1. HELMET – It is used for the protection of head and prevention of major in
Injury of body and other mental disease.
2. INDUSTRIAL SHOES – It is prevention for the industrial solid wastes like
bolts, nuts and other steel and metal blocks of our feet.
3. GOGGLES – It is used for the eyes protection from the flammable,
hazardous gases or flying dust fine particles.

6.4 WORK PERMIT SYSTEM:

1. HAZARDOUS WORK PERMIT (CATEGORY-1): Confined space entry, hot
work, height job and rigging job .
2. NON- HAZARDOUS WORK PERMIT (CATEGORY-2)
3. EXCAVATION WORK PERMIT (CATEGORY-3)

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7.Conclusion
Cost optimization of the product has been successfully performed and
verified with minor differences in the actual and theoretical values.
Calibration of tank is important for measuring level of liquid and it is derived
properly. Ejector is the most important equipment in industry. How to create
vacuum in tank was learned. In this industry steam ejector is use.
Consumption of utilities like power, natural gas in efficient and effective
manner to optimize our cost of production and to gain maximum profits.
Safety analysis before every job to be performed is very essential in the
industry. About MSDS of product and which thinks are provide in MSDS are
learning. Official work is notice and what is the work system of company is
know very well.

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8.References
 https://en.wikipedia.org
 Unit Operations, McGraw Hill
 http://www.mechanicalengineeringsite.com

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