JUNE 30, 2023

FINAL REPORT
SUMMER INTERNSHIP

ABHISHEK UPADHAYAYULA
AARTI INDUSTRIES LTD.
ZONE-II, Jhagadia
 Acknowledgement

I would like to express my sincere gratitude and appreciation to all those who have contributed
to the successful completion of this internship report.
First and foremost, I would like to extend my heartfelt thanks to Aarti Industries Ltd. for providing
me with the opportunity to undertake this internship. I am grateful for the trust and confidence
bestowed upon me, allowing me to gain invaluable experience and apply the knowledge I have
acquired during my academic journey.
I am deeply indebted to Mr. Lahu Chavan, my supervisor, for their constant guidance, support,
and encouragement throughout the internship period. Their expertise, patience, and constructive
feedback have been instrumental in shaping this report and enhancing my understanding of the
subject matter.
I would also like to express my gratitude to the entire Process Department and Operation
Department of Ruby Division at Aarti Industries Ltd. The staff members have been exceptionally
kind, welcoming, and helpful, making my internship experience truly enriching. Their willingness
to share their knowledge and experiences has played a significant role in my personal and
professional growth.
I would like to acknowledge the assistance and cooperation of my colleagues and fellow interns,
whose camaraderie and shared experiences have added value to my internship journey. The
collaborative work environment fostered by their presence has made each day a memorable one.
I am indebted to my professors and mentors at National Institute of Technology, Warangal for
equipping me with the necessary skills and knowledge, which laid the foundation for a successful
internship experience. Their unwavering support and guidance have been crucial in shaping my
academic and professional pursuits.
To all those mentioned above and to anyone whose contribution may not have been explicitly
stated, please accept my deepest appreciation for your support and involvement in the
completion of this internship report. Your assistance has been invaluable, and I am truly grateful
for your unwavering commitment.

Thank you.
Abhishek Upadhyayula

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 Declaration Statement

I, Abhishek Upadhyayula, hereby declare that the internship report titled Final Report submitted
in partial fulfillment of the requirements for the B.Tech Chemical Engineering at National Institute
of Technology Warangal, is a product of my own work.
I confirm that the contents of this report are based on my personal experiences, observations,
and research conducted during the internship period at Aarti Industries Ltd. Any external sources
used, including references, have been duly acknowledged and cited in accordance with the
established academic standards and guidelines.
I further declare that this report has not been submitted, in part or in full, for the award of any
other degree, diploma, or certification. It is solely prepared for academic purposes and the
evaluation of my internship performance.
I understand the significance of academic integrity and the consequences of any form of
plagiarism or misrepresentation. Therefore, I affirm that this report is entirely my original work
and does not contain any unauthorized or unacknowledged material.
I acknowledge that the findings, conclusions, and recommendations presented in this report are
based on my understanding and interpretation of the internship experience, and they may vary
from other perspectives or interpretations.
I take full responsibility for the accuracy, authenticity, and ethical conduct associated with the
information presented in this report. In the event of any discrepancy or error, I am willing to
provide necessary clarifications and rectifications as required.

By signing this declaration, I affirm my commitment to uphold the principles of academic honesty
and integrity in all aspects of my academic and professional endeavors.

Signature: Abhishek Upadhyayula

Date: June 30, 2023

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 Table of Contents
Acknowledgement ........................................................................................................................................ 1
Declaration Statement .................................................................................................................................. 2
1. Introduction .......................................................................................................................................... 4
1.1 Aarti Industries Limited ................................................................................................................. 4
1.2 Products at Aarti Industries Limited.............................................................................................. 5
2. Toluidine (TL) Plant................................................................................................................................ 7
2.1 Basic Plant Details ......................................................................................................................... 7
2.2 Process Flow Diagram ................................................................................................................... 8
2.3 Process Description ....................................................................................................................... 9
2.4 Instruments Used ........................................................................................................................ 11
2.5 Interlocks ..................................................................................................................................... 11
2.6 Mass Balance .............................................................................................................................. 12
3. New PDA (Phenylene Diamine) Separation......................................................................................... 14
3.1 Basic Plant Details ....................................................................................................................... 14
3.2 Process Flow Diagram ................................................................................................................. 15
3.3 Process Description ..................................................................................................................... 16
4. Power Plant ......................................................................................................................................... 19
5. Utilities ................................................................................................................................................ 21
6. Equipment Design ............................................................................................................................... 22
6.1 Condenser Design ....................................................................................................................... 22
6.2 Reboiler Design ........................................................................................................................... 26
6.3 Pump Design and Piping ............................................................................................................. 30
References................................................................................................................................................... 34

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1. Introduction
1.1 Aarti Industries Limited
Aarti Industries manufactures and sells pharmaceutical intermediates and specialty
chemicals. The company was established in 1975, has developed into a major force in the
global chemical sector.

Aarti Industries works in a variety of industries, such as agrochemicals, medicines, dyes,

pigments, surfactants, and polymers. A broad range of specialty chemicals utilized in
numerous industries make up the company's product line. They offer goods such
pharmaceuticals, specialty chemicals, agrochemicals, surfactants, and benzene-based
intermediate.

The business places a high priority on research and development (R&D) and has built cutting-
edge R&D facilities to provide novel and environmentally friendly chemical solutions. The
development of various patented goods and procedures because of Aarti Industries' research
and development efforts has helped the company gain a competitive edge in the market.

With operations in Europe, the Americas, and Asia, Aarti Industries has a sizable international
reach in addition to its domestic business in India. The company has a global clientele and
exports its goods to more than 60 nations.

Aarti Industries has had steady growth over the years because of its focus on operational
excellence, quality, and client happiness. For its effectiveness and contributions to the
chemical industry, it has won various awards and accolades.

Aarti Industries places a high priority on sustainability and is dedicated to reducing its negative
effects on the environment. To cut waste, save energy, and encourage sustainable practices
across its operations, it has put in place several programs.

Overall, Aarti Industries is a top manufacturer of specialty chemicals and pharmaceutical

intermediates with a focus on sustainability, a strong global footprint, and excellent R&D skills.

Currently (2023), 2,5 DCNB plant in Jhagadia is undergoing Commissioning.

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1.2 Products at Aarti Industries Limited
• Benzene based Intermediates:
o Benzene Sulphonic Acid
o Benzene Sulfonyl Chloride
o Sodium Benzene Sulphonate
o Potassium Benzene Sulphonate
o Benzene Sulphonic Acid Monoethanolamine Salt
o Benzene Sulphonamide
• Specialty Chemicals:
o Ethyl Acetate
o Acetic Acid
o Ethyl Acrylate
o Ethyl Hexanol
o Methyl Isobutyl Ketone
o Ethyl Acrylate
• Agrochemicals:
o Glyphosate Acid
o Butachlor
o Chlorpyrifos
o Metolachlor
o Quizalofop Ethyl
o Pendimethalin
• Pharmaceuticals:
o Ibuprofen
o Phenylephrine
o Metformin
o Diclofenac Sodium
o Guaifenesin
o Ambroxol Hydrochloride

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• `Dyes and Pigments:
o Acid Dyes
o Reactive Dyes
o Solvent Dyes
o Direct Dyes
o Pigment Green 7
o Pigment Blue 15:3
• Surfactants:
o Sodium Lauryl Sulfate (SLS)
o Sodium Lauryl Ether Sulfate (SLES)
o Alkyl Phenol Ethoxylates (APEO)
o Fatty Alcohol Ethoxylates (FAEO)
o Sorbitan Esters
o Glycerol Esters

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2. Toluidine (TL) Plant
2.1 Basic Plant Details
• Raw Material: ONT (Ortho-Nitro Toluene), Hydrogen
• Catalyst: 1%Pt/C (C-49% and water-50%)
• Solvent: Water (During plant startup)
• Reaction Conditions: 120 C and 14kg/cm2
• Process: Hydrogenation
• Product: OT (Ortho-Toluidine)
• Plant Capacity: 70TPD (Currently operating at approx. 55TPD)
• Reaction:

• Physical Properties of Ortho-Nitro Toluene:

o Boiling Point – 222 C
o Melting Point – -9 C
o Flash Point – 95 C
o pH – 6-8
o Density – 1163 kg/m³
o Appearance – Yellow in Color
• Physical Properties of Ortho-Toluidine:
o Boiling Point – 200 C
o Melting Point – -24C to -16C
o Flash Point – 85 C
o pH – 6-8
o Density – 998 kg/m³
o Appearance – Colorless to light yellow

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2.2 Process Flow Diagram

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2.3 Process Description

Plant operating in Continuous mode:

• During Startup, Raw Material (ONT) and Solvent are pumped into the Autoclave along with
Hydrogen which then passes through the Shell and Tube heat Exchanger in order to reach
the desired Temperature of 120 C, which is further again passed into the Autoclave
(Recycled) through a Venturi meter. The Majority of the Reaction takes place in the
Constriction of the Venturi meter (Low Pressure and High Velocity).
• Since the Reaction is Exothermic in nature, the temperature of the Reaction System
increases and so to bring back the products to its Initial Temperature of 120 C , We pass it
through the Shell and Tube heat exchanger, On reaching the temperature of 120 C the
product stream is passed through a Inline Filter (Candle Type) in order to filter out the
Catalyst and send it back to the Autoclave while the rest of the products( OT, water and
Hydrogen) is passed to the Product cooler (Shell and Tube Heat exchanger) to bring down
the Temperature of the Product stream to 54C.
• Now the Stream is passed is passed to a Product Expansion vessel where the excess
Hydrogen is removed (purged) with the help of an Inert Nitrogen and the rest (OT and
Water) is passed through DC Coalescer to separate out water and OT. DC Coalescer works
on the principle of Density difference, Water (traces of OT) which is denser is sent to the
Effluent tank and the OT(Crude) is sent to the Product Day tank which is further sent to
Unit-1(Pearl Division) for Further purification (using Distillation).

Plant operating in Batch mode:

• During Batch operation the product formed is taken into Intermediate vessel (IDV) instead
of sending it to the product cooler through Inline filter.
• The product stream (OT, Hydrogen, water, Catalyst) is first passed through FUNDA Filter to
remove the catalyst and then is passed through a safety filter to remove the remaining
Catalyst.
• The filtered stream (OT, Hydrogen) is then sent to DC Coalescer to separate water and OT.
OT is then sent to the product day tank and then to unit-1 for further purification.

Secondary circuit for Cooling and Heating purpose:

• The cooling water from the cooling tower is passed through a 3-way valve to one of the 2
secondary heat exchangers depending upon for what purpose it is to be used.
• If used for heating purpose, then sent to H-4 where heating is done by MPS while if used
for cooling then sent to H-3.

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• The secondary circuit is based upon the Cascade control system to determine which way
the flow of water is allowed.

BUSS Technology currently used in the TL pant:

• The Buss Loop reactors are intended to boost your productivity, efficiency, and process
flexibility, resulting in extremely cost-effective production facilities. The best ecological
solutions are provided by the Buss Chemtech safety philosophy in conjunction with
enhanced yields.
• A specially created reaction mixer is included with the BCT-Loop Reactor. With this
characteristic, regardless of reactor size, we actively optimize the surface area between
the gaseous and liquid phases, which is the key variable in every mass transfer limited
reaction. The size of the gas bubble remains in the micrometer range even in reactors with
capacity up to 65 m3 and beyond.
• The entire reactor system, which includes the loop lines, the pump, and the heat
exchanger, is distributed with the intense, homogenous gas/liquid dispersion. In addition
to the solid catalyst, BCT's highly dependable customized reaction pump feeds up to 30%
gas and is built for heavy-duty, long-life cycles and trouble-free operation.
• The independent heat exchanger design, which has no size or heat removal capacity limits,
smoothly removes the reaction heat, especially in highly exothermic reactions.

ETP:

• The Effluent from the TL plant is first sent to the Stripper column where the traces of OT
is removed (COD is reduced) and then the effluent water is sent to the ETP plant for further
treatment.
• The wastewater is first passed through a Neutralization tank where the pH of it is reduced
that is bought near the neutral conditions by addition of a base.
• After which it is passed through a Multiple effect evaporator, where the solid contents are
removed as much as possible, and the vaporized water is condensed and sent to the
process of Bio-Aeration.
• In Bio-Aeration the amount of organics in the waste water is reduced with the help of
microorganisms and then is sent to Chlorination to remove any bacteria present.
• Once Chlorination is complete, it is sent to RO (Reverse Osmosis), where the permit is sent
for use in the cooling tower while the residue is sent to MEE back.
Before sending the effluent from storage tank to ETP, there must be certain parameters that
must be met:

• PH – Minimum 7
• TDS (Total Dissolved Solids) – Max. 100 ppm
• COD (Chemical Oxygen Demand) – Max. 3000 ppm

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• A/N (Ammoniacal Nitrogen) – 8-13

2.4 Instruments Used

Level Transmitters:
• Radar Transmitter
• DPT Transmitter
• Displacer Transmitter
• Ultrasonic Transmitter
Flow Transmitters:
• Magnetic Transmitter
• Vortex Transmitter
• Mass Transmitter – based on Coriolis and density effect.
• Orifice and Venturi meter
Temperature Transmitter:
• Resistance Temperature detector (RTD)
• Thermocouple (Power Plant)
Pressure Transmitter:
• Diaphragm Pressure Transmitter (DPT)
• Capacitance cell
PH meter
Hydrogen detectors

2.5 Interlocks
• Hydrogen main line:
o P< 15 kg/cm2 (Differential pressure of 1.5 kg/cm2 between Hydrogen main line
and Autoclave)
• Autoclave:
o P>19 kg/cm2 (12-15 kg/cm2)
o T>130 C (110-125 C)
o Level < 35% or Level>70% (50-60%)
o H2 main line and Autoclave line D.P.<1.5 kg/cm2
o D.P Ejector and Autoclave < 0 (100-500 mbar)
• Raw Material Day Tank:
o Level<1600 kg OR Level>4800 kg (2000-4000 kg)

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• Raw Material line Pressure > 19.5 kg/cm2
• Secondary Circuit:
o T > 130C (85-120 C)
o Cooling Tower to secondary cooler < 400 m³/hr (500-750 m³/hr)
o Secondary circuit flow < 250 m³/hr (320-350 m³/hr)
• Stripper Column:
o Bottom T > 115 C (100-105 C)
o Reboiler Outlet T > 120 C (105-110 C)
Top T <95 C (98-100 C)
o Level <10%

2.6 Mass Balance

Material Properties:

Basis:

M.B. Across Autoclave:

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M.B. Across Inline Filter:

M.B. Across Product Cooler:

M.B. Across Product Expansion Vessel:

M.B. Across DC Coalescer:

M.B. Across Product Day Tank:

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3. New PDA (Phenylene Diamine) Separation
3.1 Basic Plant Details
Feed: Crude PDA

o-PDA:

• Molecular Weight: 108 kmol/kg

• Normal Boiling point: 257°C
• Melting point: 103-104 °C
• Flash Point: 156 °C
• Density: 1030 kg/m³
• Appearance: brownish-yellow

p-PDA:

• Molecular Weight: 108 kmol/kg

• Normal Boiling point: 267°C
• Melting point: 145-147 °C
• Flash Point: 156 °C
• Density: 1100 kg/m³
• Appearance: purple to black

m-PDA:

• Molecular Weight: 108 kmol/kg

• Normal Boiling point: 287°C
• Melting point: 62-63 °C
• Flash Point: 187 °C
• Density: 1140 kg/m³
• Appearance: red/purple

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3.2 Process Flow Diagram

15
3.3 Process Description
Overall Description:

• The storage tank ST-121 holds dehydrated crude PDA (Phenylene Diamine) as the feed for the
PDA separation section, with a capacity of 100 KL.
• The crude undergoes a process to separate its individual isomers, namely o-PDA, p-PDA, and
m-PDA, into their pure forms.
• A portion of the crude stored in ST-121 is directly fed into a packed column C-1600 as a liquid
feed, while another portion is flashed in a flash vessel and fed into the bottom of the C-1600
column as a vapor feed. The top of the column removes the lighter fractions, o-PDA, and p-
PDA, while m-PDA is obtained as the bottom product.
• The top product is stored in ST-103, and the bottom product is stored in ST-102, both with a
capacity of 30 KL each.
• The top product, consisting mainly of o-PDA and p-PDA, along with a fraction of m-PDA, is sent
to column C-1100 for o-PDA purification from the top, resulting in a product with a purity of
less than 99%. The purified product is then processed into flakes, stored in bags, and shipped.
The bottom product, containing the remaining p-PDA, m-PDA, and a small fraction of o-PDA,
is stored in the ST-105 tank, which acts as the feed for the C-700 column.
• The feed from ST-105 is introduced into C-700, where an initial collection of o-PDA is made.
Once all the o-PDA is collected and stored, a cut of p-PDA is obtained from the top and
processed into flakes. The bottom product, rich in m-PDA fraction and traces of other isomers,
is recycled back into the crude tank (ST-121) for further processing.
• The bottoms of the C-1600 column, stored in ST-102, are fed into the C-1400 column, where
pure m-PDA with a purity of less than 99.85% is collected and stored in tanks or processed
into flakes from the top. The bottom product is recycled back into the ST-121 crude tank.

Steam Generation, Reflux, and Product Collection

• The top of C-1600 and C-1100 columns are connected to two condensers (primary and
secondary) mounted on top. These condensers utilize hot water streams to condense the
process vapors and generate steam used throughout the plant.
• The hot vapors from the column enter the primary condenser's shell side, while hot water
below 100°C (approximately 95-98°C) from the DM Water Tank is heated and circulated on
the tube side, entering a steam drum.
• The hot process vapor exchanges heat with the incoming hot water, resulting in partial
condensation and vaporization of the water stream, generating steam that is directed into the
steam drum.
• The uncondensed vapor ascends to the secondary condenser, where it undergoes processing
with hot water at approximately 80°C, a temperature lower than that of the primary
condenser. The hot water, which experiences a temperature increase of 3-5°C, is then
circulated into a tank and subsequently cooled down using a plate type heat exchanger (PTHE).
• The condensed feed falls back into the column, acting as internal reflux due to the condensers
being top mounted onto the column.
• When the desired product purity is achieved, the product is collected from the top through a
line connected to the internal reflux line. By closing the valve, the column operates under total

16
 reflux condition. The collection line extends deep into a dip pot, where the product is
collected. Since the line is submerged in liquid, it prevents the entry of any vacuum into the
tank.

ETP:

• The effluent generated from the dehydration process of PDA product in the BUSS-3 plant is
directed to an Effluent tank, where the water separated from the crude is collected and later
treated in the ETP.
• The effluent from the storage tank is transferred to a stripper column, where volatile organic
compounds are removed from the top, while the remaining effluent from the bottom is
conveyed to the MEE feed tank.
• The top portion of the effluent is heated and introduced into a GLR-system (Glass Lined
Reactor) for treatment using FeSO4/H2O2/Spent acid. After cooling to 30-40°C in a graphite-
type heat exchanger, the acidic product is stored in a tank.
• The acidic solution from the storage tank is then treated in a neutralizer reactor, where lime
is added to bring the effluent to a pH of 7.

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• Subsequently, the effluent undergoes filtration using a filter press equipped with polystyrene
sheets as filters. The sludge is extracted from the bottom, while the filtered effluent passes
through the filter press.
• The filtered effluent enters a system of Multiple Effect Evaporators, which consists of several
evaporator units operating in series. In the primary effect, steam is used to heat the effluent,
causing water to evaporate, and increasing the concentration of impurities while reducing the
volume. The vapor produced in each effect is then transferred to the subsequent effect,
further concentrating the effluent. This process continues until the final effect, where the
concentrated effluent is collected from the bottom, while the remaining vapor is condensed
and collected from the top.
• The purified water (top product) is directed to the Soil Biotech plant (SBT), where it passes
through layers of rocks and sand with varying particle sizes, effectively filtering out any
remaining impurities. In some cases, bio-organisms may also be utilized in the process.
• The bottom product from the MEE is either recycled back into the filter press or directed to
an agitator thin film dryer (ATFD) to remove any remaining moisture. In the ATFD, water which
forms a thin film against the walls of the dryer is vaporized from the top, while the solids are
collected at the bottom.
• The filtered water is then sent to an RO plant, which includes three main tanks: feed,
permeate, and reject. The water obtained from the SBT is introduced into the feed tank and
passes through two sets of filters (Cartridge filter with a range of 10-50 microns and Sand filter
with a size of <0.05 microns) to remove particles of respective sizes. The filtered water is then
pumped using a high-pressure pump (up to 30 bar) through three sets of membrane filters
(<0.01 micron) in series, each employing its own high-pressure pump.
• The purified water (permit) is directed to a degasser tank to release any dissolved gases. It is
then sent to a cooling tower for circulation or used as makeup water. The reject stream is
recycled back into the MEE system for further purification.

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4. Power Plant
• The captive power plant constructed within the Zone-II campus is designed to meet the power
requirements for operating various facilities. Its maximum capacity is 8 MW, but it typically
operates at around 4-5 MW.
• The power plant's design is based on the Rankine cycle principle, where coal is burned to produce
heat that vaporizes water, driving a turbine to generate electricity.
• The power plant involves three primary cycles: the coal cycle, water cycle, and air cycle.
• In the coal cycle, bituminous coal is stored in a coal yard and fed into a crusher through a belt
conveyor. The crushed coal is then sieved, with particles smaller than 8 mm passing through, while
larger particles are recycled back into the crusher.
• The crushed coal is collected in a hopper through various feed lines, which are equipped with
forced draft fans to evenly distribute the particles and prevent back flushing and fires.
• The coal is combusted in the furnace, reaching temperatures exceeding 650°C. Combustion occurs
on the shell side of the furnace, producing heat and flue gases that are utilized to generate steam.
• The hot flue gases pass through an economizer, where they heat up the nearby water, and then
proceed through an air preheater, which heats the incoming air with the remaining heat from the
flue gases.
• The cooled gases are directed to an electrostatic precipitator, where the particles are ionized and
collected on charged plates. The collected particles are then removed by shaking the plates from
the bottom. The remaining gases are released through the stack with the assistance of an induced
draft fan, which pulls the air towards the stack.
• In the water cycle, water from the GIDC undergoes treatment in the DM plant and is stored in a
DM tank. High-pressure pumps transport the DM water to the steam drum, which is pressurized
due to the presence of steam. The water circulates on the tube side through the economizer,
where it is heated by the hot flue gases, reducing the overall heat load required and efficiently
utilizing the heat generated during combustion. The heated water then enters the furnace, where
the generated heat vaporizes the water on the tube side.
• The vaporized water is directed into the steam drum, and from there, it passes through a series of
superheaters, further increasing the steam temperature.
• The superheated steam is divided into two streams: one is sent to the turbine for electricity
generation, while the other is supplied to other plants through a common header, where steam is
used.
• The superheated steam drives the turbine, rotating it at a rate of 8330 rpm. The mechanical energy
is then converted into electrical energy by an alternator connected to the turbine via a gearbox,
regulating the shaft speed. The electricity generated by the alternator is transmitted to a
substation and connected to different plants through a grid.
• The air cycle involves the supply of air required for ignition and combustion into the furnace,
facilitated by primary air (PA) fans and forced draft (FD) fans, respectively. The resulting flue gases
pass through the economizer, air preheater, and electrostatic precipitator before being pulled into
the stack by an induced draft (ID) fan.

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20
5. Utilities
• Cooling water
o Two Induced draft cooling water working in counter current manner of blue chip
company.
▪ 2000 TR which is used for the main plant.
▪ 500 TR used for ETP plant.
• Chilled water
o It is used in liquid ring vacuum pump for maintaining the fluid (ODCB) temperature.
Screw type chiller with capacity of 100TR is used to chill process water. The
refrigerant used is R134. Chiller is of Daikin company.
• Instrument Air
o As the plant is automated, all the control valves are worked on air. So instrument
air tank with a capacity of 560CFM and an instrument air dryer to remove the
pneumatic moisture from the air, Dryer is a Heatless Desiccant Air dryer from
Kaesar company.
• Breathing Air
o Primarily used to provide respiratory protection to workers in hazardous
environments and during confined space entry, ensuring a safe breathing
environment free from contaminants, toxic gases, and oxygen deficiency. They are
available on every floor in the form of a "SCBA" (Self-Contained Breathing
Apparatus) mask. Two Breathing Air receiver tanks with a capacity of 4.5m3 and
1m3 and two breathing air compressors with a capacity of 91CFM from Anesta
Iwata company.
• Nitrogen
o It is used for blanketing all reactors and storage tanks to prevent contact with air
and other impurities. Nitrogen receiver with a capacity of 18m3, nitrogen comes
from a neighboring plant.
• DM water plant
o It is used to remove ions and impurities from water, specifically to produce high-
purity water which is used in washer 3. DM Plant Package with a capacity of 40KLD
from Anil and co
• Soft Water Plant:
o It is used to remove hard minerals, primarily calcium, and magnesium, from water.
o Soft Water Plant Package with a capacity of 50m3/hr from Wipro water.
• Steam
o Steam comes from coal-based power plants, 20TPH steam is used for the process
of the plant and the rest is used in a turbine to generate electricity for the plant.

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6. Equipment Design
6.1 Condenser Design

1. List the Component Properties and Process Parameters of the system to be designed:

2. Calculate the Heat Load and LMTD based on the inlet and outlet temperatures and the
mass flowrate of the system.
3. And calculate heat transfer area based on the assumed Overall Heat Transfer Coefficient
(U) based on the system on shell and tube side.

22
4. Specify the Tube Details based on which the number of tubes is obtained for our initial
guess. Use standard values available in literature.

5. Tube and Shell side calculation:

a. For selected pitch type (triangular/square) select the corresponding K and n values
and calculate the tube bundle diameter.
b. Select the clearance required based on the type of heat exchanger being designed
and calculate the corresponding shell diameter.
c. Baffle spacing can be determined by the baffle spacing factor chosen for design.
d. Cross flow area, shell and tube side velocity are calculated individually.

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6. Shell and Tube Side Heat Transfer Coefficients:
a. For the tube side normal heat transfer coefficient correlation based on Reynolds
and Prandtl numbers as given for shell and tube exchanger design.
b. For the shell side, since phase change is to be accounted for and the heat transfer
coefficient is calculated based on modified correlation which accounts for
condensate rate per unit length.
c. The jh factor is to be obtained from the corresponding graphs for shell and tube
sides.

7. Overall Heat Transfer Coefficient: define fouling factors on tube and shell side and based
on the shell and tube heat transfer coefficients obtained, overall heat transfer coefficient
is calculated (Ucalc).
8. Iterate the process till error% is less than 10%, or till it is satisfactory for the user. Based
on this updated U, heat transfer area, number of tubes are updated accordingly.

24
9. Pressure Drop Calculations: heat exchanger is overdesigned for practical applications,
updated velocity on shell and tube side is taken.
10. Corresponding friction factor is be obtained from the graph for both tube and shell side
respectively based on which the pressure drop on each side is calculated. Make sure
specifications fit design requirements. Make changes as seen fit to optimize the system.

25
6.2 Reboiler Design

1. List the Component Properties and Process Parameters of the system to be designed:

2. Calculate the Heat Load and LMTD based on the inlet and outlet temperatures and the
mass flowrate of the system.
3. And calculate heat transfer area based on the assumed Overall Heat Transfer Coefficient
(U) based on the system on shell and tube side.

26
4. Specify the Tube Details based on which the number of tubes is obtained for our initial
guess. Use standard values available in literature.

5. Tube and Shell side calculation:

a. For selected pitch type (triangular/square) select the corresponding K and n values
and calculate the tube bundle diameter.
b. Select the clearance required based on the type of heat exchanger being designed
and calculate the corresponding shell diameter.
c. Baffle spacing can be determined by the baffle spacing factor chosen for design.
d. Cross flow area, shell and tube side velocity are calculated individually.

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6. Shell and Tube Side Heat Transfer Coefficients:
a. For the shell side, phase change is to be accounted for and the heat transfer
coefficient is calculated based on modified correlation which accounts for
condensate rate per unit length.
b. For the tube side, accounting for multiphase flow, calculate the heat transfer
coefficient based on Chens method for convective boiling coefficient.

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7. Overall Heat Transfer Coefficient: define fouling factors on tube and shell side and based
on the shell and tube heat transfer coefficients obtained, overall heat transfer coefficient
is calculated (Ucalc).
8. Iterate the process till error% is less than 10%, or till it is satisfactory for the user. Based
on this updated U, heat transfer area, number of tubes are updated accordingly.

9. Pressure Drop Calculations: heat exchanger is overdesigned for practical applications,

updated velocity on shell and tube side is taken.
10. Corresponding friction factor is be obtained from the graph for both tube and shell side
respectively based on which the pressure drop on each side is calculated. Make sure
specifications fit design requirements. Make changes as seen fit to optimize the system.

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6.3 Pump Design and Piping
1. Define fluid properties, pumping requirements, and suction and discharge lengths.

2. Detail the number and types of fittings on suction and discharge sections.

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3. Discharge Section Calculation
a. Define the maximum velocity allowed, based on which the minimum diameter of the pipe
is calculated. Pick the closest standard pipe available.
b. Check if the flow is in turbulent region.
c. Calculate Pressure drop per unit length based on Fanning or Darcy equation.
d. Pressure drop across fitting scan be calculated either by using equivalent length method
or based on number of velocity heads (K) lost in pipe.
e. Total pressure drop is summed up across the length of the pipe and the fittings.

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4. Suction Section Pressure Drop
a. Similar calculation is done on the suction side.

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5. Calculate the Net positive Suction Head available (NPSH)A
Note: make sure NPSHA > NPSHR (NPSHR vs capacity curves are provided by the manufacturer).

6. Calculate Dynamic Head (difference between discharge and suction head).

7. Motor Power Required for pumping the fluid is calculated for given capacity. Motor needs to be
designed accordingly to fulfill pumping requirements.

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References

• Coulson & Richardson’s Chemical Engineering, Volume 6, Fourth edition, Chemical

Engineering Design, R. K. Sinnott
• Thakore, S. B. (2015). Introduction to process engineering and Design. McGraw hill
education(India) Pvt. Ltd.

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