ACKNOWLEDGEMENTBeing a student of chemical engineering I have studied various chemical processes and equipments used in chemical industries.

Even then also there was a keenness to do the practical study ang I got this opportunity during my summer training at HIGH POLYMER LABS ADDITIVES LIMITED. So I would like to give honourable regards to the management of HIGH POLYMER LABS ADDITIVES LTD. Specially to DR.BALDEV SINGH(Executive Director)and N.K.GOSAI(Buisness Head,Plant Administrator)who provided me this opportunity of doing this practical training. I am highly grateful to the entire project department for helping me at every stage of my training.My special thanks goes to Mr.PANDEY(Deputy Manager),RAJU TYAGI(Assistant Manager),who guided me time to time and under whom I got a very valuable experience,which will help me in future. I am also thankful to the entire production department for their full cooperation to get me introduced with the plant and helping me time to time to complete my training successfully.

Thanks are also to the research & development department for getting me introduced with the products. During the course of training I joined the help of so many people directly and indirectly and may be because of human nature I might miss to mention certain names, I am thankful to them for their help and support.

AJAY SHEKHAWAT B.TECH(CHEMICAL ENGINEERING),3rd year. JMIT-RADAUR

CONTENTSS.NO1. 2.

PARTICULARSINTRODUCTION CLASSIFICATION OF PLANT SECTION

3. 4.

HDC/ADC PLANT LAYOUT OF HDC/ADC PLANT

5.

CHLORINE VAPOURISATION PLANT

6.

REFRIGERATION AND BRINE CHILLER PLANT

7. 8.

BOILER SECTION EFFULENT TREATMENT PLANT

9. 10. 11. 12.

LAYOUT OF E.T.P UTILITIES SAFETY PARAMETERS CONCLUSION

INTRODUCTIONHIGH POLYMER LABS ADDITIVIES LIMITEDThe flagship company if the HPL ADDITIVES GROUP was established in 1964. Over the years the company has grown from being solely a blowing agent manyfacturers to include other polymer additives,speciality chemicals and industrials chemicals. The group has established a formidable in the global market for being a producer of world class chemicals. Being the single largest player with over 75% share of the Indian market,for most of its product,HPL ADDITIVES LTD.products have also been accepted in the developed markets of the west.It exports nearly 50% of its products to over 38 countries through its international and agency network. Over the years,HPL ADDITIVES LTD. has established a strong manufacturing base through appropriate and timely investment in the requisite

infrastructure.HPL ADDITIVES has 4 main sites 3 in DELHI region and 1 in PUNJAB region. The plants have a high degree of automation including DCSs & PLCs to control and monitor the process.Besides these,there are other state-of-art equipments , instruments and control built in to the processes that ensures consistent quality and safety. Research & development has been the mainstay at HPL ADDITIVES LTD. right from the inspection.HPL ADDITIVES LTD. has researched all its products lines inhouse and it does not have any collaboration or bought out technology from any company for any of the products/processes. It has bench scale facilities and a multi-functional pilot plant.These are managed by highly qualified and experienced scientists and engineers

HPL ADDITIVES AWARDS & CERTIFICATES*NATIONAL AWARD winner for the research &

development efforts in chemical and allied industries. *ISO 9001 certification by DNV for its quality system. *ISO 14001 certification by DNV for env. Protection. *OHSAS 18001 certification by DNV for health & safety.

MISSIONTo be a financially successful corporation with a global presence,through investment in systems processes, Technology & human assets to ensure high levels of quality,services efficiency,safety & environmental consciousness.

Proactive upgradation of technology & manufacturing facilities to meet future challenges. .Excellence in systems & processes to improve throughout,efficiency & productivity. .Continious product development & research to cater to ever evolving customer needs. .Consistent quality,timely delivery & world class service to meet the exacting expectation of all coustomers. .Upgradation of knowledge,competence and skills of empowered human assets. .Complete safety and healthy work conditions. .Conservation of natural resources. .Preservation of pollution & waste minimization. .Compliance with statutory provision.

OBJECTIVE

PRODUCT DIVISIONThe HPL ADDITIVES GROUP is organized into three divisions:The POLYMER ADDITIVES division manufacturers:-

*MODIFIERS:-Chemical blowing agent are used for production of unicellular products.tailor-made products are provided for customer-specific needs & operating conditions when required decomposition mechanism in the end application.partical size is crucial for these products. *The microfine range for CBAS have a whole range of products for different applications.The range is designed to provide lowest possible relative density,reduced surface,yellowing & smooth surface. *Modifiers include Azobisnitriles,Azodicarbonamide,Dinitrosopentamet hylenetetramine,Sulfonyl Hydrazides & Sulfonyl Semicarbazides.This also include chain extenders & cross polymers.

POLYMERIZATION CATALYST:Polyazo initiators are known sources of free radicals and are used in the polymerization of common monomers like vinyl chloride,styrene,vinyl acetate,ethylene & methyl methacrylate.There Polyazo initiators can be classified into two groups organic solvent soluble Azo initiators & water soluble azo initiators.The Polyazo initiators include products such as Polyazo AZDN,Polyazo AZDV,Polyazo AZMB,Polyazo AZCC. PROPERTY EXTENDERS:Antioxidants are used to retard the reaction of organic materials with atmospheric oxygen,which can cause degradation.The range of kinox-phenolics& phosphites belong to primary and secondary antioxidants.

UV light stabilizers prevent photo degradation processes in polymers such as colour changes,chalking,cracking,& loss of mechanical properties such as tensile strength,impact strength,etc.The range of Hilite-HALS(Hindered Amine Light Stabilizer),Benzophenons & Benzotriazoles belong to this class of UV light stabilizers.

Chain extenders are cross-linking agents for biodegradable polymeric films used in drug delivery systems.This is also used as a stabilizer for synthetic rubber.The range of Hichem-ADH belongs to this category.Optical Brighteners are used dyes or with pigments to bring about specific shades.These alter the visual properties of polymers & are also known as fluorescent agents.

The speciality chemicals division caters to intermediate for pharmaceutical & agro chemicals,photographic chemicals,corrosion inhibitors. Biocides are used used for water treatment & effulent management industries,for cooling towers,evaporative condensers,pulp mill effluents & oil recovery systems.They are also used for disinfecting swimming pools.

CLASSIFICATION OF PLANT SECTIONING1. ADC PLANT HDC(intermediate) Plant & Ammonia Recovery Plant . Description of Washing section of HDC. HDC Manufacturing section ADC Packing section 2 .CHLORINE VAPORIZATION PLANT 3 .REFRIGRATION SECTION 4. EFFULENT TREATMENT SECTION

5 .BOILER SECTION

ADC PLANTADC Plant manufacturers one of the major product of the industry i.e. ADC(azodicarbonamide) which is used as a blowing agent.During the manufacturing of the product an intermediate HDC(Hydrosodicarnamide)is formed & ammonia is recovered.processing of plant is given below:RAW MATERIAL USED

Hydrazine Hydrate(HH) Sulphuric Acid(H2SO4) Urea Water Chlorine BrominePLANT CAPACITY:14200Kg/day

PROPERTIES OF PRODUCT:MAIN CONSTITUENT : Azodicarbonamide Mol.Formula C2H4O2N4 Mol.Wt. 116 PHYSICAL FORM : ODOUR SOLUBILITY : : Pale yellow free flowing powder Odourless Insoluble in water &benzene Soluble in dimethylformamide PH : 7.30.5 Eye & skin irritation,respiratory& Digestive tract irritation. USES : As a chemical blowing agent for Foaming plastics & Rubber. ADC-CHEMICAL REACTION:NH2NH2H2O+2NH2CONH2+H2SO4NH2CONHNHCONH2+HDC+2NH3+ H2O NH2CONHNHCONH2+CL2NH2CON=NCONH2+ADC+2HCL

HEALTH EFFECT :

EQUIPMENT LIST IN HDC & ADC PLANTS.NO1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

DESCRIPTIONUREA TANK NEUTRALIZATION TANK HDC REACTOR WASHING VESSELS NUTSEHE FILTER FILTERS UREA TRANSFER PUMP FILTERTE TRANSFER PUMP HDC SLURRY TRANSFER PUMP SCRUBBER PUMP H2SO4 DAY TANK HH DAY TANK SCRUBBER TANK SCRUBBER BLOWER AMMONIA SCRUBBER VENT SCRUBBER CONDENSER AQUEOUS NH3 SOL. TANK PLATE HEAT EXCHANGER BLOWER ADC REACTOR DUST COLLECTOR HOPPER BLENDER ROTAMETER

CAPACITY10 KL 22 KL 22 KL 22 KL 22 KL 5 KL 60 KL

MOCSS 316 SS 316 SS 316 SS 316 SS 316 SS 316 SS 316 SS 316 SS 316 MS MS SS 316 FRP FRP MSFRP SS 316 SS 316 SS 316 SS 316 TITANIUM

3 KL

4750 LT/HR 3000 LT/HR 17.65 m2 5 KL

50 NM3/hr 22 KL

SS 316 MDFRP SS SS SS

10-200 Kg/hr

HDC PLANT & AMMONIA RECOVERY PLANT HDC plant consists of two feed reactors which are anchor type reactor.The inner surface of the reactor is coated with resin plastic. In the first reactor hydrazine(PH-10.5)is charged & is neutralized with H2SO4 which form dihydrosulphate.Temperature rises to 85-900 C and pressure is maintained at 1.2kg/cm2.During agitation vapors of hydrazine & H2O are formed and are condensed in vertical condensers. In the second reactor Urea solution is formed.Steam is cir culated in the jackets of the reactor to maintain the temperature around 70-720C for dissolving Urea into water. After the agitation in both the reactors, the material is discharged at the bottom and with the help of centrifugal pump the material is sent to candle filters. After filtration slurry(80-900C)goes into another anchor agitator type reactor.Steam is fed at the top of the reactor from the boiler section.The temperature of the steam is 100-1200C.Initially the pressure is .7kg/cm2,after reaching 1kg/cm2 steam is switched off and pressure automatically reaches to 2.5kg/cm2.The slurry is boiled for 7

hrs,exothermic reaction takes place in the reactor.In this the conversion of material is 95-96%. The slurry settles down and discharged at the bottom as in the form of HDC.Discharged HDC is sent to washing plant. During boiling NH3 is liberated and is recovered.The ammonia leaving the top of the reactor is passed to the condenser through the pipe line. In condenser cooling water is circulated in the shell and hot ammonia in the tubes.The temperature of cooling water is 200C. Heat transfer takes place between water and ammonia due to which the temperature of water rises & that of ammonia lowers down. Hot water leaves out from top of the condensers and goes to cooling tower.Ammonia is discharged from the bottom of the condenser and goes to heat exchanger.Double pipe heat exchanger is used to minimize the temperature of ammonia. The uncondensed ammonia into packing & brine solution is circulated into jackets.Aqueous ammonia gets cooled and goes to aqueous ammonia solution tank.

DESCRIPTION OF WASHING SECTION OF HDCIn this plant HDC slurry is washed.The temperature of HDC slurry is 80-900C. The HDC slurry comes through pipe with the help of high pressure. In this plant anchor agitator type reactor is used.In the reactor equal volume of water & HDC slurry is taken.Water comes from the chiller tank. The slurry is perfectky mixed with the help of agitator upto5-7 hours. During the agitation the flue gases are created.The flue gases leaves out at the top of the reactor and goes to the scrubber. In the scrubber the flue gases dissolve in water and the water with these impurities is sent to effluents treatment plant. After agitation,the slurry is settled down and filterate is siphoned in the filtered tank. The filterate tank consists of polypropylene cloth onwhich the HDC content present in the siphoned filterate gets deposited and the filterate is sent to the neutralization reactor of hydrazine hydrate.

The water level of washing reactor is maintained as the filterate is siphoned. Ice cubes are used to cool the HDC.The temperature of HDC is maintained upto 10-120C. After cooling the HDC slurry is discharges from the bottom of the washing reactor and with the help of centrifugal pump slurry goes to ADC plant in the form of alkaline solution.

DESCRIPTION OF ADC MANUFACTURING AND PACKINGADC is manufactured in anchor agitator type reactor,its anner surface is coated with fiber resin plastic.Jacket is provided with the reactor to circulate brine solution. Firstly the viscous HDC slurry from the washing plant is fed to the reactor with the help of centrifugal pump at a temperature 10-120C. Then chlorine from chlorine vapourization plant through chlorine header is purged into the reactor. A catalyst is added to the above material in the reactor.Cold water is also added to it for perfect dilution. The temperature is maintained by circulating brine in the jacket of the reactor. The brine from the outlet of jacket is sent to the heat exchanger to chill the water and then sent to the refrigeration plant. In the reactor slurry is mixed up to 24-30 hours.the temperature is maintained at 250C. Extra chlorine leaves out at the top of the reactor and goes to the scrubber where the chlorine gets dissolved in the caustic and forms hypo solution.

After the completion of mixing ADC slurry is discharged at the bottom of the reactor. The ADC slurry is acidic containing 10%HCL.So the slurry is pumped to the agitated nutche filter(ANF)for filteration or either can be sent to centrifuge also. ANF consists of the agitator which rotates and also moves up and down to press the material.1.5 kg air pressure is also applied.Polypropylene cloth in ANF is used to separate out ADC and HCL filterate. The HCL filterate is sent to effulent treatment plant. The ADC from ANF is sent to spin flash dryer for drying.The dried ADC with 10-15% moisture is sent to the packing section. In the packing section first the ADC goes to the dryer cum pulverizer where hammer mill are used for hammering the ADC. In the pulverizer stean heater is used,the temperature of the air which goes to the pulverizer is 120-1400C at a pressure 6-8 kg/cm2.The size of ADC is 10-12 microns. Then through the air pressure ADC powder goes to classifier or air jet mill is used.Filter bags made of PP cloth are attached to solenoid valve and are used to separate ADC powder and air.

The ADC powder is fed to the hopper which goes to blender where filters and chemicals are added for better quality of product. The filterate are completely mixed with the help of rotating shaft. After mixing the powder is sent to vibrating screen and screened up to 5-6 micron.The ADC is then weighed and packed.

CHLORINE VAPORIZATION PLANTIn chlorine vaporization plant,the liquid chlorine gets converted into chlorine gas and applied to ADC plant. PLANT CAPACITY : 600 kg/hr EQUIPMENT LIST : S.NO 1. 2 3 4.. 5. 6. 7. 8. DESCRIPTION CHLORINE CYLINDER EXPANSION CHAMBER VAPORIZER FILTER PRRESSURE REDUCING VALVE ROTAMETER SCRUBBER CAUSTIC TANK CAPACITY 900 kg MOC MS MS MS MS+COTTON 2.5 kg/cm2 35-700 kg/hr MS

MS MS

PROCESS DESCRIPTIONThe liquid chlorine contained in concave shaped cylinder is passed to the vaporizer through the mild steel pipe at the pressure of 4-6 kg/cm2. If the pressure is increased from 6 kg/hr the excess chlorine through safety valve goes in expansion chamber which is connected to the chlorine scrubber. The liquid chlorine enters into vaporizer from the top.Steam supplied from the boiling section enters at the bottom of jacket and circulated.Heat transfer takes place between steam and liquid chlorine.Liquid chlorine gets vaporized and converts into gas,a temperature controller is attached to the vaporizer.When the temperature is increased from 600C it stops the supply of the steam with the help of solenoid valve.Condensate steam comes out from the bottom of the other side of the jacket.

Chlorine gas leaves out at the top of the vaporizer at the pressure of 3.8 kg/cm2,if the pressure increases the rupture disk sends the chlorine to the chlorine scrubber. From the vaporizer chlorine gas goes to filter.The filters are filled with glass wool.After the filteration the chlorine passes into PRV(Pressure reducing valve)which reduces the pressure 2.5 kg/cm2.After decreasing pressure,chlorine gas supplied to the ADC Plant..

REFRIGERATION PLANT AND BRINE CHILLER PLANTRefrigeration plant is the major unit of the industry.The ice and chilled brine that is used in the whole plant is supplied from refrigeration plant only.

PLANT CAPACITY:50400 kgs/day.

EQUIPMENTS LIST:S.NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. DESCRIPTION AMMONIA COMPRESSOR OIL SEPERATOR ACCUMULATOR AMMONIA RECEIVER GAS PURGE SUCTION LINE ACCUMULATOR CONDENSER BRINE TANK CHILLER BRINE PUMP MOC CS MS IS2062 MS IS2062 MS IS2062 MS IS2062 MS IS2062 MS IS2062 MS IS2062 MS IS2062 MS

PROCESS DESCRIPTIONIn this plant Ammonia is used for the refrigeration purpose. Ammonia from the receiver tank goes to the refrigeration tank through the expansion valve.The expansion valve reduces the pressure of ammonia. In the refrigeration tank Ammonia(-8 to -100C)circulates in the coils,brine(-2 to -30C) circulates in the tank and water is filled in the ice canes for refrigeration the water to ice. Ammonia also passes to the shell and tube heat exchanger for chilling the brine.The chilled brine is supplied to the plant. Ammonia from refrigeration tank and heat exchanger passes through the accumulator where the gases and liquid ammonia seperates out. The gaseous ammonia goes to reciprocating compressor where the lubricating oil is separated from gaseous ammonia. Then the gaseous ammonia gets condensed in the condenser. The liquid ammonia from the condenser goes to the ammonia receiver tank and is kept under pressure.

BOILER SECTIONThe boiler generating steam is fire tube type.It is multi fuel two-pass boiler.Pet coke is used as a fuel.The pressure of steam generated is 10kg/cm2.The process foe generating steam through boiler described below: The pet coke is fed to the Hopper through the conveyer belt.From the Hopper fuel enter the furnance which is fluidized bed type with water walls. The fuel is ignited and air for combustion is supplied from the bottom of the furnance. When the fuel is burnt, the temperature of fuel is 80010000C. The smoke enters the tube in the water tank.The deminiralized water in the shell heats up and generates steam of pressure 10kg/cm2. The water level is maintained in the water tank and is indicated by water level gauge.Safety valve are set to pressure 11 kg/cm2. The water tank has the holding capacity of 3.5 tons. The flue gases with high temperature leaves the furnance and are collected in the dust collector.

From the dust collector the dust seperates out and hot air is passed to the air pre-heater. In air pre-heater the hot air transfer heat to the water,so that the water is pre-heated to feed in the water tank. The furnance is provide with the water walls.The water circulates in these walls to protect the furnance wall from getting heated. The water in walls gets heated due to the fire in the furnance and heated water is sent to water tank. The heat generated is supplied to the plant as per requirement. CAPACITY: 2 TPH THERMAL EFFICI0ENCY: 822% Pet coke.

EFFLUENT TREATMENT PLANTIn this plant effluents from various units treated and made free various impurities.The processing of the plant described below: The effluent is collected in the raw water tank. From the tank the impure water us sent to the zigzag tank where the impurities separates out such as oil and grease and water is made oil free. Then the water is added to tank where lime is added through bubbling.The lime is added to neutralize the acidic effluents. After lime addition the water is further sent to the neutralization tank then to the flash mixer and then to flocculater tank. The water is then passes to the primary classifier where the solid impurities seperates out. An agitator is attached to the primary classifier which agitates the effluent,the solid impurities floats at the top surface and the effluent is discharged from the bottom. The discharged effluent is passed through the carbon filters.

Either the discharged effluent can be passed through the filter presses.The filter presses consists of polypropylene cloth as filters in series.These filter are pressed with rotating shaft.The solid remain stick to the bio-reactor for further treating of impurities such as to kill bacteria. The bacteria free classifier is sent to secondary classifier. The discharged water is then sent to chlorinator.In the chlorinator the dissolved impurities are seperared out and water is treated to become pure. The water from chlorinator is again sent to candle filter where impurities get absorbed by the candles in filter. The water for further purification is further sent to R.O purifier.In this plant the water is purified by reverse osmosis technology. This treated water is then be carried out as the mineral water.

UTILITIESThe following off-site facilities and utilities are available at the plant premises: Liquid Fuel Storage Tank Farm Diesel Generator(2x625 KVA & 3x320 KVA) Boilers(3.6 MT/HR & 1 MT/HR) Transformer(2 x 500 KVA) Brine Refrigeration Section& Ice Pant With Ammonia Air Compressor Raw Material Store Finished Goods Store ETP Water Softening Plant Cooling Tower(200 TR) The plant banks upon its captive power generation for meeting the power requirement.A total of five diesel generators are available at plant. A boiler of 3.6MT/HR capacity is provided for generating steam at 10.5 kg/cm2 for the process requirements.

Ammonia is used as a refrigerant for chilling brine in the ice plant of the capacity of 720 Slabs/day. Cooling towers of 200TR capacity are provided forcooling water which is supplied to various plant sections. Thermo packs are provided for meeting the requirement of hot oil and cold oil for the process.

SAFETY MEASURESFIRE EXTINGUISHERS & EXTINGUISHING APPLIANCES:Fire extinguishers of suitable type are provided at selected locations for extinguishing fire in their incipient stages.A total of 67 portable fire extinguisher of Carbon Dioxide,Pressurized Water type,Dry Chemical& Foam type provided at various locations in the plant depending on their compatibility.

HYDRANT SYSTEMS:The chemical manufacturing unit of HPL is protected fires by a functional hydrant system.The facility is provided with a total water storage of 140cm3.Besides Overhead storage,an underground storage of 50cm3 of water is always reserved. Safety valves are used in the lines to prevent excess pressure in the reactor. In case of the leakage of chlorine cylinder emergency kit is fitted to the cylinder and leaked chlorine is sent to chlorine scrubber. Temperature controller are provided so that the temperature should not raise beyond requirement.

Pressure gauges are provided with the lines to indicate the pressure. Rupture disk are also on reactor,in case the pressure increases from design pressure the diesel ruptures and the excess pressure vent through nozzle. The reactor are insulated with glass or glass cotton to prevent heat loss to the surrounding. Use of personnel protective equipments are: Helmets,Rubber hand gloves for handling products. Nitrile hand gloves for handling bromine. Self breathing apparatus in case of chlorine leakage. Apron,goggles,gum boots to protect from hazardous materials. Constary type mask prevents inhaling of HCL & NH3.

CONCLUSIONThe summer training at HPL for me has been a very good practical experience which would definitely help me in shaping my future in chemical field. Fine graded and good quality of products are manufactured in the plant.Various plans are implemented for full optimization of the plant to reduce man power and to get better efficiency. New product development and research work is regularly practiced.The main motto of the company is the safety of the man and machine. Though the company is coming up very well,the efficiency can be improved by having proper instrumentation department setup which can see all the instruments whether they are working properly or not. Iassure that I have done the training with the companys guidelines with my true ability,sincerity & honesty.

HIGH POLYMER LABS ADDITIVES LTD. SUMMER TRAINING REPORT SUBMITTED BY:AJAY SINGH SHEKHAWAT SUBMITTED TO: ROLL NO :1208504

B.TECH CHEMICAL ENGINEERING SETH JAI PRAKASH MUKAND LAL INSTITUTE OF TECHNOLOGY