ACKNOWLEDGEMENT

I take this opportunity to express my profound gratitude and deep regards to my guide Mr.
PANKAJ PADHIYAR (HOD Of Chemical engineering department) for his exemplary guidance,
monitoring and constant encouragement throughout the course of my project, ‘CRESOL’. The
blessing, help and guidance given by him time to time shall carry me a long way in this journey
of life on which I am about to embark.

I also take this opportunity to express a deep sense of gratitude to Mr. JIMIT KANSARA for
their cordial support, valuable information and guidance which helped me in completing this
project through various stages.

I am obliged to staff members of Chemical Engineering Department, for the valuable

information provided by them in their respective fields. I am grateful for their cooperation during
the period of my Project.

Lastly, I thank to my parents and my classmates for their constant encouragement without which,
this Project would not have been possible.
 ABSTRACT

Cresols are found in many foods and in wood and tobacco, smoke, crude oil, coal tar, and in
chemical mixtures used as wood preservatives. Small organisms in soil and water produce
cresols when they break down materials in the environment. It is a partially lyophilic moiety
which strongly binds to plasma protein (close to 100%) under normal conditions. p-Cresol is
metabolized through conjugation, mainly sulphation and glucuronization, but removal of the
unconjugated p-cresol is, at least in part, via the urine. Therefore, it is not surprising that this
compound, together with several other phenols, is retained when the kidneys fail. P-Cresol is an
end-product of protein breakdown, and an increase of the nutritional protein load in healthy
individuals results in enhanced generation and urinary excretion. The serum p-cresol
concentration in uremic patients can be decreased by changing to a low-protein diet. p-Cresol is
one of the metabolites of the amino acid tyrosin, and to a certain extent also of phenylamine
which are converted to 43-hydroxyphenylacetic acid by intestinal bacteria, before being
decarboxylated to p-cresol. As phenol derivatives, cresols can be used in phenol-formaldehyde
resins. m-Cresol is also used in making photographic developer and explosives. p-Cresol can be
converted to butylated hydroxytoluene (BHT), an important antioxidant in foods. The cresols are
strong germicides, and in low concentrations they are effective disinfectants and antiseptics.
Methods of production are 1) Manufacturing of cresol from hydrolysis by fusion of toluene
sulfonic acid which is simple in nature and production it contains 99 % yield and purity of 99%
is achieved 2) p-cresol is systematically prepare methylation of phenol which contains 43%
yield. It is difficult in handling and the method of manufacturing is complex.
 INDEX
CHAPTER CHAPTER PAGE
NO. NO.
1. Introduction and History 1-2
1.1 Introduction and History of Cresol 2
2. Literature survey 3-4
2.1 Top Manufacturing Industries of Cresol 4
3. Properties of Cresol 5-6
3.1 Physical Properties of Cresol 6
4. Methods of Production 7-8
4.1 Methods of Production 8
5. Preparation Method 9-12
5.1 Raw Material 10
5.2 Chemical Reaction 10
5.3 Process Flow Diagram 11
5.4 Process Description 12
6. Details of Selected Process 13-14
6.1 detail of selected process 14
7. Material Balance 15-18
7.1 Material Balance for Acidification 16
8. Utilities Required for Selecting Process 19-21
8.1 Power Supply System 20
8.2 Steam 20
8.3 Process Water 20
8.4 Cooling Tower 21
9. Plant Location and Layout 21-23
9.1 Plant Location and Layout 23
10. Cost Estimation 24-30
10.1 The Capital Investment for The Year 2007-08 25
10.2 Estimation of Capital Investment Cost 25
10.3 Total Capital Investment (TCI) 27
10.4 Estimation of Total Product Cost 27
10.5 Plant Overhead Cost 28
10.6 Rate of Return 30
 11. Important Aspect of Safety Pollution control 31-35
11.1 Hazard Summary 32
11.2 Ways of reducing exposure 32
11.3 Health & Hazard summary 32
11.4 Personal Protective Equipment 33
11.5 Hazard & Storage 35
12. MSDS of Product 36-41
12.1 composition and information of cresol 37
12.2 Hazard identification 37
12.3 First aid measures 37
12.4 Fire and explosion data 38
12.5 Accidental Release Measure 39
12.6 Handling and storage 39
12.7 Personal protection 40
12.8 physical and chemical properties 40
12.9 Stability and reactivity data 40
12.10 toxicological information 41
12.11 ecological information 41
12.12 Transport Information 41
12.13 Other regulatory Information 41
13. Solid Waste treatment 42-43
13.1 Sodium sulphate Recovery 43
13.2 Process Description 43
14. Conclusion 45
15. Reference 47
TABLE INDEX
SR.NO. TABLE PAGE NO.
1 6.1 Material Balance Chart 15
 CHAPTER: -1
INTRODUCTION AND HISTORY OF CRESOL

1
1.1 INTRODUCTION AND HISTORY OF CRESOL

CRESOL is a speciality chemical that is primarily employed in the synthesis of antioxidant such
as butylated hydro-oxytoluene and in the preparation of thermosetting resins such as Resols and
Novosols. Through cresols can be obtained directly from naphtha fractions of coal and oil.

Cresol is a volatile low-molecular weight compound, it is a PHENOL. They are a widely

occurring natural and manufactured group of organic compounds, which are known as a phenol.
Depending upon the temperature, cresols can be solid or liquid. Because they have melting
points not far from room temperature. In their Pure form, They are colourless solids and may be
liquid, If they are mixtures.

In its chemical structure, a molecule of cresol has methyl group substituted onto the ring of
phenol. There are three forms that differ slightly in their chemical structure:

1. Ortho-CRESOL
2. Para-CRESOL
3. Meta-CRESOL

About half of the world’s supply of cresol are extracted from coal-tar. Cresol is a Derivatives of

❖ Xylenols
❖ Bromo-cresol
❖ Phenol

The mixtures of cresols obtained from coal tar is called Cresylic acid. And the cresols are mainly
used in the disinfectants and synthetic resins.

2
 CHAPTER: -2
LITERATURE SURVEY

3
2.1 TOP MANUFACTURING INDUSTRIES OF CRESOL

• Sasol Chemicals, South Africa

• Atul Chemicals, Ankleshwar

• SABIC, Bangalore

• RuTGERS Group, Germany

• Deepak Novochem Technologies, Pune

• JEF Chemicals, Japan

4
 CHAPTER: -3
PROPERTIES OF CRESOL

5
3.1 PHYSICAL PROPERTIES OF CRESOL

➢ Molecular Formula:- C7 H8 O
➢ Molecular weight - 108
➢ Systematic Name :- METHYLPHENOL
➢ Melting Point:-
• O-Cresol=29.8 °C
• P-Cresol=11.8 °C
• M-CRESOL=35.5 °C
➢ Boiling Point:-
• O-Cresol=191 °C
• P-Cresol=202 °C
• M-Cresol=201.9 °C
➢ Density:-
• O-Cresol=1.05gm/cm3
• P-Cresol=1.03gm/cm3
• M-Cresol=1.02gm/cm3
➢ Appearance:-
• O-Cresol= Colourless crystals
• P-Cresol=Thicker liquid
• M-Cresol= Greasy looking solid
➢ Solubility:-
• O-Cresol=2.5gm/ml
• P-Cresol=2.4gm/ml
• M-Cresol=1.9gm/ml
➢ Flash Point:-
• O-Cresol=81 °C
• P-Cresol=86 °C
• M-Cresol=86 °C

6
 CHAPTER: -4
METHODS OF PRODUCTION

7
4.1 METHODS OF PRODUCTION

There are mainly two methods of Production: -

1. Manufacturing of cresol from hydrolysis by fusion of Toluene sulfonic acid

2. Manufacturing of cresol by methylation of phenol

➢ By fusion of toluene sulfonic acid

➢ By methylation of phenol
▪ 43% Yield
▪ Difficult in handled
▪ Complex method

8
 CHAPTER: -5
PREPARATION METHOD

9
5.1 RAW MATERIAL
▪ Toluene
▪ Liquid SO 3
▪ SO 2 gas
▪ Acetic acid(CH3 COOH)

5.2 CHEMICAL REACTIONS

1) Sulfonation of Toluene

CH3C6H5+H2SO4 = CH3C6H4SO3H + H2O

P-Toluenesulfonic acid

2) Hydrolysis of the sulfonate salt gives the cresol

CH3C6H4SO3Na+ 2NaOH = CH3C6H4OH + Na2SO3 + H2O

Cresol

10
5.3 PROCESS FLOW DIAGRAM

SULFONATION

SODIFICATION

FUSION

QUENCHING

ACIDIFICATION

DISTILLATION

CRESOL

11
5.4 PROCESS DESCRIPTION

5.4.1 Sulfonation:
Liquid SO3 is used as the sulfonating agent in sulfonation of Toluene, which is kept in a special
type of storage tank in a room maintained at a temperature just above the freezing point of SO3
Mixtures of Toluene and SO3 are sent to the plug flow reactor for sulfonation reaction.
Sulphonated mass is kept under a solvent to keep in a flowable conditions. The sulfonation of
toluene is carried out at low temperature & toluene sulfonic acid is formed. Temperature is
controlled by the chilled brine.
After sulfonation step, TSA is then sent for sodiation.

5.4.2 Sodiation:
The sodiation process involves the neutralization of toluene sulfonic acid by adding NaOH
where pH becomes slightly basic, to form NaTSA.
NaTSA is then stored in the storage tanks. From these tanks, it is fed to the fusion pots in the
fusion unit.

5.4.3 Fusion:
In fusion section NaTSA is fused with a concentrated solution of NaOH which is produced by
the evaporation of 48% NaOH solution in the evaporator. The moisture comes out from the
evaporator is condensed out with cold water to produce process hot water. Fusion is very high
temp reaction . At first caustic is fed to the fusion reaction pot & NaTSA is then slowly charged,
with continuous starring. Entire water vapour is taken out from the system by an ejector system.
This is a very critical operation as far as fusion is concerned.

5.4.4 Quenching & Sulphite Separation:

Fusion mass is then quenched in this water. Then , solid sulphite is separated by centrifuging,
The clear Na-Cresolate oil from the Panwell centrifuge is sent for acidification.

5.4.5 Acidification:
The acidifier is a CSTR type reactor in which H2SO4 is added with Na-Cresolate oil. This is an
exothermic reaction. After acidification reaction crude Cresols & Na2SO4 is formed. Here the
crude cresols and Na2SO4 form two different phases. It is separated by a continuous decanter.
The bottom part containing Na2SO4, The upper organic part (crude cresols) is pumped into a
storage tank and is sent for distillation.

5.4.6 Distillation:
Crude cresols are fed to a continuous fractionation system where p-cresol is separated as 99%
pure product.

12
 CHAPTER: - 6
DETAIL OF SELECTED PROCESS

13
6.1 DETAIL OF SELECTED PROCESS
➢ By fusion of toluene sulfonic acid
▪ 99% Yield
▪ Easiest method
▪ 99% Purity achieved

14
 CHAPTER: -7
MATERIAL BALANCE

15
7.1 MATERIAL BALANCE FOR ACIDIFICATION
𝟐𝑪𝑯𝟕 𝑶𝑵𝒂 + 𝑯𝟐 𝑺𝑶𝟒 → 𝟐𝑪𝟕 𝑯𝟖𝑶 + 𝑵𝒂𝟐 𝑺𝑶𝟒

130 98 108 142

Assumption: (16 Ton per day)

99% Conversion Na-Cresolate

98% Sulphuric acid

First Find Moles

𝐰𝐞𝐢𝐠𝐡𝐭 𝐨𝐟 𝐜𝐫𝐞𝐬𝐨𝐥
Number of moles = 𝐦𝐨𝐥𝐞𝐜𝐮𝐥𝐚𝐫 𝐰𝐞𝐢𝐠𝐡𝐭 𝐨𝐟 𝐜𝐫𝐞𝐬𝐨𝐥

16000
= 108

=148.14 kmol

From Reaction

2 Mole OF 𝐶𝐻7 𝑂𝑁𝑎= 𝐶7 𝐻8 𝑂

For produce 2 kmol cresol, 2 kmol of Na-Cresolate required

Production of cresol = 148.14

Here, 99% Conversion assumed

Na−Cresolete reacted ∗100
Na-Cresolate charge =
% 𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛

=149.63kmol

Here, Amount of Na-Cresolate required to produce cresol

=149.63*130kg

=19451.9kg

=19.45Ton

Now for 𝑯𝟐 𝑺𝑶𝟒

From reaction , 2kmol Na-Cresolate =1kmol 𝐻2 𝑆𝑂4

1
*149.63= 74.815 kmol
2

16
𝐻2 𝑆𝑂4 = moles * molecular weight

= 74.815* 98

= 7331.87 kg

=7.3 ton

For 𝑁𝑎2 𝑆𝑂4

2 kmol Na = 1 kmol 𝑁𝑎2 𝑆𝑂4

149.63
=
2

= 74.815 kmol

𝑁𝑎2 𝑆𝑂4 weight = moles * molecular weight

= 74.815 * 142

= 10623.73

= 10.63 ton

Unreacted Na- cresolate = 99% conversion

= 100 - 0.99

= 0.01 * 19.454 ton

= 0.195 ton

Unreacted 𝐻2 𝑆𝑂4 = 0.02 * 7.407 ton

= 0.148 ton

Material balance chart Table

INPUT OUTPUT
Na-Cresolate = 19.454 Cresol =16
H2SO4 = 733.87 𝑵𝒂𝟐 𝑺𝑶𝟒= 10.62
Unreacted 𝑯𝟐 𝑺𝑶𝟒= 0.148
Unreacted Na cresolate= 0.195

= 26.781 =26.963
Table 6.1

17
 𝑖𝑛𝑝𝑢𝑡
Yield=
𝑜𝑢𝑡𝑝𝑢𝑡

26.781
=26.963

=99.32%

18
 CHAPTER:- 8
UTILITIES REQUIRED FOR SELECTING PROCESS

19
 ➢ UTILITIES REQUIRED FOR SELECTING PROCESS
• Power
• Steam
• Water
• Instrument Air

8.1 POWER SUPPLY SYSTEM

As the plant generates electrical power & steam, that’s why the plant is called Co-generation
plant (COGEN). The plant requires 59760KWH /day for continuous production.
There are three types of sources of power supply in the plant.
Captive Power plant ( CPP)
Gujarat electricity board (GEB)
Diesel generator (DG)

8.1.1 Captive Power Plant:

There are four gas turbines IC engine (having 12 cylinder engines) in the power generation plant,
in which three are in operating condition & one is kept in stand by mode. Three of them having
capacity of 0.9 MW /day and one have 1 MW. CNG is used as fuel in the combustion engine,
which is supplied by Gujarat Gas Company Ltd. The supplied gas is of 6 bar pressure and it is
reduced to 3 bars before use.

8.1.2 Diesel Generator:

150TR-chilling plant contains 215HP motors, which need high electricity to start. DG is started
for 15-20 mins when 150 TR chilling plant starts. If any of the engines fail to produce the power,
then to maintain the continuous power supply, DG set (Having 16 cylinder engine) starts within
10 secs in auto synchronization mode.

8.1.3 Steam Generation System:

Hot flue gas coming from IC engines enters into boiler. The boiler is equipped with Preheater and
economizer. Feed water first goes to Preheater then returns to the water tank. From tank heated water
enters into economizer and then enters into boiler. Steam of 8KG/cm2 is produced from it and it is
used as low pressure steam.

8.2 STEAM

Each day around 400 MT steam is required to run all the processes in the plant. There are mainly
two types of steam which are used in this plant.
Low-pressure steam
Medium pressure steam

For production of saturated steam three boilers is running. All the boilers are having 3 passes,
fire tube dual firing type, as they can handle natural gas and furnace oil as fuel. Out of these
three, two boilers are having capacity of 12 ton/hr and another one is of 16 ton/hr. Pressure of the
LPS and MPS are 2.5 kg/cm2 and 12kg/cm2 respectively.
20
Co-gen plant produces steam of 8kg/cm2 pressure which is totally converted into low pressure
steam.
Each day 290 m3 DM water and some raw water (<50 m3) is required for steam generation.
Supplied raw water from G.I.D.C has a TDS of 80-90ppm.The soft water is first deaerator by
heating up to 105º C and some amount of steam is injected to remove all the dissolved oxygen
and send to economizer to preheat up to 127o C. The furnace oil is pre-heated up to 120º C by a
electrical Preheater & a steam Preheater
Gear pump is used to pump the furnace oil to bring it to the burner. Multistage centrifugal pump,
operating at 25 Kg /cm², is used to feed the water in the boiler chamber. There are two pressure
releasing valve operating at 13.5 &14.5 Kg /cm² respective ly.

8.2.1 Use of Steam:

In steam jet ejectors

In heating purpose
In pipe lines to prevent choking
In steam tracing
To drive steam turbine

8.3 PROCESS WATER

A huge amount of water required daily for this plant. Three types of water are utilized in the
plant: -
1) Raw water
2) Soft water
3) De-mineralized water.

Total consumption of water in the plant is ~1000 m3./day. Raw water is used mainly for washing
purpose.

8.4 COOLING TOWER

A cooling tower is equipment used to reduce the temperature of a water stream by extracting heat
from water and emitting it to the atmosphere. Cooling towers make use of evaporation whereby
some of the water is evaporated into a moving air stream and subsequently discharged into the
atmosphere. As a result, the remainder of the water is cooled.

21
 CHAPTER:- 9

PLANT LAYOUT & LOCATION

22
9.1 PLANT LAYOUT & LOCATION

MATERIAL
GATE

ASSEMBLY
POINT 2

MEE

PLANT

FUSION

PLANT ASSEMBLY
POINT 1

PAA
PARA-CRESOL
PLANT
PLANT

STORAGE LABORATORY ETP

PLANT

CANTEEN

MAIN ADMIN TOLUENE

GATE OFFICE TANK

Plant Layout Of Atul Chemical Limited, Ankleshwar

23
 CHAPTER:- 10
COST ESTIMATION

24
10.1 THE CAPITAL INVESTMENT FOR THE YEAR 2007-08
The capital investment for the 16 TPD cresol plant was found to be 290.8 crore in year of 2007-
08.

Chemical Engineering plant cost index

Cost index in 2007=551

Cost index in 2017=1125

Thus, Present cost of plant

= (original cost) * (present cost)/(past cost index)

=290.8*1125/551

=591.7*107

10.2 ESTIMATION OF CAPITAL INVESTMENT COST

(1) Direct cost

Material and labor involved in actual installation of complete facility (70-80%) of fixed
capital investment

Equipment +installation + Piping + Electrical +insulation + Painting

(50-60% of FCI)

(a) Purchased equipment cost (15-20%of FCI)

PEC =25% OF 593.7*107
=0.25*(593.7*107 )

= 148.4*107
(b) Installation including insulation and painting
40% of 148.7*107
=59.36*107

(C) Electrical installed (10-40% PEC)

25% of 148.4*107

=37.175*107
25
 (B) Building process and auxiliary (10-70% PEC)

Consider building, process and auxiliary

=40% of PEC
=0.40*(148.4*107 )
=59.36*107
i. Service facilities: (40-100% of PEC)
Consider the cost of service facilities and yard improvement 50% PEC
=0.50*(148.4*107 )
=74.2*107
ii. Yard improvement (10-50% PEC)
Considering 12% PEC
=0.12*(148.4*107 )
=17.808*107
iii. Land (4-8 % PEC)
Consider the cost of land of 5 % PEC
=0.05*(148.4*107 )
=7.42*107
(2) Indirect Cost

Expenses which are not directly Involved with material and labour factual installation of
complete facility (15-30% of FCI )

A. Engg. & Supervision : (5-30 % direct cost )

Consider the cost of Engg. & supervision= 10% direct cost

=0.1*(7.42*107 )

=0.742*107

B. Construction Expense: (10% of direct cost)

Consider the construction expense = 10% of DC
= 0.1*(7.42*107 )
=0.742*107

i. Constructor’s fee : (2-7 % of DC)

26
 Consider 4% of DC
Constructor’s fee= 0.4 *(4.42*107 )
= 2.968 *107
ii. Contijency : (5-15 % of DC )
Consider of 10% of DC
= 0.10*(7.42*107 )
=0.742*107

Thus indirect cost= 0.742*107

(3) Fixed Capital Investment:

Fixed capital investment= Directg cost + Indirect cost
= 7.42*107 + 0.742*107

=8.162*107

(4) Working capital (10-20 % of FCI)

Consider WC = 15% of Fixed Capital Investment
= 0.15*(8.162*107 )
=1.2243*107

10.3 TOTAL CAPITAL INVESTMENT (TCI)

TCI= FCI+ Working capital

=8.162-107 +1.2243*107

=9.992*107

10.4 ESTIMATION OF TOTAL PRODUCT COST

1. Mfg. cost = Direct production cost+ fixed charge+ plant overhead cost

Fixed Charge: (10-20 % total product cost)

I. Depreciation: (depends on life period salvage value and method of calculation about
13 % of FCI for machinery and equipment & 2-3 % for Building value)

Consider Depreciation = 10 % of FCI or machinery & Equipment & 3% for building value for
building.

i.e Depreciation = (0.1 * 8.162*107 )

= 0.8162*107

1. Local Taxes = (1-4 % of fixed capital investment)

27
 3% of FCI

i.e. Local Taxes = 0.3*(8.162*107 )

= 0.12243*107

2. Insurance (0.4-1 % of FCI )

0.7% Fixed Capital Investment

=0.007*(8.162*107 )

=0.057134*107

3. Rent = (8-12% value of rented land and building)

Rent 10% value of (rented land and building)

Rent=0.1(59.36*107 +7.42*107 )

Fixed charge=678*107

B. Direct production Cost: (About 60% of TPC)

Now we have fixed charges= 10-20% total production charges

Consider fixed charges= 15% of TPC

𝐹𝐶
Total production Charges= 0.15

10.5 PLANT OVERHEAD COST

60% of OL, DS & DL & M & R

=0.60*OL*DS*DL*M&R

Mfg. cost (13.1036*107 )

1. Administrative Cost (40-60 % of OL)

Consider the administrative cost of 5 % of OL
=0.05*(6.678*107 )
=0.3339*107
2. Distribution & Selling Costs (2-20% of PC)
10% TDC

28
 =0.10*TDC
=4.452*107

Research and development Cost

(about 3 % of TPC)

=0.03*(44.52*107 )

=1.3356*107

TPC= Mfg, cost + general Expense

= 10.1036+(1.3356*107 )

= 14.4392*107

1. Gross Earnings/Income

Wholescale Selling price of cresol per Kg

Rs.=230Rs.

Total Income = Selling Price * quantity of product Manufactured

=230*(16 TPD)*(330days/year)

= 121.44*107

Gross Income= Total income -Total Product Cost

= (121.44*107 ) – (9.992*107 )

=111.4*107

Let the Tax rate be the 39.6% (common taxes)

40% of Gross income

=0.4*111.4

=445.76 *107

Taxes=495.14

Net profit= Gross income-Taxes

= Gross income* (1-Tax rate Net Profit)

= 111.4*(1-3.96)
29
 = 668.64*107

10.6 Rate of return

𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡
Rate of return = ∗ 100(𝑅𝑎𝑡𝑒 𝑜𝑓 𝑅𝑒𝑡𝑢𝑟𝑛)
𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

668 .64∗107
= 9.992∗107 ∗ 100

= 66.9% = 70%

30
 CHAPTER 11
IMPORTANT ASPECT OF SAFTEY POLLUTION CONTROL

31
11.1 HAZARD SUMMARY
• Cresols can affect you when breathed in and by passing through your skin.
• Cresols are corrosive chemicals and contact can severely irritate and burn the skin and eyes
with possible eye damage.
• Breathing Cresols can irritate the nose, throat and lungs.
• High exposure to Cresols can cause collapse and death within minutes.
• Cresols may cause a skin allergy. If allergy develops, very low future exposure can cause
itching and a skin rash.
• Cresols may damage the liver and kidneys.
• Long-term exposure can lead to chronic poisoning, with trouble swallowing, loss of appetite,
vomiting, diarrhea, headache and dizziness.

11.2 WAYS OF REDUCING EXPOSURE

• Where possible, enclose operations and use local exhaust ventilation at the site of chemical
release. If local exhaust ventilation or enclosure is not used, respirators should be worn.
• Wear protective work clothing.
• Wash thoroughly immediately after exposure to Cresols and at the end of the work shift.
• Post hazard and warning information in the work area. In addition, as part of an ongoing
education and training effort, communicate all information on the health and safety hazards
of Cresols to potentially exposed workers.

11.3 HEALTH HAZARD INFORMATION

11.3.1 Acute Health Effects
The following acute (short-term) health effects may occur immediately or shortly after
exposure to Cresols.
• Contact can severely irritate and burn the skin and eyes with possible eye damage.
• Breathing Cresols can irritate the nose, throat and lungs.
• High exposure to Cresols can cause collapse and death within minutes.

11.3.2 Chronic Health Effects

32
The following chronic (long-term) health effects can occur at some time after exposure to
Cresols and can last for months or years:

11.3.3 Cancer Hazard

• While Cresols have not been identified as carcinogens, three specific isomers have been
determined to be human carcinogens. Cresols should be handled with extreme caution.

11.3.4 Reproductive Hazard

• While Cresols have been tested, they are not classifiable as to their potential to cause
reproductive harm.

11.3.5 Other Long-Term Effects

• Cresols may cause a skin allergy. If allergy develops, very low future exposure can cause
itching and a skin rash.
• Cresols may damage the liver and kidneys.
• Long-term exposure can lead to chronic poisoning, with trouble swallowing, loss of appetite,
vomiting, diarrhea, headache and dizziness.

11.4 PERSONAL PROTECTIVE EQUIPMENT

11.4.1 Clothing
• Avoid skin contact with Cresols. Wear protective gloves and clothing. Safety equipment
suppliers/manufacturers can provide recommendations on the most protective glove/clothing
material for your operation.
• Safety equipment manufacturers recommend Butyl Rubber; Neoprene; and Viton® for
gloves, and DuPont Responder® and DuPont Tychem® BR/LV, SL and TK for protective
clothing.
• All protective clothing (suits, gloves, footwear, headgear) should be clean, available each
day, and put on before work.

11.4.2 Eye Protection

• For solid Cresols wear eye protection with side shields or goggles.
• Wear indirect-vent, impact and splash resistant goggles when working with liquids.

33
• Wear a face shield along with goggles when working with corrosive, highly irritating or toxic
substances.
• Contact lenses should not be worn when working with this substance.

11.4.3 Respiratory Protection

• Where the potential exists for exposure over 2.3 ppm, use a NIOSH approved full facepiece
respirator with an organic vapor cartridge and particulate prefilters. Increased protection is
obtained from full facepiece powered-air purifying respirators.
• If while wearing a filter or cartridge respirator you can smell, taste, or otherwise detect
Cresols, or if while wearing particulate filters abnormal resistance to breathing is
experienced, or eye irritation occurs while wearing a full facepiece respirator, leave the area
immediately. Check to make sure the respirator-to-face seal is still good. If it is, replace the
filter or cartridge. If the seal is no longer good, you may need a new respirator.
• Be sure to consider all potential exposures in your workplace. You may need a combination
of filters, prefilters or cartridges to protect against different forms of a chemical (such as
vapor and mist) or against a mixture of chemicals.
• Where the potential exists for exposure over 23 ppm, use a NIOSH approved supplied-air
respirator with a full facepiece operated in a pressure-demand or other positive pressure
mode. For increased protection use in combination with an auxiliary self-contained breathing
apparatus operated in a pressure-demand or other positive-pressure mode.
• Exposure to 250 ppm is immediately dangerous to life and health. If the possibility of
exposure above 250 ppm exists, use a NIOSH approved self-contained breathing apparatus
with a full facepiece operated in a pressure-demand or other positive-pressure mode equipped
with an emergency escape air cylinder.

11.5 HANDLING AND STORAGE

• Prior to working with Cresols you should be trained on its proper handling and storage.
• Cresols are not compatible with Oxidizing Agents (Such as Perchlorates, Peroxides,
Permanganates, Chlorates, Nitrates, Chlorine, Bromine And Fluorine); Strong Acids
(Such As Hydrochloric, Sulfuric And Nitric); Strong Bases (Such As Sodium Hydroxide

34
 And Potassium Hydroxide); Metals (Such As Potassium, Sodium, Magnesium And Zinc);
Amines; And Amides.
• Store in Tightly Closed Containers In A Cool, Well-Ventilated Area Away From Light
And High Temperatures.
• Sources of ignition, such as smoking and open flames, are prohibited where Cresols is
used, handled, or stored in a manner that could create a potential fire or explosion hazard.

35
 CHAPTER: - 12
MSDS OF CRESOL

36
12.1 COMPOSITION AND INFORMATION ON INGREDIENTS
Composition:

Name- Cresol

CAS # -106-44-5

% by Weight- 100

Toxicological Data on Ingredients:

Para-Cresol: ORAL (LD50): Acute: 207 mg/kg [Rat]. 344 mg/kg [Mouse]. DERMAL
(LD50): Acute: 301 mg/kg [Rabbit]. VAPOR (LC50): Acute: 355.5 ppm 4 hour(s) [Rat].

12.2 HAZARDS IDENTIFICATION

12.2.1 Potential Acute Health Effects:

Very hazardous in case of skin contact (corrosive, irritant), of ingestion. Hazardous in case of
skin contact (sensitizer, permeator), of eye contact (irritant), of inhalation. The amount of tissue
damage depends on length of contact. Eye contact can result in corneal damage or blindness.
Skin contact can produce inflammation and blistering. Inhalation of dust will produce irritation
to gastro-intestinal or respiratory tract, characterized by burning, sneezing and coughing. Severe
over-exposure can produce lung damage, choking, unconsciousness or death.

12.2.2 Potential Chronic Health Effects:

Very hazardous in case of skin contact (corrosive, irritant), of ingestion. Hazardous in case of
skin contact (sensitizer, permeator), of eye contact (irritant), of inhalation. Repeated exposure of
the eyes to a low level of dust can produce eye irritation. Repeated skin exposure can produce
local skin destruction, or dermatitis. Repeated inhalation of dust can produce varying degree of
respiratory irritation or lung damage. Repeated exposure to a highly toxic material may produce
general deterioration of health by an accumulation in one or many human organs.

12.3 FIRST AID MEASURES

12.3.1 Eye Contact:

37
Check for and remove any contact lenses. Immediately flush eyes with running water for at least
15 minutes, keeping eyelids open. Cold water may be used. Do not use an eye ointment. Seek
medical attention.
12.3.2 Skin Contact:
If the chemical got onto the clothed portion of the body, remove the contaminated clothes as
quickly as possible, protecting your own hands and body. Place the victim under a deluge
shower. If the chemical got on the victim's exposed skin, such as the hand: Gently and
thoroughly wash the contaminated skin with running water and non-abrasive soap. Be
particularly careful to clean folds, crevices, creases and groin. Cold water may be used. If
irritation persists, seek medical attention. Wash contaminated clothing before reusing.

12.3.3 Serious Inhalation:

Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie,
belt or waistband. If breathing is difficult, administer oxygen. If the victim is not breathing,
perform mouth-to-mouth resuscitation. WARNING: It may be hazardous to the person providing
aid to give mouth-to-mouth resuscitation when the inhaled material is toxic, infectious or
corrosive. Seek immediate medical attention.

12.3.4 Ingestion:
Do not induce vomiting. Examine the lips and mouth to ascertain whether the tissues are
damaged, a possible indication that the toxic material was ingested; the absence of such signs,
however, is not conclusive. Loosen tight clothing such as a collar, tie, belt or waistband. If the
victim is not breathing, perform mouth-to-mouth resuscitation. Seek immediate medical
attention.

12.4 FIRE AND EXPLOSION DATA

Flammability of the Product: May be combustible at high temperature.
Auto-Ignition Temperature: 559°C (1038.2°F)
Flash Points: 86°C (186.8°F).
Flammable Limits: Lower: 1%
Products of Combustion: These products are carbon oxides (CO, CO2).

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12.4.1 Explosion Hazards in Presence of Various Substances:
Risks of explosion of the product in presence of mechanical impact: Not available. Risks of
explosion of the product in presence of static discharge: Not available.
12.4.2 Fire Fighting Media and Instructions:
SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do
not use water jet.

12.5 ACCIDENTAL RELEASE MEASURES

12.5.1 Small Spill:
Use appropriate tools to put the spilled solid in a convenient waste disposal container.
12.5.2 Large Spill:
Corrosive solid. Stop leak if without risk. If the product is in its solid form: Use a shovel to put
the material into a convenient waste disposal container. If the product is in its liquid form: Do
not get water inside container. Absorb with an inert material and put the spilled material in an
appropriate waste disposal. Do not touch spilled material. Use water spray to reduce vapours.
Prevent entry into sewers, basements or confined areas; dike if needed. Eliminate all ignition
sources. Call for assistance on disposal. Be careful that the product is not present at a
concentration level above TLV. Check TLV on the MSDS and with local authorities.

12.6 HANDLING AND STORAGE

12.6.1 Precautions:
Keep container dry. Keep away from heat. Keep away from sources of ignition. Empty
containers pose a fire risk, evaporate the residue under a fume hood. Ground all equipment
containing material. Do not breathe dust. Never add water to this product In case of insufficient
ventilation, wear suitable respiratory equipment If you feel unwell, seek medical attention and
show the label when possible. Avoid contact with skin and eyes
12.6.2 Storage:
Keep container dry. Keep in a cool place. Ground all equipment containing material. Corrosive
materials should be stored in a separate safety storage cabinet or room.

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12.7 EXPOSURE CONTROLS/PERSONAL PROTECTION
12.7.1 Engineering Controls:
Use process enclosures, local exhaust ventilation, or other engineering controls to keep airborne
levels below recommended exposure limits. If user operations generate dust, fume or mist, use
ventilation to keep exposure to airborne contaminants below the exposure limit.
12.7.2 Personal Protection:
Splash goggles. Lab coat. Vapor and dust respirator. Be sure to use an approved/certified
respirator or equivalent Gloves.
12.7.3 Personal Protection in Case of a Large Spill:
Splash goggles. Full suit. Vapor and dust respirator. Boots. Gloves. A self contained breathing
apparatus should be used to avoid inhalation of the product. Suggested protective clothing might
not be sufficient; consult a specialist Before handling this product.

12.8 PHYSICAL AND CHEMICAL PROPERTIES

Physical state and appearance: Solid.
Odour: Strong.
Molecular Weight: 108.13 g/mole
Colour: White.
Boiling Point: 201.9°C
Melting Point: 34.8°C
Specific Gravity: 1.035
Vapor Density: 3.72
Odour Threshold: 0.1 ppm
Water/Oil Dist. Co-eff.: The product is equally soluble in oil and water; log (oil/water) = 0
Dispersion Properties: See solubility in water, methanol, diethyl ether.
Solubility: Soluble in methanol, diethyl ether. Partially soluble in cold water.

12.9 STABILITY AND REACTIVITY DATA

Stability: The product is stable.
Corrosivity: Non-corrosive in presence of glass.
Polymerization: No.
40
12.10 TOXICOLOGICAL INFORMATION
Routes of Entry: Dermal contact, Eye contact, Inhalation, Ingestion.
Toxicity to Animals:
Acute oral toxicity: 207 mg/kg [Rat]. Acute dermal toxicity: 301 mg/kg [Rabbit]. Acute toxicity
of the vapour 355.5 ppm 4 hour(s) [Rat].
Other Toxic Effects on Humans:
Very hazardous in case of skin contact (corrosive, irritant), of ingestion. Hazardous in case of
skin contact (sensitizer, permeator), of inhalation.
12.11 ECOLOGICAL INFORMATION
Products of Biodegradation:
Possibly hazardous short-term degradation products are not likely. However, long term
degradation products may arise.
Toxicity of the Products of Biodegradation: The products of degradation are more toxic.

12.12 TRANSPORT INFORMATION

DOT Classification: Poisonous material.
Identification: Cresol.
Special Provisions for Transport: Marine Pollutant.

12.13 OTHER REGULATORY INFORMATION

12.13.1 Federal and State Regulations:

Pennsylvania RTK: Para-Cresol Massachusetts RTK: Para-Cresol TSCA 8(b) inventory: Para-
Cresol SARA 313 toxic chemical
notification and release reporting: Para-Cresol: Hazardous substances.: Para-Cresol
12.13.2 Other Regulations: OSHA: Hazardous by definition of Hazard Communication
Standard (29 CFR 1910.1200).

41
 CHAPTER: - 13
SOLID WASTE TREATEMENT

42
13.1 WASTE RECOVERY PLANT
Waste recovery plant involves the recovery of waste ,that is further saleable in the market.
Previously the waste obtained from cresol plant was sent to the effluent treatment plant and
finally disposed off, But in the recent years some modifications have been done where the waste
generated in the cresol plant is recovered and selled in the market instead of disposing off.

13.2 PROCESS DESCRIPTION:

13.2.1 Sodium Sulphate Recovery:

At present, the waste containing 28% sodium sulphite is treated with 98% concentrated sulphuric
acid in a reactor. Sodium sulphate along with sulphur dioxide and water is produced. The sodium
sulphate thus obtained undergoes neutralization with caustic soda in another reactor before it is
fed to MEE plant. The sulphur dioxide and water generated in this reaction is used for
acidification of sodium cresolate.

Na2 SO 3 + 98% H2 SO 4 Na2 SO 4 + SO 2 + H2 O

43
CHAPTER: - 14
CONCLUSION

44
 CONCLUSION
According to my research, the alkylphenols like cresols are important fine chemicals widely
employed as intermediates for resins, dyes, anti-oxidants, pharmaceuticals and agrochemicals,
etc. O-cresol together with 2,6 xylenols are produce through the high temperature gas phase
alkylation of phenol with methanol, at 400-500 C. M-cresol, they are normally synthesized by
complicated and environmental unfavorable processes ex: - toluene dehydration for P-cresol and
alkaline chlorotoulene hydrolysis. Facing the urgency of sustainable develop it is not desirable to
develop energy saving and ecofriendly synthesis routes. As an alternative, especially for the
production of o-cresol and p-cresol because they can be complicate to separating through
distillation in the absence of m-cresol.

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CHAPTER:- 15

REFERENCE

46
 REFERENCE
• www.chemdating.com
• https://pubchem.ncbi.nlm.nih.gov
• https://en.m.wikipedia.org
• www.sigmaaldrich.com
• www.webbook.nist.gov>cgi>cbook
• www.epu.gov
• www.medicinescomplete.com
• www.merckmillipore.com
• www.chemspider.com
• www.chemicalland21.com

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