Internship

Overview
 L.D.COLLEDE OF ENGINEERING

CHEMICAL ENGINEERING
(2023-24)

SUMMER INTERNSHIP

PRESENTATION BY : HARSH SAVANI

ENROLLMENT NO : 200280105037
GUIDED BY :
DR.SATISH SHAH
 SUMMER INTERNSHIP
AT
NIRAV DYES AND CHEMICAL LTD.

PLANT LOCATION :
C-1/194, Vinoba Bhave Nagar,
Dibiyapur, Phase 2 GIDC, Vatva
Ahemdabad, Gujarat 382445
Plant Manager : Mr.Pareshbhai
Babariya
Organization structure

Owner

Manager

Engineer

Operator

Workers
Selection of process
The selection of process depends on following criteria :
 The process which is pocket friendly and which lowers the overall cost of manufacturing our
product including raw material, energy consumption, labour, equipment, and maintenance.
 The process which has high efficiency in terms of yield, reaction rates, and throughput.
 The process that aligns with sustainability goals and adhere the green chemistry principles.
 The process which is safer in terms of potential for hazardous reactions, the use of toxic
substances, and the risks of accidents.
 The process that gives good quality product ensuring that the selected process meets the
required specifications for the intended application.
 The process that allows for flexibility in handling different raw materials, accommodating
changes in production requirements, or adapting to new technologies.
From all the above points, batch process is used as manufacturing process.
 BLOCK DIAGRAM
CARBON
ONCDSA
PNA + HCL+ IRON POWDER SLUDGE
PPD SOLUTION

REDUCTION FILTRATION CONDENSATION FILTRATION

CENTRIFUG PH
DRYING FILTRATION CONTROLLER
ATION

(NUTSCHE FILTER)

PULVERISATION 2- NADPSA
Process details
Reduction

 Reduction is the process of removing oxygen and adding hydrogen to the compound.
Here, reduction process deals with the removal of oxygen from the “nitro” group
attached to PNA and adding of hydrogen with the nitrogen.

C6H6N2O2 + 2Fe + 2HCl + Na2CO3 C6H8N2 + 2NaCl + CO2 + Fe2O3

 Material balance of the reduction process

PNA PPD

Fe, HCl Reactor CO2, NaCl

Na2CO3 Fe2O3
Basis: 400 Kg of PNA fed to the reactor

C6H6N2O2 + 2Fe + 2HCl + Na2CO3 --------------- C6H8N2 + 2NaCl + CO2 + Fe2O3

According to the above reaction,

1 mole of PNA produces 1 mole od PPD.
Moles of PNA taking part in the reaction =Amount of PNA fed to the reactor = 400 = 2.898 moles.
Molecular weight of PNA 138
So, 2.898 moles of PNA produces 2.898 moles of PPD.
Hence, weight of PPD produced = No. of moles of PPD produced * Molecular weight of PPD
= 2.898 * 108
= 312.98 Kg of PPD produced.
1 mole of PNA requires 2 moles of iron.
So, 2.898 moles of PNA requires 5.796 moles of iron.
Hence 2.898 moles of PNA requires 323.67762 Kg of iron.
1 mole of PNA requires 2 moles of HCl.
So, 2.898 moles of PNA requires 5.796 moles of HCl.
Hence, 2.898 moles of PNA requires 211.554 Kg of HCl.
1 mole of PNA requires I mole of Na2CO3.
Hence, 2.898 moles of PNA require 2.898 moles of Na 2CO3.
So, 2.898 moles of PNA require 307.188 Kg of Na2CO3.
1 mole of PNA produces 2 moles of NaCl.
So, 2.898 moles of PNA produces 5.796 moles of NaCl.
Hence, 2.898 moles of PNA produces 339.066 Kg of NaCl.
1 mole of PNA produces 1 mole of CO2.
So, 2.898 moles of PNA produce 2.898 moles of CO2.
Hence, 2.898 moles of PNA produce 127.512 Kg of CO2.
1 mole PNA produces 1 mole Fe2O3.
So, 2.898 moles of PNA produces 2.898 moles of Fe 2O3.
Hence, 2.898 moles of PNA produces 462.78162 Kg of Fe2O3
 Compound Input Amount (Kg) Output Amount (Kg)
PNA 400 0
Iron 323.67762 0
HCl 211.554 0
Na2CO3 307.188 0
PPD 0 312.98
NaCl 0 339.066
CO2 0 127.512
Fe2O3 0 462.78162
Total 1242.41962 1242.33962

Input = Output

Conversion = Amount Of Product Produced = 312.984 *100 = 78.546%

Amount Of Raw Material Fed Into Reactor 400
condensation
 Condensation is the process of converting gas into liquid by lowering down its
temperature. Condensation reaction typically involves the combination of two
molecules with the elimination of smaller molecule like water. The condensation
takes place in condenser. The condenser is a brick-lined condenser.

 Material balance for condenser

C6H8N2+ C6H3­ClNO2SO3H -----------C12H11N3SO5 + HCl

 To nullify the effect of HCl formed in above reaction, Na 2CO3 is added.

C12H11N3SO5 + 2HCl + Na2CO3 -----------C
90-95°C H N SO5+ H2O + 2NaCl + CO2
12 11 3

PPD 2-NADPSA
ONCBSA Condenser
Na2CO3 NaCl, CO2
Basis:312.984 Kg of PPD fed to the condenser.
According to the reaction,
1 mole of PPD react with 1 mole of ONCBSA.

Total Moles Of Ppd = Amount Of Ppd Fed To Condenser = 312.984 = 2.9898 Moles
Molecular Weight Of Ppd 108
So, 2.898 moles of PPD react with 2.898 moles of ONCBSA.
312.984 Kg of PPD react with 688.275 Kg of ONCBSA.
Similarly, 1 mole PPD produces 1 mole of 2-NADPSA.
Hence, 2.898 moles of PPD produces 2.898 moles of 2-NADPSA.
So, 312.984 Kg of PPD will produce 895.482 Kg of 2-NADPSA.
Now, 1 mole of PPD produces 1 mole of HCl.
So, 2.898 moles of PPD produces 2.898 moles of HCl.
Hence, 312.984 Kg of PPD produces 105.777 Kg of HCl.
According to the second reaction,
2 moles of HCl react with 1 mole of Na2CO3.
So, 2.898 moles of HCl react with 1.449 moles of Na 2CO3.
Hence, 105.777 Kg of HCl react with 153.59 Kg of Na 2CO3.
Also, 2 moles of HCl produces 2 moles of NaCl.
So, 2.898 moles of HCl will produce 2.898 moles of NaCl.
Hence, 105.777 Kg of HCl will produce 169.533 Kg of NaCl.
Now, 2 moles of HCl produces 1 mole of 1 mole of H2O.
So, 2.898 moles of HCl produces 1.449 moles of H2O.
Hence, 105.777 Kg of HCl will produce 26.082 Kg of H2O.
Similarly, 2 moles of HCl produces 1 mole of CO2.
So, 2.898 moles of HCl will produce 1.449 moles of CO2.
Hence, 105.777 Kg of HCl will produce 63.756 Kg of CO2.
 Material Input (Kg) Output (Kg)
PPD 312.984 0
ONCBSA 688.275 0
2-NADPSA 0 895.482
HCl 105.777 0
Na2CO3 153.59 0
NaCl 0 169.533
H2O 0 26.082
CO2 0 63.756
Losses 0 105.777
Total 1260.63 1260.63

Input = output
Effluent treatment plant
An Effluent Treatment Plant (ETP) is a facility to treat industrial wastewater, also known
as effluent, before it is discharged into the environment. The primary goal of an ETP is to
remove pollutants and contaminants from wastewater ensuring that the discharge meets the
environmental regulations and standards.
Following steps are included in the effluent treatment plant:
a. Screening: The incoming wastewater is passed through the screen which remove the
large objects like leaves, sticks and other foreign particles from it.
b. Primary Treatment: In this step physical process, such a sedimentation and flotation
are employed to remove the suspended solids and reduce the biochemical oxygen
demand (BOD) of the wastewater.
c. Secondary Treatment: Biological processes are used to further break down organic
matter present in wastewater. This can be done through activated sludge processes,
aerobic or anaerobic digestion, or biological treatment methods.
a. Tertiary Treatment: This stage involves additional treatment process to further
polish the effluent. It may include chemical treatment filtration and other advanced
techniques to remove remaining impurities.
b. Disinfection: The treated affluent is often disinfected to kilo inactivity remaining
pathogenic microorganisms. Command disinfection method includes chlorination
ultraviolet (UV) radiation and ozonation.
c. Sludge Treatment: The solid separated during the treatment process is known as
sludge needs proper handling. Sludge is often treated through methods like digestion,
dewatering and drying before disposal or beneficial reuse.
d. Monitoring and Control: To continue monitoring of effluent quality is crucial to
ensure compliance with environmental regulations. Control systems are implemented
to adjust treatment processes based on variation in wastewater characteristics.
 Screening Primary Secondary
Aeration tank
Treatment Settling

WASTEWATER Air Chlorine

contact
chamber

Sludge
Thickener Drying bed
digester

Sludge Disposal

BLOCK DIAGRAM OF ETP PLANT

THANK YOU