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Chaper 1 .......................................................................................................................................... 4 1.1. Company Profile .............................................................................................................. 5 Pak China Chemicals ................................................................................................ 5 Quality Assurance Program ...................................................................................... 5 Quality Control ......................................................................................................... 6 Pak China Polymers .................................................................................................. 6 1.1.1. 1.1.2. 1.1.3. 1.1.4. 1.2. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7.
Progress ............................................................................................................................ 6 Products ............................................................................................................................ 8 Capacity............................................................................................................................ 8 Raw Materials for Emamectin benzoate .......................................................................... 8 Main Steps Involved in Emamectin benzoate production ................................................ 8 Process description ........................................................................................................... 9 Process Flow Diagram ................................................................................................... 11 Operating temperatures and the time history ................................................................. 14 Utilities for EB production plant .................................................................................... 19 Introduction: ................................................................................................................... 22 Raw Materials ................................................................................................................ 22 Process Description ........................................................................................................ 22 Process Flow Diagram ................................................................................................... 23 Plant description ............................................................................................................. 24 Description of Plate and frame filter press ..................................................................... 24 Introduction: ....................................................................................................................... 27 Capacity.......................................................................................................................... 27 Products .......................................................................................................................... 27 Production of Emulsifiable Concentrate and Soluble Liquid: ....................................... 27 Production of Soluble Concentrate, Emulsion Wet and Soluble Emulsion: .................. 28 Process Flow Diagrams .................................................................................................. 29 Utilities for liquid formulation plant .............................................................................. 31 Diaphragm pumps ................................................................................................... 31 1
Chaper 2 .......................................................................................................................................... 7
Chaper 3 ........................................................................................................................................ 21
Chaper 4 ........................................................................................................................................ 26
4.7.1.
Chaper 5 ........................................................................................................................................ 34 Introduction: ................................................................................................................... 35 Capacity:......................................................................................................................... 35 Products: ......................................................................................................................... 35 Raw Materials ................................................................................................................ 35 Sticker solutions for Products: ....................................................................................... 35 Sticker Solution for Mono mehypo hydrochloride: ................................................ 36 Sticker Solution for Cartap hydrochloride .............................................................. 36 Sticker Solution for Carbofeuron ............................................................................ 36
5.5.1. 5.5.2. 5.5.3. 5.6. 5.7. 5.8. 6.1. 6.2. 6.3. 6.4. 6.5.
Process description ......................................................................................................... 36 Block Diagram ............................................................................................................... 37 Equipment description: .................................................................................................. 39 Introduction: ................................................................................................................... 42 Steps in Refrigeration Cycle .......................................................................................... 42 Block Diagrams: ............................................................................................................. 43 Process Flow Diagram: .................................................................................................. 44 Equipment Description:.................................................................................................. 45 Compressor: ............................................................................................................ 45 High pressurized ammonia container (Receiver): ................................................... 46 Evaporator ............................................................................................................... 46 Accumulator ............................................................................................................ 46 Condenser: .............................................................................................................. 47 Throttling Devices: ................................................................................................. 47 Oil Separator: .......................................................................................................... 48 Air Separator: .......................................................................................................... 49 Inter Cooler: ............................................................................................................ 49
Chaper 6 ........................................................................................................................................ 41
6.5.1. 6.5.2. 6.5.3. 6.5.4. 6.5.5. 6.5.6. 6.5.7. 6.5.8. 6.5.9. 7.1. 7.2. 7.3.
Chaper 7 ........................................................................................................................................ 50 Introduction: ................................................................................................................... 51 Boiler Description .......................................................................................................... 51 Process Flow Diagram for Boiler House: ...................................................................... 53 2
Water Softener: .............................................................................................................. 54 Boiler Maintenance: ....................................................................................................... 54 Introduction: ................................................................................................................... 56 Facts of safety & health in a chemical industry: ............................................................ 56 Protection zones (explosion protection, separation distances): ...................................... 56 Setup of fire and safety at Pak China Chemical Plant: .................................................. 57
Chaper 8 ........................................................................................................................................ 55
References: .................................................................................................................................... 58
Chaper 1
Today, Ali Akbar Group is a leading crop protection company in Pakistan and comprises of a diversified group of five companies having its Head Office in Lahore, including:
All the plants are highly equipped with process control instrumentation. All the machinery and equipment is of explosion prove grade. The packaging units are completely automatic and formulation area has designed to meet OSHA, USA requirements for occupational health and safety. The plant has a finished product storage facility of 1,600,000 liters at one time. The storage areas are well ventilated and equipped with fire safety detection. This is the first ever EPA approved and ISO 9000-2001 certified plant in Pakistan.
The facility is equipped with technological advanced equipment developed over a period of many years of experience in the field by the leading manufacturers of PET equipment. These advanced technologies contain but not limited to following: Injection Machine from Krupp, Germany Blowing Machine Blowmax-6 Series from SIQ Corp plastic, Germany
The technological superiority of these machines gives certain advantages to this facility over other manufacturers of PET bottles in Pakistan. The reliability and process control system provide consistent quality. At time of delivery and after sales, services of the company combines into a winning solution for the customers.
1.2. Progress:
They started marketing of agrochemical since 1993, as natural response to the opportunity arising from the ever-growing demand for crop protection chemicals in Pakistan. First direct sale was carried out at the end of 1993 with improved Methyl Parathion. From 1993 up till now they are offering a comprehensive range of products such as herbicides, fungicides, matricides and plant growth regulators every year.
Chaper 2
2.1. Introduction:
In 2005, a state of art PCM plant is installed with the aim of producing micro nutrients and pesticides for the plants. All the technology is used in the plant is imported from China. Regular check and balance is done by Chinese engineers in every six months. As the raw materials used in this plant are highly explosive, all safety measures have been introduced in order to avoid any accident.
2.2. Products:
Emamectin benzoate Liquid humic acid8% w/w
2.3. Capacity:
The plant operates in batch wise manner, with capacity of producing 2800 ltrs/day.
7) Product is than shifted to reactor R6 where two main processes occurs, De oxidation Removal of protection
8) De oxidation is done using ethanol and H.Removal of protection is done using ethanol, H and catalyst (B). 9) During these processes particles are dispersed in the whole solution which is removed in the next reactor. 10) In R7 or R8 that are standby reactors of each other there is addition of diatomaceous earth along with acid and base. diatomaceous earth collect the particles dispersed in the solution and the product is send to centrifuge 1 or 2 where the particles in the solution are removed and clear solution is again send to reactor R7 or R8 where organic layer is separated from inorganic and is transferred to Reactor R10 or R11 that are standby of each other. Inorganic layer is drained out. 11) In R10 or R11, benzoic acid is added in in order to obtain emamectin benzoate. DCM and IPA are recovered by distillation, condensed by condensers E2, E3 and E4 and stored in storage tanks T11, T12 and T13, T14, T15 respectively. 12) If product is in powdered form it is taken in trays and dried in tray dryers using steam. 13) Product packing is done and transferred to market.
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Sodium bicarbonate
Vapor DCM
Condenser
R1
Phosphoric Acid
R2
R3 Add IPA
R4
Condensed DCM
To R 5
TP
T1
T2
T3
T4
P-56
To DCM storage
R1: Reactor 1 R2: Reactor 2 R3: Reactor 3 R4: Reactor 4 R5: Reactor 5
TP: Storage tank of H3PO3 T1: Storage tank 1 T2: Storage tank 2 T3: Storage tank 3 T4: Storage tank 4
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Acetic acid -5 C
NaOH -5 C
Addition of G and A
Addition of H and B
Diatomite
Aminization 55 C R5
R6
R7
R8
To R 9 From R 4
T5
T6
T7
T8
Centrifuge
T9
T 10
R5: Reactor 5 R6: Reactor 6 R7: Reactor 7 R8: Reactor 8 T5: Storage tank 5
T6: Storage tank 6 T7: Storage tank 7 T8: Storage tank 8 T9: Storage tank 9 T10: Storage tank 10
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E2
E3
E4
IPA Vapors
IPA Vapors
IPA Vapors
Benzoic acid
P-25
Condensed IPA
Condensed IPA
Condensed IPA
R9
R 10
R 11
From R8
T11
T12
T13
T14
T15
To R 4
R9: Reactor 9 R10: Reactor 10 R11: Reactor 11 T11: Storage tank 11 T12: Storage tank 12
T13: Storage tank 13 T14: Storage tank 14 T15: Storage tank 15 T9: Storage tank 9 T10: Storage tank 10
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Removal of moisture
Process Addition of Abmactin & DCM Removal of moisture Temp (Celsius) Room temperature 40-50
Table 2.1
Time (min) 10 25
Protection
Process After demoisturization<0.05% Addition of C solution (half) Reaction Addition of C and D solution Reaction for protection Temp (Celsius) 45 -20 -22 -15 to -20 -15 to -20
Table 2.2
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Oxidation
Process After protection is Ok Addition of D & E Addition of F Reaction for oxidation Temp (Celsius) -20 -20 -15 to -20 -15 to -20
Table 2.3
30 10 90 15
15
Aminization Reaction
Process
After moisture <0.05% A) Addition of G and A Reaction of Aminization
Temp (Celsius)
20 20 55
Table 2.5
Time (min)
0 Immediately 120
Deoxidation
Process After Aminization is Ok Addition of Ethanol Addition of H (Nitrogen Protection) Reaction for deoxidation Temp (Celsius) 55 -10 -15 -10
Table 2.6
Removal of Protection
Process After Deoxidation is Ok Addition of Ethanol Temp (Celsius) -10 -10 Time (min) 0 Immediately
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-10 -5 to -10
Immediately 20 to 30
-5 to 5
Table 2.7
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Separation
Process Product + Acetic Acid (12% Solution) PH (5~6) Agitation Addition of NaOH (10% Solution) Agitation Settling Addition of Ditomate Agitation Filtration by centrifuge Received R-7 Agitation Settling Separation Temp (Celsius) -5 -5 -5 -5 No control No control No control No control No control No control No control No control No control
Table 2.8
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The Figure 2.4 shows the distribution of pipelines for temperature control in the reactors. Following are the color codes for various pipes line expressed in Figure 2.4.
Color Codes
Raw Water In Raw Water Out Steam Hot Water In Hot Water Out Brine at -15C Brine at -40C
9 -1bar
4 Stainless steel
Filtering type
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Other common utilities are: Storage vessels Ball and gate valves Stainless steel pipelines Glass wool insulation Pressure gauges Temperature gauges Level sensors
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Chaper 3
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3.1. Introduction:
Zinc sulfate (ZnSO4) is a colorless crystalline, water-soluble chemical compound. The hydrated form, ZnSO47H2O, the mineral goslarite, was historically known as "white vitriol" and can be prepared by reacting zinc with aqueous sulfuric acid. The product is 10% zinc sulphate. This is mainly use directly as a pesticide and sometimes ingredients are added in it. The product is in form Liquid form
This is an exothermic reaction, heat and lots of fumes are evolved during the reaction After 2-3 hours zinc sulfate is taken into Pit. Here the solution is given time to settle down. Dust particles settled down and product is tested from laboratory, if there is need of more mixing than it is done through compressed air. The solution from Pit is sent into the Plate and frame filter press through the high Pressure centrifugal pump. After filtration, a pure solution of 10% zinc sulfate is taken into tanks.
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Sedimentation tank
Reactor
P-8
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24
Other common utilities used in Zinc sulphate plant are: Valves Centrifugal pump Storage tank Batch reactor Diaphragm pump Sedimentation tanks Level sensors
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Chaper 4
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4.1. Introduction:
The formulation plant mainly deals with the production of liquid phase pesticides. The plant mainly consists of batch reactors and pumps for the requirement of the product. The plant is equipped with the best process control instrumentation. All the machinery and equipment is of explosion prove grade.
4.2. Capacity:
Formulation capacity: 300,000 liters of liquid/day Finished product storage capacity: 1,600,000 liters at a time
4.3. Products:
Emulsifiable Concentrate: Cypermethrane 10EC
Acetamyprid 20SL Glyposate 48SL Soluble Concentrate: Diaphrenthrun 50SC Atratox 38SC Emulsion Wet: Tegula 12.5 EW Phenoxaprop-p-ethyl 6.9 EW Break 7.5 EW Soluble Emulsion: Weed out 40SE
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Xylene is then added. During the charging the weight charged of the mixture is noticed in the control room. Now required residence time is provided to the mixture in the reacting tank and we also provide circulation of the mixture receiving from bottom and again charging it from top. During the agitation sample is taken from the reacting tank with help of a small cylinder attached to rod. This sample is then sent to the laboratory for its final quality test and as it is approved the batch is then transfer to the holding tanks using centrifugal pump. Before the transfer, the batch is allowed to settle for few minutes. This settles the slug at the bottom of tank if present. Then the slug is removed and the product is transferred to the holding tanks. Cycle time of batch is nearly 1 hour and 30 minutes.
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Cold Water in Furnace Oil in Furnace Furnace oil out Shell and tube Heat exchanger
Membrane Filter
exhaust
Motor Bi-pass exhaust To RT-1 circulating To RT-2 To RT-3 Flushing line DCP Water out Hot Water in Reacting tank-1 For packing Sample Valve Holding tank1
DCP
Nitrogen cyclinder
Nitrogen cylinder
To RT-4
To holding Tank-2
Product
Preformulated Product
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Water in Furnace Oil in Furnace Furnace oil out Hot Water Out
Membrane Filter
Nitrogen cylinder
To RT-6
DCP
exhaust Reaction tank-5 Cold Water out Hot Water in Reaction tank-6
Sample Valve
Circulating line
Side Mirror
Bead Mill
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Description of above mentioned utilities is given but with the exception of common utilities;
Figure 4.3a
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Figure 4.3b
4.7.2. Strainers:
Filter provided to remove any solid particle from the outlet of the reacting tank. It contains mesh screen which pass the fluid and stops any suspended particle present.
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Chaper 5
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5.1. Introduction:
In 2009, the plant was established with the aim of producing insecticides in granule form. The plant is equipped with all necessary machinery and latest control instrumentations. The plant mainly consists of mixers and dryers for producing the desired product.
5.2. Capacity:
Production capacity of granule formulation plant is 80,000 kg/day.
5.3. Products:
Mono mehypo hydrochloride 4% Cartap hydrochloride 4% Carbofeuron
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Product is then transferred to vibrater 2 here screen used are of 10-24 Mesh size in order to remove the agglomerates which are removed and wasted. Final product is than send to bucket elevator 3. Dust collectors are attached to all the three bucket elevators. The air used for collecting dust comes from the compressor. Bucket elevator 3 moves product to hopper 3. Hopper 3 is used as final storage Below hopper 3 there is granular filling section where granular product is filled in 7 kg bags. Bags are than send to the sealing section where seals are putted on the bags. Sealed bags are than packed and sent to transportation.
Drying
Screening
Packing
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1 2 3 4 5 6 7
Type of Bucket elevator Type of Hoppers Type of dryer Type of mixers Type of heat exchanger Type of Pumps Dust collecting system
Centrifugal type Conical type Rotary type Rotary type Shall and tube Gear pumps Cyclone
Bucket elevator:
A bucket elevator or grain leg is a piece of equipment which is used to move silica sand from ground level to hoppers at some height. A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend entirely on the action of centrifugal force to get the material into the discharge chute and must be run at speeds relatively high. Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They pick up their load from a boot, a pit, or a pile of material at the foot pulley. The buckets can be also triangular in cross section and set close to on the belt with little or no clearance between them. This is a continuous bucket elevator. Its main use is to carry difficult materials at slow speed.
Figure 5.3
Rotary Dryers:
Two rotary dryers are installed in granule formulation plant, one for drying of silica sand and other for our final product. Length of the dryer is 20 ft and its diameter is 3ft. A latest temperature controlling instrumentation system is also installed in the dryers in order to maintain our required temperature.
Construction:
The dryer is made up of large, rotating cylindrical tube, steel beams. The dryer slopes slightly so that the discharge end is lower than the material feed end in order to convey the material through the dryer under gravity.
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Figure 5.4
Working:
Material to be dried enters the dryer, and as the dryer rotates, the material is lifted up by a series of internal fins lining the inner wall of the dryer. When the material gets high enough to roll back off the fins, it falls back down to the bottom of the dryer, passing through the hot gas stream as it falls. This gas stream can either be moving toward the discharge end from the feed end (known as co-current flow), or toward the feed end from the discharge end (known as counter-current flow). The gas stream can be made up of a mixture of air and combustion gases from a burner, in which case the dryer is called a direct heated dryer.
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Chaper 6
REFRIGERATION SYSTEM
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6.1. Introduction:
Well-designed refrigeration system with good escape routes not only in the machinery room, but also in the vicinity of air coolers, is installed in order to cool brine solution up to -40oC. Four compressors are used for the refrigeration of brine, two are single stage and other two are double stage compressors. Temperature of -15oC (of brine solution) is achieved by following single stage refrigeration Temperature of -40oC (of brine solution) is achieved by following double stage refrigeration cycle.
Ammonia is used as a refrigerant. Ammonia is inherently more efficient than halocarbon refrigerants because of its high latent heat, its high critical temperature and its low molecular weight.
The compressor in the refrigerator compresses the ammonia gas (the refrigerant). The compressed gas heats up as it undergoes pressurization. The induced draft cooling tower let the hot ammonia gas dissipate its heat and thus the hot ammonia gas condenses into liquid ammonia at high pressure. The high-pressure ammonia liquid flows through the expansion valve. The expansion valve is just like a small hole. One side of the hole contains high-pressure ammonia liquid and the other side is a low-pressure area because the compressor is sucking gas out of that side. The liquid ammonia evaporates immediately in brine box as its temperature drops. In fact heat is transferred between brine and ammonia. Saturated refrigerant vapor is usually superheated to ensure that liquid refrigerant does not ow into the compressor. The compressor sucks up the cold ammonia gas and thus the cycle keeps on repeating itself, maintaining a constant cold temperature inside the brine box.
The following refrigeration processes occur during the operation of Ammonia gas expansion refrigeration system: Compression. Air or gas is compressed to a higher pressure and temperature. Heat release. Heat is released to the surroundings at constant pressure in order to reduce the temperature of the air or gas. Throttling and expansion. Air or gas is throttled and expanded so that its temperature is lowered. Heat absorption. Heat is absorbed from the surroundings because of the lower air or gas temperature.
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Vapour/Liquid Refrigerant
Vapour/Liquid Refrigerant
Vapour Refrigerant
Liquid Refrigerant
Compressor
Vapour Refrigerant
Oil Separator
Vapour Refrigerant
Condenser
Liquid Refrigerant
Vapour/Liquid Refrigerant
Vapour/Liquid Refrigerant
Vapour Refrigerant
Liquid Refrigerant
Compressor
Vapour Refrigerant
Oil Separator
Vapour Refrigerant
Condenser
Inter Cooler
Throttling Devices
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Air Separator
Condensor
Inter Cooler
Oil Separator
Oil Separator
Oil Separator
Oil Separator
Oil type Double Stage Compressor Double Stage Compressor Single Stage Compressor Single Stage Compressor
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Oil Separator
Oil Separator
6.5.1. Compressor:
The refrigeration compressor is the heart of the refrigeration system. It removes the vapor from the evaporator and introduces vapor to the high-pressure side of the systems. It maintains the low-side pressure at which the refrigerant evaporates, and the high-side pressure at which it condenses. In brief, it supplies the pressure differences necessary to keep the system refrigerant flowing through the system
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Two compressors are used here for compressing ammonia. 6.5.1.1. Single acting Compressor : It has single suction and discharge. It consists of piston and cylinder assembly, which compresses the ammonia The water circulation is applied so as to make it cool during working. High power and compression unit. Oil lubrication is also present to make it work smooth.
6.5.1.2.Double acting Compressor: It has two suctions and discharges that allow it to perform double compressing action using inter cooler. It consists of piston and cylinder assembly, which compresses the ammonia The water circulation is applied so as to make it cool during working High power and compression then single unit Oil lubrication is also present to make it work smooth
6.5.3. Evaporator:
Inside the evaporator heat from the cooled region or medium is absorbed into the refrigerant, as a result, the refrigerant changes from a liquid to a vapor. In a given refrigeration system, Coil type heat exchangers are used to chill the brine solution.
6.5.4. Accumulator:
It is used to store the ammonia vapors that are coming from the brine box or evaporator. The purpose of accumulator is to remove the ammonia liquid from the vapors if they present. . If the gas is directly send to the compressor it may damage it because of presence of liquid.
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6.5.5. Condenser:
The condenser transfers the heat from the refrigerant to a coolant medium, usually ambient air. Inside the condenser the refrigerant changes from a vapor to a liquid. There are three basic types of condensers: o Air-cooled o Water-cooled o Evaporative The condenser installed in the given is evaporative type.
An evaporative condenser is a combination of an air-cooled and a water-cooled condenser. As the hot refrigerant vapor flows though the bank of tubes, water is sprayed over the tubes and evaporates. As the water evaporates, it absorbs heat from the refrigerant, which increases the efficiency of the condensation. Because of the increased efficiency, evaporative condensers can be smaller than air-cooled units.
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Chaper 7
BOILER HOUSE
50
7.1. Introduction:
There are two boilers installed in Pak China Chemicals Ltd. The main purpose of boilers is to produce steam. The generated steam is given to all running plants e.g. Formulation plant, Granule formulation plant, PCM Plant according to their requirement. The steam pressure for every plant is different according to their requirement as mentioned above.
Type of boiler Type of fuel Inner sheet of boiler Outer sheet of boiler Insulation of boiler Maximum pressure of steam Maximum temperature of steam Number of tubes Diameter of each tube Length of each tube Capacity of boiler Flue gases temperature
Fire tube Boiler Diesel Stainless steel Mild steel Glass wool 9 bar 270oC 42 2.5 inch 10 ft 2ton of steam/hr 100-110oC
Table: 7.1
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STEAM OUT
GATE VALVE STRAINER GATE VALVE GATE VALVE GLOBE VALVE HOLD UP RELIEF VALVE WATER WITH HIGH SALTS(BLOW UP)
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Acid cleaning: For washing boilers, acid cleaning is done. In Pak China Chemicals,
acid cleaning is done by using dilute sulfuric acid.
Silicate removal from walls: For removing silicates, 5-10% soda ash is introduced
and water is boiled. It removes silicates from boiler wall and also neutralizes the effect of acid.
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Chaper 8
55
8.1. Introduction:
The significance of Safety & Health in chemical industries has been a vital issue in achieving productivity and an edge in the competitive world. As Pak China Chemicals formulates most of the organic compounds for the production of pesticides and insecticides. Being organic, these compounds are highly explosives and flammable. They can cause severe action when inhaled for even more then 2 minutes. So, in order to avoid any danger, necessary safety system is installed.
Dangerous Materials: Explosives Gases Inflammable Liquids Inflammable Solids Oxidizing substances Toxic and Infectious substances
Hazards of Pressure Vessels: Leakage or Bursting of Pressure Vessels Design defects Failure of Relief Systems Lack of Proper Instrumentation or Instrumentation Failure Lack of routine inspections
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substance (Class), and explosive rating of the substance (Group) and the degree of hazard created (Division). The plant layout has been designed as per established engineering practices in conformity with the provisions of required safety separation distances have been maintained. The layout of plants, under the purview of the various statutory regulations has been granted and these regulations are being renewed regularly. In addition to the fulfillment of statutory requirements, compliance of recommendations of various other national and international standards and Code of Practices has been kept in view for the layout of the plant facilities. Separation distance maintained in protection zones as per rules. The equipments, pipings and instruments action are provided for explosion protection. Explosion proof motors and fittings are used for hazardous areas.
Explosive meters are also provided to plant in-charges for checking gas leak, if any. Proper fire prevention and protection equipments installed, checked and kept ready.
8.4.
All staff of Fire & Safety, Health and Environment sections is well qualified Engineers, Fire& safety officers and Doctors.
Fixed Installations:
All Xylene tanks are protected by installation of automatic fixed foam pouring system at their top which is checked periodically and record is maintained. Smoke detection system is provided at all the important buildings and control rooms. Well Laid underground Fire Hydrant System, underground fire hydrant pipes has been laid throughout the premises.
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References:
1. J.f Rechardson, J.H Herker, J.R Backhurst, Chemical Engineering, Ed. 2002. P.919-925 2. Electronic source: http://www.aliakbargroup.com
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