GSFC Trainning Report

CAPROLACTAM PLANT INSIGHT

Six weeks Industrial Training Report
At
GUJARAT STATE FERTILIZER & CHEMICALS LIMITED
Submitted in partial fulfillment of the requirements for the award of degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by:
JAY JOSHI
Roll No: 13BME043
KENIL SHAH
Roll No: 13BME110
MECHANICAL ENGINEERING DEPARTMENT
INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
1st June 2016 09th July 2016
Nirma University
Page 1
Nirma University
Page 2
CERTIFICATE
This is to certify that, Mr. Jay R. Joshi and Mr. Kenil S. Shah students of
Mechanical engineering, 7th semester, of Nirma University, Institute of Technology,
has satisfactorily completed the Industrial Training at Gujarat State Fertilizer &
Chemicals Limited, Vadodara, during 1st June to 9th July 2016 and found sincere
and hardworking in tenure period of training.
Dated: 9th July, 2016
(Name of Faculty member)
Countersigned by
(Head of Department)
Stamp
Nirma University
Page 3
ACKNOWLEDGMENT
A dream come true by working & seeing the world class production taking place with
enthusiasm. We were allowed to take part in the competition where industries try to
nudge the other & get the top. So we are glad to submit this training report as a part of
working memory in CAPROLACTAM-I PLANT GSFC Baroda.
Whatever we have learnt during our training has been brought out in the form of this
training report. We hereby take an opportunity to thank the people who have imparted the
knowledge to us.
We are very thankful to the authority of Nirma University for including industrial training as
a part of the curriculum. It gave us a chance to explore and learn more on the topic of our
interest.
We heartily thank Mrs. ANITA GANGULI, Sr.V.P. (HR,IR,CC,GAD & MS) for allowing us
to pursue our Industrial training at such the largest fertilizer plant of Asia and an esteemed
organization.
We are highly thankful to Mr. H.J PARIKH (Chief, Main Capro-1, MEK-O, Nylon-6),
Mr. S. J. BHATT(Chief Capro-1), Mr. SAJI.T. (Sr. Manager), Mr. Y.J.SHAH (Manager),
R.M.PARMAR (Dy. Manager) & Mr. Rajan Sadaria for providing us necessary
information, guidance and support.
We are also thankful to Mr. Mehul and Mr. Rushil Bhrambhatt for their enthusiastic support.
We are also thankful to Mr. Hiren Patel and Ms. Raxita Rana for their support and experience
in the company.
We would like to show our immense gratitude to Mr. S.K.SHAH (Instrument Dpt.,
SA-3,4) for his valuable guidance & support. Also with the help of him and his contacts,
we could visit the different plants of GSFC and see the different technology used by
company.
We would also like to thank all the GSFC employees who have helped us during the course of
our training. It would always remain a memorable experience to work with such high caliber.
Nirma University
Page 4
ABSTRACT
This report gives information based on our training at GSFC Ltd., Vadodara. We learnt
theoretical concepts at the University, but how those concepts are applied to industrial solutions
is also important. There is a certain gap between industrial approach and theoretical-bookish
approach and to fully understand the prior, the later needs to be understood first. In this report,
basic policies and history of the company are described. Also main products and different plants
of GSFC are discussed. But this report is mainly focused on maintenance of various equipments
used in the company. The point of focus here is Maintenance of different components like
pumps, compressor, boiler, mixer, centrifuge, gear box, evaporator, reactor, heat exchanger etc.
During training we get opportunity to get experience of shutdown. Actually it was prior planned
to take shutdown in September month but due to emergency in the mother plant (Ammonia-IV
Plant), shutdown in Capro-1 was also done. We learnt lots of new things during shutdown. This
report also contains highlights of the GSFC Ltd.
Nirma University
Page 5
TABLE OF CONTENTS
Acknowledgement
Abstract
Chapter
No.
1
ABOUT INDUSTRY
1.1
1.2
2.3
I
II
Topic
Introduction
1.1.1 Timeline of GSFC
1.1.2 Financial Status of GSFC
1.1.3 Vision and Mission of GSFC
Main GSFC Plant - Vadodara
1.2.1 Products and Production
1.2.2 Environmental Aspects
1.2.3 Different Plants and their working at main unit
CAPROLACTAM-1 PLANT
2.1
2.2
Introduction
Product
2.2.1 Chemical Details
2.2.2 Importance
2.2.3 Production
Plant Divisions and Process
2.3.1 Anone
2.3.2 HX
2.3.3 Lactam
2.3.4 Services
IMPORTANT MECHANICAL COMPONENTS

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
Nirma University
Page No.
Pumps
Compressor
Heat Exchanger
Gear Box
LUWA Evaporator
Centrifuge
Cooling Tower
Coupling
Gaskets
Metal Bellows
Page 6
3.11
3.8
Steam Ejector
Flaker
SHUT DOWN REPORT

Conclusion
Bibliography
Nirma University
Page 7
LIST OF FIGURES
Figure 1.1
Nirma University
Page 8
Page No.
LIST OF TABLES
Table 1.1
Nirma University
Page 9
Page No.
CHAPTER 1
ABOUT INDUSTRY
1.1
Introduction
Gujarat State Fertilizers & Chemicals Limited (GSFC) is an Indian manufacturer of

fertilizers and Industrial Chemicals. GSFC was founded in 1962. Oil and gas discoveries in
Bombay High and South Basin triggered the birth of 8 new generation fertilizer plants to fulfill
the growing food needs of India.
GSFC manufactures fertilizers, plastics, nylons, fibers, industrial gases and varied chemicals
including urea, ammonia, ammonium sulfate, sulfuric acid, phosphoric acid & diammonium
phosphate, Caprolactam, Malemine, and Methanol. It is located nearby Vadodara in the State
of Gujarat, on theVadodara-Ahmedabad National Highway.
1.1.1 Time line of GSFC
1962
o The Company was incorporated on 15th February, nearby Vadodara city in
Gujarat.
1967
o The first phase of plants consisting of ammonia, sulphuric acid, phosphoric acid,
urea, ammonium sulphate and diammonium phosphate units were commissioned.
1972
o The Company set up its own development and research department.
1974
o The Caprolactam facility plant was commissioned on 25th March.
1979
o On 1st June, the Company completed and put into operation a debottlenecking
program with a view to increase the production of phosphoric acid.
1981
o During December, the Company commissioned another sulphuric acid plant for
manufacture of 1,32,000 TPA of sulphuric acid.
1982
o During November, the Company commissioned a 5,000 TPA of melamine and
fluorine recovery plant.
Nirma University
Page 10
o During July, the Company commissioned a factory for conversion of methane into
oxosyngas.
o The Company undertook to set up its second DAP complex with a capacity of
4,50,000 tonnes of phosphorous pentoxide (P 2O5) per annum on the Saurashtra
coast (known as Sikka plant).
o The Company and Gujarat Maritime Board jointly formed a technical committee
in order to speedily set up the development of Sikka port for handling imports for
the DAP complex. The main process plant was commissioned in December 1986.
1983
o Polymers Corporation of Gujarat Ltd., was amalgamated with the Company with
effect from 1st January as per approval of Gujarat High Court dated 16th January,
1985.
1985
o 4 polymer blends and alloys of Nylon-6 and SAN were developed. During the
year, industrial license for methacrylic acid (MAA) was received.
1987
o The Company's multipurpose fertiliser pilot plant to be set up in collaboration
with International Fertilizer Development Centre (IFCD), USA, received
Government approval in the year.
o The pilot plant for xylitol from bagasse was commissioned.
o The Company in collaboration with ATIRA, Ahmedabad developed an acrylic
based synthetic thickener.

1988
o (15 months), agreements with foreign collaborators and Indian engineering
construction companies were completed for the establishment of the Caprolactam
facility plant.
o Gujarat Industries Power Co., Ltd. (GIPCL), was set up through the joint efforts
of Gujarat State Fertilizer Co. Ltd., (GSFC), Gujarat Narmada Valley Fertilizers
Co. Ltd. (GNFC), Gujarat Alkalies and Chemicals Ltd. (GACL), Petrofils, Heavy
Water project collaboration with GEB and Government of Gujarat, for
establishing a joint captive power plant IX 120 MV capacity.
1989
Nirma University
Page 11
o The DAP production at Sikka was hampered due to non-availability of

imported/canalized raw materials like phosphoric acid and ammonia. As a result,
the Sikka plant remained closed for a period of 193 days.
o Requisite permissions were received to import 1,500 tonnes of melamine. It was
proposed to increase the melamine capacity from the present 5,000 TPA to 15,000
TPA and the project was under implementation.
o The Company decided to set up one more sulphuric acid plant with a capacity of
1000 TPD at a cost of about Rs 55 crores.
1990
o The Company proposed to set up a 1350 MTPD ammonia plant at Fertilizernagar.
Linde AG West Germany was selected as the contractor for the project.
o The Company set up a project for the production of argon gas required for
industrial purposes and also for saving of naphtha and gas consumption in the
manufacture of ammonia.
o Another plant was set up for recovery of methane synthesis gas and argon gas in
1990.
1991
o A three bed modified design contact furnace with improved material of
construction was installed in the melamine plant.
o At the instance of Gujarat Maritime Board (GMB), the Company decided to take
over the ownership of the Sikka Jetty from GMB right from the day of the start up
of construction of the jetty.
1995
o With a view to take care of the investments in new schemes and small projects,
the Company promoted a new company "GSFC Investment & Leasing Co., Ltd."
(GILC).
1996
o Effective from 1st October the name of the company was changed from Gujarat
State Fertilizers Co. Ltd. to Gujarat State Fertilizers & Chemicals Ltd.
1997
o All DCS systems, Electrical sub-station, Air separation unit and Argon recovery
units, TG set, Air & Nitrogen compressors were commissioned.
1998
Nirma University
Page 12
o With a view to enhancing the production of Cyclohexanone, the Company

undertook to set up a debottlenecking project.
1999
o Fertilizer major Gujarat State Fertilizers and Chemicals Ltd (GSFC) has taken an
in-principle decision to sign a joint venture (JV) agreement with engineering and
infrastructure major Larsen and Toubro Ltd. (L&T) for the construction of
buildings at its Rs 200 crore Infocity project.
o The company has entered the agro service sector with the launch of various plant
breeding, bio-fertilizers and tissue culture products.

2002
o Rationalizes the plant load of Urea-I and Melamine-I & II plants.
o Seeks relief from the Union Ministry of Chemicals and Fertilizers for the capital
expenditure incurred by the company on its 1350 MTPD ammonia plant
(ammonia- IV plant).
o Completes DAP Expansion project Train "C" of the capacity of 3,96,000 tonnes
per annum at Sikka Unit.
o Government of Gujarat declares GSFC as Relief Undertaking.
2006
o GSFC has entered into agreement to supply fertilizers to Morocco and South
Africa for 10 yrs.
2011
o GSFC ventures for expansion of Nylon-6 Project.
2014
o Neem Coated Urea launched by GSFC.
1.1.2
Financial Status of GSFC
Nirma University
Page 13
1.1.3
Vision and Mission of GSFC
Vision
Our vision is to efficiently produce an array of valuable, superior and reliable products
that enrich lives of millions in farms, industries and homes. The Company envisions
operating in synergy with its environment and seeks to be recognized as an enterprise that
is for total customer satisfaction and creates credible long term value for its stakeholders.
Integrity and transparency remains the corner-stones of Company's governance.
Mission
The Company seeks to enrich lives;
of customers by providing goods and services that add value to farm enterprises,
industries and homes

of stakeholders by continuously adding value by managing responsibly, sensibly
and maintaining ethical standards of highest quality

of neighbourhood community by working in synergy with its environment and
enriching the bio-diversity

of employees by providing them a work environment that fosters growth,
learning, achievement, team work and a perfect work-life balance.
1.2
Main GSFC Plant Vadodara

1.2.1 Products
With a market presence exceeding 45 years GSFC has carved out an irreplaceable image
for itself on the Indian marketing scene.
Integration of technologies and brilliant innovative research ensures that the products
touch all walks of life. From household consumer to core industrial consumer, GSFC
continuously fulfils multi-fold needs of the market.
GSFC's incessant strive for product diversification and value addition has created a
product mix ranging from more than 24 brands of fertilizers to petrochemicals,
chemicals, industrial gases, plastics, fibers and other products.
Nirma University
Page 14
Conforming to the strictest international standards, GSFC continuously achieves and

maintains best quality, superior packaging, prompt deliveries & services of highest
standards for every product. This claim is well substantiated by a string of National &
International Awards, but TOTAL Customer Satisfaction is the MOST VALUED AWARD
at GSFC.
GSFC today stands for superior quality with many of its products being ISO 9001
certified. GSFC believes in providing highest value for the Customer's money through
economies of scale, continuous product improvement & Value addition to the products.
Main Products of GSFC
1. Fertilizer
a. Urea
b. Ammonium Sulphate
c. Di Ammonium Sulphate
d. Ammonium Phosphate Sulphate
e. Water Soluble Fertilizers
f. Hybrid Seeds
2. Petro Chemicals
a. Phosgene Oxime
b. Caprolactam
c. Methyl Ethyl Ketoxime
3. Plastics
a. Nylon-6
b. Malemine
c. Acrylics
4. Industrial Gases
a. Argon
b. Methane
c. Ammonia
Product Details Briefly:

1. Urea:
NH2CONH2 46.6%
Raw Material Ammonia and Carbon Dioxide
2. Ammonium Sulphate
((NH4)2)SO2
20.6% N2
Raw Material Benzene, Oleum, Ammonia, Phospheric Acid
3. DAP (Di-Ammonium Phosphate)
(NH4)2HPO4
18% N2 46% P2O5
Raw Material Benzene, Ammonia, Phospheric Acid
4. Caprolactam
C5H10CONH
Raw Material Benzene, Oleum, SO2, NH3
Nirma University
Page 15
5. Nylon-6
GUJLON is the registered trade name. Nylon is the non corrosive material.
Raw Material Caprolactam
6. Melamine
GUJLAMINE is the registered trade name. Pure chemical powder is manufactured by GSFC.
C3N6H6
Raw Material Urea, NH3
7. Ammonia
NH3
Raw Material Neptha (From Natural Gas-taken from Reliance) and Nitrogen (From Air)
8. MEK-O
GUJOXIME is the registered trade name.
C4H3N(OH)
Raw Material MEKO, NH3, HX
9. Sulphuric Acid
H2SO4
98.5% 98.6% wt
Raw Material Sulphur and Oxygen (From Air)
1.2.2 Green Revolution

As a responsible corporate citizen, GSFC ensures to leave a legacy of clean and green
environment to the future generations. Being already green, GSFC aspires for getting
greener. With the objective of combating climate change, GSFC aligns its business
objectives with practices of resource conservation and environment protection. GSFC is
deeply committed to satisfy its social obligations and has made consistent and effective
endeavors for creating better environmental conditions through abatement of pollution
and adopting sustainable development practices. Regular technological initiatives are
pressed into service with great vigor to improve and retain the purity of air, water and
soil. GSFC's clean development mechanism (CDM) initiatives bear testimony to the drive
to reduce greenhouse emissions. The first CDM project envisages use of waste gas from
company's plants to manufacture Ammonia, thereby obviating the need for natural gas
fuel for its production. It is a matter of pride that the technology for replacing the fossil
fuel has been developed through in-house R&D efforts. Meanwhile, the second CDM
initiative is for generating 152.8 MW green energy through a cluster of windmills. Some
other green initiatives are:
Nirma University
Page 16
Concerted efforts towards achieving Zero pollution levels by investing substantial funds
for preventing, minimizing, recycling/reusing of liquid effluents, gaseous emissions and
hazardous solid wastes.

Implementation of zero process effluent discharge system for Phosphoric group of plants.
Installation of sophisticated air pollution devices like ESP, De-Nox unit, ECS, scrubbers
and filters for abatement and recovery of gaseous pollutants.

Reuse of treated sewage for gardening and tree plantation purpose and recycling/reuse of
process water within the plant to the extent possible, thereby conserving natural resource
'Water' to large extent.

Supporting Vadodara Enviro Channel Ltd (VECL) for promotion of 56 km long common
effluent channel for discharge of effluents into the sea and ensuring cleaner environment
in the region.
Online round the clock monitoring of ambient air through four online Ambient Air
Monitoring stations installed at the periphery of GSFC for efficient and better controls.
Installation of SO2 and Ammonia gas detectors in various process plants for monitoring
of gaseous emissions at source and subsequently better control and implementation of
proactive corrections.
Environment training and awareness to employees and surrounding villages for joining
hands in the noble cause of environment protection.

Encapsulation of the chalk waste on 14 hectares of land and development of greenery on
it.
GSFC has always remained in forefront to make the company green & clean by
Landscaping, development of large & beautiful gardens within the complex & in colony
and massive Green belt in 105 Ha area (33% of the total land area).
Development of a beautiful lotus pond with garden, ducks and natural landscaping within
sulphuric acid plant area.
Nirma University
Page 17
Preserving a natural habitat for the national bird - Peacocks (can be seen roaming in the
premises as well as in the colonies) speaking volumes about GSFC's concern for the
environment. The below photograph was taken in the GSFC garden by the formal MD
Mr. Atanu Chakraborty.
GSFC has carried out assessment of Biodiversity in and around the premises through
M/s. Gujarat Ecology Society (GES), Vadodara in the year 2011, which shows positive
changes with respect to biodiversity.
1.2.3
Different Plants in GSFC

Ammonia IV (A IV) Plant:
Commissioned in July 1998, the Ammonia IV plant has a capacity of 1,350 MTD. This
plant was established, with an investment of Rs. 1,140 crore, to replace the high energy
consuming 450 and 500 MTD Ammonia plants. The Ammonia plant is the mother plant
for those fertilizer and industrial products of the company for which Ammonia is required
as a basic raw material. Carbon Dioxide and Argon are gas products that meet captive
requirements, with the surplus quantity of these gases being saleable. Oxygen is
recovered as co-product for captive utilization.
Ammonia III (A-III) Plant:

Originally owned by Heavy Water project, the Ammonia III plant was bought by GSFC
in 2009 and its production was revived to create a stand by Synthesis Gas production
facility for the Caprolactam plants. The additional Ammonia production of 100 MTD
from A IV plant was then available for either sale or transfer to Sikka unit. This plant
produces Synthesis Gas at a lower cost.
Di Ammonium Phosphate (DAP) plant:
Nirma University
Page 18
The DAP plant of 340 MTD capacity was commissioned in May 1967 as part of GSFC's
Phase I. The plant was supplied by Hitachi-Zosen Limited, Japan. GSFC selected M/s
TVA & Chemico (USA) process for this plant, based on a worldwide survey of all the
available processes during that time. The DAP plant is also designed to produce 800
MTD (Solid route) of APS. A new indigenous process was developed to produce APS by
slurry route. After stabilization of this process since Jan 2002, GSFC can produce 900
MTD APS on continuous basis by discontinuing production of DAP.
Melamine I and II Plants:

GSFC has two Melamine plants having rated capacities of 5,000 TPA and 10,000 TPA,
which utilize molten urea as a principal raw material sourced from GSFC's own Urea
plant. The 5,000 TPA Melamine I plant was commissioned in 1982 and the 10,000 TPA
Melamine II plant in 1997.
Melamine has become one of GSFC's leading industrial products, used for the production
of laminates, adhesives, surface coating, molded products and flame retardant products.
Melamine is also used for textile and paper treatment and coating, leather tanning,
pigment binders and glass fibre binders.
Phosphoric Acid (PA) plant:

The Phosphoric Acid plant of 165 MTD (100% P2O5) capacity is based on Chemico
Dihydrate process, used for the first time in the world by GSFC. This plant was put up as
part of GSFC Phase I and was commissioned in May 1967.

Sulphuric Acid (SA) III and IV Plants:
GSFC has two Sulphuric Acid plants of 400 MTD and 1,350 MTD capacity respectively.
This plants work on the principle of Double Contact Double Absorption method.
In the year 1990, an additional facility to produce 29% Oleum was also incorporated to
meet the requirement for Capro II plant.
Urea I and II Plants:
Nirma University
Page 19
The Urea plants of 323 and 800 MTD capacities were commissioned in 1967 and 1969
respectively. Both these vintage plants are operating well at nameplate capacity, thanks to
continual improvements through the replacement or refurbishment of equipment and
modifications to achieve energy conservation.
Caprolactam (Capro I and II) Plants:

Caprolactam (Capro I and II) plants at Vadodara unit Caprolactam is a blue chip product
in GSFC's portfolio. The Capro I plant was part of GSFC's third phase where the
company diversified into petrochemicals. Capro II was part of GSFC's 1989-2002
expansion and diversification plan. GSFC's two Caprolactam plants have rated capacities
of 20,000 TPA and 50,000 TPA respectively.
Methanol plant:
GSFC has commissioned a plant to produce 525 MTD of Methanol. The product will
conform to US federal norms.
Most of the feedstock for making Methanol, like Synthesis Gases, is available from
GSFC's existing plants. Methanol is used in the production of fertilizers, pharmaceuticals
and industrial chemicals. Methanol is converted to formaldehyde, used for diverse
products like plastics, plywood, paints, explosives, and permanent press textiles.
Ammonium Phosphate Sulphate plant:

GSFC's Ammonium Phosphate Sulphate (APS) plant has a capacity of 2,56,000 TPA. The
DAP plant is designed in such a way that APS also can be produced. Sulphuric Acid,
Phosphoric Acid and Ammonia are used to produce this product, which is a complex
fertilizer.
Nirma University
Page 20
Ammonium Sulphate plant:

GSFC's Ammonium Sulphate plant (NH4)2SO4 (20.6% N) has a capacity of 1,96,000
TPA. Ammonium Sulphate is available as co-product from Caprolactam plants. This
product is a slow releasing nitrogenous fertilizer and raw material for various chemicals,
dyes and pharmaceuticals.
Nylon-6 (Gujlon) Plant:

GSFC has the largest capacity Engineering Plastic Nylon-6 plant in the country with a
rated capacity of 7,000 MT. The main raw material for Nylon-6 is Caprolactam which is
available from captive capacity.
Gujlon is the registered trade name of Nylon-6 chips manufactured by GSFC.
Nirma University
Page 21
CHAPTER 2
CAPROLACTAM 1 PLANT
2.1
INTRODUCTION
Caprolactam 1 plant at Vadodara unit was established in 1974. Caprolactam is a blue chip
product in GSFC's portfolio. The Capro I plant was part of GSFC's third phase where the
company diversified into petrochemicals. GSFC's Caprolactam 1 plant has rated capacity of
20,000 TPA. The main raw materials are Benzene, Oleum, Ammonia, Carbon dioxide, Synthesis
Gas, Sulphur dioxide, Caustic soda and Sulphuric acid.
CAPROLACTAM -1 plant is comprise of FOUR main plants and associated Ammonium
Sulphate plant. The plants and there capacities are as under:
1. Cyclohexanone plant : 22,250 MT/Annum
2. HydroxylAmine Sulphate plant : 14,750 MT/Annum
3. Caprolactam plant : 20,000MT/Annum
4. Services comprise of Waste liquor combuston unit, Refrigeration compressprs, Organics
storages, utilities.
5. Ammonium Sulphare AS-II plant : 84,000MT/ Annum
6. MEK-O I&II 1200& 3250Mt/Annum
2.2
PRODUCT
2.2.1
Chemical Specifications
Caprolactam is an organic compound with the formula (CH2)5C(O)NH. This colourless

solid is a lactam (a cyclic amide) of caproic acid. Caprolactam is an irritant and is
mildly toxic. In water, caprolactam hydrolyzes to aminocaproic acid, which is used
medicinally.
Nirma University
Page 22
Properties
Chemical formula
C6H11NO
Molar mass
113.16 gmol1
Appearance
White solid
Density
1.01 g/cm3
Melting point
69.2 C (156.6 F; 342.3 K)
Boiling point
270.8 C (519.4 F; 544.0 K) at

1013.25 hPa
Solubility in water
866.89 g/L (22 C)
Vapor pressure
0.00000008 mmHg (20 C)

Table 2.1: Specifications of Caprolactam [1]
2.2.2
Importance
Caprolactam is the precursor to Nylon 6, a widely used synthetic polymer. Around 68%
of caprolactam is consumed in the production of nylon fibres for textile, carpet and
industrial yarns with the rest used in engineering resins and films. Caprolactam is
also used in production of brush bristles, textile stiffeners, film coatings, synthetic leather,
plastics and plasticizers, paint vehicles, cross-linking for polyurethanes, lysine (synthesis)
etc.
2.2.3
Process
Nirma University
Page 23
Figure 2.1: Process of Caprolactam plant [1]

2.3
Plant Divisions and Process

2.3.1
Anone
The cyclohexanone is manufactured from Benzene. The various steps are involved in the
process of manufacturing and those are mentioned below:
a)
b)
c)
d)
e)
f)
Hydrogenation of benzene into cyclo-hexane.

Oxidation of cyclo-hexane into cyclo-hexanone and cyclo-hexanol.
Saponification of mixture to remove byproducts.
Distillation for separation.
Dehydrogenation of cyclo-hexanol to cyclo-hexanone.
Pure cyclo-hexanone distillation.
Section 401
Section 402
Section 403
Section 404
Section 405
Section 406
The unreacted cyclo-hexane is recycled to the process. The hydrogen liberated during
dehydrogenation of the cyclo-hexanol is also recycled back to the Benzene
hydrogenation.
Nirma University
Page 24
401 Benzene Hydrogenation

Benzene is the main raw material for the production of the cyclo-hexanone which is also
termed as Anone. Benzene is supplied by the nearby Gujarat Refinery and Reliance. It is
vaporized and mixed with hydrogen for hydrogenation process. The hydrogen rich
benzene is passed over the desulphurising catalyst bed of Cobalt Molybdenum, where
sulphur gets converted into hydrogen sulphite and zinc oxide to absorb hydrogen
sulphite. Thus benzene is made sulphur free. This desulphurising process is necessary as
sulphur reacts with hydrogenation catalyst (Nickel).
After cooling, the sulphur-free benzene and hydrogen mixture is fed to the hydrogenation
reactors filled with nickel catalyst (pallets). There are two reactors in series. The primary
reactor (Tubular Type) is operating under isothermal conditions between the temperature
range of 130 C to 180 C at 10 atm inlet partial pressure of hydrogen. The reaction is
almost completed in primary reactor. The vapour/gas mixture from primary reactor is
passed through secondary adiabatic reactor, which reacts between 180C to 200C. The
gases leaving secondary reactor are cooled in condenser and send to the high pressure
separator. The gases from high pressure separator are recycled to benzene hydrogenation
section and cyclo-hexane is flashed in low pressure separator.
402 Oxidation of cyclohexane
In the subsequent step, cyclohexane is oxidized with air in multi compartment reactor at a
temperature of 150 C to 160 C and around 10 atm pressure. The oxidation process goes
further as reactants flow in series from one chamber to another.
The original oxidizer has been replaced by a new design with more emphasis on safety
aspects. The new oxidizer, as a part of anone debottlenecking scheme, was designed and
manufactured from Poland based company.
The radiation based tripping device is used in this oxidizer. Oxidizer is the horizontal
reactor. On that one side radioactive material is placed, which continuously emits
radiations and on the other side receiver is placed, which receives those radiations. When
the mixture level interrupts the radiation path means the level is above the permitting
Nirma University
Page 25
level, the oxidizer stops working. This is the new tripping method used for the safety
purpose.
403 Saponification
The product stream from oxidation is saponified aqueous solution almost at about temp
and 10 atm pressure to neutralize and saponofied esters and to decompose hydrogen
peroxide the sodium salt in an aqueous solution which is immiscible which gives main
product stream are separated in a gravity settler. The organic phase consisting mixture of
cyclo-hexane, cyclo-hexanol, cyclo-hexanone and low and high boiling products is fed to
the cyclo-hexane distillation column.
404 Cyclohexane Distillation
Cyclo-hexane boils at temperature of 80 C lower than the boiling point of cyclo-hexane
(156 C) and cyclo-hexanol (161 C). In this section, unreacted cyclo-hexane is removed
from the organic phase of saponification by distillation. To achieve better heat economy,
two fractnation columns in double effects are used. Traces of cyclo-hexane are removed
in the presence of high temperature. These distillations columns are under the vacuum
pressure. Cyclo-hexane is recycled to the oxidation section.
405 Dehydrogenation of Cyclo-hexanol
The mixture containing mainly cyclo-hexanol and some cyclohexanone is treated over
zinc carbonate abd calcium carbonate catalyst at about 1.2 atm pressure and around
360C to 400C temperature. The reaction is endothermic and the heat is supplied by
circulating the molten salt which uis heated in nature draft furnace. Cyclo-hexanol is
dehydrogenated to cyclo-hexanone and hydrogen. The gases leaving the reactor are
cooled. The condensed cyclo-hexanone is treated in LBP column to remove low boiling
point products like phenol.
406 Pure Anone Distillation
Nirma University
Page 26
The production of pure anone is achieved in a stat of distillation column after removing
low boiling point components like phenol and caproic aldehyde in first step. The mixture
is separated in second step into pure cyclohexanone and mixture containing mostly
cyclohexanol and cyclohexane. The distilled cyclohexanone is collected and stored at
around 15C-20C to minimize thermal degradation.
2.3.2
Lactam
Cyclohexanone reacts with HX Sulphate to produce CyclohexanoneOxime Four

compartments type Oxime Reactor. Agitators and cooling coils are provided in each
compartment for better mixing and control. Liberated free acid is neutralized by NH3
Solution to produce A.S. solution. A.S. solution is sent to AS-II plant. The Oxime is
rearranged in presence of Oleum to produced Lactam Suphate, which is neutralized by
NH3 solution to produce lactam oil and AS solution. Lactam oil is extracted by Benzene.
to remove impurities. A.S. solution is separated, after recovering Lactam, A.S. solution is
then sent to A.S.-II plant Impurities from Extract from Lactam are further removed in
Ion- Exchange unit. Water separates out in Dewatering and Topping section and Crude
Lactam is produced. Waste liquor stream is sent to W.L.-i storage tank. Crude Lactam is
further purified by melt crystallization and lactam crystals are produced. The Crystallized
caprolactam is filled in 25 kg Bags.
Nirma University
Page 27
CHAPTER 3
IMPORTANT MECHANICAL COMPONENTS
3.1
Pumps:
It is a machine or device which is used for raising, compressing, or transferring fluids. Basically
two types of pump used in Anone section.
a) Centrifugal pump
b) Reciprocating pumps
I.
Centrifugal Pump
i.
Defination
A centrifugal pump is a rotodynamic pump that uses a rotating impeller to create flow by
the addition of energy to a fluid. Centrifugal pumps are commonly used to move liquids
through piping. 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
Nirma University
Page 28
(casing), from where it exits into the downstream piping. Centrifugal pumps are used for
large discharge through smaller heads.
ii.
How It Works
Like most pumps, a centrifugal pump converts mechanical energy from a motor to
energy of a moving fluid; some of the energy goes into kinetic energy of fluid motion,
and some into potential energy, represented by a fluid pressure or by lifting the fluid
against gravity to a higher level.
The transfer of energy from the mechanical rotation of the impeller to the motion and
pressure of the fluid is usually described in terms of centrifugal force, especially in older
sources written before the modern concept of centrifugal force as a fictitious force in a
rotating reference frame was well articulated. The concept of centrifugal force is not
actually required to describe the action of the centrifugal pump.
In the modern centrifugal pump, most of the energy conversion is due to the outward
force that curved impeller blades impart on the fluid. Invariably, some of the energy also
pushes the fluid into a circular motion, and this circular motion can also convey some
energy and increase the pressure at the outlet.
iii.
MAIN PARTS OF A CENTRIFUGAL PUMP
Nirma University
Page 29
The following are the main parts of Centrifugal pump.

a) Impeller:
The impeller is a vane-disk (or disc) mounted on the shaft. Its function is to
increase the pressure of the liquid by means of its rotating action. The impeller may
be of open, semi-open, or enclosed type, and may have anywhere

between two to ten vanes. It may also be of single, or double, suction design.
b) Casing:
The casing (or case) contains the liquid and acts as a pressure
containment vessel that directs the flow of liquid in and out of the pump. In
most cases the casing includes the suction and discharge nozzles of the pump
that connect it to the external piping. In some vertical pumps the casing may
Nirma University
Page 30
be referred to as bowl, and in some small pumps they may be called as

housing.
c) Suction pipe:
The liquid is sucked in from the storage tank and goes from suction pipe to
the impeller.
d) Delivery pipe:
The pressurized liquid from the pump is delivered to tank or reactor is from
the delivery pipe.
e) Shaft:
The shaft is usually the longest part of a pump and is made of one piece.
Its function is to transmit the input power from the driver into the impeller. In
a close-coupled pump, the motor has an extended length of shaft that acts as
the pump shaft. In some vertical pumps, the so-called lineshaft pump, the
shaft may be supplied in more than one piece of ten Feet sections depending
on the pump bowl setting below the ground surface.
Nirma University
Page 31
f) Bearings:
The functions of the bearings are to support the weight of the shaft
(rotor) assembly, to carry the hydraulic loads acting on the shaft, and to keep
the pump shaft aligned to the shaft of the driver.
There are two types of bearings are used in centrifugal pump. They are:
Roller bearing:
A rolling-element bearing, also known as a rolling bearing, is a bearing which

carries a load by placing round elements between the two pieces. The relative
motion of the pieces causes the round elements to roll with very little rolling
resistance and with little sliding.
One of the earliest and best-known rolling-element bearings are sets of logs
lay on the ground with a large stone block on top. As the stone is pulled, the
logs roll along the ground with little sliding friction. As each log comes out
the back, it is moved to the front where the block then rolls on to it. It is
possible to imitate such a bearing by placing several pens or pencils on a table
and placing an item on top of them.
A rolling element rotary bearing uses a shaft in a much larger hole, and
cylinders called "rollers" tightly fill the space between the shaft and hole. As
the shaft turns, each roller acts as the logs in the above example. However,
since the bearing is round, the rollers never fall out from under the load.
Rolling-element bearings have the advantage of a good tradeoff between cost,

size, weight, carrying capacity, durability, accuracy, friction, and so on. Other
bearing designs are often better on one specific attribute, but worse in most
other attributes, although fluid bearings can sometimes simultaneously
outperform on carrying capacity, durability, accuracy, friction, rotation rate
Nirma University
Page 32
and sometimes cost. Only plain bearings are used as widely as rolling-element
bearings.
Angular contact ball bearing:
Angular contact ball bearings are able to support radial load and axial load.As
single row angular contact ball bearings can only support axial load in single
direction,,matched bearing mounting is often adopted to them .As matched
pairs of bearings,preload for them is more convenient .Retainer are made of
brass,synthetic ,Resins or others subject to individual bearing features and
application condition.
Main usages: Motor, machine tools, oil, rolling mill handling various types of
machinery and transportation machinery industry.
Self Aligning Roller Bearing
Self-Aligning Double Row Ball Bearings are designed to work in applications

where severe misalignment exists whether from mounting or shaft deflection.
Nirma University
Page 33
The concave raceway of the outer ring in combination with two rows of balls
operates over a wide range of contact angles. Furthermore it aligns itself
correctly with the shaft and assembly without causing undue stress on the rest
of the bearing assembly.
Standard Self-Aligning Double Row Ball Bearings are produced with straight
bores; however, tapered bores are available upon request. Noteworthy is that
the self-aligning ball bearing has the lowest friction of all rolling bearings,
which enables it to run cooler even at high speeds. Furthermore, the design
allows for easy mounting and dismounting.
Maintenance & lubrication of Bearings:
Many bearings require periodic maintenance to prevent premature failure,

although some such as fluid or magnetic bearings may require little
maintenance.
Most bearings in high cycle operations need periodic lubrication and cleaning,
and may require adjustment to minimize the effects of wear.
Bearing life is often much better when the bearing is kept clean and welllubricated. However, many applications make good maintenance difficult. For
example bearings in the conveyor of a rock crusher are exposed continually to
hard abrasive particles. Cleaning is of little use because cleaning is expensive,
yet the bearing is contaminated again as soon as the conveyor resumes
Nirma University
Page 34
operation. Thus, a good maintenance program might lubricate the bearings

frequently but never clean them.
Nirma University
Page 35
Packing
Some bearings use thick grease for lubrication, which is pushed into the gaps between the
bearing surfaces, also known as packing. The grease is held in place by a plastic, leather, or
rubber gasket (also called a gland) that covers the inside and outside edges of the bearing race to
keep the grease from escaping.
Bearings may also be packed with other materials. Historically, the wheels on railroad cars used
sleeve bearings packed with waste or loose scraps cotton or wool fiber soaked in oil, and then
later used solid pads of cotton.
a) Coupling:
The function of a coupling is to connect the pump shaft and the driver shaft, and
to transmit the input power from the driver into the pump.
b) Mechanical seal:
A pump may be provided with one of two types of sealing elements packing rings or
mechanical seal. The sealing element prevents the leakage of the pumped liquid into
the atmosphere.
The mechanical seal acts as a check valve and a slider bearing. The obvious function
is that of a check valve to prevent liquid under pressure from leaking out of the
pump, or from drawing air into the pump when under vacuum conditions.
Nirma University
Page 36
For proper working of pump proper alignment is done:

What is alignment?
It is the correction of the relative position of two machines that are connected, such as a pump
and motor, so that the center lines of the shafts form a straight line when the machines are
working at normal operating temperature.
Effect of misalignment:
Most experts agree that 50% of machinery problems are caused by misalignment.
Misalignment usually causes the bearing to carry a lesser or higher load than its design
specification. higher load in turn causes bearing failure due to fatigue.
Misalignment causes vibration which destroys the critical parts of the machines such as
bearings, seals, gears, couplings, etc these failures are sometimes not identified and
analyzed as normal wear and tear.
Misalignment increases 2-17% power consumption.
Alignment Method:
Dial indicator method is probably the most widely used and oldest dial indicator
method. It can be used to take the face reading on the motor shaft. If the motor shaft
is above the centre line then the stem of the dial gauge is pressed so the pointer will
move in the clockwise direction then it read +ve and when the motor shaft is below
the centre line then the stem of the dial gauge is not pressed so the pointer will move
in counter clockwise direction then it reads ve.
So, to bring the motor shaft in proper alignment the shims are added or removed
from under the motor location.
II.
Reciprocating Pump
i.
DEFINATION:
A reciprocating pump is a positive plunger pump. It is often used where relatively small
quantity of liquid is to be handled and where delivery pressure is quite large.
Reciprocating pump is a positive displacement pump. The given pump is single acting
single cylinder pump with vessel. It can be used for less discharge at higher heads.
Nirma University
Page 37
Priming is not required because it is a positive displacement pump. Reciprocating pumps

are used in pumping water in hilly areas. Reciprocating pumps has lower efficiency
compared to centrifugal pumps.
ii.
CLASSIFICATION
Reciprocating pumps can be classified based on
I.
Sides in contact with liquid

a) Single acting Reciprocating pump
b) Double acting reciprocating pump
II.
Numbers of cylinder used

a) Single cylinder pump
b) Two cylinder pumps
c) Multi-cylinder pumps
3.2
Compressors:
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.
Nirma University
Page 38
Types of compressor
Centrifugal compressor
The idealized compressive dynamic turbo-machine achieves a pressure rise by adding kinetic
energy/velocity to a continuous flow of fluid through the rotor or impeller. This kinetic energy is
then converted to an increase in potential energy/static pressure by slowing the flow through a
diffuser. The pressure rise in impeller is in most cases almost equal to the rise in the diffuser
section.
Components of a simple centrifugal compressor
(i) Inlet
The inlet to a centrifugal compressor is typically a simple pipe. It may include features
such as a valve, stationary vanes/airfoils (used to help swirl the flow) and both pressure
and temperature instrumentation. All of these additional devices have important uses in
the control of the centrifugal compressor.
(ii) Centrifugal impeller
The key component that makes a compressor centrifugal is the centrifugal impeller,
which contains a rotating set of vanes (or blades) that gradually raises the energy of the
working gas. This is identical to an axial compressor with the exception that the gases can
reach higher velocities and energy levels through the impeller's increasing radius. In
Nirma University
Page 39
many modern high-efficiency centrifugal compressors the gas exiting the impeller is
traveling near the speed of sound.
Impellers are designed in many configurations including "open" (visible blades),
"covered or shrouded", "with splitters" (every other inducer removed) and "w/o splitters"
(all full blades). Most modern high efficiency impellers use "backward" in the blade
shape.
(iii) Diffuser
The next key component to the simple centrifugal compressor is the diffuser.
Downstream of the impeller in the flow path, it is the diffuser's responsibility to convert
the kinetic energy (high velocity) of the gas into pressure by gradually slowing
(diffusing) the gas velocity. Diffusers can be vane less, vanned or an alternating
combination. High efficiency vanned diffusers are also designed over a wide range of
solidities from less than 1 to over 4. Hybrid versions of vanned diffusers include: wedge,
channel, and pipe diffusers. There are turbocharger applications that benefit by
incorporating no diffuser. Bernoullis plays an important role in understanding diffuser
performance.
(iv)Collector
The collector of a centrifugal compressor can take many shapes and forms. When the
diffuser discharges into a large empty chamber, the collector may be termed a plenum.
When the diffuser discharges into a device that looks somewhat like a snail shell, bull's
horn or a French horn, the collector is likely to be termed a volute or scroll. As the name
implies, a collectors purpose is to gather the flow from the diffuser discharge annulus
and deliver this flow to a downstream pipe. Either the collector or the pipe may also
contain valves and instrumentation to control the compressor.
Nirma University
Page 40
http://machinedesign.com/site-files/machinedesign.com/files/uploads/2015/04/Centrifugal%20Air%20Compressor_0.jpg
Reciprocating Compressor
A reciprocating compressor is a positive-displacement compressor that uses pistons driven by a
crankshaft to deliver gases at high pressure. The intake gas enters the suction manifold, then
flows into the compression cylinder where it gets compressed by a piston driven in a
reciprocating motion via a crankshaft, and is then discharged. Applications include oil refineries,
gas pipelines, chemical plants, natural gas processing plants and refrigeration plants.
Types of Reciprocating Compressor by suction
(i)Single Acting
(ii)Double Acting
Single acting
They are the reciprocating compressor which has piston working only in one direction. The other
end of the piston is often free or open from which no work is performed. There is only one side
compression or the upper part of the piston is used to compress the air. The bottom part is open
to crankcase and is not utilized for the compression of air
Double acting
As from its name it uses its both sides to compress the air. These type of compressors have two
sets of suction/intake and delivery/exhaust valve on both sides of the piston. As the piston moves
up and down, both sides of the piston is utilized in compressing the air. The intake and exhaust
Nirma University
Page 41
valve operates corresponding to the movement of the piston or with the stroke of the compressor.
The air is compressed accordingly and delivered continuously as compared to single-acting air
compressor.
http://aermech.com/wp-content/uploads/2015/03/recip.gif
3.3
Heat Exchanger
A heat exchanger is a device used to transfer heat between one or more fluids. The fluids may be
separated by a solid wall to prevent mixing or they may be in direct contact. 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.
Types of Heat Exchanger:
(i)Tube and Shell type
(ii)Plate type
(i) Tube and shell type 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
Nirma University
Page 42
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
https://upload.wikimedia.org/wikip
edia/commons/c/cd/Straight-tube_heat_exchanger_1-pass.PNG
(ii)Plate Type 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", 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
Nirma University
Page 43
important difference is that plate exchangers employ more counter-current flow rather than cross
current flow, which allows lower approach temperature differences, high temperature changes,
and increased efficiencies.
3.4
Gear box
Every machine works at different speeds .But the prime movers runs at fixed RPM (1440, 2880
etc.). Hence it is necessary to use mechanism to get require RPM which is known as Gear Box.
Main components of a gear box:
In any device two or more component works together and fulfills the required function. In a
transmission box four components are required to fulfill its function. These components are:
1. Counter shaft:
Counter shaft is a shaft which connects with the clutch shaft directly. It contains the gear
which connects it to the clutch shaft as well as the main shaft. It may be run runs at the
engine speed or at lower than engine speed according to gear ratio.
Nirma University
Page 44
2. Main shaft:
It is the shaft which runs at the vehicle speed. It carries power form the counter shaft by
use of gears and according to the gear ratio, it runs at different speed and torque compares
to counter shaft. One end of this shaft is connects with the universal shaft.
3. Gears:
Gears are used to transmit the power form one shaft to another. They are most useful
component of transmission box because the variation is torque of counter shaft and main
shaft is depend on the gear ratio. The gear ratio is the ratio of the driven gear teeth to the
driving gear teeth. If gear ratio is large than one, the main shaft revolves at lower speed
than the counter shaft and the torque of the main shaft is higher than the counter shaft. On
other hand if the gear ratio is less than one, than the main shaft revolves at higher speed
than the counter shaft and the torque of the main shaft is lower than the counter shaft. A
small car gear box contains four speed gear ratio and one reverse gear ratio.
4. Bearings:
Whenever the rotary motion, bearings are required to support the revolving part and
reduce the friction. In the gear box both counter and main shaft are supported by the
bearing.
Types of gear
(i)
(ii)
(iii
Spur
Bevel
Spiral
(iv) Helical
(v) Worm
(vi) Planetary
Nirma University
Page 45
http://www.mech4
study.com/2014/03/what-is-gear-box-what-are-main-components-of-gear-box.html
Advantages of helical gear
As we have discussed in our previous post that in case of helical gear, engagement of
helical gear teeth will be gradual and engagement will start from one end of a tooth of
helical gear with the other tooth of mating helical gear and spread continuously
throughout the tooth as gear rotates. Such gradual engagement of helical gear will
provide the silent and smooth operation.
Helical gears are preferred for heavy load applications.
Helical gears could be used to transmit the motion and power between two parallel shafts and
also between two non-parallel shafts.
Helical gears will have more capability to transmit load between two parallel shafts as
compared to similar module and equivalent width of spur gears.
There will be less wear and tear in case of helical gear during operation as compared to
wear and tear in case spur gears operation as if we consider helical gears operation, load
will be distributed between several teeth at any time and that is why there will be less
wear and tear in operation of helical gears.
Nirma University
Page 46
http://www.hkdivedi.com/2015/12/advantages-disadvantages-and.html
Advantage of worm gear
Higher speed reduction could be secured; speed reduction could be secured up to 300: 1.
Worm and worm gears operate silently.
Worm and worm gears will have one characteristics i.e. self locking. Reverse movement
will be restricted but this characteristic depends on lead angle and friction angle, we have
discussed this concept in our discussion in previous post during study of worm and worm
gear.
Worm and worm gear unit will be preferred to use if space is restricted as we have
already discussed that worm and worm gear unit could be used for heavy speed reduction
in compact space also.
Handsome output torque will be secured here with the application of worm and worm
gear.
Nirma University
Page 47
http://www.hkdivedi.com/2015/12/advantages-and-disadvantages-of-worm.html
3.5
Luwa Evaporater
The LCI agitated thin film evaporator (also commonly referred to as a "wiped film
evaporator") consists of two major assemblies: a cylindrical heated body and a rotor.
Product is introduced above the heated zone and is evenly distributed over the
evaporator's inner surface by the rotor. As the product spirals down the wall, the high
rotor tip speed generates highly turbulent flow resulting in the formation of bow waves
(see illustration above) and creating optimum heat flux and mass transfer conditions.
Volatile components are rapidly evaporated via conductive heat transfer. Vapors flow
either counter-currently or co-currently through the unit, depending on the application
requirements. In both cases, vapors are ready for condensing or subsequent processing
(i.e. fractionation) after exiting the vapor discharge section.
Nonvolatile components are discharged at the outlet. Continuous agitation and mixing by
the rotor blades minimizes fouling of the thermal wall where the product or residue is
most concentrated.
Nirma University
Page 48
The combination of 1) extremely short residence time, 2) narrow residence time

distribution, 3) high turbulence, and 4) rapid surface renewal permits the LCI thin film
evaporator to successfully handle heat-sensitive, viscous and fouling-type fluids.
http://lcicorp.com/thin_film_evaporators/thin_film_wiped_film_evaporator/
http://www.globalspec.com/RefArticleImages/2CBF9BA9E7A30DB74A133B83C14FAD9D_im
g11_01.jpg
3.6
Centrifuge
A centrifuge is a piece of equipment that puts an object in rotation around a fixed axis (spins it in
a circle), applying a potentially strong force perpendicular to the axis of spin (outward). The
centrifuge works using the sedimentation principle, where the centripetal acceleration causes
denser substances and particles to move outward in the radial direction. At the same time, objects
that are less dense are displaced and move to the centre. In a laboratory centrifuge that uses
Nirma University
Page 49
sample tubes, the radial acceleration causes denser particles to settle to the bottom of the tube,
while low-density substances rise to the top.
Chemical centrifuge
Chemical Centrifuge is widely used in all type of Chemical Industries to separate solid
from Liquid from the chemicals. Chemical Centrifuge works on the principal of
Centrifugal force. The High speed revolution of Basket through the Liquid or Chemicals
outside and keep the Solid in the basket.
Centrifuge is applying centrifugal force to separate the useful component in mixtures of
liquids and solids or liquids and liquids.
Centrifuge is mainly used to separate solids from liquids in suspension or separate two
liquids with different density and non-homogenous liquids, for example, separate cream
form milk; and also it can be used to remove liquids existed in solids, such as special
speeding tubular centrifuges can separate the mixed gas content with different density,
depending different density and particle size of solid particles in the liquid and different
characteristics of the subsiding speed centrifuge, the sedimentation centrifuge also can
classified solids according to different density and particle size.
Centrifuge is widely used in chemical, oil, food, pharmaceutical, beneficiation, coal, and
water treatment and shipping etc. part.
Centrifuge has a drum rotating its axle called bowl, generally driven by motor.
Suspension or emulsion is introduced to the bowl and rotate with bowl with the same
speed, eject separately under the centrifugal force. Usually, high separation speed, high
separation ratio.
The principle of centrifuge is divided to centrifugal filtering and centrifugal
sedimentation. Centrifugal filtering is made suspension become filtrate under the
centrifugal force. And the centrifugal sedimentation is applied different density to
separate suspension and emulsion and realize liquid-solid or liquid-liquid separation.
Nirma University
Page 50
http://www.huading-separator.com/news/industryNews/6920.shtml
http://chemical.centrifugemachinery.com
3.7
Cooling tower
A cooling tower is a heat rejection device which 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.
Induced draft cooling tower
Induced draft (industrial) cooling towers can be used to remove heat from various sources such
as machinery or heated process material. The primary use of large, induced draft(industrial)
cooling towers is to remove the heat absorbed in the circulating cooling water systems used in
power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food
processing plants, semi-conductor plants, and for other industrial facilities such as in condensers
of distillation columns
Nirma University
Page 51
If that same plant had no cooling tower and used once-through cooling water, it would require
about 100,000 cubic meters an hour and that amount of water would have to be continuously
returned to the ocean, lake or river from which it was obtained and continuously re-supplied to
the plant. Furthermore, discharging large amounts of hot water may raise the temperature of the
receiving river or lake to an unacceptable level for the local ecosystem. Elevated water
temperatures can kill fish and other aquatic organisms. A cooling tower serves to dissipate the
heat into the atmosphere instead and wind and air diffusion spreads the heat over a much larger
area than hot water can distribute heat in a body of water.
http://images4.hellotrade.com/data4/QD/UK/MY-675574/induced-draft-cooling-tower250x250.jpg
3.8
Coupling
A coupling is a device used to connect two shafts together at their ends for the purpose of
transmitting power. Couplings do not normally allow disconnection of shafts during operation.
The primary purpose of couplings is to join two pieces of rotating equipment while permitting
some degree of misalignment or end movement or both.
Nirma University
Page 52
http://www.bibbytransmissions.co.uk/images/grid-coupling.png
http://www.bibbytransmissions.co.uk/images/pin-bushings-coupling.png
3.9
Gasket
A gasket is a mechanical seal which fills the space between two or more mating surfaces,
generally to prevent leakage from or into the joined objects while under compression.Gaskets for
specific applications, such as high pressure steam systems, may contain asbestos. However, due
to health hazards associated with asbestos exposure, non-asbestos gasket materials are used when
practical.
It is usually desirable that the gasket be made from a material that is to some degree yielding
such that it is able to deform and tightly fill the space it is designed for, including any slight
irregularities. A few gaskets require an application of sealant directly to the gasket surface to
Nirma University
Page 53
function properly. Some gaskets are made entirely of metal and rely on a seating surface to
accomplish the seal; the metal's own spring characteristics are utilized.
http://cfnewsads.thomasnet.com/images/cmsimage/image/
gaskets.jpg
3.10
Metal Bellows
Metal bellows are elastic vessels that can be compressed when pressure is applied to the outside
of the vessel, or extended under vacuum. When the pressure or vacuum is released, the bellows
will return to its original shape.
http://image.ec21.com/image/pumpseals/oimg_G
C06913348_CA06918502/Metal_Bellows_Mechanical_Seals.jpg
3.11
Steam Ejector
Steam ejector is used as alternative of vacuum pump when steam is available in large quantity.
There are no rotating parts which makes it very reliable in critical operation.
Working of Steam ejector:
A high-pressure motive gas enters the steam chest at low velocity and expands through
the converging-diverging nozzle. This results in a decrease in pressure and an increase in
Nirma University
Page 54
velocity. Meanwhile, the suction fluid enters at the suction inlet. The motive fluid, which
is now at high velocity, entrains the suction fluid and combines with it.
The two fluids are then recompressed through the diffuser. Potential energy is converted
to kinetic energy; thus, velocity increases and pressure decreases. The mixture reaches its
maximum velocity and lowest pressure at the venturi throat. The fluid then is charges at
an intermediate pressure, which is higher than the inlet suction fluid pressure, but much
lower than the inlet motive fluid pressure.
3.12
Flaker
The drum flaker is used primarily to process chemical and pharmaceutical products. However,
more and more applications for these machines are also being found in the food industry. The
closed design is ideally suited for processing of toxic or offensively smelling products. With the
drum flaker, a molten product is converted into a solid form. A thin layer of the liquid product
adheres to the outside of the rotating, internally cooled drum in a continuous process. Heat is
extracted from the product by contact with the cooled drum surface, and the product solidifies
and cools to the required final temperature. A stationary knife removes and breaks up the
solidified layer. The required flake size is achieved by controlling circumferential speed, layer
thickness, and knife angle. Careful design ensures optimum use of the drum surface area to
maximize capacity at the chosen operating conditions. The drum flaker is primarily used to
produce flakes, but there are also ways of converting your product into easily manageable
pastilles or prills.
Nirma University
Page 55
These chemical applications can be processed on the flaker
Fatty acids
Oleochemicals
Phtalic anhydride
Polyethylene glycols (PEG)
Maleic anhydride
Calcium chloride
Caprolactam
Resins
Bisphenol A
Sulphur
Nirma University
Page 56
CHAPTER 4
SHUT DOWN REPORT
Rearmament Reactor shift at 12 meter height at lactam Plant (zone 30). There is tube and shell
type Heat exchanger to maintain temperature inside the reactor. There are 1134 tubes inside heat
exchanger. Oxime and oleum react inside the reactor and it is an exothermic reaction because of
that dissipation of heat is necessary to run reaction. Oxime enters from top side via 12 nozzle
.there is propeller for fluid motion. Oleum enters from bottom via nozzle and both will react with
each other and via overflow line we get Lactam sulphate. There is flow of fluid from top to
bottom inside the reactor. Reactor is surrounded by heat exchanger.
During shutdown we did NDT testing of reactor. We used die penetration testing method to find
crack at surface. We didnt find any crack inside reactor. There are thee liquid for DP(die
penetration) testing. Before doing DP we did buffing of reactor. IN buffing we clean surface any
make it smooth. after that we apply cleaner for cleaning of surface then we apply die (blue or red
colour). It is very crucial stage for testing because distance from where we are applying liquid is
very important if we apply spray from very short distance it will not convert into small particle
and not penetrate inside crack. After that we wait for 10 mints then we clean surface and apply
developer and we find crack if there are any. If crack is minor we neglect it and if cracks are big
we grinding it and by using welding we fill that area and by that we prevent damage to drum or
vessel.
During NDT for workers it very difficult to breath especially inside drum r vessel for that we
used nozzle. We have lots of compressed air we used for air circulation. At small area pressure
drop is there it suck all compressed and also air from drum or vessel. That will generate air flow
inside drum or vessel.
We did Hydro-Testing and Hydro-Jetting of Heat Exchanger. It is very important to for heat
exchanger .because of there is any leakage inside Heat Exchanger then both fluid will mix each
other and it will affect the final product to prevent we do hydro testing. First we do hydro jetting
Nirma University
Page 57
for cleaning of heat exchanger tubes. For hydro testing , first we stop both inlet and outlet of heat
exchange then by using plunger pump we built pressure inside shell which is already specify by
manufacture. Then we wait and if pressure reduces during testing then we find leakage tube and
seal that tube. To find tube first we used steam to evaporate water and then we do hydro testing
and we can easily find leakage tube by that we can solve that problem.
We disassemble Luwa evaporator check its alignment and also check condition of bushes and
condition of coupling. We used nozzle to spray LCS (lactam sulphate) from bottom and from top
we get Lactam vapour and from bottom we get lactam liquid which will supply to zone 40.
Vapour passes through different heat exchanger and it convert into liquid. We used ejector
system for continues flow of vapour.
Nirma University
Page 58
CONCLUSION
As an undergraduate of the Nirma University, we would like to say that this training program is
an excellent opportunity for us to get to the ground level and experience the things that we
would have never gained through going straight into a job. We are grateful to the Nirma
University and GSFC for giving us this wonderful opportunity.
The main objective of the industrial training is to provide an opportunity to undergraduates to
identify, observe and practice how engineering is applicable in the real industry. It is not only to
get experience on technical practices but also to observe management practices and to interact
with fellow workers.
It is easy to work with sophisticated machines, but not with people. The only chance that an
undergraduate has to have this experience is the industrial training period. We feel that we got
the maximum out of that experience. Also we learnt the way of work in an organization, the
importance of being punctual, the importance of maximum commitment, and the importance of
team spirit.
In our opinion, we have gained lots of knowledge and experience needed to be successful in a
great engineering challenge. Also it is said that, Engineering is after all a Challenge, and not a
Job.
Nirma University
Page 59
BIBLIOGRAPHY
1234-
Nirma University
Page 60

GSFC Trainning Report

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

GSFC Trainning Report

Загружено:

Авторское право:

Доступные форматы

CAPROLACTAM PLANT INSIGHT

CAPROLACTAM PLANT INSIGHT

GUJARAT STATE FERTILIZER & CHEMICALS LIMITED

Submitted in partial fulfillment of the requirements for the award of degree of

MECHANICAL ENGINEERING DEPARTMENT

CAPROLACTAM PLANT INSIGHT

CAPROLACTAM PLANT INSIGHT

Dated: 9th July, 2016

(Name of Faculty member)

CAPROLACTAM PLANT INSIGHT

CAPROLACTAM PLANT INSIGHT

CAPROLACTAM PLANT INSIGHT

IMPORTANT MECHANICAL COMPONENTS

CAPROLACTAM PLANT INSIGHT

SHUT DOWN REPORT

CAPROLACTAM PLANT INSIGHT

CAPROLACTAM PLANT INSIGHT

CAPROLACTAM PLANT INSIGHT

Gujarat State Fertilizers & Chemicals Limited (GSFC) is an Indian manufacturer of

CAPROLACTAM PLANT INSIGHT

based synthetic thickener.

CAPROLACTAM PLANT INSIGHT

o The DAP production at Sikka was hampered due to non-availability of

CAPROLACTAM PLANT INSIGHT

o With a view to enhancing the production of Cyclohexanone, the Company

breeding, bio-fertilizers and tissue culture products.

Financial Status of GSFC

CAPROLACTAM PLANT INSIGHT

Vision and Mission of GSFC

industries and homes

and maintaining ethical standards of highest quality

enriching the bio-diversity

Main GSFC Plant Vadodara

CAPROLACTAM PLANT INSIGHT

Conforming to the strictest international standards, GSFC continuously achieves and

Product Details Briefly:

CAPROLACTAM PLANT INSIGHT

1.2.2 Green Revolution

CAPROLACTAM PLANT INSIGHT

hazardous solid wastes.

and filters for abatement and recovery of gaseous pollutants.

'Water' to large extent.

hands in the noble cause of environment protection.

CAPROLACTAM PLANT INSIGHT

Different Plants in GSFC

Ammonia III (A-III) Plant:

Di Ammonium Phosphate (DAP) plant:

CAPROLACTAM PLANT INSIGHT

Melamine I and II Plants:

Phosphoric Acid (PA) plant:

part of GSFC Phase I and was commissioned in May 1967.

Urea I and II Plants:

CAPROLACTAM PLANT INSIGHT

Caprolactam (Capro I and II) Plants:

Ammonium Phosphate Sulphate plant:

CAPROLACTAM PLANT INSIGHT

Ammonium Sulphate plant:

Nylon-6 (Gujlon) Plant:

CAPROLACTAM PLANT INSIGHT

Caprolactam is an organic compound with the formula (CH2)5C(O)NH. This colourless

CAPROLACTAM PLANT INSIGHT

69.2 C (156.6 F; 342.3 K)

270.8 C (519.4 F; 544.0 K) at

866.89 g/L (22 C)