Training Report

on
CHEMICAL GROUP PLANT

Submitted by
Mr. Nikhil Rama Zore
Acknowledgement
I'm very much grateful to the "Rashtriya Chemicals and Fertilizers
Ltd." for giving me a training. I greatly thanks to training in charge
HRD Mr. Vinay Govilkar sir for giving me an opportunity in elaborating
my knowledge towards industry.
I am also very thankfull to Ujjwal Kabir sir. Salim Hannuse · Amit Jage
S.N.Patri Bharat T. mhatore Amit Ramteke Pawan Patil Si to share
their experience and knowledge in my training Period.
I'm also thanking to all my members of chemical group plant for
helping me. They are always ready to solve our problems and explain
in working handling in plant. They all have guided me during training.
 Overview of the company
Rashtriya Chemicals and Fertilizers (RCF) a government of India under
taking is a chemical and fertilizers manufacturing company.
RCF was in corporated on 6th of March 1978 on the recognization of
erstwhile fertilizer corporation of India limited (FCIL) and a result of
recognizing public sector fertilizer industries into five industries etc.

• Fertilizer corporation of India limited (FCIL)

• Hindustan fertilizers corporation limited (HFCL)
• Rashtriya Chemicals and Fertilizers limited (RCFL)
• Projects and Development India limited (PDIL)
• National fertilizer limited (NFL)
The ujjwala urea a d complex fertilizer suphales brand of fertilizer
manufacturing by RCF carry high brand equity and are recognised all
over the country .
Safety is a paramount important factor RCF work culture safety work
culture is always practicied in RCF. RCF also has disaster management
plant in case of emergency.
AIM : Scope of integrated management system production and
supply of steam, power, DM process to down stream process of
plant.

VISION : To be the world class company in the field of fertilizers and

chemicals with dominant position in “INDIAN MARKET” ensuring the
optimum utilization of resources taking due to case of environment
and manufacturing value of shake floders.

Objective of company :
The main objectives of company as :-

• To produce and market fertilizers and chemicals efficiently and

economically in an environmentally manner.
• To maintain optimum level of efficiency and productivity in the
use of resources and to serve optimum returns on investment.
 General information of plant

Plants
1) Methyl Amines Plant (Old) Capacity – 5000
MT/year
2) Methyl Amines Plant (New)
Capacity - 6400 MT

Process Licensor
M/s Acid Amine Technologies, U.S.A
Design basis including Production & consumption Figure

MAP
design basis
Plant capacity - 5000 MT/year
Plant operating - 8000 hour per year.
 MT/year MT/day Kg/hr
Monomethyl MMA 500 1.5 62.5
amine
Dimethyl DMA 4000 12 500
amine
Trimethyl TMA 500 1.5 62.5
amine
Total 5000 MT/yr 15 MT/day 625 kg/hr

• Different types of Process available

Methyl Amines Synthesis by Nitto chemical.

Methyl Amines Synthesis by Johnson Matthey. (Davy Technology)

Methyl Amines Synthesis by Leonard (Aid Amine Technology)

Raw material details:-

1) Methanol
2) Ammonia
Specifications
1) Methanol

Methanol content (wt % ) 98.9 % min

Colour (APHA) 15 max
Water (PPM) 1000 max
Specific gravity at 20°C 0.792 – 0.798
Acidity index 0.02 % wt max
Permanganate test 30 minutes min
Non volatile matter 0.001 % wt max

2) Ammonia

Ammonia content 99.8 % wt min

Oil 5 ppm max
Water 0.2 wt % max
Chlorine Nil
Sulphur Nil

Specific consumption ( per MT of product )

 Ammonia 0.43 MT
Methanol 1.42 MT
Steam 7.5 MT
Cooling water 8 m3
Electricity 440 KWH

Auxiliary system

Steam
Low pressure 6.2 kg/cm2 saturated (151°c)
Medium pressure 20 kg/cm2 saturated (214°c)
Cooling water 5.0 kg/cm3 g ( 71 psi.g)
Max temp Summer 36 °c
Return water Max temp 46°c

Electricity
400 v Ph / 50 cycles
220 v Ph / 50 cycles

Instrument air = 6.5 kg/cm2g

Dew point = -40°c
Condensate tank = Psig LP steam 5.2 kg/cm2g

Product details
Specification
Methyl Amines Anhydrate

Particular MMA DMA TMA

NH3 (% wt max) 0.02 0.01 0.01
H2O (% wt max) 0.10 0.1 0.10
Other amine(% 0.30 0.2 0.20
wt max)
Product Purity 99.69 99.70 99.70
(% wt min)

Properties of Monomethyl amine

Chemical Formula CH3NH2

Molar Mass 31.06 g-mol
Colorless gas Fichy
Appearance
ammoniacal
Odor 656.2kg/m3 (At 20°c)
density -93.10°C
Melting Point -6.6 to -6.0°C
Boiling Point
Solubility in water 1.08 kg/l (At 20°c)
Vapour Pressure 186.10 KPa (At 20°c)

Basicity (P. Kb) 3:36

Dimethyl amine

Chemical Formula (CH3) NH

Appearance Colourless gas
odoux density Ashy-Ammonical
Melting Point 649.6kg/m²(at25°c)
Boiling point -93°C
Solubility in water 7.40 9°C (6.9°c)
Vapour Pressures 3.540 kg/L
Acidity 170.3 kPa
10.64
Bascity 3.29

Trimethyl amine
 Chemical Formula CH3 Hg N
Appearance Colorless gas
odour density Fishy, Ammonical
Melting Point 6.70 kg/m³ (at o°c)
Boiling Point -117°c
Solubility in water 3 to 7°C (2.9°c)
vapour Pressure miscible
Basicity 188.7 kPa (at 20c).
4.19

Chemical reaction:-
Methylamine are Product by Reacting with methanol (CH3OH)
in Ammonia Presence of dehydration. There are three amines formed
in reaction mono methylamine, Dimethylamine and Trimethylamine.

Reaction:-
3NH3 + 6 CH₂OH →(CH3)3N+(CH3)2NH+(CH3)NH+6H2O
TMA DMA MMA

The equilibrium series of Reaction is best Reaction in an

article by Removille and david, Hydrocarbon Product July, 1981. It is

CH3OH + NH3 ⇋ CH3NH2 + H2O

quite complex in nature.
 MMA

CH3OH + CH3NH2 ⇋ ( CH3)2NH + H2O

DMA

CH3OH + (CH3)2NH ⇋ (CH2)3N + H2O

TMA
Catalyst:-

Alumina Silicate
Trade Name [KDC-6]
Converter unit (V-101) which is packed with a newly developed
Proprietary catalyst Alumina Silicate [KDC-67]

Specifications :-

Al2O3 78.24 wt %
SiO2 21.4 wt %
Na2O 0.15 wt %
Fe 0.01 wt %
SO4 0.20 wt %
Specific volume 470 wt %
Catalyst Poisoning

1) Sometimes oily content is Present in the NH3 which deactivates

the catalyst

2) N/C i.e. of nitrogen to carbon ratio below 1.3 which Shows

excessive CH3OH undergoing Pyrolysis & by Products are
formed due to high temperature

3) Frequent Startup & shutdown which results in expansion

4) Thermal deteOriation of catalyst.

5)Formation of carbon on catalyst Surface.

Product Synthesis:-

In the synthesis Section from ammonia is fed to the top of NH3

column (v-200) when it vaporized with measured steam of methanol
and Amines recycle which are fed continuously through two
Preheater methanol vaporizer and From the common vaporizer HE-
100 heat exchanger into converter unit (v -101) which is packed with
a newly developed. Propriety Catalyst (alumina Silicate) In the
converter the Ammonia and methanol react with two from a mixture
of MMA, DMA,TMA and water and small amount of CO & H₂ The hot
gases From heat exchanger to heat to the forward gas And then to
gas cooler which condense all the NH3 amines And water and
discharge from then into gas liquid Separator (V-102) From which
Inert (H2 and co) and a small amount of Hydrogen and carbon
monoxide are vented to the vent absorber system, Condensed liquid
feed to the NH3 column.
In gas Liquid Separator the Pressure maintain at 17.8 kg/cm².
The NH3 column hold at a Pressure of 39.2 kg/cm2 so that
gaseous overheated takeoff from the column flow by differentiate
pressure back to vaporize as a catalyst to converter become warm
and carbonized in operating Pressure did not exceed 21.7 kg/cm2
and temperature do not exceed in 450°C.
In order to maintain Full form?. Flow rates through the
system the Synthesis? Pressure Setting can be decrease or NH3
column Pressure increased. Since this equilibrium reaction any of the
monomethyl amine, dimethylamine or trimethylamine separates out
in the distillation Section which is unwanted as product may be
recycles with the feed.

Distillation :-

The amines can be separated and Purified In different way but in this
unit Distillation Columns are used.
In NH3 Column NH3 separated from overheat as an
Azeotrope with TMA, the NH3 Column Feed Comes from the effluent
treatment section (vent absorber) of the plant fresh Ammonia is Fed
to the top of this column. The Ammonia Column bottoms are fed to
the extract column (v-201) with extract water which is used to break
azeotrope and ensure that TMA for produced as on overhead Product
Over the Preferentially. Soluble MMA & DMA extract column bottoms
containing 90 moles percent Water Fed to the Dehydration column
(V-202) . Anhydrous MMA/DMA is taken over head and then
separated in the Product Column (v-203) to give pure DMA taken of a
vapour Product from tray near the bottom a column along with
MMA as the Over head Product A Small bleed steam from the
bottoms of the Product Column is recirculated o the dehydrate
Column. The system is used to reduce the water content the DMA
Product Any NH3 When is Present in MMA product is taken overhead
to vent column MMA Product is taken from fifth trays from the top
of the column.
Effluent Treatment

The Vent
The vent gas are Scrubbed Free of ammonia and Flared in low
visibility flare unit scrubber liquid are returned to the distillation
System

Liquid Effluent :-

Methanol removal is primary by of Distillation and then the effluent

From the dehydration Column and Recovery column bottom is
Cooled and fed at 50°f to the effluent treatment system.

The effluent is first of all neutralized. With Sulfuric acid and PH

controlled to 7.0 Plus minus 0.05 The effluent to aerated in the
Presence of activated sludge and BOD and COD levels reduced to
100ppm or less. The Sludge is taken as a Slurry and Pumped back to
main aeration tank. The Supernatant guide is discharged to sewer. Air
from this unit must be scrubbed before o discharge.
 Uses of Methylamines

Agricultural chemicals:-

Methylamines are used to make inter me dilate for a wide range of

Agricultural chemicals including herbicides, fungicides, insecticides,
biocides And matricides Agricultural chemicals are one of Widest
Uses of Methylamines.

Catalyst:-

Methylamines are used directly as catalysts or Raw material to

Produce other compounds with catalytic. DMAE made From DMA is
also used as urethane catalyst to Promote from Rise and get Strength
For Insulation application Such as Refrigerators.

Electronics:-

Dimethylamine & benzyl chloride are used to make benzyl

dimethylamine which can be used as an orc elevator for epoxy Resin
in Laminates for electrical equipment.

Fuel Additive:-

DMA hydra-chloride is also used as an additive in aviation fuel as an

antiknock compound mixture of MMA, DMA and TMA in water have
been tested as coolants in Some high-speed engines.
Equipment Details :-

1) Ammonia Column (v-200)

Mechanical design data

Design process 26.4 kg/cm2

Design temperature 200°C
Material SA 285°C
Relief valve setting 24.6 kg/cm2

Operating condition

Operating pressure 19.8 kg/cm2

Top temperature 50°C
Bottom temperature 115°C
Reflux ratio 0.4/1
No. of stage 17
Feed stage 10

2) Ammonia Column Condenser

Process design data
 Tube Out/In 4/36
Shell In/Out 50
Area calculate 30.39 m2

Mechanical design data

Type Fixed tube sheet

Design temperature 100°C
Tube sheet 60mm
Shell 26.4 kg/cm2g
Tube 7.04 kg/cm2g

3) Extract column (v-201)

Mechanical design data

Design pressure 141 kg/cm2g

Design temperature 200°C
Material specification SA 2856
No. of tray 70
Feed tray 45
Extract water feed tray 60

Operating condition
 Operating pressure 9.8 kg/cm2g
Top temperature 81°C
Bottom temperature 151°C
Type Tray column
Reflux ratio 5/1

4) Extract column condenser (v-201c)

Process design data

Tube Out/In 46/36

Shell In/Out 81
Tube flow material Cooling water

Material design data

Type Fixed tube sheet
Shell 14.1 kg/cm2g
Tube 7.04 kg/cm2g
Tube area (actual) 13.9 m2

5) Dehydration Column (v-202)

Mechanical design data

Design pressure 14.1 kg/cm2g

Design temperature 200°C
 MOC of shell SA 285°C

Operating condition

Operating pressure 78 kg/cm2

Top temperature 63°C
Bottom temperature 170°C
Reflux ratio 35/1
No. of stage & feed 25 & 13
stage
Type Packed bed

6) Dehydration Column Condenser

Tube Out/In 46/36

Shell In/Out 63
MOC of shell SA 285°c
Tube flow material Cooling water
Type Fixed tube sheet
Shell design 14.1 kg/cm2
procedure
Tube area (actual) 58.1 m2

7) Product Column (v-203)

Operating condition
 Operating pressure 6.6 kg/cm2
Top temperature 46°c
Bottom temperature 65°c
Reflux ratio 5/1
No. of tray 70
Feed tray 32

Mechanical design data

Design temperature 150°c

Design pressure 14.1 kg/cm2g
MOC of shell SA 285

8) Converter (v101)
Mechanical design data

Design temperature 500°c

Design pressure 24.5 kg/cm2g
Corrosion allowance Nil
No. of bed 4
Type Plug flow reactor
Catalyst per bed 575 kg
Catalyst weight 470 kg/m3
 Process design data
Flow 119.01kg/hr
Operating pressure 21 kg/cm3g
9) Storage tank

Name of the Product stored Capacity of tank

Tank (MT)
T – 401A MMA Anhydrous 17
T – 401C MMA Anhydrous 45
T – 423A DMA Anhydrous 75
T – 423B DMA Anhydrous 75
T – 402A TMA Anhydrous 44
T – 402B TMA Anhydrous 44
T – 404A/B MMA Solution 17/35
T – 406A/B DMA Solution 35/35
T – 405 TMA Solution 17

Pollution Control Measure

All the vent of the different column in the port are connected to vent
absorber in these gases are Scrubbed with water before venting them
into the atmosphere.

Special type of Pump (canned Pump) are used in Plant. These

Pump are Seal less eco-friendly they are not having seal . These
Pumps are Installed in 2000 to have better control over a emission
and for trouble free Service. These are used for handling anhydrous
amine & solution. In this way nearly zero gaseous affluents are
generated by the Plant as well as no solid waste is main source of
liquid effluent is generated and being treated is liquid effluent main
source of the Liquid effluent is Steam condensate in used.. as extract
water and as an azeotrope breaker in the ammonia colours. This
facility reduces the amount of effluent generation Plant.

All Other drain Point in the plant are interconnected and

connected to the effluent fit from where the effluent is pumped to
the effluent treatment Plant only Dehydrate coloum bottom is sent
directly to the ETP through a separate line. The heat associated with
this effluent treatment is used in Preheater to pre heat. The feed
before sending it on the ETP.

Unit operations used in Plant

1) Distillation

Distillation is unit operation in which the constituent of Liquid

mixture (solution) are Separated using thermal energy Basically the
difference in vapour pressure is responsible for Such a separation

In Distillation the phase involved are Liquid and vapour (vapour

Phase is created by supplying heat to one another by vaporization
from Liquid Phase and by condenser From the vapour Phase.
 2) Azeotropic Distillation

An Azeotropic is liquid mixture with on equilibrium vapour of the

same composition as the Liquid dew point. And bubble Point are
Identical at Azeotropic composition and the mixtures vaporized at
single temperature as Azeotropes are called constant separation by
boiling
Point Mixture

Such cases complete Separation by ordinary fraction may not be

possible that constituent of binary azeotrope are Separated
completely by

1) Adding third component to the binary Mixture forming

azeotropes and
2) Changing the System. The third component (which is Relatively
Volatile) added in binary mixture azeotropes usually from a low
boiling azeotrones which of the feed constituent and with
withdrawn as Overhead Process distruction.

The third component added to break the binary azeotrope to effect

it sepration into Pure componant is called as azeotrope break
 The Process of distillation where in a
This component is to a binary azeotrope to effect the complete
separation is azeotropic Distillation

3) Vaporization

The vaporization unit operation that Separated or convert the liquid

into a vapour heat transfer by vaporization the vaporizer unit most
commonly used from low Pressure heat transfer by incorporation the
vaporized Stream as the heat exchanger fluid. They can also to
vaporizer Liquid fuel or Cryogenic Liquid.

4) Gas liquid separater

Gras-Liquid seperator A liquid separator is a device and in In

industrial applications to Separate Vapours liquid into its constituent
Phase It can be vertical or horizontal vessel and can act as 2 Phase
or 3 Phase separator.

A gas Liquid Separator also referred to as flash drum break fat Knock
out drum or krock out pot or vent scrubber when uses to remove
suspended Water droplet from Stream of air it is often called a
demister.
Method of operation:

To vapour Liquid separators gravity utilized to cause the denser Liquid

to settle to the bottom of the vessel where it is with drown less
dence fluid (vapour) is with drown from the top of the vessel

CONCLUSION
The Internship training in very important spect of
chemical engineering I would like to say that this training Program is
an excellent Opportunity for us to ground level to the grow and
experience the things that we would have never gained straight into
giving us this wonderful opportunity.

The main objective of the training is to Provides pron Opportunity to

undergraduate to Identify observe and Practise how engineering is
applicable in the Real Industry It is not only to get experience on
technical practices but also to observe management Practical to
Interact with People

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 I feel I got the maximum out of that
experience Also I learnt work the way of In an organisation the
Important of team spirit

Training helped me in the area of so fatty and it taught. Me that the

Safety comes before everything. In my opinion. I have gain soms
knowledge and experiences
 *Reference*
1)
Wikipedia
2)Thal unit process book
3)Lab manual
4)Industrial source
5)Guided by industrial staff