Shraddha Bukkanure - Lupin Internship Report

INTERNSHIP REPORT
AT
LUPIN LIMITED
T-142, MIDC
TARAPUR - 401506, MAHARASHTRA
SUBMITTED BY
SHRADDHA BUKKANURE
ROLL NO 194007
THIRD YEAR CHEMICAL ENGINEERING
THADOMAL SHAHANI ENGINEERING COLLEGE, BANDRA

UNIVERSITY OF MUMBAI
ACKNOWLEDGEMENT
The internship opportunity I had with Lupin Limited, Tarapur was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was provided
with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful
people and professionals who led me though this internship period.
The two weeks technical internship at the Process Engineering department was a life changing
experience. It proved to be an invaluable opportunity to gain insights into applying theoretical
knowledge practically. It has not only strengthened my concepts, but also given me much more clarity
in my field of work.
A lot of time and effort has been put into this internship and it would not have been possible without
the support of many people who guided me throughout.
I take this opportunity to express my gratitude to Dr. Elizabeth Joseph, Head of Department of
Chemical Engineering at Thadomal Shahani Engineering College, Bandra, for always supporting me
in all my endeavours.
I am immensely thankful to my Industry mentor and guide Mr. Pranay Patil, Executive, Process
Engineering Department for his constant guidance, support and encouragement during my internship.
He has been a remarkable source of inspiration and helped me achieve full potential during my
internship.
It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Mr. Mahesh
Kate (HR Manager), Mr. Nitin Munat (Deputy General Manager), Mr. Pankaj Patil (Manager), Mr.
Amit Shinde, Mr. Onkar Sangle, Mr. Dipesh Parekh, Mr. Rushikesh Patil and Mr. Shridas Nair from
the Process Engineering Department for their guidance and encouragement throughout the internship.
I express my deepest thanks to all the workers and operators at Lupin Limited, Tarapur for their co-
operation and support.
I perceive as this opportunity as a big milestone in my career development. I will strive to use gained
skills and knowledge in the best possible way, and I will continue to work on their improvement, in
order to attain desired career objectives. Hope to continue cooperation with all of you in the future.
Sincerely,
Shraddha Bukkanure
TABLE OF CONTENTS
SR. NO. TOPIC PAGE NO.

1. INTRODUCTION TO LUPIN 1
1.1 History and Evolution 1
1.2 Research and Development 2
1.3 Global Presence 3
1.4 Products 5
1.5 Various Plants at Lupin Limited, 6
Tarapur
1.6 Departments Roles and 7
Responsibilities
2. SOLVENT RECOVERY UNIT 9
11
2.1 Advantages of SRU
2.2 Solvent Properties 11
2.3 MPP-4 SRU 13
2.4 Distillation 14
2.5 Heat Exchanger 24
3. P&ID AND CALCULATION 30
30
3.1 BFD
3.2 PFD 33
3.3 P&ID 35
3.4 Mass and Energy Balance of 39
Distillation Column Operation
4. CONCLUSION 46
5. REFERENCES 47
INTERNSHIP REPORT SHRADDHA BUKKANURE | 194007
1. INTRODUCTION TO LUPIN
Lupin Limited is an Indian multinational pharmaceutical company based in Mumbai, Maharashtra,
India. It is one of the largest generic pharmaceutical companies by revenue globally. The company's
key focus areas include paediatrics, cardiovascular, anti-infectives, diabetology, asthma and anti-
tuberculosis.
Figure 1: Lupin Plant
1.1 History and Evolution

Lupin was founded in 1968 by Dr. Desh Bandhu Gupta, who was a professor of chemistry at BITS-
Pilani, Rajasthan. Gupta Sir moved to Mumbai in the 60s to work on his business enterprise for which
initially he had initially borrowed Rs 5000 from his wife to fund his venture. Subsequent funding from
Central Bank of India, the company was able to start their manufacturing facility for producing folic
acid and iron tablets for Government of India mother and child health program. Later Lupin started
manufacturing anti TB drugs which at one point formed 36% of the company sales and was considered
as the largest TB drugs manufacturer in the world.
After success with Lupin, in 1988 Gupta Sir founded the group's CSR arm, the Lupin Human Welfare
& Research Foundation (LHWRF). This initiative was dedicated to sustainable rural development with
the aim to uplift families living below the poverty line. As the company grew, in July 2015 the
company announced its intention to acquire Gavis Pharmaceuticals and Novel Laboratories for $880
million.
THADOMAL SHAHANI ENGINEERING COLLEGE, BANDRA 1

Over the years, Lupin has grown and expanded into new areas and regions, manufacturing drugs that
extend the promise of good health to communities across the globe. Beginning with two employees —
a peon-cum-packer and a part-time typist — Lupin’s current global footprint spans 11 countries, across
six continents. This journey has been made possible thanks to the vision and conviction of Mr. Desh
Bandhu Gupta.
DBG, as Mr. Desh Bandhu Gupta was fondly called, named the company after the Lupin flower. The
Lupin flower can grow in harsh conditions and also nourish the soil. Inspired by nature’s example of
selfless giving and resilience, DBG set up Lupin to address unmet medical needs despite the challenges
on ground.
1.2 Research and Development
At Lupin, Research and Development (R&D) division drives their industry positioning as a leading
pharmaceutical solutions provider in the US and in India. It develops solutions that allow them to
deliver on their purpose and vision.
Lupin’s R&D effort is aligned with their enterprise goal — to bring affordable, quality medicines to
market in order to address unmet patient needs.
This vision drives their 1,500+ scientists and R&D personnel in seven research centres spread across
five countries – India (Pune and Aurangabad), the US (New Jersey and Florida), Mexico, Brazil and
the Netherlands. The R&D teams leverage cutting-edge technologies, superior competencies and
strategic partnerships to deliver unique solutions that give Lupin an advantage in the regions it operates
in.
Lupin's R&D covers:
 Generics Research
 Process Research
 Pharmaceutical Research
 Advanced Drug Delivery Systems (ADDS) Research
 Intellectual Property Management
 Novel Drug Discovery and Development (NDDD)
 Biotechnology Research

1.3 Global Presence
Lupin has expanded and grown manifold since its inception in 1968. We have operations in 11
countries across six continents, allowing for safe and reliable delivery of medicines to our patients
across 100+ countries.
 India: Lupin’s journey began in India, when Dr Desh Bandhu Gupta (fondly called DBG)
established the company in 1968. From one facility in Aurangabad in 1979, the company now
has 11 state-of-the-art manufacturing facilities across the country. Scientists and R&D
personnel at the company’s two research centres in Pune and Aurangabad leverage cutting-
edge technology to provide unique solutions, including those in the field of high quality
affordable biosimilars. Along with the commercial enterprise, DBG also founded the Lupin
Human Welfare & Research Foundation, which promotes holistic rural development in India.
 USA: Lupin Pharmaceuticals Inc., established in 2003 in Baltimore, Maryland, currently has
five offices along the US East Coast with its salesforce across the country. Lupin is present in
the US through manufacturing, research and development, and commercial divisions for
generics, complex generics, biosimilars and branded pharmaceuticals. In 2015, the company set
up the Center of Excellence for Inhalation Research in Coral Springs, Florida. Subsequently, it
acquired Novel Laboratories, Inc. to create Lupin Somerset — its first manufacturing facility in
the US. In 2017-18, Lupin achieved a milestone when US revenues crossed $1 billion.
 UK: Lupin Healthcare, Lupin’s subsidiary in the UK has a portfolio consisting of high-quality
generics with a focus on anti-retroviral and oral contraceptives. In January 2019, they launched
their first set of medicines in the neuromuscular space for the UK market. The entrepreneurial
spirit, external focus and pipeline strength transitions Lupin in the U.K. from standard generics
through to a more specialist organization partnering with the NHS to deliver value.
 South Africa: Pharma Dynamics, Lupin’s subsidiary in South Africa, is committed to

expanding access to effective, affordable healthcare and helping create a healthy future for all
South Africans. Their quality generic medicines offer patients cost savings of up to 70%. They
also invest in various wellness programmes to support patients on their journey to holistic
wellness.
 Australia: Generic Health, Lupin’s subsidiary in Australia, is among the fastest growing
pharmaceutical companies in the country. It is a leading provider of high-quality generic
prescription, injectable and over-the-counter medicines, supplying to pharmacies and hospitals
across Australia. We are committed to supporting the health and wellbeing of all Australians
through our comprehensive product range, competitive pricing, and healthcare expertise.
 Philippines: Multicare, Lupin’s subsidiary in the Philippines, is among the top five branded
generic companies in the country. It is committed to providing high-quality products that
enhance healthcare for patients and deliver greater value for medical professionals. Multicare

strategically focuses on therapeutic areas and specialties, and has established a reputation in
women’s health, especially in their journey of becoming mothers. Other areas of focus for the
company include rheumatology, respiratory, oncology, neuroscience, diabetes,
gastroenterology, paediatrics, and nephrology.
 Germany: Lupin’s subsidiary in Germany, Hormosan, focuses on offering innovative drugs

through to generics for affordable treatment of various acute and chronic diseases. They have
made constant progress in select therapy areas including rare diseases in neurology, pain
management, sexual health and HIV. As a pharmaceutical company, Hormosan is an integral
part of German society, contributing with medication for optimal, guideline-compliant care for
the individual patient.
 Netherlands: Nanomi, Lupin’s subsidiary in the Netherlands, is a leader in the field of

microsphere and nanoparticle manufacture and development of long-acting release medicines.
Its proprietary Microsieve technology guarantees cost-effective, highly controlled and
reproducible production of these medicines. Through Nanomi, Lupin’s mission is to become a
global leader in the field of complex injectables and introduce a wide portfolio of branded and
generic products in key markets.
 Mexico: Laboratorios Grin, Lupin’s subsidiary in Mexico, is currently dedicated to the

development, manufacture and commercialisation of ophthalmological products, proteolytic
enzymes, oral antibiotics and antivertiginosis, among others. Its focus areas include visual
health, food supplements, respiratory diseases, algology, male health and angiology. Products
manufactured here are exported to seven countries in the region.
 Brazil: Medquímica, Lupin’s subsidiary in Brazil, is one of the most prominent pharmaceutical
companies in the region, manufacturing drugs that are high in quality, reliability and safety.
Here, we manufacture solid and liquid medicines for five focus areas: over-the-counter (OTC),
similar drugs, hospital, generics, and dietary supplements. Like every other Lupin
manufacturing site, quality is of utmost importance and the Medquimica site has been awarded
the certificate of Good Manufacturing Practices (GMP).
 Japan: Lupin is the fastest-growing Top 10 generic pharmaceuticals player in Japan (IMS). It
operates in Japan through its subsidiary, Kyowa Pharmaceutical Industry Co. Ltd. (Kyowa), a
company acquired in 2007 and I’rom, Pharmaceutical Co. Ltd (IP), acquired in 2011. Kyowa
has an active presence in Neurology, Cardiovascular, Gastroenterology and the Respiratory
therapy segments. I'rom is a niche injectables company. In 2014, Lupin entered into a strategic
joint venture agreement with Toyama-based Japanese pharmaceuticals company, Yoshindo
Inc. to create YL Biologics (YLB). YLB will be jointly managed by both partners and will be
responsible for conducting clinical development of certain biosimilars including regulatory
filings and obtaining marketing authorization in Japan.

1.4 Products
Lupin Limited contributes in medical field largely by manufacturing all the important anti disease
medicines such as:
Antibiotics CEPHALOSPORIN
Cephalexin
Cefaclor
Cefadroxil
Cefprozil
Rifaximin
Cardiovascular Lisinopril
Simvastatin
Prasugrel
Anti-tuberculosis Ethambutol
Pyrazinamide
Rifampicin
Rifabutin
Central Nervous System Levitracetam

Lacosamide
Pregablim
Not only these but there are many more products’ which are manufactured by Lupin limited and
achieved many awards for its contribution in pharmaceutical field.

1.5 Various Plants at Lupin Limited, Tarapur

The plant is for the manufacturing of Active Pharmaceutical ingredient (API). It is a huge plant where
the main plants are classified as – T1 plant, T2 plant and T3 plant. There are two effluent treatment
plants which are zero discharge plants. The zero-discharge plant was started in 2016. Each main plant
has a solvent recovery unit (SRU) which are T1 SRU, T2 SRU and T3 SRU (A & B). The sub plants
include-
1. Multi-Purpose Product (MPP-1)
2. MMP-2
3. MMP-3
4. MMP-4
5. MMP-5
6. MMP-6
7. MMP-7
8. MMP-8
9. MMP-9
All MPP have their own powder processing area.

There are over 40 products made in this plant where most of the processes are carried in batch
processing.

1.6 Departments Roles and Responsibilities

The success of a company is possible due to the various departments. Following is a brief information
on roles and responsibilities of various departments at Lupin Limited, Tarapur:
1. R&D: The research and development (R&D) process is a critical stage in drug development in
the pharmaceutical (Pharma) industry. The process starts after an initial candidate drug is
identified and encompasses the rigorous research tests that determine its therapeutic suitability.
2. Quality Control (QC): Quality Control is one of the key departments in any Pharma company.
After R&D large number of people works in the QC department. A chemist executing a
qualitative analysis seeks to identify the substances in the sample. A quantitative analysis is an
attempt to determine the quantity or concentration of a specific substance in the sample. For
example, determining whether a sample of salt contains the element iodine is a qualitative
analysis; measuring the percentage by weight of any iodine in the sample is a quantitative
analysis.
3. Quality Assurance (QA): In the pharmaceutical industry, quality assurance (QA) is essential
for ensuring that pharmaceutical products are manufactured to a safe and consistent standard.
QA is a very broad field that refers to any aspect that may affect a drug's quality during its
research, development, manufacturing, and sales phases.
4. Process Development Lab: Process development is used to establish, implement, or improve a

pre-existing manufacturing process. It ensures a product can be routinely made aseptically and
meet specifications before manufacturing at scale.
5. Process Engineering: Coordinates with production department to troubleshoot and

debottleneck. Coordination to project dept for completion of project, New Equipment sizing,
Solvent Recovery monitoring & identify Scope of improvement in existing operation &
process.
6. Project Management: Most of the pharmaceutical companies have a separate project

management department. This department is responsible for coordinating the functions of all
departments and also ensures smooth and efficient functioning. The Project management
department also monitors particular projects.
7. Purchase department: Purchase departments help keep organizations financially healthy. They
procure goods and services designed to meet operational needs while providing the highest
possible value. They established procurement policies and procedures to ensure their
organization operates with integrity and the marketplace.
8. Civil Department: While following the local building codes is fairly straightforward, pharma
industry has some specific requirements like easy to clean non-porous surface finishes, resistant
to bacterial growth, vapor barrier walls for areas of low RH, avoid corners and niches on wall-

floor joints, providing for extensive HVAC, steam, water, air and other utilities as per GMP
requirements etc.
9. Production Department: Preparing, reviewing, approving and distributing the instructions for
the production of drug substances &/or drug products according to written procedures.
Evaluating proposed changes in product, process or equipment. Making sure that new and,
when appropriate, modified facilities and equipment are qualified.
10. Utility Department: The primary use of a utility system is to help pharmaceutical companies
check the quality and safety of their products and to ensure they comply with the laws and
statutes in the FDA dossier. Without meeting these requirements, a product may fail to be
cleared for marketing.
11. Finance and Administration: The Finance and Administration department comprises different
functional areas including finance, administration, legal and information systems.
Responsibilities include managing activities related to finance management, handling legal
relations with employees, investors, creditors as well as government regulators.
12. Operations: The Operations department produces a saleable amount of a drug. Once a drug has
passed the clinical trials, the manufacturing and production department manufacture the final
product, along with the packaging and labelling. Also housed under the operations umbrella is
the environmental health and safety function, which assesses the environmental impact of a
potential product.
13. Warehouse: The warehouse plays a pivotal role in manufacturing quality products, as it is
responsible for all incoming goods (including labelling and packaging) and for releasing
finished products.
14. Safety: Safety requirements, safety organogram, safety measurements, safety training.
15. Marketing: Product marketing, marketing companies support, logistics, finished product
inventory, product sales.

2. SOLVENT RECOVERY UNIT

The pharmaceutical industry is constantly exploring methods for process optimization and
improvement. Reduction of solvent use and recovery of waste solvents are issues of importance in
most API (Active Pharmaceutical Ingredient) manufacturing processes. Process waste streams are
often characterized by high volumes of organic solvents that sometimes are difficult to recover and
reuse due to azeotropes, resulting in high cost of waste disposal and a large life cycle environmental
footprint.
Solvent recovery and reuse operations must meet stringent pharmaceutical industry requirements for
solvent purity. Rowan University and Pfizer have collaborated to explore green engineering
alternatives for waste minimizing solvent recovery processes for the Celecoxib process. A case study
has been performed that explores pollution prevention and remission opportunities for the current
process. Two viable techniques, evaporation-distillation hybrids and extractive distillation, have been
identified to treat the process waste. The case study describes equipment and processing issues,
financial costs and benefits; and environmental impacts through life cycle assessment techniques.
Solvents such as acetone, methyl ethyl ketone and tetrahydrofuran are commonly used as reaction
media and for extracting products in the pharmaceutical, specialty chemicals and fragrance industries.
For various reasons, there is an increasing interest in recovering solvents, as well as in related tasks
such as monitoring oxygen concentrations so as to minimize the use of purge gases.
Perhaps the strongest commercial argument for recovering and reusing solvents is the direct cost
savings. In some processes with intensive solvent use, the cost of the solvent can be a significant
proportion of the overall product cost. Another compelling reason for recovering solvents is the
increasing environmental legislation against emissions; such emissions may be as a result of a process
design where solvent recovery was not incorporated at the outset, or where venting has occurred as a
result of plant problems.
With heavy pressures on chemical and pharmaceutical companies to get new products to market as
quickly as possible and with high standards of quality, it is hardly surprising that solvent recovery and
reuse is not always a priority during the plant design phase. However, plant refurbishments and
upgrades often include the installation of a solvent recovery system.
The most popular method of recovering solvents is filtration and distillation. Carbon bed adsorbers are
used for filtration and steam is then used to desorb and recapture the solvents. The disadvantage of this
is that water is introduced into the recovered solvents and this must be removed before they can be
reused. A batch distillation process is therefore employed to purify the solvent to an acceptable level
for reuse or possibly for sale to other solvent users. Clearly there is no advantage in purifying the
solvent beyond the required level as this would represent wasted resources.

Figure 2: Solvent Recovery Plant

2.1 Advantages of SRU

The main benefits of being able to reuse solvents in-house include:
• Lowering your EPA reporting liability
• Reduce the cost and required volume of purchased solvents
• Lowering solvent removal and transport costs
• Minimizing legal exposure
• Solvent Recovery Rate
• Residual Water Content
• Low Energy Demand
• Problem-Specific Design
• High Economic Efficiency
• Short Payback Time
2.2 Solvent Properties


2.3 Multi-Purpose Plant-4 Solvent Recovery Unit (MPP-4 SRU)

During my internship I visited MPP-4 SRU plant. Following is the information regarding the MPP-4
SRU plant:
Product: LOSARTAN
All the distillation columns have structured packing.
SR.
EQUIPMENT SPECIFICATION
NO.
4 Stainless Steel Reactors

1 Reactors
(SSR)
2 Reactors with Column

2 Reactor with Column
(Batch)
4 Columns
3 Column
(Continuous)
8 Shell & Tube Heat Exchangers
4 Heat Exchanger
12 Plate Type Heat Exchangers
5 Centrifuge 1
6 Pressure Filter 2
7 Pumps Centrifugal
8 Vessel & Tanks -

2.4 Distillation
Distillation is one of the most popular separation techniques of separating chemical substances
depending on differences in their volatilities in a boiling liquid mixture. It is a process in which a
mixture of liquid or vapour with two or more substances is separated into its desired purity component
fractions by the application and removal of heat. It is usually a part of a larger chemical process and
hence also referred to as a unit operation.
A distillation column is used widely in various industrial applications, especially in gas plants, to make
the process of distillation more efficient. Distillation columns are specially designed columns in the
shape of a tall metal cylinder internally fitted with perforated horizontal plates to achieve this
separation efficiently.
Following are the types of distillation column:
1. Batch column: When particularly complex or small operations require recovery of the more
volatile component, APV can offer batch distillation systems of various capacities. Essentially
a rectification type process, batch distillation involves pumping a batch of liquid feed into a
tank where boiling occurs. Vapor rising through a column above the tank combines with reflux
coming down the column to effect concentration. This approach is not too effective for
purifying the less volatile component since there is only the equivalent of one stripping stage.
For many applications, batch distillation requires significant amount of control
instrumentation. While a batch system is more energy intensive than a continuous system,
steam costs generally are less significant on a small operation. Furthermore, it is highly flexible
and a single batch column can be used to recover many different solvents.
2. Continuous column: In continuous distillation, feed constantly is charged to the column at a

point between the top and bottom sections. The section above the feed point rectifies or purifies
the more volatile component while the column section below the feed point strips out the more
volatile from the less volatile component. In order to separate N components with continuous
distillation, a minimum of N-1 distillation columns is required. Side draws can be taken to
remove extra streams from the column but only when high purity of individual components is
not required. In a continuous distillation, each of the fraction streams is taken simultaneously
throughout operation; therefore, a separate exit point is needed for each fraction. In practice
when there are multiple distillate fractions, the distillate exit points are located at different
heights on a fractionating column. No interruptions occur unless there is a problem with the
column or surrounding process units. They are capable of handling high throughputs and are
the most common of the two types.
The key difference between batch and continuous distillation is that the batch distillation is done in
batch-wise whereas continuous distillation is done as a continuous process.

Figure 3: (a) Batch Distillation Column ;(b) Continuous Distillation Column
In the pharmaceutical industry separation is one of the most widely used unit operations. Its main uses
include the recovery of reactants and solvents for recycling, the purification of products for sale, and
the processing of by product streams for waste minimization. Though many separations techniques
exist, the one most often used is distillation. Distillation is simple, has few moving parts, is well
understood, can be simulated readily, and often has a low capital cost. On the negative side is the high
operating cost associated with high energy requirements to vaporize and condense. Most distillation
simulations are done on the computer now.

Following are the various methods of distillation:
1. Simple distillation:
Distillation accomplishes separation by maintaining a composition gradient between the vapor and
liquid phases caused by difference in volatilities of the components. The separating agent is the
heat energy supplied. Simple distillation is usually a continuous process with the lighter or more
volatile fraction leaving the top as the distillate and the less volatile or heavy fraction recovered as
the bottom product. A portion of the overhead vapor is condensed and returned as reflux to enrich
the vapor rising through the column.
Figure 4: Simple Batch Distillation

2. Flash Distillation:
Flash distillation is a special operation within distillation, where a liquid mixture is heated up and
fed – with constant flowrate – into a distillation equipment. The resulting vapor and liquid phases
enter a phase separator – an equilibrium chamber – and are drained separately. During the
operation, the total pressure and temperature of the system, as well as the compositions of the two
phases in equilibrium remain constant over time.
Figure 5: Flash Distillation

3. Fractional distillation:
Fractional distillation is the separation of a mixture into its component parts,

or fractions. Chemical compounds are separated by heating them to a temperature at which one or
more fractions of the mixture will vaporize. It uses distillation to fractionate. Generally, the
component parts have boiling points that differ by less than 25 °C (45 °F) from each other under a
pressure of one atmosphere. If the difference in boiling points is greater than 25 °C, a simple
distillation is typically used.
Fractional distillation is the most common form of separation technology used in petroleum
refineries, petrochemical and chemical plants, natural gas processing and cryogenic air
separation plants. In most cases, the distillation is operated at a continuous steady state. New feed
is always being added to the distillation column and products are always being removed. Unless
the process is disturbed due to changes in feed, heat, ambient temperature, or condensing, the
amount of feed being added and the amount of product being removed are normally equal. This is
known as continuous, steady-state fractional distillation.

Industrial distillation is typically performed in large, vertical cylindrical columns known as

"distillation or fractionation towers" or "distillation columns" with diameters ranging from about 0.65
to 6 meters (2 to 20 ft) and heights ranging from about 6 to 60 meters (20 to 197 ft) or more. The
distillation towers have liquid outlets at intervals up the column which allow for the withdrawal of
different fractions or products having different boiling points or boiling ranges. By increasing the
temperature of the product inside the columns, the different products are separated. The "lightest"
products (those with the lowest boiling point) exit from the top of the columns and the "heaviest"
products (those with the highest boiling point) exit from the bottom of the column.
Figure 6: Fractional Distillation

4. Azeotropic Distillation:
For special cases where in a mixture the differences in effective volatilities are very small, these
systems are known as close boiling mixtures. In some cases, the difference is zero, called an
azeotropic mixture. These two systems require special handling to be separated. In close boiling
mixtures simple distillation is prohibitively expensive and an azeotrope is impossible to separate.
Azeotropic distillation or extractive distillation could be an option to make the separation possible.
In azeotropic distillation an additional component is added which will azeotrope with one or more
of the components in the original mixture. This new azeotrope must be easily recoverable and
recycled for reuse or else one separation problem has been traded for another. Selection of the
azeotrope agent is of great importance and since there are a plethora of compounds to choose from,
a selection technique is necessary to winnow down the choices.
Figure 7: Azeotropic distillation of pyridine from acetic acid using water and subsequent
dehydration of pyridine using caustic soda

5. Extractive Distillation:
Extractive distillation is commonly used to separate close boiling compounds or azeotropes. It

takes advantage of a relatively non-volatile component which has a greater affinity for one or more
components in the original mixture. When this extractive agent is added to the column this affinity
pulls these components down to the bottom of the column thus allowing the remaining components
to rise overhead very readily. The agent is added a few trays below the top so the effect can be seen
throughout the column. The top few trays are required to knock back any agent that might be
carried up the column. The extract agent is chosen to induce a greater relative volatility between
the compounds to be separated, but by the same token it must not have so great an affinity that it
becomes immiscible. Once the agent separates it has no effect on the remaining extractive
compound in the other phase.
Figure 8: Extractive distillation of nitric acid from water using sulfuric acid and subsequent
reconcentration of sulfuric acid.

6. Vacuum Distillation:
Some compounds have very high boiling points. To boil such compounds, it is often better to lower
the pressure at which such compounds are boiled instead of increasing the temperature. Once the
pressure is lowered to the vapor pressure of the compound boiling and the rest of the distillation. This
technique is also very useful for compounds which boil beyond their decomposition temperature at
atmospheric pressure and which would therefore be decomposed by any attempt to boil them under
atmospheric pressure.
Vacuum distillation is the process of lowering the pressure in the column above the solvent to less than
the vapor pressure of the mixture, creating a vacuum, and causing the elements with lower vapor
pressures to evaporate off. Vacuum distillation is sometimes used in fire refining. In this process,
molten tin is heated in a dense graphite vessel at high temperatures (1,100 to 1,300 °C, or 2,000 to
2,375 °F). A vacuum is applied, and impurities are removed by selective distillation.
Distillation Column Design Packing

Distillation columns are designed on the basis of the properties of the boiling point of the components
in the mixtures being separated. This is done using the vapor-liquid equilibrium data for the mixtures
to be separated. The vapor-liquid equilibrium characteristics of the mixture will determine the number
of stages, and also the number of trays required for the separation. In other words, the sizes, particularly
the height of distillation columns and the overall design are determined by the vapor- liquid
equilibrium data for the mixtures.
Types of Packing
The column can be filled with various types of packing creating a random packed column or
with structured packing sections, which are arranged or creating a stacked packed column. In the
column, liquids tend to wet the surface of the packing and the vapours pass across this wetted surface,
where mass transfer takes place. Packing material can be used instead of trays to improve separation
in distillation columns. Packing offers the advantage of a lower pressure drop across the, which is
beneficial while operating under vacuum. Differently shaped packing materials have different surface
areas and avoid space between the packing. Both of these factors affect packing performance.
1. Tray Device: Typical tray While there are perhaps five basic distillation trays suitable for industrial
use, there are many design variations of differing degrees of importance and a confusing array of trade
names applied to their products by tray manufacturers. The most modern and commonly used devices
include sieve, valve, bubble cap, dual flow, and baffle trays – each with its advantages and preferred
usage. Of these, the sieve and valve type trays currently are most often specified. For a better
understanding of tray design and locates typical tray components.
The material of construction usually is 14 gauges with modern trays adopting the integral truss design
which simplifies fabrication. For columns less than 3 ft (0.9m) in diameter, it is not possible to assemble
the truss trays in the column; therefore, trays must be preassembled on rods into a cartridge section for
loading into the column size. The hydraulic design of a tray is a very important factor. The upper
operating limit generally is governed by the flood point, although in some cases, entrainment also can

restrict performance before the onset of flooding. Flooding is usually caused by either massive
entrainment, termed jet flooding, or by downcomer back-up. Downcomer back-up occurs when a tray
design provides insufficient downcomer area to allow for the liquid flow or when the pressure drop
across the tray is high, which forces liquid to back up in the downcomer.
When the downcomer is unable to handle all the liquid involved, the trays start to fill and pressure drop
across the column increases. This also can occur when a highly foaming liquid is involved. Flooding
associated with high tray pressure drops and small tray spacing takes place when the required liquid seal
is higher than the tray spacing. Downcomer design also is particularly important at high operating
pressure due to a reduction in the difference between vapor and liquid densities.
The lower limit of tray operation, meanwhile, is influenced by the amount of liquid weeping from one
tray to the next. Unlike the upward force of entrainment, weeping liquid flows in the normal direction
and considerable amounts can be tolerated before column efficiency is significantly affected. As the
vapor rate decreases, however, a point eventually is reached when all the liquid is weeping truss design.
And there is no liquid seal on the tray. This is known as the dump point, below which there is a severe
drop in efficiency.
2.Structured Packing: The term structured packing refers to a range of specially designed materials for
use in absorption and distillation columns and chemical reactors. Structured packings typically consist
of thin corrugated metal plates or gauzes arranged in a way that they force fluids to take complicated
paths through the column, thereby creating a large surface area contact between different phases.
Figure 9: Structured Packing

3. Bubble Cap Tray: Although many bubble cap columns still are in operation, bubble cap trays rarely
are specified today because of high-cost factors and the excellent performance of the modern valve
tray. The bubble cap, however, does have a good turndown ratio and is good for low liquid loads.
Figure 10: Bubble Cap Tray
Figure 11: Types of Packing

2.5 Heat Exchanger

A heat exchanger is a heat transfer device that exchanges heat between two or more process fluids.
Heat exchangers have widespread industrial and domestic applications. Many types of heat exchangers
have been developed for use in steam power plants, chemical processing plants, building heat and air
conditioning systems, transportation power systems, and refrigeration units.
The actual design of heat exchangers is a complicated problem. It involves more than heat-transfer
analysis alone. Cost of fabrication and installation, weight, and size play important roles in the
selection of the final design from a total cost of ownership point of view. In many cases, although cost
is an important consideration, size and footprint often tend to be the dominant factors in choosing a
design.
Most heat exchangers may be classified as one of several basic types. The four most common types,
based on flow path configuration, are illustrated in the following figure below.
Figure 12: Types of flow path configuration through heat exchanger

a. In concurrent, or parallel-flow, units the two fluid streams enter together at one end, flow
through in the same direction, and leave together at the other end.
b. In counter current, or counter-flow, units the two streams move in opposite directions.
c. In single-pass crossflow units one fluid moves through the heat transfer matrix at right angles
to the flow path of the other fluid.
d. In multipass crossflow units one fluid stream shuttles back and forth across the flow path of
the other fluid stream, usually giving a crossflow approximation to counterflow.
Classification of Heat Exchangers:
Figure 13: (a) Classification according to process function; (b) classification of condensers
(c) classification of liquid-to-vapor phase-change exchangers

Tubular Heat Exchanger:

Tubular exchangers are widely used, and they are manufactured in many sizes, flow arrangements, and
types. They can accommodate a wide range of operating pressures and temperatures. The ease of
manufacturing and their relatively low cost have been the principal reason for their widespread use in
engineering applications. A commonly used design, called the shell-and-tube exchanger, consists of
round tubes mounted on a cylindrical shell with their axes parallel to that of the shell. Figure 15
illustrates the main features of a shell-and tube exchanger having one fluid flowing inside the tubes
and the other flowing outside the tubes. The principle components of this type of heat exchanger are
the tube bundle, shell, front and rear end headers, and baffles. The baffles are used to support the tubes,
to direct the fluid flow approximately normal to the tubes, and to increase the turbulence of the shell
fluid. There are various types of baffles, and the choice of baffle type, spacing, and geometry depends
on the flow rate allowable shell-side pressure drop, tube support requirement, and the flow-induced
vibrations. Many variations of shell-and-tube exchanger are available; the differences lie in the
arrangement of flow configurations and in the details of construction.
Figure 14: A shell-and-tube heat exchanger; one shell pass and one tube pass
The character of the fluids may be liquid-to-liquid, liquid-to-gas, or gas-to-gas. Liquid-to-liquid

exchangers have the most common applications. Both fluids are pumped through the exchangers;
hence, the heat transfer on both the tube side and the shell side is by forced convection. Since the heat
transfer coefficient is high with the liquid flow, generally there is no need to use fins. The liquid-to-
gas arrangement is also commonly used; in such cases, the fins usually are added on the gas side of
the tubes, where the heat transfer coefficient is low. Gas-to-gas exchangers are used in the exhaust-gas
and air preheating recuperators for gas gas-turbine systems, cryogenic gas-liquefaction systems, and
steel furnaces. Internal and external fins generally are used in the tubes to enhance heat transfer.

Plate Heat Exchanger:

As the name implies, plate heat exchangers usually are constructed of thin plates. The plates may be
smooth or may have some form of corrugation. Since the plate geometry cannot accommodate as high
pressure and/or temperature differentials as a circular tube, it is generally designated for moderate
temperature and/or pressure differentials of the compactness factor for plate exchangers ranges from
about 120 to 230 m2 /m3. A plate heat exchanger is a type of heat exchanger that uses metal plates to
transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in
that the fluids are exposed to a much larger surface area because the fluids are spread out over the
plates.
Figure 15: Plate Type Heat Exchanger

Reboiler:
Although there are many types of reboilers, the shell and tube thermosyphon reboiler is used most
frequently. Boiling within the vertical tubes of the exchanger produces liquid circulation and
eliminates the need for a pump. For certain duties, particularly when the bottoms liquid has a tendency
to foul heat Transfer surfaces, it is desirable to pump the liquid through a forced circulation reboiler.
Since boiling can be suppressed by use of an orifice plate at the outlet of the unit, fouling is reduced.
The liquid being pumped is heated under pressure and then is flashed into the base of the column where
vapor is generated. An alternate approach is the use of a plate heat exchanger as a forced circulation
reboiler. Segment of high efficiency metal mesh packing. With this technique, the very high liquid
turbulent flow which is induced within the heat exchanger through the use of multiple corrugated plates
holds fouling to a minimum. Meanwhile, the superior rates of heat transfer that are achieved reduce
the surface area required for the reboiler.
Figure 16: Thermosyphon Reboiler

Condenser:
Since most distillation column condensers are of shell and tube design, the processor has the option of
condensing on either the shell or tube side. From the process point of view, condensation on the shell
side is preferred since there is less subcooling of condensate and a lower pressure drop is required.
These are important factors in vacuum duties. Furthermore, with cooling water on the shell side, any
fouling can be removed more easily. Tube side condensation, on the other hand, can be more
advantageous whenever process fluid characteristics dictate the use of more expensive, exotic
materials. Capital cost of the unit can be reduced by using a carbon steel shell.
Figure 17: Shell and Tube Condenser

3. P&ID AND CALCULATION

In this section, I have explained what a BFD, PFD & P&ID is. I have also calculated various factors
of distillation column operation through mass balance and energy balance.
3.1 BFD
Block Flow Diagram (BFD) is a schematic illustration of a major process. A block flow diagram (BFD)
is a drawing of a chemical processes used to simplify and understand the basic structure of a system.
A BFD is the simplest form of the flow diagrams used in industry. Blocks in a BFD can represent
anything from a single piece of equipment to an entire plant. For a complex process, block flow
diagrams can be used to break up a complicated system into more reasonable principle stages/sectors.
Uses: Creating a BFD is often one of the first steps in developing a chemical process. Different
alternatives can be easily and inexpensively compared at an early stage using simple BFDs. Once
alternatives have been chosen, the BFD serves as a starting point for a complete process flow diagram
(PFD). A BFD is a useful tool for reports, textbooks and presentations when a detailed process flow
diagram is too cumbersome. These models allow for the reader to get an overall picture of what the
plant does and how all the processes interact. These can be understood by people with little experience
with reading or creating flow diagrams.
Models: BFDs come in many forms and styles. They can be extremely simple or very detailed in their
explanation of a process.
I/O Diagrams: The simplest form of BFD, the I/O (input/output) diagram), provides the material
streams entering and exiting the process. The diagram is modelled below using arrows entering and
exiting a process box to represent the inputs and outputs, respectively.
Figure 18: I/O Diagram

Block Flow Plant Diagram: This model of flow diagram is used to explain the general material flows
throughout an entire plant. They will be generalized to certain plant sectors or stages. These documents
would help orient workers to the products and important operation zones of a chemical facility.
Block Flow Process Diagram: This model will concentrate on a particular sector/area of a chemical
plant. This would be a separate flow diagram that details what would have been present inside of one
of the blocks in the plant diagram. These diagrams may be more or less complicated than the plant
diagram but will focus on only a small sub-section of the overall process.
Conventions: There are several conventions regarding the construction and format of BFDs that are
commonly used in the engineering community. Some of the recommended conventions are:
1. Operations/equipment are represented with blocks
2. Material flows are represented with straight lines with arrows giving the direction of flow
3. Lines are horizontal and/or vertical, with turns at 90 degree angles
4. Flows go from left to right whenever possible
5. If lines cross, the horizontal line is continuous and the vertical line is broken
6. Light streams (gases) are typically closer to the top of the BFD than are heavy streams (liquids
or solids)
7. Critical information unique to the process (such as a chemical reaction) is supplied
8. A simplified material balance should be provided
This figure depicts a very small and simplified BFD:
Figure 19: BFD

Example: Production of Benzene:

Toluene and hydrogen are used as feed stocks for the production of benzene. The toluene and hydrogen
are sent to a reactor, and the effluent is sent to a gas separator where the non-condensable gases are
discharged from the system.
The bottoms of the separator provides a liquid feed to a still where the lighter benzene gas is collected
as the distillate and the bottom toluene draw is recycled back into the reactor. The BFD provided shows
the reaction, the stream names, and the mass flow of the inlets and outlets. There are many components
of this system (heat exchangers and pumps, etc.) that are not represented because they are not vital for
an understanding of the main features of the process.
Figure 20: Block flow process diagram for the production of benzene

3.2 PFD
A process flow diagram (PFD) is a diagram commonly used in chemical and process engineering to
indicate the general flow of plant processes and equipment. The PFD displays the relationship between
major equipment of a plant facility and does not show minor details such as piping details and
designations. Another commonly used term for a PFD is a flowsheet. A Process Flow Diagram - PFD
- (or System Flow Diagram - SFD) shows the relations between major components in a system. PFD
also tabulate process design values for components in different operating modes, typical minimum,
normal and maximum. A PFD does not show minor components, piping systems, piping ratings and
designations.
Typical content of a process flow diagram:
Typically, process flow diagrams of a single unit process will include the following:
 Process piping
 Major equipment items
 Connections with other systems
 Major bypass and recirculation (recycle) streams
 Operational data (temperature, pressure, mass flow rate, density, etc.), often by stream
references to a mass balance.
 Process stream names
Process flow diagrams generally do not include:
 Pipe classes or piping line numbers

 Instrumentation details
 Minor bypass lines
 Instrumentation
 Controllers like Level Control or Flow Control
 Isolation and shutoff valves
 Maintenance vents and drains
 Relief and safety valves
 Flanges
Process flow diagrams of multiple process units within a large industrial plant will usually contain
less detail and may be called block flow diagrams or schematic flow diagrams.

Example of PFD:
Figure 21: PFD and Equipment Specifications

3.3 P&ID
A piping and instrumentation diagram (P&ID) is a detailed diagram in the process industry which
shows the piping and process equipment together with the instrumentation and control devices. P&ID
is a schematic illustration of a functional relationship between piping, instrumentation and system
components. P&ID's shows all piping including physical sequences of branches, reducers, valves,
equipment, instrumentation and control interlocks. The P&ID's are used to operate process systems. A
P&ID is defined as follows:
1. A diagram which shows the interconnection of process equipment and the instrumentation used
to control the process. In the process industry, a standard set of symbols is used to prepare
drawings of processes.
2. The primary schematic drawing used for laying out a process control installation.
A P&ID should include:
 Instrumentation and designations

 Mechanical equipment with names and numbers
 All valves and their identifications
 Process piping, sizes and identification
 Miscellaneous - vents, drains, special fittings, sampling lines, reducers, increasers and
swagers
 Permanent start-up and flush lines
 Flow directions
 Interconnections references
 Control inputs and outputs, interlocks
 Interfaces for class changes
 Seismic category
 Quality level
 Annunciation inputs
 Computer control system input
 Vendor and contractor interfaces
 Identification of components and subsystems delivered by others
 Intended physical sequence of the equipment
A P&ID should not include:
 Equipment rating or capacities

 Instrument root valves
 Control relays
 Manual switches and indicating lights
 Primary instrument tubing and valves
 Pressure temperature and flow data
 Elbows and similar standard fittings
 Extensive explanatory notes

Symbols of chemical apparatus and equipment
Thermally Cooled or
Jacketed
Pipe insulated heated
pipe
pipe pipe
Vacuum
Flexible Hydraulic pump or
Pump
connection pump compress
or
Axial fan,
Fan Radial fan Dryer
MK,
Jacketed
Half pipe Pressurized Pressurize
mixing
mixing horizontal d vertical
vessel
vessel vessel vessel
(autoclave)
Packed Plate Cooling

Furnace
column column tower
Plate &
Heat Coil heat
Cooler frame heat
exchanger exchanger
exchanger

Fixed
Double U shaped
straight Spiral heat
pipe heat tubes heat
tubes heat exchanger
exchanger exchanger
exchanger
Covered Curved Funnel or

(Air) filter
gas vent gas vent tundish
Pressure
Viewing
Steam trap reducing Valve
glass
valve
Control Manual Check

Gate valve
valve valve valve
Needle Butterfly Diaphragm

Ball valve
valve valve valve
Check Back draft

Bag Gas bottle
valve damper

The figure below illustrates a P&ID:
Figure 22: P&ID

3.4 Mass & Energy Balance of Distillation Column Operation

Given: R = 8, dt = 16 °C, ΔT = 70 °C
Flow rate = 250 kg/hr
Component A = 52-53% = 52.5% 52.5% x 250 kg/hr = 131.25 kg/hr
Component B = 1% 1% x 250 kg/hr = 2.5 kg/hr
Component C = 40% 40 % x 250 kg/hr = 100 kg/hr
Component D = 5-8% = 6.5% 6.5 % x 250 kg/hr = 16.25 kg/hr
Top Product:
Flow Rate = 104-150 kg/hr = 145 kg/hr
Component A = 89-91% = 90%
Component B = 1%
Component C = 2-3% = 2.5%
Component D = 5-8% = 6.5%
Bottom Product:
Flow Rate = 100-110 kg/hr = 105 kg/hr
Component A = 0.4%
Component B = 0%
Component C = 99.5%
Material Balance of Component A:

Basis = 250 kg/hr
Fxf = Dxd + Wxw
(250)(52.5%) = D(90%) + W(0.4%)
131.25 = D(90%) + (F-D)(0.4%) (⸪ F = D + W)
131.25 = (90%-0.4%)D
⸫ D = 146.48 kg/hr
⸫W = 103.52 kg/hr

Boil up rate = D ( 1 + R ) = 146.48 ( 1+ 8 ) = 1318.32 kg/hr
CpA = 0.513 kcal/kgK, λA = 125 kcal/kg

CpB = 0.157 kcal/kgK, λB = 79 kcal/kg
CpC = 0.457 kcal/kgK, λC = 102 kcal/kg
CpD = 1 kcal/kgK, λD = 540 kcal/kg
Average Cp = (90%)(0.513) + (1%)(0.157) + (2.5%)(1) + (6.5%)(0.457) = 0.517975 kcal/kgK

Average λ = (90%)(125) + (1%)(79) + (2.5%)(540) + (6.5%)(102) = 133.42 kcal/kg
Average Cp(column feed)=(52.5%)(0.513)+(1%)(0.157)+(40%)(1)+(6.5%)(0.457)=0.7006 kcal/kgK
Condenser Duty, Qc = mCpdt + mλ = 1318.32 [(0.517975)(16) + (133.42)] = 186815.96 kcal

Reboiler Duty, Qr = mCpΔT + mλ = (250)(0.7006)(70) + (1318.32)(133.42) = 188150.75 kcal
Assuming 90% for primary condenser & 10% secondary condenser

Primary condenser = (Qc x 90%)/3024 = 55.3792 TR
Secondary condenser = (Qc x 10%)/3024 = 6.1532 TR
Steam requirement, ms = Qr/λ = 188150.75/510 = 368.92 kg/hr /2.163 = 170.56 m3/hr

Water requirement, mw = Qc/CpΔT = 186815.9632/1x5 = 37363.192 kg/hr /1000 = 37.36 m3/hr
Line size calculations: We know that Q = V x A,
D= .
Velocity criteria: for liquid = 1.5 – 3 m/s, for gases = 15 – 30 m/s, pump suction = 0.8 – 1.5 m/s, vapour
line = 10 – 25 m/s, saturated steam = 10 – 35 m/s, superheated steam = 60 – 75 m/s
.
For steam: line size = .
= 0.049043 m = 1.939 in
.
For water: line size = .
= 0.081144 m = 3.194 in


Steam Table:
Specific Specific Enthalpy Specific Enthalpy

Absolute Boiling Density Latent heat of Specific
Volume of Liquid Water of Steam
Pressure Point (steam) Vaporization Heat
(steam) (sensible heat) (total heat)
(bar) (oC) (m3/kg) (kg/m3) (kJ/kg) (kcal/kg) (kJ/kg) (kcal/kg) (kJ/kg) (kcal/kg) (kJ/kg K)
0.02 17.51 67.006 0.015 73.45 17.54 2533.64 605.15 2460.19 587.61 1.8644
0.03 24.10 45.667 0.022 101.00 24.12 2545.64 608.02 2444.65 583.89 1.8694
0.04 28.98 34.802 0.029 121.41 29.00 2554.51 610.13 2433.10 581.14 1.8736
0.05 32.90 28.194 0.035 137.77 32.91 2561.59 611.83 2423.82 578.92 1.8774
0.06 36.18 23.741 0.042 151.50 36.19 2567.51 613.24 2416.01 577.05 1.8808
0.07 39.02 20.531 0.049 163.38 39.02 2572.62 614.46 2409.24 575.44 1.8840
0.08 41.53 18.105 0.055 173.87 41.53 2577.11 615.53 2403.25 574.01 1.8871
0.09 43.79 16.204 0.062 183.28 43.78 2581.14 616.49 2397.85 572.72 1.8899
0.1 45.83 14.675 0.068 191.84 45.82 2584.78 617.36 2392.94 571.54 1.8927
0.2 60.09 7.650 0.131 251.46 60.06 2609.86 623.35 2358.40 563.30 1.9156
0.3 69.13 5.229 0.191 289.31 69.10 2625.43 627.07 2336.13 557.97 1.9343
0.4 75.89 3.993 0.250 317.65 75.87 2636.88 629.81 2319.23 553.94 1.9506
0.5 81.35 3.240 0.309 340.57 81.34 2645.99 631.98 2305.42 550.64 1.9654
0.6 85.95 2.732 0.366 359.93 85.97 2653.57 633.79 2293.64 547.83 1.9790
0.7 89.96 2.365 0.423 376.77 89.99 2660.07 635.35 2283.30 545.36 1.9919
0.8 93.51 2.087 0.479 391.73 93.56 2665.77 636.71 2274.05 543.15 2.0040
0.9 96.71 1.869 0.535 405.21 96.78 2670.85 637.92 2265.65 541.14 2.0156


11) 99.63 1.694 0.590 417.51 99.72 2675.43 639.02 2257.92 539.30 2.0267
1.1 102.32 1.549 0.645 428.84 102.43 2679.61 640.01 2250.76 537.59 2.0373
1.2 104.81 1.428 0.700 439.36 104.94 2683.44 640.93 2244.08 535.99 2.0476
1.3 107.13 1.325 0.755 449.19 107.29 2686.98 641.77 2237.79 534.49 2.0576
1.4 109.32 1.236 0.809 458.42 109.49 2690.28 642.56 2231.86 533.07 2.0673
1.5 111.37 1.159 0.863 467.13 111.57 2693.36 643.30 2226.23 531.73 2.0768
1.6 113.32 1.091 0.916 475.38 113.54 2696.25 643.99 2220.87 530.45 2.0860
1.7 115.17 1.031 0.970 483.22 115.42 2698.97 644.64 2215.75 529.22 2.0950
1.8 116.93 0.977 1.023 490.70 117.20 2701.54 645.25 2210.84 528.05 2.1037
1.9 118.62 0.929 1.076 497.85 118.91 2703.98 645.83 2206.13 526.92 2.1124
2 120.23 0.885 1.129 504.71 120.55 2706.29 646.39 2201.59 525.84 2.1208
2.2 123.27 0.810 1.235 517.63 123.63 2710.60 647.42 2192.98 523.78 2.1372
2.4 126.09 0.746 1.340 529.64 126.50 2714.55 648.36 2184.91 521.86 2.1531
2.6 128.73 0.693 1.444 540.88 129.19 2718.17 649.22 2177.30 520.04 2.1685
2.8 131.20 0.646 1.548 551.45 131.71 2721.54 650.03 2170.08 518.32 2.1835
3 133.54 0.606 1.651 561.44 134.10 2724.66 650.77 2163.22 516.68 2.1981
3.5 138.87 0.524 1.908 584.28 139.55 2731.63 652.44 2147.35 512.89 2.2331
4 143.63 0.462 2.163 604.68 144.43 2737.63 653.87 2132.95 509.45 2.2664


4.5 147.92 0.414 2.417 623.17 148.84 2742.88 655.13 2119.71 506.29 2.2983
5 151.85 0.375 2.669 640.12 152.89 2747.54 656.24 2107.42 503.35 2.3289
5.5 155.47 0.342 2.920 655.81 156.64 2751.70 657.23 2095.90 500.60 2.3585
6 158.84 0.315 3.170 670.43 160.13 2755.46 658.13 2085.03 498.00 2.3873
6.5 161.99 0.292 3.419 684.14 163.40 2758.87 658.94 2074.73 495.54 2.4152
7 164.96 0.273 3.667 697.07 166.49 2761.98 659.69 2064.92 493.20 2.4424
7.5 167.76 0.255 3.915 709.30 169.41 2764.84 660.37 2055.53 490.96 2.4690
8 170.42 0.240 4.162 720.94 172.19 2767.46 661.00 2046.53 488.80 2.4951
8.5 172.94 0.227 4.409 732.03 174.84 2769.89 661.58 2037.86 486.73 2.5206
9 175.36 0.215 4.655 742.64 177.38 2772.13 662.11 2029.49 484.74 2.5456
9.5 177.67 0.204 4.901 752.82 179.81 2774.22 662.61 2021.40 482.80 2.5702
10 179.88 0.194 5.147 762.60 182.14 2776.16 663.07 2013.56 480.93 2.5944
11 184.06 0.177 5.638 781.11 186.57 2779.66 663.91 1998.55 477.35 2.6418
12 187.96 0.163 6.127 798.42 190.70 2782.73 664.64 1984.31 473.94 2.6878
13 191.60 0.151 6.617 814.68 194.58 2785.42 665.29 1970.73 470.70 2.7327
14 195.04 0.141 7.106 830.05 198.26 2787.79 665.85 1957.73 467.60 2.7767
15 198.28 0.132 7.596 844.64 201.74 2789.88 666.35 1945.24 464.61 2.8197
16 201.37 0.124 8.085 858.54 205.06 2791.73 666.79 1933.19 461.74 2.8620


17 204.30 0.117 8.575 871.82 208.23 2793.37 667.18 1921.55 458.95 2.9036
18 207.11 0.110 9.065 884.55 211.27 2794.81 667.53 1910.27 456.26 2.9445
19 209.79 0.105 9.556 896.78 214.19 2796.09 667.83 1899.31 453.64 2.9849
20 212.37 0.100 10.047 908.56 217.01 2797.21 668.10 1888.65 451.10 3.0248
21 214.85 0.095 10.539 919.93 219.72 2798.18 668.33 1878.25 448.61 3.0643
22 217.24 0.091 11.032 930.92 222.35 2799.03 668.54 1868.11 446.19 3.1034
23 219.55 0.087 11.525 941.57 224.89 2799.77 668.71 1858.20 443.82 3.1421
24 221.78 0.083 12.020 951.90 227.36 2800.39 668.86 1848.49 441.50 3.1805
25 223.94 0.080 12.515 961.93 229.75 2800.91 668.99 1838.98 439.23 3.2187
26 226.03 0.077 13.012 971.69 232.08 2801.35 669.09 1829.66 437.01 3.2567
27 228.06 0.074 13.509 981.19 234.35 2801.69 669.17 1820.50 434.82 3.2944
28 230.04 0.071 14.008 990.46 236.57 2801.96 669.24 1811.50 432.67 3.3320
29 231.96 0.069 14.508 999.50 238.73 2802.15 669.28 1802.65 430.56 3.3695
30 233.84 0.067 15.009 1008.33 240.84 2802.27 669.31 1793.94 428.48 3.4069

4. CONCLUSION
It was a great experience to do an internship at Lupin Limited Tarapur. The practical knowledge that
I gained will surely be helpful to me in the future. During my internship I understood the working of
all the various equipment’s and the different processes performed in different plants, practically. The
internship gave me an opportunity to correlate theoretical knowledge obtained through my college and
practical things learned at plant.
With training I was able to visualize practical situation better and find it easier to adopt factory working
later. I was also able to study relevant subject and integrate teaching and training for gainful
employment. During the time period, I met people at different levels, so that I can understand their
psychology, concepts and their approach to problem solving. Along with the practices followed at
plant, I also understood the need of coordinated effort of various people at different levels in achieving
set goals and targets.
A pharmaceutical plant is the combination of various fields like mechanical, civil, electrical,
production, process, chemical & instrumentation. This internship helped me to overcome different
problems faced in different fields.
In short, thankful to the internship, I am now familiar to industrial environment which cannot be
stimulated in the college. This internship has definitely increased my confidence and will surely help
me in my future endeavours, not only as a Chemical Engineer but also as a human being.

5. REFERENCES
 http://www.lupin.com/
 https://www.engineeringtoolbox.com/
 https://www.wikipedia.org
 Perry's Chemical Engineers' Handbook, Eighth Edition
 Process Heat Transfer Book by Donald Quentin Kern
 Coulson & Richardson's Chemical Engineering Design: Chemical Engineering Volume 6

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INTERNSHIP REPORT

THADOMAL SHAHANI ENGINEERING COLLEGE, BANDRA

SR. NO. TOPIC PAGE NO.

Figure 1: Lupin Plant

1.1 History and Evolution

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1.2 Research and Development

Lupin's R&D covers:

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1.3 Global Presence

 South Africa: Pharma Dynamics, Lupin’s subsidiary in South Africa, is committed to

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 Germany: Lupin’s subsidiary in Germany, Hormosan, focuses on offering innovative drugs

 Netherlands: Nanomi, Lupin’s subsidiary in the Netherlands, is a leader in the field of

 Mexico: Laboratorios Grin, Lupin’s subsidiary in Mexico, is currently dedicated to the

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Central Nervous System Levitracetam

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1.5 Various Plants at Lupin Limited, Tarapur

1. Multi-Purpose Product (MPP-1)

All MPP have their own powder processing area.

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1.6 Departments Roles and Responsibilities

4. Process Development Lab: Process development is used to establish, implement, or improve a

5. Process Engineering: Coordinates with production department to troubleshoot and

6. Project Management: Most of the pharmaceutical companies have a separate project

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2. SOLVENT RECOVERY UNIT

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Figure 2: Solvent Recovery Plant

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2.1 Advantages of SRU

2.2 Solvent Properties

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2.3 Multi-Purpose Plant-4 Solvent Recovery Unit (MPP-4 SRU)

4 Stainless Steel Reactors

2 Reactors with Column

8 Shell & Tube Heat Exchangers

12 Plate Type Heat Exchangers

8 Vessel & Tanks -

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2. Continuous column: In continuous distillation, feed constantly is charged to the column at a

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Figure 3: (a) Batch Distillation Column ;(b) Continuous Distillation Column

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Following are the various methods of distillation:

Figure 4: Simple Batch Distillation

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Figure 5: Flash Distillation

Fractional distillation is the separation of a mixture into its component parts,

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Industrial distillation is typically performed in large, vertical cylindrical columns known as

Figure 6: Fractional Distillation

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Extractive distillation is commonly used to separate close boiling compounds or azeotropes. It

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