BTP

A Report on

Production of Phenol from 99.9% pure Cumene from Naptha Cracker Production of 99.9% pure Bisphenol A from 99.9% pure Phenol February-14-2015

Major Project Report Submitted by Mukul Goyal Department of Chemical Engineering IIT Roorkee

Index 1. Material and Energy Balance 1.1 Material Balance 1.2 Energy Balance 2. Environmental Protection & Energy Conservation 2.1 Air Pollution 2.2 Liquid Effluents 2.3 Solids disposal 2.4 Noise Pollution 2.5 Energy conservation 3. Organizational Structure and Manpower Requirement 3.1 Organizational Principles and Basics 3.2 Hierarchy 3.3 Manpower Requirement 4. SITE SELECTION & PROJECT LAYOUT 4.1 Plant Location 4.2 Plant Layout

1|Page

1. MATERIAL AND ENERGY BALANCE 1.1

Material Balance

BASIS: 22831 kg/hr production of phenol 1.1.1 Overall reactions: 1. Oxidation of Cumene: NaOH C6H5CH(CH3)2

+

(120)

O2

C6H5C (CH3)2OOH

(32)

(152)

2. Decomposition of Cumene hydroperoxide: C6H5C (CH3)2OOH

+

H2S04

C6H5OH

(152)

+

(94)

1.1.2 Molecular weights of components: Cumene (Isopropyl benzene) = 120 kg moles Cumene Hydroperoxide

= 152 kg moles

Oxygen

= 32 kg moles

Phenol

= 94 kg moles

Acetone

= 58 kg moles

Mass of inlet of Cumene and oxygen

= 120+32=152 kg moles

Mass of outlet of phenol and acetone INLET

= 94+52= 152 kg moles

=

1.1.3 Feed: Cumene = 1650 kg (For 1000 kg of Phenol) Required oxygen = 440 kg 1 kg of air contains 0.23 kg of O2 X kg of air contains 440 kg of O2 Amount of air supplied = 1913 kg of air 25% excess air supplied = 478 kg of air Actual amount of air supplied = 2319 kg of air 1.1.4 Balances:

2|Page

OUTLET

CH3COCH3 (58)

OXIDIZER: COMPONENTS

INLET kg/hr

OUTLET kg/hr

Cumene

35786.025

9065.793

Air

51857.2035

---

Cumene hydroperoxide

---

36263.172

Off gases

----

42314.2635

Total

87643.2285

87643.2285

COMPONENTS

INLET kg/hr

OUTLET kg/hr

Cumene hydroperoxide

38171.76

9545.223

Cumene

9542.94

---

Cleavage

---

38180.892

H2SO4

11.415

---

Total

47726.115

47726.115

COMPONENTS

INLET kg/hr

OUTLET kg/hr

Cumene hydroperoxide

38180.892

9545.223

Carryover Cleavage

---

954.294

Cleavage

9545.223

37226.598

Total

47726.115

47726.115

ACIDIFIER:

SEPARATOR:

3|Page

WASH TOWER: COMPONENTS

INLET kg/hr

OUTLET kg/hr

Cleavage

37226.598

---

Water

547.92

---

Acid free Cleavage

---

37112.448

Acidified wash water

---

662.07

Total

37774.518

37774.518

ACETONE COLUMN: COMPONENTS

INLET kg/hr

OUTLET kg/hr

OVERHEAD BOTTOM

Cleavage

37112.448

---

---

Acetone

---

11387.604

---

Carryover cleavage

---

114.15

---

---

---

114.15

Residue

---

---

25496.544

Total

37112.448

11501.754

25610.694

INLET kg/hr

OUTLET kg/hr

OVERHEAD

Carryover acetone in residue

CUMENE COLUMN: COMPONENTS

BOTTOM Feed

25610.694

---

---

Cumene

---

1856.079

---

---

114.15

---

Residue

---

---

23640.465

Total

25610.694

1970.229

23640.465

Carryover acetone in Cumene

4|Page

α - METHYL STYRENE COLUMN: COMPONENTS

INLET kg/hr

OUTLET kg/hr

OVERHEAD BOTTOM

Feed

23640.465

---

---

α - methyl styrene

---

520.524

---

Residue

---

---

23119.941

Total

23640.465

520.524

23119.941

INLET kg/hr

OUTLET kg/hr

OVERHEAD

PHENOL COLUMN: COMPONENTS

BOTTOM Feed

23119.941

---

---

Phenol

---

22896.207

---

Carryover acetophenone

---

86.754

---

Acetophenone

---

---

114.15

Total

23119.941

22982.961

114.15

The amount product phenol = 22983 kg/hr Purity of the product phenol = 99.9%

5|Page

1.2

Energy Balance

OXIDIZER: A) Inlet heat@ 70°C: 1. Cumene @ 30°C

mass 1

35786.025 kg

Cp1

0.415

ΔT1

5

Q1

kcal/kg °C °C

74256.00188 Kcal 310761.3678 KJ

2. Air @ 30°C

mass 2 Cp2 ΔT2 Q2

54586.53 1.005 5

kg kJ/kg °C °C

274297.313

KJ

38171.76

kg

3. Total heat inlet Q = Q1+ Q2= 327117.229 + 274297.313 Q = 601414.54 kJ B) Outlet heat@ 110°C: 1. Cumene Hydroperoxide @ 110°C mass 1 Cp1 ΔT1 Q1

0.45 85 1460069.82

kcal/kg °C °C Kcal

6110392.2

KJ

38171.76

kg

2. Cumene @ 110°C mass 1 Cp1 ΔT1

6|Page

0.45 85

kcal/kg °C °C

Q1

1460069.82 6110392.2

Kcal KJ

3. Off gases @ 110°C a) Oxygen mass 3 Cp3

2511.3 0.936

ΔT3

25

Q3

kg kJ/kg °C °C

58764.42

KJ

42030.03

kg

b) Nitrogen mass 4 Cp4

1.035

ΔT4

25

Q4

1087527.026

kJ/kg °C °C KJ

4. Total heat outlet Q= Q1+ Q2+ Q3+ Q4 Q = 8801255 KJ Heat of reaction of Cumene Hydroperoxide = 736 KJ/kg For 1672 kg of Cumene Hydroperoxide

= 8361192.254

COMPONENTS

INLET HEAT kJ

OUTLET HEAT kJ

Cumene

327117.229

1544571.361

Air

274297.313

---

Cumene hydroperoxide

28094415.4

---

Cumene hydroperoxide

---

6110392.197

Off gases

---

1146291.446

Heat removed by water

---

19894575

Total

28695829.9

28695830

COOLER: A) Inlet heat @ 110°C: Heat taken by Cumene Hydroperoxide =6110392.19 KJ Heat taken by Cumene = 1544571.361 KJ

7|Page

Total heat inlet = 7654963.55 KJ

B) Outlet heat @70°C: 1. Cumene hydroperoxide @ 70°C: mass 1 Cp1

38171.76 0.45

ΔT1

45

Q1

772978.14

kg kcal/kg °C °C Kcal

3234913.516

KJ

9542.94

kg

2. Cumene @ 70°C: mass 2 Cp2

0.435

ΔT2

45

Q2

3.

kcal/kg °C °C

186803.0505

Kcal

781770.7663

KJ

Total heat outlet Q= Q1+ Q2 = 3234913.52+781770.76 Q = 4016684.282 KJ

COMPONENTS

INLET HEAT kJ

OUTLET HEAT kJ

Cumene hydroperoxide

6110392.197

3234913.516

Cumene

1544571.361

781770.7663

Heat removed by water

---

3638279

Total

7654963.558

7654963.282

ACIDIFIER: A) Inlet heat @ 70°C: 1. Heat taken by Cumene Hydroperoxide = 3234913.516KJ Heat taken by Cumene = 781770.7663 KJ Total heat inlet in product (Q1) = 4016684.282 KJ 2. H2SO4 @ 30°C:

8|Page

mass 2 Cp2

11.415 1.44

ΔT2

45

Q2

739.692

Kg kJ/kg °C °C KJ

3. Total heat inlet Q = Q1+Q2 = 4016684.282 +739.69 =4017423.974 KJ B) Outlet heat @ 80°C: 1. Mass of cleavage = 38180.892 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

23672.427

2.29

Acetone

11835.072

1.481

Cumene

1908.588

1.842

α - methyl styrene

536.505

1.406

Acetophenone

232.866

1.97

Q1=((23672.4×2.29)+( 11835.072×1.481)+( 1908.58×1.842)+( 536.50×1.406)+( 232.866×1.97)) ×(80-25) Q1= 4205645.983 kJ 2. Cumene hydroperoxide@ 80°C: mass 2 Cp2 ΔT2 Q2

3. Total heat outlet Q = Q1+Q2 = 5194328.25 kJ Heat of reaction of cleavage = 2983 KJ/kg For 38180.9 kg of cleavage =113893624.7

9|Page

9545.223 0.45 55

kg kcal/kg °C °C

236244.2693

Kcal

988682.2668

KJ

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Cumene Hydroperoxide

3234913.516

988682.2668

Cumene

781770.7663

---

H2SO4 Heat of reaction of cleavage Cleavage

739.692

---

113893624.7

---

---

4205645.983

Heat removed by water

---

112716720.4

Total

117911048.7

117911048.7

SEPARATOR: A) Inlet heat @80°C: Heat in Cumene Hydroperoxide = 988682.2668 kJ Heat in Cumene = 4205645.983 kJ Total heat inlet = 5194328.25 kJ

B) Outlet heat @80°C: Heat in Cumene Hydroperoxide = 988682.2668 kJ Heat in cleavage = 4205645.983 kJ Total heat outlet = 5194328.25 kJ WASH TOWER: A) Inlet heat @80°C: 1. Mass of Cleavage =37226.598 kg COMPONENTS

MASS kg

Phenol

23081.13

2.29

Acetone

11540.565

1.481

Cumene

1860.645

1.842

α - methyl styrene

520.524

1.406

Acetophenone

223.734

1.97

Q1= 4100100.69 kJ

10 | P a g e

SPECFIC HEAT KJ/Kg°C

2. Water @ 30°C

mass 2 Cp2

547.92 4.18

ΔT2

5

Q2

11451.528

kg kJ/kg °C °C KJ

3. Total heat inlet Q = Q1+Q2 = 4111552.218 kJ B) Outlet heat @75°C: 1. Acid free cleavage = 37112.48 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

23008.074

2.29

Acetone

11501.754

1.462

Cumene

1856.079

1.821

α - methyl styrene

520.524

1.367

Acetophenone

223.734

1.97

Q1=4071995.728 kJ 2. Acidified wash water @ 40°C mass 2 Cp2

547.92 4.18

ΔT2 Q2

15 34354.584

kg kJ/kg °C °C KJ

3. Heat taken by carryover cleavage Q3=5201.9KJ 4. Total heat outlet Q= Q1+Q2+ Q3= 4111552.212 kJ COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Cleavage

4100100.69

---

11 | P a g e

Water

11451.528

---

Acid free cleavage

---

4071995.728

Acidified wash water

---

34354.584

Carryover cleavage

---

5201.9

Total

4111552.218

4111552.212

HEATER: A) Inlet heat @75°C: Cleavage Mass of cleavage = 37112.48 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

23008.074

2.29

Acetone

11501.754

1.462

Cumene

1856.079

1.821

α - methyl styrene

520.524

1.367

Acetophenone

223.734

1.97

Q = 4071995.728 kJ B) Outlet heat @90°C: Mass of cleavage = 37112.448 kg COMPONENTS

MASS kg

Phenol

23008.074

2.29

Acetone

11501.754

1.509

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

Q = 4108248.352 kJ

12 | P a g e

SPECFIC HEAT KJ/Kg°C

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Cleavage

4071995.728

4108248.352

Heat added by steam

36252.62

Total

4108248.348

--4108248.352

ACETONE COLUMN: A) Inlet heat @90°C: Mass of cleavage =37112.448 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

23008.074

2.29

Acetone

11501.754

1.509

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

Q = 4855202.59 KJ

B) Outlet heat: 1. Acetone vapours @ 56°C Mass 1

11387.604

kg

λ1

212.3

kJ/kg °C

Q1

2417588.329

KJ

114.15

kg

2. Cleavage vapours @ 56°C Mass 2 λ2

109.96

Q2

12551.934

3. Total heat outlet as vapour = 2430140.263

13 | P a g e

kJ/kg °C KJ

4. Bottom residue @90°C Mass of residue= 2666.544 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

2.32

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

Q3= 2025471.813 kJ

5. Carryover acetone @90°C mass 4 Cp4

114.15 1.509

ΔT4

65

Q4

11196.40275

kg kJ/kg °C °C KJ

6. Total heat outlet Q = Q1+Q2+ Q3+ Q4 Q =4466808.479 kJ

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Cleavage

4855202.598

Vapour acetone

---

2417588.329

Vapour cleavage

---

12551.934

Bottom residue

---

2025471.813

Carryover acetone in residue

---

11196.40275

Total

4855202.598

4855203

---

OVERHEAD ACETONE CONDENSER: A) Inlet heat @ 56°C: 1. Acetone vapours @ 56°C Mass 1

14 | P a g e

11387.604

kg

λ1

212.3

kJ/kg °C

Q1

2417588.329

KJ

114.15

kg

2. Cleavage vapours @ 56°C Mass 2 λ2

109.96

Q2

12551.934

KJ

kJ/kg °C

11387.604

kg

3. Total heat inlet as vapour Q = Q1+Q2 Q= 2430140.263kJ B) Outlet heat@50°C: 1. Acetone mass1 Cp1

1.397

ΔT1

25

Q1

397712.0697

kJ/kg °C °C KJ

2. Heat produced by Cleavage Q2 = 4837.75 kJ 3. Total heat outlet Q = Q1+Q2 Q = 402549.8197kJ

COMPONENTS

INLET HEAT KJ

Vapour acetone

2417588.329

---

Vapour cleavage

12551.934

---

Heat removed by water

---

2027590.4

Condensed acetone

---

397712.0697

Condensed cleavage

---

4837.75

Total

2430140.263

2430140.22

HEATER: A) Inlet heat @90°C:

15 | P a g e

OUTLET HEAT KJ

1. Mass of residue= 2666.544 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

2.32

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

Q1 = 2025471.813 kJ

2. Acetone mass2 Cp2

114.15 1.509

ΔT2 Q2

65 11196.40275

kg kJ/kg °C °C KJ

3. Total heat inlet Q = Q1+Q2 Q =2036668.215 kJ B) Outlet heat @95°C: 1. Mass of residue= 2666.544 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

2.32

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

Q1=2025471.813 kJ 2. Acetone mass2 Cp2 ΔT2 Q2

16 | P a g e

114.15 1.51 70 12065.655

kg kJ/kg °C °C KJ

3. Total heat outlet Q = Q1+Q2 =2037537.468 kJ COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Residue

2025471.813

2025471.813

Carryover acetone

11196.40275

12065.655

Heat added by steam

869.25

Total

2037537.465

--2037537.468

CUMENE COLUMN: A) Inlet heat @95°C: 1. Mass of feed= 2666.544 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

2.32

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

Q1=4050943.625 KJ 2. Acetone mass2 Cp2 ΔT2 Q2 3. Total heat inlet Q = Q1+Q2 = 4063009.28 kJ B) Outlet heat: 1. Cumene vapours @ 90°C

17 | P a g e

114.15 1.51 70 12065.655

kg kJ/kg °C °C KJ

Mass 1

1856.079

kg

λ1

343.9

kJ/kg °C

Q1

638305.5681

KJ

114.15

kg

2. Acetone vapours @ 90°C Mass 2 λ2

212.3

Q2

24234.045

kJ/kg °C KJ

3. Residue @ 95°C Mass = 23640.465 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

2.32

Cumene

1856.079

1.863

α - methyl styrene

520.524

1.445

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Feed

4050943.625

---

Vapour Cumene

---

638305.5681

Vapour acetone

---

24234.045

Residue

---

4050943.625

Carryover acetone in feed

12065.655

---

Total

4713483

4713483.238

Q3 = 4050943.625 kJ 4. Total heat outlet Q = Q1+Q2+Q3=4713483.238 kJ

18 | P a g e

CUMENE VAPOUR CONDENSER: A) Inlet heat: 1. Cumene vapours @ 90°C Mass 1

1856.079

kg

λ1

343.9

kJ/kg °C

Q1

638305.5681

KJ

114.15

kg

2. Acetone vapours @ 90°C Mass 2 λ2

212.3

kJ/kg °C

Q2

24234.045

KJ

1856.079

kg

3. Total heat inlet Q Q1+Q2 = 662539.61 kJ B) Outlet heat@80°C: 1. Cumene mass1 Cp1

1.842

ΔT1 Q1

55

kJ/kg °C °C

188039.3635

KJ

114.15

kg

2. Acetone mass1 Cp1

1.51

ΔT1

55

Q1

9480.1575

kJ/kg °C °C KJ

3. Total heat outlet Q = Q1+Q2 = 197519.521 kJ COMPONENTS

INLET HEAT KJ

Vapour Cumene

638305.5681

---

Vapour acetone

24234.045

---

19 | P a g e

OUTLET HEAT KJ

Heat removed by water

---

465020.1

Condensed Cumene

---

188039.3635

Condensed acetone

---

9480.1575

Total

662539.6131

662539.621

HEATER: A) Inlet heat @ 95°C: 1. Mass = 23640.465 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

2.32

Q = 3808892.363 kJ B) Outlet heat @ 110°C: 1. Mass = 23640.365 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

α - methyl styrene

520.524

1.445

Acetophenone

223.734

1.97

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Residue

3808892.363

4625083.583

Heat added by steam

816191

Total

4625083.363

2.32

Q=4625083.583 kJ

20 | P a g e

--4625083.583

α - METHYL STYRENE COLUMN: A) Inlet heat @ 110°C: 1.

Mass 23640.465 kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22939.584

α - methyl styrene

520.524

1.523

Acetophenone

223.734

1.97

2.32

Q=4628534.658kJ B) Outlet heat: 1. α - methyl styrene vapours @ 100°C Mass 1

520.524

λ1

449.1

Q1

233767.3284

kg kJ/kg °C KJ

2. Residue @110°C Mass = 23119.941kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22896.207

Acetophenone

223.734

1.97

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Residue

4628534.658

Vapour α - methyl styrene

---

2.32

Q2 = 4552596.279 KJ 3. Total heat outlet Q = Q1+Q2 = 4786363.607 KJ

21 | P a g e

--233767.3284

Bottom residue

---

4552596.279

Total

4628534.658

4628534.5

α - METHYL STYRENE CONDENSER: A) Inlet heat: 1. α - methyl styrene vapours @ 100°C Mass 1

520.524

kg

λ1

449.1

kJ/kg °C

Q1

233767.3284

KJ

520.524

kg

B) Outlet heat: 1. α - methyl styrene condensed @ 95°C mass 1 Cp1

1.445

ΔT1

70

Q1

52651.0026

kJ/kg °C °C KJ

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Vapour α - methyl styrene

233767.3284

Heat removed by water

---

181116.3

Condensed α - methyl styrene

---

52651.0026

Total

233767.3284

233767.3026

COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22896.207

2.32

Acetophenone

223.734

1.97

---

HEATER: A) Inlet @110°C 1. Mass =23119.941kg

22 | P a g e

Q=4552596.279 kJ

B) Outlet @130°C 1. Mass =23119.941kg COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22896.207

2.32

Acetophenone

223.734

1.97

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Residue

4552596.279

5623795.403

Heat added by steam

1071199

Total

5623795.279

Q=5623795.403 KJ

--5623795.403

PHENOL COLUMN: A) Inlet @130°C 1. Mass =23119.941kg COMPONENTS

MASS kg

Phenol

22896.207

Acetophenone

223.734

SPECFIC HEAT KJ/Kg°C 2.32 1.97

Q=5623795.403 KJ B) Outlet heat 1. Phenol vapours @ 120°C Mass 1

22896.207

λ1

296.7

Q1

6793304.617

kg kJ/kg °C KJ

2. Acetophenone vapours @ 120°C Mass 2

23 | P a g e

86.754

kg

λ2

116.1

kJ/kg °C

Q2

10072.1394

KJ

3. Bottom acetophenone @130°C mass 3 Cp3

114.15 1.97

ΔT3

105

Q3

23611.9275

kg kJ/kg °C °C KJ

4. Total heat outlet Q= Q1+Q2+ Q3= 6826988.684 kJ COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Feed

6826988.5

Vapour phenol

---

6793304.617

Vapour Acetophenone

---

10072.1394

Acetophenone

---

23611.9275

Total

6826988.5

6826988.684

---

PHENOL VAPOUR CONDENSER: A) Inlet heat 1. Phenol vapours @ 120°C Mass 1

22896.207

kg

λ1

296.7

kJ/kg °C

Q1

6793304.617

KJ

86.754

kg

2. Acetophenone vapours @ 120°C Mass 2 λ2

116.1

Q2

10072.1394

3. Total heat inlet Q= Q1+Q2=6803376.756 kJ B) Outlet heat@ 100°C 1. Mass = 22982.961 kg

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kJ/kg °C KJ

COMPONENTS

MASS kg

SPECFIC HEAT KJ/Kg°C

Phenol

22896.207

2.32

Acetophenone

86.754

1.97

Q=3996757.922kJ

COMPONENTS

INLET HEAT KJ

OUTLET HEAT KJ

Vapour phenol

6793304.617

---

Vapour Acetophenone

10072.1394

---

Heat removed by water

---

2806618

Condensed phenol & acetophenone

---

3996757.922

Total

6803376.756

6803375.922

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2. Environmental Protection & Energy conservation 2.1 AIR POLLUTION In this section, air emissions are characterized by location, effective emission heights, and emission factors for criteria pollutants and selected pollutants; the hazard potential of each pollutant is quantified, and the affected population is determined; the national and state emission burdens are calculated; and the growth factor of the industry’s emissions is determined. The data in this section were obtained through industry cooperation. SELECTED POLLUTANTS Compounds identified as potential emissions from the manufacture of acetone and phenol from cumene are listed in Table 12. A sampling program was undertaken to quantify these compounds plus others which may not previously have been known to be present. TABLE 12. SUSPECTED EMISSIONS FROM ACETONE AND PHENOL MANUFACTURE FROM CUMENE PRIOR TO SAMPLING Acetaldehyde Acetic acid Acetone α-Hydroxyacetone Diacetone alcohol Acetophenone Benzene Ethylbenzene n-Propylbenzene Methyl isobutyl carbinol Cumene Cumene hydroperoxide Dicumyl peroxide 1,1,2, 2—Tetramethyl—l,2—diphenylethane Formaldehyde Formic acid 2-Methylbenzofuran Methylgioxal Heavy tars 2, 6—Dimethyl-2, 5—heptadiene—4-one l-Hydroxyethyl methyl ketone Methyl isobutyl ketone Lactic acid Methanol α-Methylstyrene Dimers of α-methylstyrene 2-Methyl-3, 4-pentanediol

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4-Hydroxy-4-methyl- 2-pentanone Phenol 2,4,6-Tris (2-phenyl-2-propyl)phenol Toluene 2-Phenyl-2- (4-hydroxyphenyl) propane TABLE 13. CHARACTERISTICS OF EMISSIONS IDENTIFIED DURING SAMPLING OR REPORTED FROM ACETONE AND PHENOL PLANTS USING CUMENE PEROXIDATION MATERIAL EMITTED Acetaldehyde Acetone Acetophenone Benzene Cumene Ethyl benzene Formaldehyde α methyl styrene Naphthalene Phenol

HEALTH EFFECTS Local irritant; central nervous system narcotic Skin irritant, narcotic in high concentrations Narcotic in high concentrations Carcinogen Narcotic ; toxic Skin and mucous membrane irritant Irritant ; toxic Toxic Moderate irritant Toxic & irritant

TABLE 14. EMISSION SOURCES BY PROCESS TYPE AT A PLANT MANUFACTURING ACETONE AND PHENOL FROM CUMENE Process technology Allied

Hercules

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Emission source Cumene peroxidation. Cumene hydroperoxide concentration vent. Separation column vent. Acetone concentration column vent. Cumene column vent. α Methylstyrene column vent. Refined α-methylstyrene column vent. Phenol column vent. Acetophenone column vent. Cumene tank vent. Acetone tank vent. Catalyst tank vent. Acetone transport loading vent. α-Methylstyrene transport loading vent Phenol transport loading vent. Acetophenone transport loading vent. Acetophenone transport loading vent. Cumene peroxidation vent. Cumene hydroperoxide wash vent. Cumene hydroperoxide concentration vent.

Vent of cuxnene hydroperoxide cleavage and product wash operations combined. Separation column vent. Acetone column vent. Separation column vent. Dewatering column vent Hydrogenation column vent Acetone tank vent α-Methylstyrene tank vent Phenol tank vent Buffer tank vent

TABLE 15. EMISSION SOURCES AT A REPRESENTATIVE PLANT MANUFACTURING ACETONE AND PHENOL FROM CUMENE 1. Cumene Peroxidation Vent The cumene feed is contacted with air in a reaction vessel to peroxidize the cumene. Air is continuously introduced and removed. The off—gas stream carries vaporized hydrocarbons and some volatile trace elements. Cumene is recovered from the spent gas for recycle by condensation. The emission control equipment is the last piece of equipment before the gas is emitted to the atmosphere. That is, any prior equipment is process equipment, and the control of any material released to the atmosphere is performed by the last piece of equipment prior to release. For example, in the Allied process the emission control equipment is the carbon bed system, and in the Hercules process it is the refrigerated condenser, unless another piece of equipment is added on. 2. Cleavage Section Vents, Combined The composite emission factors, Table 18, are determined by aggregation of the emission factors available from sampling and industry communication. These emission factors combine values for the cumene hydroperoxide concentration vent (Allied process technology) and the cumene hydroperoxide wash vent, the cumene hydroperoxide concentration vent, and the combined cunene hydrøperoxide cleavage and product wash vent (Hercules process technology). TABLE 18. AVERAGE EMISSION FACTORS FOR THE CLEAVAGE SECTION Material emitted Total nonmethane hydrocarbon Acetone Acetophenone Benzene 2—Butanone 0.0000018 2—Butenal t—Butylbenzene Cumene

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g/kg phenol produced 0.17 0.0000060 0.0000044 0.000031 0.0000018 0.000000085 0.000023 0.14

Ethylbenzene Formaldehyde 2—Hydroxy-2—phenylpropane Isopentanal

0.0000050 <0.00000026 0.0000034 0.00000085

Briefly, in the cleavage section the CUMENE hydroperoxide stream is Washed (Hercules process only) and concentrated to 80% or more cumene hydroperoxide, the cumene removed is recycled, the cumene hydroperoxide is cleaved to products using an acid catalyst, and the catalyst is removed from the product stream. 3. Storage Tank Vents, Combined The emission factor for the Phenol tanks in an average of the calculated value 0.06g phenol/kg phenol produced and an estimate of 0.012 g phenol/ phenol produced. However, based upon plant experience, he used other data for some of the input variables Such as storage temperature, vapor pressure, etc. The two estimates were determined using the same procedure but different input variables; therefore, the estimates were averaged. 4. Product Transport Loading Vent; Combined The emissions from product transport loading are caused by displacement of hydrocarboncontaining vapors in the compartment being filled. One source reports emissions of 0.061 g acetone/kg phenol produced from the acetone loading area and 0.20g Phenol/kg phenol produced from the phenol loading and shipping area. 5. Fugitive emissions Fugitive emissions occur from pressure relief valves, pump seals, compressor seals, pipeline valves and flanges, equipment purges, Process drains, wastewater separators, and laboratory analysis Sampling. An estimate of the total non-methane hydrocarbons (as methane equivalents) from pumps and sewers has been reported to 0.022 g/kg phenol produced. Pump and sewer caused emissions are not the total fugitive emissions, nor are they necessarily the most significant. CONTROL TECHNOLOGY Air emissions from the manufacture of acetone and phenol from cumene Consist of hydrocarbons. Existing emission control technologies for the industry are described in this section. These control methods include condensation, absorption, adsorption, floating roof tanks, and incineration. Future considerations in emissions control technology are also discussed in this section. Adsorption is the most commonly used method to control emissions from the cumene peroxidation vent. Condensation, absorption and incineration are also used.

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Emissions in the cleavage section are most often controlled by condensation. Absorption and incineration are also used. Emissions in the product purification section are controlled by condensation, adsorption, absorption, and incineration. Floating roofs are used to control emissions from tanks, particularly acetone and cumene storage tanks. Condensation, sealed dome roofs, and conservation vents are also used for this purpose, but not as commonly as floating roofs. Product transport loading emissions are controlled by absorption or vapor recovery. Not all plants control this emission source. The Scope of fugitive emissions and control methods are under study by EPA. VARIOUS EMISSION CONTROL METHODS IN USE AT CUMENE PEROXIDATION PLANTS VAPOUR CONDENSATION Organic compounds can be removed from an air stream by condensation. A vapor will condense when, at a given temperature, the partial pressure of the compound is equal to or greater than its vapor pressure. Similarly, if the temperature of a gaseous mixture is reduced to the saturation temperature (i.e., the temperature at which the vapor pressure equals the partial pressure of one of the constituents), the material will condense. Thus, either increasing the system pressure or lowering the temperature can cause condensation. In most air pollution control applications, decreased temperature is used to condense organic materials, since increased pressure is usually impractical. Equilibrium partial pressure limits the control of organic emissions by condensation. As condensation occurs, the partial pressure of material remaining in the gas decreases rapidly, preventing complete condensation. ACTIVATED CARBON ADSORPTION Adsorption is a phenomenon in which molecules become attached to the surface of a solid. The process is highly selective, and a given adsorbent, or adsorbing agent, will adsorb only certain types of molecules. The material adhering to the adsorbent is called the adsorbate. Adsorption involves three steps. First, the adsorbent comes in contact with the stream containing the adsorbate, and separation due to adsorption results. Next, the unadsorbed portion of the stream is separated from the adsorbent. Finally, the adsorbent is regenerated by removing the adsorbate. Activated carbon is the most suitable adsorbent for organic vapors. Carbon adsorbs 95% to 98% of all organic vapor from air at ambient temperature regardless of variations in concentration and humidity given a sufficient quantity of carbon. The adsorption of a mixture of organic vapors in air by carbon is not uniform, however, higher boiling point components are preferentially adsorbed. When a contaminated gas stream is passed over an activated carbon bed, the organic vapor is adsorbed and the purified stream passes through. Initially, adsorption is rapid and complete, but as

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the carbon bed approaches its capacity to retain vapor, traces of vapor appear in the exit air. This is the breakpoint of the activated carbon. If gas flow is continued, additional amounts Of Organic material are adsorbed, but at a decreasing rate. SOLVENT ABSORPTION Absorption is a process for removing one or more soluble component from a gas mixture by dissolving them in a solvent. Absorption equipment is designed to insure maximum contact between the gas and the liquid solvent to permit interphase diffusion between the materials. Absorption rate is affected by factors such as the solubility of gas in the particular solvent and the degree of chemical reaction; however, the most important factor is the solvent surface exposed. A vent gas scrubber-cooler system used on a cumene peroxidation vent is illustrated in figure. In this system off gases are scrubbed in a tray tower to absorb hydrocarbons into the scrubbing liquid, which is an aqueous Na2CO3 solution. Some of the scrubbing liquid is sent to the oxidation section, and some is recycled through the scrubber with makeup solution. The scrubbed gas is cooled, condensate is removed and sent to the oxidation section, and the gas is released to the atmosphere. INCINERATION Complete combustion of the hydrocarbons present in the emissions from a cumene peroxidation phenol plant produces carbon dioxide and water. NOx may be produced depending on the method of combustion the temperature. SOx production depends on the sulphur content of the auxiliary fuel, if any. The types of incinerators (i.e., direct flame afterburners, catalytic after burners, or flares), used to combust hydrocarbons at plants manufacturing acetone and phenol from cumene were not reported. STORAGE TANKS Six kinds of evaporation loss from storage of organic materials occur: breathing, standing storage, filling, emptying, wetting, boiling. Vapors expelled from a tank because of thermal expansion, barometric expansion, or additional vaporization are breathing losses. Vapor loss from such areas as seals, hatches, other openings (but not due to breathing or level changes) constitute standing storage loss. Vapors expelled from a tank is filled constitute filling loss. Vapors expelled from tank during emptying (due to the fact that vaporization occurs slowly, air enters to equalize pressure, vaporization stabilizes, and there is excess vapor in the tank) are emptying loss. Wetting loss is the vaporization of liquid from wetted exposed wall in a floating roof tank when the roof is lowered. Vapors expelled because of boiling are boiling loss. FLOATING ROOF TANKS Floating roof tanks are of various designs but the basic concept is that the roof floats on the surface of the stored material. A seal provides intimate contact between the roof and the tank wall. These tanks reduce breathing and filling losses by reducing the space available for vapor accumulation. Wetting losses are small and not a problem.

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SEALED DOME ROOF TANKS This type of tank can withstand relatively large pressure variations without incurring a loss. There is little or no breathing loss. Filling loss will depend on the tank design. CONSERVATION VENT FOR TANKS The conservation vent is a device to inhibit evaporation loss while protecting the tank from possible damage due to under pressure or overpressure. The vent has two set points, an upper a lower pressure. If the pressure is outside this range the vent opens to allow pressure equalization with the atmosphere. This reduces evaporation losses. VAPOR RECOVERY SYSTEM ON PRODUCT LOADING FACILITIES This control device collects the vapors produced from product loading and disposes of them by one of the control methods previously described, such as condensation, adsorption, etc. Vapor recovery is a general term for emission control practices.

2.2 Liquid effluents Acetophenone Acetophenone is a colorless liquid with a sweet, pungent odor that is sparingly soluble (0.55 wt % at 20°C) in water. Acetophenone is used as a chemical Intermediate for resins, pharmaceuticals, corrosion Inhibitors and dyestuffs; as a solvent for gums, resin dyestuffs and high—melting aromatic chemicals; as a polymerization catalyst and photosensitizer. In organic synthesis; as a flavoring agent for tobacco and in perfumery. If acetophenone is released to water, microbial degradation and volatilization are expected to be the major environmental fate and transport processes. Biodegradation studies have shown that acetophenone is significantly biodegradable. The volatilization half—life from a river 1m deep flowing at 1 m/sec with a wind velocity of 3 m/sec was estimated to be 3.7 days. Hydrolysis, oxidation, adsorption to sediments and bioconcentration are not expected to be significant. When acetophenone is released to the ambient atmosphere, reaction with photochemical)y—produced hydroxyl radicals is expected to be the dominant removal mechanism; the half—life for this reaction has been estimated to be —2 days (U.S. EPA. 1981). In the atmosphere, acetophenone will exist almost entirely in the vapor phase. If acetophenone is released to soil, microbial degradation is likely to be the major degradation process. Based on various adsorption studies acetophenone is expected to be mobile in soil and susceptible to significant leaching. Acetophenone is also expected to evaporate from dry soil surfaces. Acetophenone occurs naturally. In varius plant oils, in the buds of balsam poplar and In Concord grapes (Dorsky et al., 1963; NIcholas, 1973). It has been detected in drinking waters, surface waters, groundwaters and waste effluent waters. The presence of acetophenone in environmental waters is most likely the result of discharges from industrial sources. Metabolism and toxicity data indicate that acetophenone is absorbed by both gastrointestinal and respiratory tracts. Studies using rabbits indicate that acetophenone Is metabolized to (—)1—phenylethanol, which is excreted in the urine as glucuronide and sulfate conjugates.

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Health Hazard Information Acute Effects:  Acute exposure of humans to acetophenone vapor may produce skin irritation and transient corneal injury. One study noted a decrease in light sensitivity in exposed humans.  Acute oral exposure has been observed to cause hypnotic or sedative effects, hematological effects, and a weakened pulse in humans.  Congestion of the lungs, kidneys, and liver were reported in rats acutely exposed to high levels of acetophenone via inhalation.  Tests involving acute exposure of rats, mice, and rabbits have demonstrated acetophenone to have moderate acute toxicity from oral or dermal exposure. Reproductive/Developmental Effects:  No information is available on the reproductive or developmental effects of acetophenone in humans.  In one study of pregnant rats exposed dermally, no effects on reproduction or development were noted. Cancer Risk:  No information is available on the carcinogenic effects of acetophenone in humans or animals.  EPA has classified acetophenone as a Group D, not classifiable as to human carcinogenicity. Potential Health Effects Inhalation: May cause irritation to the respiratory tract; symptoms may include sore throat, coughing, headache, and dizziness. Higher concentrations may cause narcosis. Ingestion: May cause sore throat, abdominal pain, nausea, coughing, headache, dizziness, anesthetic effects, and central nervous system effects. Skin Contact: May cause irritation with redness and pain. Eye Contact: May cause severe irritation, redness, pain, and transient corneal injury. Chronic Exposure: Prolonged or repeated skin exposure may cause dermatitis. Aggravation of Pre-existing Conditions: No information found.

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First Aid Measures Inhalation: Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Call a physician. Ingestion: Induce vomiting immediately as directed by medical personnel. Never give anything by mouth to an unconscious person. Call a physician. Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes. Remove contaminated clothing and shoes. Wash clothing before reuse. Call a physician. Eye Contact: Immediately flush eyes with plenty of water for at least 15 minutes, lifting lower and upper eyelids occasionally. Get medical attention immediately. Fire Fighting Measures As in any fire, wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear. During a fire, irritating and highly toxic gases may be generated by thermal decomposition or combustion. Use water spray to keep fire-exposed containers cool. Combustible liquid and vapor. Extinguishing Media: Use water spray, dry chemical, carbon dioxide, or appropriate foam. Flash Point: 77 deg C ( 170.60 deg F) Autoignition Temperature: 570 deg C ( 1,058.00 deg F) Explosion Limits, Lower:1.1% Upper: 6.7% Accidental Release Measures Ventilate area of leak or spill. Remove all sources of ignition. Wear appropriate personal protective equipment as specified in Section 8. Isolate hazard area. Keep unnecessary and unprotected personnel from entering. Contain and recover liquid when possible. Use non-sparking tools and equipment. Collect liquid in an appropriate container or absorb with an inert material (e. g., vermiculite, dry sand, earth), and place in a chemical waste container. Do not use combustible materials, such as saw dust. Do not flush to sewer! Environmental Regulations require reporting spills and releases to soil, water and air in excess of reportable quantities. Handling and Storage Keep in a tightly closed container, stored in a cool, dry, ventilated area. Protect against physical damage. Isolate from any source of heat or ignition. Isolate from oxidizing materials. Containers of this material may be hazardous when empty since they retain product residues (vapors, liquid); observe all warnings and precautions listed for the product. Keep away from heat and flame. Keep

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away from sources of ignition. Store in a tightly closed container. Store in a cool, dry, well-ventilated area away from incompatible substances. Exposure Controls/Personal Protection Airborne Exposure Limits: - Threshold Limit Value (TLV): 10 ppm (TWA) Ventilation System: A system of local and/or general exhaust is recommended to keep employee exposures below the Airborne Exposure Limits. Local exhaust ventilation is generally preferred because it can control the emissions of the contaminant at its source, preventing dispersion of it into the general work area. Please refer to the ACGIH document, Industrial Ventilation, A Manual of Recommended Practices, most recent edition, for details. Personal Respirators (NIOSH Approved): If the exposure limit is exceeded, a respirator with an organic vapor cartridge may be worn for up to ten times the exposure limit. Since this compound has been identified as possibly existing in both vapor and particulate phase, a dust/mist prefilter is recommended. For emergencies or instances where the exposure levels are not known, use a positive-pressure, air-supplied respirator. WARNING: Air-purifying respirators do not protect workers in oxygen-deficient atmospheres. Skin Protection: Wear protective gloves and clean body-covering clothing. Eye Protection: Use chemical safety goggles and/or a full face shield where splashing is possible. Maintain eye wash fountain and quick-drench facilities in work area. Stability: Stable under ordinary conditions of use and storage. Hazardous Decomposition Products: Carbon dioxide and carbon monoxide may form when heated to decomposition. Hazardous Polymerization: Will not occur. Incompatibilities: Strong oxidizers. Conditions to Avoid: Heat, flame, other sources of ignition.

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Maharashtra Pollution Control board Standards under Water Act 

The daily quantity of trade effluent from the factory shall not exceed 18 m3.



The daily quantity of sewage effluent from the factory shall not exceed 7 m 3.

(i) Trade Effluent Treatment: The applicant shall provide comprehensive treatment system consisting of Primary / secondary and / or tertiary treatment and is warranted with reference to influent quality and operate and maintain the same continuously so as to achieve the quality of the treated effluent to the following standards: pH Suspended Solids BOD COD Oil & Grease TDS Chlorides Sulphates Chromium Total Chromium Total metal Iron

Between Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed Not to Exceed

5.5 to 9.0 100 mg/l. 100 mg/l. 250 mg/l 10 mg/1. 2100 mg/1. 600 mg/1. 1000 mg/1. 0.1 mg/l 2.0 mg/l 10 mg/l 5.0 mg/l

(ii) Trade Effluent Disposal: The treated effluent shall be used in the process to the maximum extent and remaining shall be used on land for green belt development. (iii) Sewage Effluent Treatment: The applicant shall provide comprehensive treatment system as is warranted with reference to influent quality and operate and maintain the same continuously so as to achieve the quality of treated effluent to the following standards. (1) Suspended Solids - Not to exceed 100 mg/I. (2) BOD 3 days 27° C - Not to exceed 100 mg/I. (iv) Sewage Effluent Disposal: The treated domestic effluent shall be soaked in a soak pit, which shall be got cleaned periodically. Overflow, if any, shall be used on land for gardening / plantation only. (v) Non-Hazardous Solid Wastes: Sr. No. 1 2

Type of waste Slag Machine returns

Quantity 158267MT/Yr 10000 MT/Yr

3

Flue Dust

24000 MT/Yr

4

Fly ash

12000 MT/Yr

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Disposal Landfill By reuse in own sinter plant By reuse in own sinter plant Sale to brick & cement mfg. & landfill

(vi) Other conditions: The industry shall monitor effluent quality regularly. The applicant shall comply with the provisions of the Water (Prevention & Control of Pollution) Class Act, 1977 (to be referred as Class Act) and Rules there under: The daily water consumption for the following categories is as under: (i) Domestic -80 CMD (ii) Industrial Processing – CMD (iii) Industrial Cooling - 3135 CMD (iv) Agriculture/Gardening - 16 CMD The applicant shall regularly submit to the Board the returns of water consumption in the prescribed form and pay the Class as specified under Section 3 of the said Act.

2.3 Solid Waste Disposal There is no substantial solid waste in the plant; the only solid waste will be dried sludge from the effluent treatment plant, canteen wastes, worn office equipment and tools, stationery, cleaning rags, packing boxes, broken pallets and broken office chairs. Solid waste disposal is done by thermal incineration or by tipping. The design of a solid waste incinerator is difficult to do due to the wide variety of feed to be disposed. It is important to determine the burning characteristics of the solid waste material. A major problem with the solid incinerator is fly ash control. Various methods employed for this purpose ate two-stage combustion, filter baffle and provision of large secondary chambers where velocities are low and settling takes place. If the fly ash problem is chronic, special separation devices like electrostatic precipitators can be employed. The flash produced can be used as a land fill.

2.4 Noise Pollution The major sources of noise pollution in our plant are: 

Pumps



Burners



Electric motors



Valves



Steam Vents

Various equipment‘s noise levels and control measures are listed in the table below: Equipment

Sound level at 3ft(dB)

Electric motors

90-110

Pumps Vane(Industrial) Vane(mobile) Axial position

75-82 84-92 76-85

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Possible Noise Control measures Acoustically lined fan covers, enclosures and motor mutes, absorbent mounts. Acoustically lined fan covers, enclosures and motor mutes, absorbent mutes.

Screw type Gear Heaters and furnaces

72-78 78-88 90-110

Valves

80-108

Piping

90-105

Acoustic plenums, intake mufflers, lined/ damped ducts Avoid sonic velocities, limit pressure drop and mass flow,and replace with special low noise valves. Isolation and lagging, in liner silencers, vibration isolators.

Apart from the listed noise sources, minor sources of the noise pollution may be pipes and hoses hitting the floor, panels etc. i.e. rattling noises, which can be stabilized with adsorbent mounts. All the bolts should be tightened to prevent vibration and clatter. Venting of process gas out the condensers may result in serious noise pollutions. This is due to turbulent mixing of high velocity gas with the stationary gas. Steam leaks and another common noise problem with the sound level are reaching sometimes 100 dB at the distance of 25 feet of the leak. All steam leaks should be timely repaired. Where noise levels cannot be reduced to acceptable levels of a person, ear protection equipment should be used. The industry shall take adequate measures for control of noise levels from its own sources within the premises so as to maintain ambient air quality standard in respect of noise to less than 75 dB(A) during day time and 70 dB(A) during night time. Day time is reckoned in between 6 a.m. and 10 p.m. and night time is reckoned between 10 p.m. and 6 a.m.

Maharashtra Pollution Control Board Standards for Noise Pollution: 1) The industry should not cause any nuisance in surrounding area. 2) The industry should monitor stack emissions and ambient air quality regularly. Conditions for D.G. Set:1] Noise from the D.G. Set should be controlled by providing an acoustic enclosure or by treating the room acoustically. 2] Industry should provide acoustic enclosure for control of noise. The acoustic enclosure/acoustic treatment of the room should be designed for minimum 25 dB(A) insertion loss or for meeting the ambient noise standards, whichever is on higher side. A suitable exhaust muffler with insertion loss of 25 dB(A) shall also be provided. The measurement of insertion loss will be done at different points at 0.5 m from acoustic enclosure/room and then average. 3] The industry shall take adequate measures for control of noise levels from its own sources within the premises in respect of noise to less than 55 dB(A) during day time and 45 dB(A) during the night time. Day time is reckoned between 6 a.m. to 10 p.m and night time is reckoned between 10 p.m. to 6 a.m.

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4] Industry should make efforts to bring down noise level due to DG set, outside industrial premises, within ambient noise requirements by proper siting and control measures. 5] Installation of DG Set much be strictly in compliance with recommendations of DG Set manufacturer. 6] A proper routine and preventive maintenance procedure for DG set should be set and followed in consultation with the DG manufacturer which would help to prevent noise levels of DG set from deteriorating with use. 7] D.G. Set shall be operated only in case of power failure. 8] The applicant should not cause any nuisance in the surrounding area due to operation of D.G. Set.

2.5 Energy Conservation Chemical plants have always been designed to operate economically due to product competition. However before 1970, the objectives of building a low cost plant was generally considered more important than low operating cost. This concept changed due to the oil crisis of 1973 and the subsequent action at several environment protection agencies in promoting the use of non-low polluting attention has been paid to such topics such as energy conservation schemes, process integration, heat exchanger network design, cogeneration etc. This attention is evident by the large number of books and journals published on these topics in the recent years. The design engineer must consider appropriate energy conservation schemes that are designed to: (i) Utilize as much of the energy available within the plant. (ii) Minimize the energy requirements for the plant. The energy balances performed for the plant items provide the initial key to identify areas of high energy availability or demand. An attempt can then be made to utilize excess energy in those areas where energy must be provided. However, this is not always possible because: (i) A high energy load may constitute a large volume of liquid at relatively low temperature, exchanging this energy may require large and expensive equipment. (ii) This energy source may be distant from the sink and piping and insulating costs may make utilization uneconomic, sometimes a rearrangement of the plant lay out required. (iii) The energy source may be corrosive. Any energy conservation scheme must also consider the costs involved in removing or transferring the excess energy i.e. capital cost of heat exchangers, piping, valves, pumps, insulation and operating costs of pumping and maintenance. Energy conservation is only worthwhile if the reduction in energy costs exceed the cost of implementation. A scheme maybe devised for a plant and then held over until energy prices make the proposal attractive. This type of forward planning requires that the plant layout adopted can be easily modified. Energy conservation can be achieved at three levels: (i) Correct plan and operation and maintenance

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(ii) Major changes to existing plant and processes. (iii) New plants and new processes. The time required to implement energy conservation measures, the capital cost required, and the potential savings, all increase from level (i) to (iii) above. The cost of downtime for level.(ii) can be significant, and the level (iii) offers the greatest long term potential for energy conservation. This latter objective can be achieved either by designing new, energy efficient plants for established process routes, or adopting new and less energy- intensive process routes. The basic approach towards conservation of energy should be taken into account: i. Operational modification ii. Research and development iii. Design modification iv. Insulation v. Maintenance vi. Process integration vii. Process modification viii. Waste utilization In the near future all industrial operations that have reacted to the energy crisis must be organized to institute a systematic approach towards conserving energy in all forms through more efficient utilization of existing processes and carefully studied reduction of losses and wastes. The following examples illustrate some application of the basic engineering principles t the design of equipment for improved energy efficiency. (i) Plant Operation: Energy savings can be achieved by good engineering practice and the application of established principles. These measures may be termed as good housekeeping and include correct plant operation and regular maintenance. The overall energy savings are usually small and may not be easy to achieve and significant time may be required for regulate maintenance and checking. However, such measures do help to establish commitment of a company to a policy of energy conservation. (ii) Heat Recovery: Heat recovery is an important and fundamental method of energy conservation. The main limitations of this method are: (a) Inadequate scope for using recovered waste heat because it is too low grade for existing heat requirements, and because the quantity of waste heat available exceeds existing requirements for low- grade heat.

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(b) Inadequate heat transfer equipment. Developments and improvements are continuing in design and operation of different types of heat exchangers including the use of extended heat transfer surfaces, optimizing heat exchanger networks, heat recovery from waste fuels, heat exchanger fouling and the use of heat pumps. (iii) Combined Heat and Power Systems: Significant energy conservation is achieved by well-established method of combined heat and power generation. This is often referred to as CHP or COGEN. The heat is usually in the form of intermediate or low pressure steam and the power as direct mechanical drives or as electricity generated with the turbo alternators. The choice of system is usually between back pressure steam turbines or gas turbines with waste heat boilers for the process streams. The amount of power generated is usually determined by the demand of heat. It is not usually possible to balance exactly the heat and power loads in a system .The best method of achieving this aim is to generate excess electricity for subsequent sale, other balancing methods tend to be less efficient. Therefore it is important to forecast the heat to power ratio accurately at the design stage to avoid large imbalances and reduced system efficiency. (iv)Power recovery systems: A power recovery turbine can recover heat from an exchanger gas and then use this heat to provide a part of the energy required to drive the shaft of a motor driven process air compressor. Other examples are the use of the steam turbine drive and a two stage expansion turbine with reheating between the stages. A hydraulic turbine can be incorporated on the same shaft as a steam turbine. This arrangement can be used to provide about 50% of the energy needed to recompress the spent liquor in a high pressure absorption /low pressure stripping system. Power generation using steam or gas turbine is now well established; however power recovery by the pressure reduction of process fluids is more difficult and less common. In general the equipment is not considered to be particularly reliable.Rankine cycle heat engines have been developed to use relatively low grade waste heat sources to generate power in the form in the form of electricity or direct drives. They tend to be used when the heat source would otherwise be completely wasted, the low efficiencies do not represent a significant disadvantage. (v) Furnace efficiency Incorporating an air heater can be more economic than using a hot oil system which is designed for high level heat only. (vi) Air cooler v/s water cooler: Air coolers have higher installed cost but lower operating cost water coolers. (vii) Low pressure steam: Energy savings can be achieved by the efficient use of low pressure steam. (viii) Heat integration:

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Energy can be saved by optimum balance of heat sources and sinks in a process plant so as to maximize recycling of energy input .thus however has to be done carefully as it leads to loss of operational independence. (ix) Thermal insulation: Owing to the great size of the distillation column large amount of heat is dissipated from the surface .This necessitates thermal insulation of distillation column reboiler and other piping attached to it so that minimum heat is dissipated.Multi-layer energy saving insulation should be used which provide protection from fire, liquid spillage and result in energy savings. Usually, inner insulation layers are made from alumina silica fibers to reduce the heat loss from the valves and joints to keep the system heat constant and prevent heat loss. Instrumentation: Use of efficient instrumentation in the plant can result in consistent high quality of product and lesser no. of rejections. In a plant design utmost care must be taken to conserve energy. The reboiler and the heat exchanger should be set up after a long analysis Energy conservation in the design of complete process may be achieved in four ways: (i) Major modifications to the existing plants. (ii) New plant using an existing process route. (iii) New process routes and alternative raw materials. (iv) New processes for new products that are less energy intensive. Items (i) and (iii) represent short term and medium term energy conservation measures. Item (iv) requiring the use of new products or processes is more appropriate for new technology in the chemical industry. Although energy conservation is an obvious objective of all equipment manufacturers and plant designers, more attention iis necessary in relation to education , training and the application of new and existing technology to ensure significant medium term and long term savings. Energy conservation must be considered at various stages of the project, e.g. feasibility study, process selection, plant layout, energy balances and in conjunction with the detailed equipment design. If he energy utilization is not only an afterthought, either unnecessary or costly modifications may be required to the design work, or the plant may not be economically feasible as it originally appeared. ENERGY MANAGEMENT: The high value of energy should be acknowledged in plant operation by treating it as a product with monetary value than can be sold or traded, just like the chemical product. This should be the basis for operational policies concerned with the energy management or energy conservation. These duties can be incorporated by the process engineer. EAM&T is a means to efficient operation in this area, but there must be a commitment from all operational and managerial personnel to the importance of these tasks if they are to be successful. The reaction and product recovery areas have been

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identified as critical units from an energy perspective. Detailed monitoring and targeting should be established in these areas. ALTERNATE ENERGY RESOURCES The fuel resources of the world are fast depleting and there is an urgent need to explore the possibility of the alternate sources of energy. Although rapid breakthrough has been achieved in the use of nuclear energy for the distillation of the steam, which in turn is used for the generation of electricity, it is not used widely due to the lack of the flexibility in its utilization and because of the non-feasibility of its operation on the smaller scale. Some of the alternate energy sources being developed nowadays have been briefly discussed below: Solar energy Solar energy is the most important form of renewable energy for plant. The energy incident on the solar panel installed in the roof and other areas of the plants are highly useful in heating up the water and converting to steam. This is one renewable source of the energy which is now slowly finding wide acceptance in the process industry. In the process industry it is being used widely for heating the process water and in some cases for the production of the low pressure steam. Energy conservation is not only concerned with the process industries but is also concerned with other small household purposes carried out in the industrial areas. It can also be used for the heating and providing warm water in the canteen and the other nonproduction areas in the process plant. Energy from biomass conversion Biomass in today‘s Chemical Industries is going to play a vital role in the production of energy as well as in different chemical products. The biomass have been widely used however major considerations include:       

Which raw materials will be needed in the new situation? How will biomass be processed? How will feedstock be made available at the appropriate location? What kind of storage facilities is needed? How can the production of bio-based bulk chemicals be integrated? How will products be shipped to the (geographic) area covered by the Port? Which are the most likely companies to produce new bio-based bulk chemicals?

Two extremes can be envisioned by which the transformation to a biomass based chemical industry may take place: 1. Biomass will be refined and cracked into the familiar platform chemicals (i.e. ethylene, propylene, C4-olefines and BTX) and synthesis gas (syngas‘, a mixture of mainly carbon monoxide and hydrogen gas). From these one- to six-carbon building blocks, all other chemicals and materials can be produced. Provided that efficient processes will become available by which oxygen-rich biomass of a varying composition can be transformed into basic hydrocarbon building blocks, the big advantage is that the current petrochemicals

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infrastructure and processes can be used. The fossil feedstock refining companies of today may then become the biorefineries of tomorrow. 2. A wide range of bio-based building blocks, in which as much of the functionality of biomass as possible has been retained, become the raw materials from which all other chemicals and materials are made. Not a few refineries that produce a limited number of platform chemicals will be present, but a large number of (smaller scale) bio-refineries that produce a whole array of building blocks. Between these two extremes lies a whole spectrum of non-exclusive scenarios that are perhaps more realistic. As a less extreme example of the first scenario: ethylene, one of the current platform chemicals, can be produced from (bio) ethanol. In fact, the Brazilian company Braskem and US based Dow Chemical will each start commercial production of polyethylene from bio-ethanol. Bio-ethanol is currently made from sugar or starch. In the future, it is expected that ethanol will be made from the more abundant lignocellulosic or woody biomass. The Gobar gas concept has found wide acceptance in the rural India. Although bioconversion technology has been very successful in the waste treatment, the technology to generate energy for the industrial uses is in early stages of the development. However, this technology holdsgreat promise as its fundamental advantage is that apart from being a clean source of the fuel, it is a renewable source of energy. Ocean thermal energy: The Ocean energy is one of the contributors in renewable energy. The temperature of the water in the ocean varies drastically with the depth. The principal here is to run a heat engine to retract heat energy from ocean by utilizing the difference in temperature of the ocean at various depths. This technology is in the very early stages of the development and can only be utilized if the plant is situated close to the coastlines.

Wind energy: The unequal heating of the earth by the sun causes winds. This effect is particularly pronounced in the coastal areas with a difference between the temperature for the land and the sea. The force of the wind is used to rotate windmills, which are rotating blades to collect the force of the wind. This mechanical energy produced can be used directly on it can be converted into electrical energy. These have been used with partial success in the process industry, mainly to pump water both process water and the water to effluent treatment plants.

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3. Organizational Structure and Manpower Requirement 3.1 Organizational Principles and Basics According to one of the prominent scholars, “organizations are social units (or human groupings) deliberately constructed and reconstructed to seek specific goals”. (Etzioni, 1964). Organization is a prescribed pattern of relations among the various tasks and the individuals who perform the tasks. Organizations are characterized by explicit, common parts which require the coordination of individuals and group efforts towards their attainment. The co-ordination is achieved by the establishment of vertical and horizontal network of relationships among various components of the organization. The basic goals of the organization are three-folds: 1. To produce the best quality product at the lowest cost 2. To sell the product to the consumer in a manner that maximizes profit, both in the short as well as long term. 3. To do these in a manner that is sustainable and is in the interest of the society. In order to achieve these goals, an effective organizational structure is required both at the management and operational levels. There are various steps involved in specifying the kind of organization and the total labour requirement of the plant complex, before beginning the construction and commissioning of the plant. We briefly take some of the important points. Consideration of objectives: One should be very clear as to what are the objectives of the enterprise. Objectives determine the various activities, which need to be performed and the type of organization, which needs to be built for the purpose. Grouping of activities into departments: Identify the activities necessary to achieve the objectives and group the similar or related activities into well-defined groups or departments. Deciding key departments: Key departments are those which render activities that are essential for the achievement of goals. These are primary departments; the others exist merely to serve these. Determine decision levels: The levels at which all the major and minor decisions in each department are to be made must be determined. The amount of decentralization and spread of authority are at the discretion of each firm. Span of Management: The next step to be taken in designing a structure is the number of subordinates who will report to each executive. Coordination mechanism: The whole structure should be like a well-oiled machine, with cohesion and co-ordination at all levels.

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Duties of organization and administration:        

Principles of work administration and control, labour organization and control, raw material and their storage Selection of site, layout of works, building and plants Problem of internal transport and material handling Construction work Proper equipment selection Minimization of labour Office administration and finance Marketing and distribution of products.

There are sixteen principles of organization: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Unity of objectives Specialization Coordination Chain of command Authority responsibility Delegation Unity of command Span of Control Balance Communication Efficiency Personal ability Decision making and control by exception Flexibility Departmentalization Goal centered and purposeful activities

But an organization that works well in one type of environment (environment being defined as combination of markets, customers, producers and technology) may fail in another. The failure may arise due to contingency factors such as: 1. Task uncertainty, technology and environment 2. Power and conflict 3. Growth and size Here task uncertainty is the degree to which the task necessary for the performance is unpredictable. Technology and environment are the sources of unpredictability. Organizational structure should manage conflict so that it helps the company. It is helpful to understand the basic determinants of power in an organization and how conflicts are related

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Organization effectiveness includes the following criteria 1. Organizational efficiencies 2. Adaptability to external changes 3. Satisfaction of individual needs

3.2 Hierarchy I.

Board of Directors i.

Establishes objectives

ii.

Overall accountability to stock holders

II.

Chief Executive Officer i.

Operates business to accomplish objectives

ii.

Accountable to board of directors.

III.

Operating management i.

Overall coordination and activities necessary to accomplish objectives

ii.

Accountable to CEO

IV.

Operating supervision i.

Supervision of non-supervisory employs

ii.

Accountable to operating Management

ORGANIZATION HIERARCHY CHART

Keeping the above factors in mind, we have divided the organization of our plant into the following categories

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

General administration



Production division



Maintenance division



Commercial and inventory division



Human recourses division



Marketing division



Research and development division

A. Finance Sector When it comes to the overall scope and duties of a finance department, there are many functions to be fulfilled. For the most part, the duties include all things related to budgeting. From appropriations to control of expenditure and auditing duties, the finance department of any given company has an array of duties. A finance department basically has three main functions: 

To provide strategic financial support regarding operational and general business planning



To provide daily financial services functions



To meet and surpass the internal and external needs and financial reporting requirements of the company at large

The finance department generally focuses on providing relevant information necessary for upper level management. Such information is crucial in determining how a company can make better financial decisions. Services and Duties of a Finance Department In order to implement these functions, there are a number of services that need to be performed. For example, the proper preparations of the annual budget as well as compliance of regulatory codes are both important services of a finance department. Key Positions in a Finance Department A finance department is comprised of several key positions that bear the burden of responsibility when it comes to maintaining the cohesiveness and overall productivity of the department as a unit of the company. When you think about the overall structure of the finance department, there are four key point people that may come to mind: 

The finance director



Deputy finance director



Accountant



Finance specialist

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Finance Director The finance director is the head of the finance department. This individual will have the supreme responsibility to ensure that all financial reports are accurate and up to date. The finance director is tasked with giving a financial forecast for the company and disclosing certain financial information about the company to the shareholders. Deputy Finance Director The deputy finance director is usually responsible for putting together the company‘s annual budget. In this position, the deputy finance director will be responsible for developing an overall financial strategy. Sometimes referred to as the finance manager, the deputy finance director is also responsible for managing the finance department‘s team of employees. Accountant The next position of importance in the department of finance is the accountant. The accountant is responsible for handling the accounts payable and accounts receivable. Accountants also process payroll. Other duties include putting together financial-related documents such as reports, auditing, and closing out accounting books. Finance Specialist The finance specialist basically handles capital investments. This position may also require a bit of analytical work such as reconciliations, maintaining the general ledger and keeping a close eye on the funds of the company. Evolution of the Finance Department With each passing year the company evolves into an entity that is responsible for increasing the company (and shareholder‘s value). This shall be done by increasing the number of employees of the department according to requirement and including other employees like clerical staff and intersection commuters. B. Personnel & Administration department Human resources is the business administration function responsible for finding, hiring, managing and retaining employees, and for ensuring that the right employees, in the right numbers, are deployed throughout the organization to achieve its goals. Human resources are a function that exists in every business regardless of size, industry or geographic location. In fact, even though small businesses may not have a formal human resource department or an employee with a title that includes "human resources," the function is performed when employees are hired, training, supervised and, hopefully, retained. Administrators, broadly speaking, engage in a common set of functions to meet the organization’s goals. These "functions" of the administrator were described by Henri Fayol as “the 5 elements of administration" (in italic below).

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Planning - is deciding in advance what to do, how to do it, when to do it, and who should do it. It maps the path from where the organization is to where it wants to be. The planning function involves establishing goals and arranging them in a logical order. Administrators engage in both short-range and long-range planning. Organizing - involves identifying responsibilities to be performed, grouping responsibilities into departments or divisions, and specifying organizational relationships. The purpose is to achieve coordinated effort among all the elements in the organization (Coordinating). Organizing must take into account delegation of authority and responsibility and span of control within supervisory units. Staffing - means filling job positions with the right people at the right time. It involves determining staffing needs, writing job descriptions, recruiting and screening people to fill the positions. Directing (Commanding) - is leading people in a manner that achieves the goals of the organization. This involves proper allocation of resources and providing an effective support system. Directing requires exceptional interpersonal skills and the ability to motivate people. One of the crucial issues in directing is to find the correct balance between emphasis on staff needs and emphasis on economic production. Controlling - is a function that evaluates quality in all areas and detects potential or actual deviations from the organization's plan. This ensures high-quality performance and satisfactory results while maintaining an orderly and problem-free environment. Controlling includes information management, measurement of performance, and institution of corrective actions. Budgeting - exempted from the list above, incorporates most of the administrative functions, beginning with the implementation of a budget plan through the application of budget controls.

C. Research and development A research and development department is responsible for innovations in design, products, and style. This department will be responsible for creating innovative new products to keep the company a step ahead of the competition. R&D Department will work on improving existing consumer products, and to explore new ways of producing them. Often, a Research and Development Department works closely with the Marketing Department. The Marketing Department studies consumer trends by surveying and researching consumer demands, purchasing methods, product sales, and the existence and development of technology across the relevant market. The marketing department gathers all the data, and makes this information available to the R&D department, which will take action in response to the findings and proceed to keep the company on top of current market needs. D. Operations

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Operations management is an area of management concerned with overseeing, designing, and redesigning business operations in the production of goods and/or services. It involves the responsibility of ensuring that business operations are efficient in terms of using as few resources as needed, and effective in terms of meeting customer requirements. It is concerned with managing the process that converts inputs (in the forms of materials, labour, and energy) into outputs (in the form of goods and/or services). The relationship of operations management to senior management in commercial contexts can be compared to the relationship of line officers the highest-level senior officers in military science. The highest level officer shapes the strategy and designs it over time, while the line officer makes tactical decisions in support of carrying out the strategy. According to the U.S. Department of Education, operations management is the field concerned with managing and directing the physical and/or technical functions of a firm or organization, particularly those relating to development, production, and manufacturing. Operations management programs typically include instruction in principles of general management, manufacturing and production systems, plant management, equipment maintenance management, production control, industrial labour relations and skilled trades supervision, strategic manufacturing policy, systems analysis, productivity analysis and cost control, and materials planning. Management, including operations management, is like engineering in that it blends art with applied science. People skills, creativity, rational analysis, and knowledge of technology are all required for success. E. Product Marketing & Sales In a manufacturing company the production function may be split into four sub-functions: Production and planning department The production and planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. In businesses focusing on lean production, quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach. Purchasing department The purchasing department will be responsible for providing the materials, components and equipment required to keep the production process running smoothly. A vital aspect of this role is ensuring stocks arrive on time and to the right quality. Stores department The stores department will be responsible for stocking all the necessary tools, spares, raw materials and equipment required to service the manufacturing process. Where sourcing is unreliable, buffer stocks will need to be kept and the use of computerized stock control systems helps keep stocks at a minimal but necessary level for production to continue unhindered. Works Department

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The works department will be concerned with the manufacture of products. This will include the maintenance of the production line and other necessary repairs. The works department may also have responsibility for quality control and inspection.

3.3 Manpower Requirement Designation

Number Required

Annual

Salary

i n Qualification

rupees Lacs/annum MD/Chairperson

1

40

Engineer with

cum 15

experience.

Board Of Directors

Designation

Number Required

Annual

Salary

i n Qualification

rupees Lacs/annum CEO

1

30

Engineer cum MBA with 10 years Experience

COO

1

30

Engineer cum MBA with 10 years Experience

CFO

1

30

Engineer cum MBA with 10 years Experience

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MBA years

Operation Vice President

2

20

Chemical Engineer (for production) with 10 year experience

Production Engineer

4

12

Chemical

Engineer

with

4

year

Experience Maintenance

4

11

Engineer

Mechanical with

Engineer 4

year

experience Instrumentation

4

8

Engineer

Instrumentation Engineer with 4 year experience

Shift Engineer

8

5.5

Chemical with

engineer 4

year

Experience Shift Operator

12

4

Diploma in Chemical Engineering

Labor(permanent)

12

Labor(temporary)

Quantity

1

depending

upon work required

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High School

High School

Administration Vice President

1

15

MBA with 10 year experience

Manager

1

12

MBA with 6 year experience

Security Officer

2

5.5

Retired

Army or

police official Fire & Safety Officer

4

5.5

8 years experience in fire and safety management

Medical Officer

2

5.5

MBBS with 4 of experience e

Medical Staff

2

2

Diploma

1

5

Graduate with 5 year

Public Officer

Relation

experience in public relations

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years

Finance: Vice President

1

20

C.A. with 10 years experience

Manager

1

15

MBA

(finance)

with

8 years experience Account Officer

2

10

C.A. with 4 year experience

Clerical Staff

8

3

B.Com with some or no experience

Marketing; Vice President

1

20

MBA

(marketing)

with 12

years

experience Manager

2

15

MBA (marketing) with 8 years

Marketing Officer

3

10

MBA (marketing) with 5 years experience

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of

Research & Development Vice President

1

20

C.A. with 10 years experience

Manager

2

15

MBA (finance) with 10 years experience

Research Assistor

3

10

C.A. with 4 year experience

Clerical Staff

8

3

B.Com with some or no experience

Total manpower requirement (permanent staff) = 95 This is the number of higher order permanent staff and highly skilled labour. The number of total employed worker, either skilled or semi-skilled varies with the project being carried out.

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4. SITE SELECTION & PROJECT LAYOUT 4.1 Plant Location One of the key features of a transformation system is the efficiency with which the output is transferred to the recipients. Any consideration of this will include the determination of where to place the plant. The selection of appropriate location can be done in two stages: 1. Evaluation of various geographic areas and the selection of an optimum area. 2. Within each area there is a choice of proper site which can be urban, suburban or rural. The fundamental object of location analysis is to maximize the profits by minimizing the

total cost

of production associated with the production process.

Total costs = Fixed costs + Operational costs Fixed costs include expenditure on land, building, machines and other equipments etc. Operational costs are the expenditure incurred on inputs, transformation process and the distribution of output etc. Plant location plays an important role in determining the sources of a process plant. Plant location refers to the various parameters, which governs the operation of the plant. The following are the major parameters which have to be carefully considered. Also there has to be a good scope for plant expansion and a conductive environment, safe living condition for easy plant operation. But other factor, such as safe living condition for plant personnel as well as the surrounding community is also important. The choice of the final site should first be based on complete survey of the advantage and disadvantage of various geographical areas and, ultimately, on the advantage and disadvantage of real estates. The following factors were considered in selecting the plant site: 1. Raw material: The raw materials must be available without any interruption to the reach of the plant. It can cause urgent shut down or reducing the production when there is a lack of raw material. This must be considered to be important.

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2. Availability of power: The electricity source must be available to the plant, because it is the prime source for the process plants. This electricity is used in agitated vessels, pumps, compressors and etc. continuous and uninterrupted power supply is essential for the continuous operation of the plant. 3. Water: Water is an essential material majorly used in the process plants and it is necessary to the labours. The water can be used for cleaning the equipments and plant. The water is also used in the wash towers, coolers and condensers. In the plant location the ground water source should be available. Water should also available in neighborhood at low cost. The process industries use large quantities of water for cooling, washing, steam generation and as a raw material in process. Hence, the plant must be located where a dependable supply of water is available. A large river or lake is preferable, although deep wells or artesian well may be satisfactory if the amount of water required is not too great. The level of the existing water table can be checked by consulting the state geological survey and information on the constancy of the water table and the year round capacity of local rivers or lakes should be obtained. If the water supply shows seasonal fluctuation, it may be desirable to construct a reservoir or to drill several standby wells. The temperature, mineral content, slit or sand content, bacteriological content, and cost for supply and purification must also be considered when choosing the water supply. 4. Transport facility: The raw material and the products want to be transported in and out of the plant. So that the road transport facilities should be good and easily available. If the harbor is nearby mean’s, its best to easy shipping. The transportation of material to or from the plant will be significant cost to us, hence it should be located at places well connected by road, railways and waterways. For the production of PHENOL main raw material is Cumene which we can bring our through well developed road and railway facilities from reliance hazira plant (310 KM) or from IPCL (430 KM) Vadodara plant thus, transportation problems will not be there. We also can import cumene through sea transportation (Nhava Sheva Sea). 5. Skilled labours and their facilities:

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The plant must require skilled labours. They should know about the process and they want the knowledge of the safe working and hard working. They want to be available at nearby location. Those labours must get their facilities like bus transportation, hospitals, canteens and shelter at nearby to the plant. The type and the supply of labor available in vicinity of a proposed plant site must be examined. Consideration should be given to prevailing pay scales, restriction on number of hours worked per week, competing industries that can cause dissatisfaction or high turnover rates among the workers, and variations in skills and productivity of the workers. As Maharashtra is a prominent industrial state labor force from all parts of India flows in there. So getting the right labor force here will not be a problem. 6. Markets: It is essential that the plant must be closed to the market or else, unreasonable amount will be spending for transporting the products to the market. 7. Climate condition: Climate and environment affect the operational efficiency of workers; excess cold may cause tiredness, fatigue or disease among the workers. Decreased humidity and climate temperature is high can cause dehydration to the employees while working. So that, plant must be located in such a place where the climate is conductive to efficient operation of the plant. 8. Meteorological data: If plant is located in cold climate, cost may be increased by the necessity for construction of protective shelters around the process equipment, and specially cooling towers or airconditioning equipment may be required if the prevailing temperatures are high. Excessive humidity or extremes of hot and cold weather can have serious effect on the economic operation of the plant, and these factors should be examined when selecting the site. In Maharashtra extremities are not experienced. Temperature ranges between 12 to 39oC. 9. Plant sewage and waste disposal: The primary source of sewage and waste in a process plants are sanitary waste, process drains and surface drainage. The sewage system is designed to conduct these to disposal without logged with solid or filled with dangerous concentration of explosive gases. 10. Local community consideration:

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The process plant must fit in with and be acceptable to the local community. Full consideration must be given to the safe location of the plant, so that it does not impose a significant additional risk to the community. On a new site, the local community must be able to provide adequate facilities for the plant personnel like school, banks, housing and faculties. 11. Taxation and legal restriction: State and local tax rates on property, income, unemployment insurance and similar items vary from one location to another. Similarly, local regulations on zoning, building codes, nuisance aspects, and transportation facilities can have a major influence on the final choice of a plant site. In fact, zoning difficulties and obtaining the many required permits can often be much more important in terms of cost and time delays then many of the factors discussed in the preceding sections. 12. Tax benefits:   

     

The incentives and facilities offered to SEZs are: (detailed instructions available at: http://www.sezindia.nic.in/index.asp ) Duty free import/domestic procurement of goods for development, operation and maintenance of SEZ units 100% Income Tax exemption on export income for SEZ units under Section 10AA of the Income Tax Act for first 5 years, 50% for next 5 years thereafter and 50% of the ploughed back export profit for next 5 years. Exemption from minimum alternate tax under section 115JB of the Income Tax Act. External commercial borrowing by SEZ units‘ upto US $ 500 million in a year without any maturity restriction through recognized banking channels. Exemption from Central Sales Tax. Exemption from Service Tax. Single window clearance for Central and State level approvals. Exemption from State sales tax and other levies as extended by the respective State Governments.

13. Clearances Clearances between adjacent plants should at least those for primary access roads. The space between edge of any road and nearest equipment must not be less than 1.5 meters. Adequate road access with properly formed roads must be provided for known maintenance purposes: e.g. compressor house, large machine areas, reactors or convertors. Minimal concrete paving should be supplied for walkways interconnecting major items of equipment, platforms, stairways and buildings. Paving should be supplied around pumps or other machinery located in the open, underneath furnaces, and any other areas where spillage is likely to occur during normal operation. Areas containing acids or other chemicals or toxic materials should be

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paved and bounded to prevent spillage spreading. Other areas of the plant are to be graded and surfaced with granite chips or similar material.

14. Economic considerations Apart from the process restrictions, position equipment for maximum economy of pipe-work and supporting steel. As compact a layout as possible with all equipment at grade, consistent with standard clearances, construction and safety requirements. Minimize runs of alloy pipe work and large bore pipe without the introduction of expensive expansion equipments. Optimize use of supporting structures in concrete or steel by duplicating their application to more than one item of equipment and ensuring that access ways, platforms etc. have more than one function. 15. SEZ ADVANTAGES Income tax incentives: 10 year corporate tax holiday on export profit, 100% for the initial five years and 50% for the next five years. Other benefits:  Exemption of electricity duty – 10 years.  Duty-free procurement of capital goods (including second hand capital goods), raw material and consumable spares from domestic market.  Full freedom for subcontracting.  Facility to realize and repatriate export proceeds within 12 months.  Facility to retain 100% foreign exchange recipient in the export earns foreign currency amount.  Indirect tax incentives (for both SEZ units and developers).  Nil customs duty.  Nil excise duty.  Exemption from central sales tax.  Exemption from service tax.  Exemption from securities transaction tax.  Exemption from tax on sale of electricity for self-generated and purchased power. Economic scope of SEZ is: 





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The SEZ has advantage of all types of transportation system such as roadways, seaport, air and railways so the special economic zone should have a good export link with the other countries in the world. The trend in the unorganized industries sectors such as information technology, jewelry and gem, toys, biotech, and leather is to come under one common roof in order to have an access to the general infrastructure facilities. The increasing in the demand for the integration of the industrial sector in India.

SEZ has the following political and strategically advantage: a) Policy framework:  Such kind of promotion activities is a designated duty free enclave and treated as foreign territory for trade operations, duties and tariffs. Units can be set up for manufacturing, trading or service activity.  Most of the times lucrative offers are given such as exemption from customs and central excise duty on import of capital goods, raw materials, consumables, spares etc.  Readymade infrastructure is provided.  Exemption from payment of central sales tax could also be given.  Such industrial zone could dispose of rejects, waste, scrap in domestic market on payment of duties. b) Procedural ease: No routine examination of import and export cargo by custom/central excise authorities. Goods can be brought to or removed from industrial zone premises on self-certification basis. Performance of the units to be monitored by a committee headed by the development commissioner and consisting of customs officials. c) Benefits available to developers:  Industrialization zone allows private individuals or firms to participate by way of creating infrastructure in the zone.  The developer infrastructure is allowed duty free (customs and central excise) import/procurement of goods for its development, operations and maintenance.  Income tax exemption for 10 years in first 15 years is allowed.  Full freedom in allocation of development plots to approve units on purely commercial basis.  Full authority to provide services like water, electricity, security, restaurant, recreation etc., on commercial lines.  Facility to develop township within SEZ with residential areas, market, play grounds, club, recreation center etc. d) Infrastructure and other facilities offered:  Built up space of any size is readily available in the standard design factory (SDF) complexes.  Backup power supply as standby arrangement.  Good quality power and water at reasonable rates.  Telephone, fax facilities on out of turn basis.  Bank, post office, courier, travels, Xerox and other support services are available within the zone premises.  Units exempted from payment of installing charges, local loop charges.  Certification of softex forms, free of cost.  Video conferencing facility at nominal cost. Infrastructure: The SEZ is self-sufficient in terms of internal roads, power, water, desalination plant, drainage system and modern effluent treatment plants under construction.

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The Maharashtra Special Economic Zone is the most strategically placed SEZ in the country. Being the most industrialized state in India, Maharashtra has undergone rapid infrastructure development such as roads, railways, airport, and seaports. These assistances have helped the industries further. The Special Economic Zones in Maharashtra have the advantages of close proximity to seaport and airfreight services that would increase India's industrial exports. Maharashtra Special Economic Zone comprises of  

Santa Cruz Electronics Export Processing Zone Navi Mumbai Special Economic Zone Maha Mumbai Special Economic Zone

1. SEEPZ Santa Cruz Electronics Export Processing Zone (SEEPZ) was set up in the year 1974 for the purpose of manufacturing and exporting electronic products. Set up in an area measuring 100 acres it has become watershed project of the Maharashtra Industrial Development Corporation. The gem and jewellery industry was introduced in the year 1988 in SEEPZ. Facilities of SEEPZ are    

The imports are license free Tax exemption on import of basic element, capital goods, etc Tax exemption on central sales tax pertaining to national purchases The SEEPZ can be involved in any type of activities among trading, manufacturing and service The SEEPZ is entitled for 100% foreign direct investments apart from a few of the sectors

2. NMSEZ The Navi Mumbai Special Economic Zone (NMSEZ) is located in the satellite township near Mumbai known as Navi Mumbai in the state of Maharashtra. Navi Mumbai Special Economic Zone (NMSEZ) is situated in the most industrialized part of India. NMSEZ is regarded to be the best SEZ in India as sea, rail, air and road and a state of the art transshipment hub connect it. Facilities of NMSEZ are 

 

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The NMSEZ has well developed transportation system including wide main roads and services roads The commercial units have the option of choosing between technologically equipped state of the art factories, land plots with proper amenities, and well-built and equipped office space The NMSEZ has adequate supply of power and also has back up provisions in case of shut downs The NMSEZ has adequate supply of water through the dams operated by the CIDCO



The NMSEZ has a very well-constructed system of disposal for solid waste and sewer water

3. MMSEZ The Maha Mumbai Special Economic Zone (MMSEZ) is proposed to be setup in Navi Mumbai area, as a standard international business center. The area where the MMSEZ would be set up is situated near Mumbai in Maharashtra. Maha Mumbai Special Economic Zone would be acquiring 10,000 hectares of land in three different stages, within a time span of ten years. Facilities of MMSEZ are   

Continuous power supply and provisions of standby power service The manufacturing units have the option of office space, technologically equipped factory space, land plots A fully developed facility of transportation system which would have wide main roads and services roads Adequate water supply and well-constructed network of pipelines and water pumps

Government of Maharashtra SEZ Policy – The main purpose Government of Maharashtra SEZ Policy is the growth of the industries in the State of Maharashtra. Area of focus of Government of Maharashtra SEZ Policy    

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The provision of granting permits and approvals pertaining to issues such as environment and human resources by the means of a single window system The exemptions of different kinds local and state duties, tariffs, and taxes pertaining to the transactions with the special economic zones The exemptions from registration fees and stamp duties The time saving procedures for the acquisition of lands in order to establish the special economic zone

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Maharastra Railway Map

Maharastra Road Map

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4.2 Plant Layout Plant Layout is the physical arrangement of equipment and facilities within a Plant. Optimizing the Layout of a Plant can improve productivity, safety and quality of Products. Un-necessary efforts of materials handling can be avoided when the Plant Layout is optimized. • Plant layout techniques apply to the case where several physical means have to be located in a certain area, either industrial processes or services. • The basic objective is to ensure a smooth flow of work, material, people and information. • There are probably two levels at which layouts are required. In one, the various departments have to be sited, and in other the items of equipment within a department need to be located.

Criteria for a good layout 1. Maximum flexibility: A good layout will be one which can be rapidly modified to meet changing circumstances. 2. Maximum co-ordination: Entry into, and disposal from, any department or functional area should be in such a manner that it is must convenient to the issuing or receiving departments. Layout requires to be considered as a whole and not partially. 3. Maximum use of volume: Facilities should be considered as cubic devices and maximum use made of the volume available. This principle is particularly useful in stores, where goods can be stacked at considerable heights without inconvenience, especially if modern lifting devices are used. In offices, racking can be installed to minimize use of floor space. 4. Maximum visibility: All the people and materials should be readily observable at all the time; there should be no ‘hidden places’ into which goods or information can get mislaid. 5. Maximum accessibility: All servicing and maintenance points should be readily accessible. For example, equipment should not be placed against a wall in such a manner that necessary maintenance cannot easily be carried out. 6. Minimum distance: All movements should be both necessary and direct. Handling work adds to cost but does not increase value; consequently any unnecessary or indirect movements should be avoided. 7. Minimum handling: The best handling of material and information is no handling, but where it is unavoidable it should be reduced to a minimum by the use of whatever devices are most appropriate. 8. Minimum discomfort: poor lighting, excessive sunlight, heat, noise, vibration and smells should be minimized and if possible counteracted.

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9. Inherent safety 10. Maximum security 11. Efficient process flow

Inputs to the Layout Decision 1. Specification of objectives of the system in terms of output and flexibility. 2. Estimation of product or service demand on the system. 3. Processing requirements in terms of number of operations and amount of flow between departments and work centers. 4. Space requirements for the elements in the layout. 5. Space availability within the facility itself.

Advantages of a good layout • The overall process time and cost will be minimized by reducing unnecessary handling and movement. • Supervision and control will be simplified by the elimination of ‘hidden corners’ • Changes in the programmers will be most readily accommodated. • Total output from a given facility will be as high as possible by making the maximum effective use of available space and resources. • A feeling of unity among employees will be encouraged by avoiding unnecessary segregation. • Quality of the products or service will be sustained by safer and more effective methods of operation.

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Tank Farm Plant Area 1

Plant Layout

Roads

Plant Utilities

Expanion EXIT

GREEN AREA

Plant Area 2

Offices

Change Rooms

Canteen

Laboratry

Workshops

FIRE STATION

Stores

Emergency water supply

Expansion

EXIT

GATE

Parking Area

PIPE BRIDGES

GATE

References I. II.

http://www.essentialchemicalindustry.org/chemicals/phenol.html http://www.sciencedirect.com/science/article/pii/S0926860X04007562

III.

https://www.google.com/patents/US5371305

IV.

https://fenix.tecnico.ulisboa.pt/downloadFile/395139430146/Cumene%20oxidation%20to%20cu mene%20hydroperoxide.pdf

V. VI. VII. VIII.

http://www.infodriveindia.com/india-import-data/cumene-import-data.aspx http://sezindia.nic.in/writereaddata/statePolicies/maharashtrapolicy.pdf https://mohdazizan.files.wordpress.com/2011/12/production-of-phenol.pdf http://www.doingbusinessinmaharashtra.org/SEZ_in_Maharashtra.aspx

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