Nirma 1.1

INPLANT TRAINING AT NIRMA PRIVATE LIMITED.
A PROJECT REPORT
Submitted by
VAGHAMASHI DHAVAL BHAVESHBHAI
(190310105073)
In partial fulfilment for the award of the degree of
BACHELOR OF ENGINEERING
in
Chemical Engineering
Lukhdhirji Engineering College, Morbi
Dr. A. D. BALDANIA Dr. R. K. MEWADA

Internal guide Head of department
Gujrat Technological University, Ahmedabad
[July, 2022]
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LUKHADHIRJI ENGINERING COLLEGE MORBI
CERTIFICATE
This is to certify that the internship entitled “In-Plant Training at NIRMA

Private Limited” Was successfully carried out by, Mr. Dhaval Bhaveshbhai
Vaghamashi Enrollment No. 190310105073 Under my guidance in fulfillment
of the degree of Bachelor of Engineering in Chemical Engineering (8th semester)
of Gujarat Technological University, Ahmedabad During the academic year
2023-24.
Dr. A. D. BALDANIA Dr. R. K. MEWADA
Internal guide Head of department
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iii
DECLARATION
We hereby declare that the Internship report submitted along with the
Internship entitled ‘In-Plant Training at NIRMA Private Limited’ submitted
in partial fulfillment for the degree of Bachelor Engineering in Chemical
Engineering to Gujarat Technical University, Ahmedabad is a bonafide
record of original project work carried out by us at NIRMA PVT LTD. under
the supervision of Mr. Piyush Patel and that no part of this report has been
directly copied from any students reports or taken from other sources, without
providing due reference.
Name of Student Sign of Student
Mr. Dhaval Bhaveshbhai Vaghamashi
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ACKNOWLEDGEMENT
I would like to make my deepest appreciation and gratitude to Mr. Piyush Patel (AGM of
training dept.) for him valuable guidance and encouragement during every stage of this
Internship. He was supportive throughout the Internship and was always ready to help. I would
like to special thanks Mr. Jatin Faldu who provided me the opportunity to work on field area.
Thanks to Rahul Thumar, Jitendra Patel & Ankur Rana for being uniformly excellent
advisor. They were always helpful & provided broad ideas. I’m thankful to Dr. A. D.
Baldania & Dr. R. K. Mewada (HOD Of Chemical Engineering Department) for him
constant support during whole Internship. I sincerely express my gratitude toward the NIRMA
PVT LTD. for providing this Opportunity.
VAGHAMASHI DHAVAL BHAVESHBHAI SIGNATURE
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ABSTRACT
An internship - a vital part of the engineering curriculum provides engineers a

chance to work with cutting-edge technologies and gives them knowledge of the
practical aspects of their studies. An internship gives a student the opportunity for
career exploration and development, and to learn new skills. It offers the
employer the opportunity to bring a new ideas and energy into the workplace,
develop talent and potentially build a pipeline for future full-time employees has
offered this Internship and for its completion I did my internship at NIRMA PVT
LTD. under the supervision of Industrial guide. The report tells us about the work
challenges/ problems/ solutions which one faces while actually working in that
environment not only in technical section but one also gets to know about the
importance of ethics which one needs to follow while doing a job.
Key Words : Soda Ash, Bicarbonate, Dense Ash, SABR, Lime Kiln Section.
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LIST OF
FIGURES
Fig 1.1 Nirma private limited..................................................................................................6

Fig 2.1 Process Flow Diagram of Soda Ash............................................................................5
Fig 3.1.1 Section – 100, Demag Plant Flow Diagram..............................................................8
Fig 3.2.1 Section – 200, Lime kiln.........................................................................................9
Fig 3.3.1 Section – 300, Absorption and Distillation.............................................................11
Fig 3.4.1 Section – 400, Carbonation.....................................................................................13
Fig 3.5.1 Section – 500, Filtration and Calcinations.............................................................15
Fig 3.6.1 Section – 600, Densification...................................................................................18
Fig 3.7.1 Section – 700, Soda Ash Storage and Bagging.......................................................21
Fig 4.1 RODM Plant................................................................................................................27
Fig 8.1 Glass Lined Reactor Mechanical Design.................................................................33
Fig 10.3.1 Safety shoes.........................................................................................................33
Fig 10.3.2 Safety helmet.......................................................................................................34
Fig 10.3.3 Safety gloves........................................................................................................34
Fig 10.3.4 Safety goggles......................................................................................................34
Fig 10.3.5 Safety mask..........................................................................................................34
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LIST OF TABLE
Table 1.6 List of raw material…...........................................................................................3
Table 1.7 List of product.......................................................................................................3
Table 1.8 Equipment used by company….............................................................................8
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i
TABLE OF CONTENT
GTU CERTIFICATE ii
INDUSTRIAL CERTIFICATE iii
DECLARATION iv
ACKNOWLEDGEMENT v
ABSTRACT vi
LIST OF FIGURE vii
LIST OF TABLE viii
TABLE OF CONTENT ix
CHAPTER 01: INTRODUCTION 1
Company overview 1
Employer detail 3
Different Plants in Our Company 3
Different Department in Soda ash Plant 3
Classification of our product 3
List of Raw Material 4
List of Product 4
Equipment used in our company 5
CHAPTER 02: PROCESS FLOW DIAGRAM (PFD) 6
2.1 Different Sections in Soda Ash Plant 6
2.2 Main Raw Material 6
2.3 Main Product 7
CHAPTER 03: UNIT PROCESS AND UNIT OPERATION 9
3.1 Section 100: Brine Preparation and Purification
3.1.1 Raw Material
3.1.2 Equipment Used
3.1.3 Process
3.1.4 Final Process
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UNIT PROCESS 7
SABR Section 7
3.3. KILN Section 12
Process House 16
Refrigeration 22
Calcination 24
Dense Ash… 26
Refined bicarbonate plant 30
CHAPTER 04: WASTE HANDLING… 31
Waste water handling 31
Noise pollution control measure 31
Solid waste handling and disposal… 32
CHAPTER 05: SAFETY… 33
Safety policy… 33
Personal protective equipment… 33
Types of PPE’s… 33
Colour coding… 35
Fire Extinguisher… 35
CHAPTER 06: CONCLUTION AND DISCUSSION… 36
Overall analysis of internship… 36
Problem encountered and possible solution… 36
Summary of internship… 37
REFERENCE 38
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293064 Introduction
CHAPTER-01: INTRODUCTION.
1.1 Company Overview:
Nirma story began in 1969, when Dr. Karsanbhai Patel rolled out the first bag of phosphate free
synthetic detergent powder. Signaling the launch of Nirma and that first bag of Nirma was
destined to change the Indian detergent industry hitherto dominated by multinational players
offering high priced products to a small segment of the population.
Within a short span of three decades, Nirma has completely rewritten the rules of the game
offering high quality products of unbeatably low prices. In the process Nirma has helped
expand the entire soaps and detergent market to a low level of Rs. 82 billion.
TODAY, Nirma has Rs. 16 billion shares in this market. This has been possible through its
focus on cost effectiveness by Integrate latest technology manufacturing facilities with
Innovative marketing strategies to create world class brand.
By, 1999, Nirma was a major consumer brand – offering a range of detergent, soaps and
personal care products. Keep in mind to provide quality products at the best possible prices.
Nirma brought in the latest technology for its manufacturing facilities at six locations in India.
Nirma's success in the highly competitive soap and detergent market was attributed to its
brand promotion efforts, which was complemented by its distribution reach and market
penetration. Nirma's network consisted of about 400 distributors and over 2 million retail
outlets across the county. This huge network enabled Nirma to make its products available at
the smallest village.
Nirma was founded on 25th Feb 1980 by chairman and managing director Dr. Karsanbhai Patel
and it registered as public limited company in 23 rd March 1993. Leading company instantly
recognized as “Indian Brand” for detergents and soaps.
Nirma is engaged in the business of consumer’s products like soap, detergent and industrial
products like sulfuric acid, oleum, distilled fatty acids, linear alkyl sodium silicate, and soda
ash.
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293064 Introduction
Fig 1.1 “NIRMA PVT LTD, BHAVNAGAR”
The company mission to provide

“Better Products, Better Value, Better Living”
Contribute a great deal to its success
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293064 Introduction
1.2 Employer Details:
 Owner Name: Dr. Karsanbhai Patel
 Managing Director & CEO: Mr. Hiren K. Patel
 Production Manager: Mr. Chirag Parekh
1.3 Different Plants in our company:

 Soda Ash Plant
 Salt Plant
 Caustic Soda Plant
 CCG Plant
1.4 Different Department in Soda ash Plant:

 Central Lab
 Section - 100
 Section - 200
 Section - 300
 Section - 400
 Section - 500
 Section - 600
 Section - 700
 RODM (Reverse Osmosis De-mineralized)
 PWP (Pure Water Plant)
 RBC (Refined Sodium Bicarbonate)
1.5 Classification of our product:

There is no other Inorganic Chemical that torches our daily lives like Soda Ash and its
derivative Sodium bicarbonate. Also, a large number of industries depend on Soda Ash.
In U.S. and other developed countries the pattern of use of soda ash in like: Glass 49%, other
chemicals 23%, Soaps and detergents 13%, flue gas desulphurization 3%, pulp and paper 2%,
others 10%.
In India the pattern of use is: Detergents 42%, glass 23%, Chemicals 17%, silicate, Water
treatment, paper and others 18%.
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293064 Introduction
Due to sophisticated modern construction practices, glass has become a vital construction
material in buildings. Use of fiber glass Reinforced polyester (FRP) is finding an increase in
Industries and infrastructure projects. In addition, demand from Automobile industries for glass
is substantial.
The other industries for which soda ash is essential are: Sodium dichromate, Sodium silicate,
sodium Nitrate, Sodium Nitrite, Sodium Tri polyphosphate. Sodium bicarbonate, Water
treatment, Textiles, Steel, Metallurgy, Petroleum industry, Organic dyes and colors", Enamel
industry, Pigments etc.
1.6 List of Raw Material:

Table 1.6 “List of Raw Material”
Sr Name Chemical State Molecular Weight

No. Formula (g/mol)
1 Salt NaOH Solid 39.997
2 Lime Stone – Porbandar Ca(OH)2 Solid 100.0869
3 Lime Stone – Oman Ca(OH)2 Solid 100.0869
4 Siberian Coal C Solid 303.353
5 South Africa Coal C Solid 303.353
6 Nat coke C Solid 303.353
7 Make up Ammonia NH3 Liquid 17.0306
8 Soda Ash for Brine Na2CO3 Powder 105.9888
Purification
1.7 List of Product:

Table 1.7 “List of Product”
Sr. Product Name Capacity Tones/Day

No
1 Soda Ash Dense
2 Soda Ash Light 2800
3 Soda Bicarbonate
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293064 Introduction
1.8 Equipment used in our Company:
Table 1.8 “Equipment used by company”

Sr. Equipment
No
1 Salt Dissolver
2 Lime Kiln
3 Gas Washer
4 Venturi Scrubber
5 Hydrator
6 Classifier
7 Hydroclone
8 Absorber
9 Tower Washer
10 Filter Gas Washer
11 Carbonating Tower
12 Rotary Drum Filter
13 Air Blower
14 Cooling Tower
15 Heat Exchanger
16 Gate Valve
17 Screw Compressor
18 Filter Tank
19 Cyclone
20 Gas Riser
21 Bubbler
22 Pre Heater
23 Condenser
24 Std Drum
25 Surge Hopper
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293064 Process flow Diagram
CHAPTER-02: PROCESS FLOW DIAGRAM (PFD)
Soda ash, also known as sodium carbonate (Na-CO), is an alkali chemical refined from the
mineral trona or naturally occurring sodium carbonate-bearing brines (both referred to as
natural soda ash), the mineral anchorite (referred to as natural sodium bicarbonate, from which
soda ash can be produced), or manufactured from one of several chemical processes (referred
to as synthetic soda ash).
It most commonly occurs as a crystalline dehydrate, which readily effloresces to form a white
powder, the monohydrate. Pure sodium carbonate is a white, odorless powder that is
hygroscopic (absorbs moisture from the air). It has a strongly alkaline taste, and forms a
moderately basic solution in water. Sodium carbonate is well known domestically for its
everyday use as a water softener. Historically it was extracted from the ashes of plants growing
in sodium-rich soils, such as vegetation from the Middle East, kelp from Scotland and seaweed
from Spain. Because the ashes of these sodium-rich plants were noticeably different from ashes
of timber (used to create potash), they became known as “soda ash”. It is synthetically
produced
in large quantities from salt (sodium chloride) and limestone by a method known as the Solvay
process.
2.1 Different Sections in Soda Ash Plant

1. Section 100:-brine preparation & purification
2. Section 200:-lime kiln & Gas Cleaning
3. Section 300:-lime grinding, absorption & distillation
4. Section 400:-carbonation
5. Section 500:-filtration & calcinations
6. Section 600:-densification
7. Section 700:-product storage & handling
Mainly it can be dividing in two parts first is DCS system or second is Panel and Field work.
2.2 MAIN RAW MATERIAL:-

 Sea water
 Calcium carbonate
 Coke
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2.3 MAIN PRODUCT: -

➢ Soda ash
Fig 2.1 “Process Flow Diagram of Soda ash”
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Process take place in each and every section is...

In section 100: Brine is prepared and purified.
In section 200: Lime stone is converted into CaO and CO2, and also combustion and gas
purification take place in lime kiln section.
In section 300: there are mainly three types of process, first is lime grinding, second is
ammonia recovery and third is distillation.
In section 400: Ammoniated liquor is converted to carbonation liquor using CO₂ in
carbonation column.
In section 500: Bicarbonate cake is filtered out from the carbonated liquor using rotary
vacuum filter while mother liquor is sent to section 300 and cake is sent to calciner for the
liberation of CO₂, here light soda ash is produced and sent for packaging section.
In section 600: In this section dense soda ash produce from light soda ash by hydrating and
drying using fluidized bed.
In section 700: Dense soda ash and Light soda ash is sent to packing.
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293064 Unit process and Unit Operation
CHAPTER-03: UNIT PROCESS AND UNIT OPERATION
3.1 SECTION 100: - BRINE PREPARATION AND PURIFICATION

3.1.1 RAW MATERIALS: -
 RO water / Treated water
 Milk of lime
 Salt
 Flocculent
 Soda ash solution
3.1.2 EQUIPMENTS USED

 Conveyor Belts
 Centrifugal Pump
 Screw Pump
 Piston Pump
 Continuous Stirred Tank Reactor
 Settler With Agitator
3.1.3 PROCESS: -
Treated water / RO water from storage and salt from local salt works are mixed in dissolver and
saturated solution of salt is made brine will have impurities like Ca+1 and Mg+2 ions, which
are to be removed for Further process. To remove this Impurities Raw Brine is mixed with
Soda Ash solution and Milk of Lime. The reaction is as following:
Ca+2 + Na2CO3 → CaC03 + 2Na+1
Mg+2 +Ca(OH)2 → MgOH + Ca+2
This reaction takes place in 3 reactors present at section 100. After these reactors the brine goes
to Settler where flocculant is added to settle down impurities present as precipitates of and Mg
(OH)2 as a slurry form. The overflow of this settler is taken out which is pure is Called as pure
brine which is collected in pure brine tank and sent to further process.
The settled slurry in settler is kept out as a waste and washed with incoming raw brine to collect
the residue of NaCl remaining in the waste slurry. Then this slurry is sent To ETP plant for
final disposal as a Waste.
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3.1.4 FINAL PRODUCT:
Pure Brine
Fig 3.1.1 “Section - 100, Demag Plant Flow Diagram”

3.2 SECTION 200: LIME KILN & GAS CLEANING
3.2.1RAW MATERIALS
 Limestone
 Coke
 Air
3.2.2 EQUIPMENT USED

 Vertical Shaft Kiln
 Vibro Feeder
 Air Fan
 Elevating Bucket
 Scrubber
 Electrostatic Precipitator
 Weigh Bin
3.2.3 PROCESS
I. Lime stone is imported from Dubai Saudi Arabia and other local mines which comes to RMH
which will have size about 60-120 mm will be converted to 30-60 mm sized stones in grinding
mill.
II. This lime stones goes to lime bunker located at the top of the section from where it is
transported to screening via vibro feeder where under size particles are recycled to the Bunker.
From screening regular size stones will go to weighing bunker where desired amount of lime
stone is feed.
III. Coke coming from RMH is stored in Coke bunker and then transferred in weighing bunker.
The mixture of Lime stone and coke is feed with conveyor belt to elevating bucket which Feeds
the mixture to the top of the kiln.
IV. At Nirma there is Vertical shaft kiln is used to decompose CaC0 3 into CaO and C02. The
height of the lime kiln is 31m each, in which effective height is 28m. To reduce heat looses by
conduction and radiation kiln is insulated with brick lining about 600mm.
V. Kiln’s outside diameter is 6.5m and inside diameter is 5.3m. This kiln is designed such that
the residence time of material is about 48hrs. There are total 8 kilns in section-200. Lime kiln
are divided into three zones.
VI. Top zone it is called pre-heater zone in which temp is maintained about 300-350°C.
VII. Middle zone it is called reaction zone in which decomposition reaction of calcium
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carbonate (CaCO3) takes place and carbon dioxide gas (CO 2) is released. The reaction is as
following:
CaCO3 → CaO + CO2
Limestone quick lime
2C + O2 → 2CO
2CO + O2 → 2CO2
viii. Cooling zone in this zone temp is maintained around 200°C by passing air by air Blower.
The CO2 gas is raised with the atm air provided by the air fan from the bottom of the kiln, and
remaining lime Cao is collected from the bottom via table and transported to section-300.
IX. The CO2 collected from the top of the kiln is sent to gas scrubber in which water is spread
from the top and the gas is passed from the bottom. Clean gas is obtained from the top of the
scrubber, thus SO2 is removed from CO2 gas.
X. From scrubber CO2 goes to electrostatic precipitators to separate dust particles from kiln Gas
in these precipitators high voltage electric current is used as an electrode to collect ionic
particles from the gas. After electrostatic precipitation the gas is sent to utility department for
compression.
3.2.4 STEPS FOR IDEAL OPERATIONS OF KILN ARE

 Charging sequence
 Discharging sequence
 Kiln air fan operation
 Gas cleaning
 Undersize material handling
3.2.5 FINAL PRODUCT

1. CO2 Gas (40%)
2. Quick Lime
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Fig 3.2.1 “Section – 200, Lime Kiln”
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3.3 SECTION: 300 Absorption, Distillation & lime grinding
3.3.1 RAW MATERIAL

 Mother liquor from section 500
 Lime from section 200
 Pure brine from section 100
3.3.2 PRODUCT
 A-liquor(NaCl + NH3 + H2O)
3.3.3 CHEMICAL REACTIONS

 Free Still
NH3(gas) → NH3(Aq.)
NH3+ H2O + CO2 → NHCO3
2NH3 + H2O + CO2 → (NH4)2CO3
NaCl + NH3 + H2O + CO2 → NaHCO3 + NH4CI
2NaCl + 2NH3 + H2O + CO2 → Na2CO3 + 2NH4CI
 Fixed Still
2NaOH + CaCO3 → Na2CO3 + Ca(OH)2
CaCO3 + H2O → CO2 + Ca(OH)2
CaCl2 + 2NH4OH → 2NH4CI+ Ca(OH)2
3.3.4 PROCESS
The section 300 is for ammonia recovery. First mother liquor from section 500 is heated
in plate type heat exchanger (PHE) by the high temperature NH3 gas to remove CO2 gas from
mother liquor. The mother liquor temperature form PHE is 60-62°C. The mother liquor
contains free ammonia in form of NH4OH and fixed ammonia in form of NH4Cl. Free ammonia
can be removed by heating but fixed ammonia is not removed by heating so milk of lime is
added for the removal of fixed ammonia.
The mother liquor is sent to free still stripping column where the free ammonia in form
of NH2OH is removed from the mother liquor by stripping with hot ammonia gas. Then mother
liquor is taken to prelimer in which milk of lime is added to recover fixed ammonia. To avoid
that ammonia still liquor to environment very slight vacuum is maintained in prelimer. The
content of prelimer is agitated by agitator to mix reaction mixture & dosed lime. Than reaction
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mixture is flows to settler coarse particles settle in settler. The precipitate is kept in mother by
scrapper to prevent coagulation.
Lime grinding and MOL preparation: The particle size of lump lime from kiln is reduce
in 2 steps s one in lime crusher to 20-50 mm and Particle size is further reduce in lime mill until
90wt% of particle is smaller than 0.15 mm. Here the pendulum roller mill is used. The lime
particles are separated from circulation air in lime cyclone. Rotary valve is purged with plant
air to prevent escaping of vapors from prelimer. Classifier separate lime in fine & coarse
particles. Fines are discharged to lime buffer and coarse lime is dissolved in purified brine to
obtain MOL which is supplied to MOL tank.
Most of the ammonia formed in prelimer is taken from the top of the prelimer and
remaining ammonia is recovered using distiller which is called fixed still. The slurry from the
prelimer is taken to settler where gases and CaCl, is separated. Overflow of settler is fed to top
of distillation column. Distillation column is having single bubble cap trays. Ammonia is
recovered after heating to 92°C with the help of 2.5 bar steam.
The steam ejector is provided for creating vacuum and recovering 2.5 bar steam from
hot water using 8 bar steam. This reduces effluent treatment load, steam requirement and
circulation cost. The recovered ammonia is taken to absorption column and ammonia is
absorbed in brine solution. The absorption column has two zones strong absorption (at bottom)
and weak absorption (at top).
This whole system is operated under vacuum.
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Fig 3.3.1 “Section – 300, Absorption, Distillation”
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3.4 SECTION 400: CARBONATION
3.4.1 RAW MATERIALS

 Ammoniated Liquor From (Section 300)
 Carbon Dioxide From (Section 200 + Section 400)

 Carbonation Tower
 Centrifugal Pump
3.4.3 COMPRESSION PROCESS

The gases required in the carbonation are compressed by compressor. The entering
gases stream are rich gas from calciner gas condensation (sec 500) with high carbon Dioxide
gas (95% by volume) lime kiln gas from kiln (sec200) with low c02 content 40% by volume.
In bottom gas compressor a mixture of kiln and calciner gas of c02 content 80% by
Volume. All recycle rich gas system for this suction pressure 4.1 bar absolute.
Middle gas compressor compresses the kiln gas from 0.9 to 2.95 bar absolute is Middle
gas and cleaning gas compressor compress 0.9 to 4.1 bar is called cleaning Gas.
Compressors are stream turbine driven with speed control for constant exhaust pressure.
The seed of turbine is controlled by stream flow. Depending on speed There is a minimum gas
through put for each compressor below this through put the compressor operation become
unstable. If the required compressor capacity is lower than minimum through put. Some
compressed gas will be recycled to prevent Surging.
In the suction of compressor process water in injected to prevent fouling of Compressor

internal; and to cool by circulation of water in scrubber.
Water flow is circulated by pump and cooled by water in PHE water of gas compression
resulting from water injection in compressor to wet controlled pump to other process section.
Ammonia contain water of bottom compression is set to Calciner gas condenser. Ammonia free
water and middle gas compression is flow controlled send to flash water tank. Liquors are
collected in sump pit and pumped to slops tank.24
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3.4.4 CARBONATION
Ammoniated brine from absorption is stored in A- liquor tank. The carbonation of A-
liquor tanks place in 2 groups of 5 carbonation tower. In each group one by one Cleaning is
done and remove bicarbonate scale sediment during production cycle.
The remaining 4 towers of this group are operating in production cycle. A cleaning take
approximately 16 hours and production cycle 64 hours. The A liquor is flow controlled pumped
by to cleaning tower.
The sediment bicarbonate in the tower will dissolve in A-liquor on its way from top of
bottom of cleaning tower. A certain amount of gas is needed to obtain sufficient agitation in
cleaning tower. Some cleaning gas is fed flow to bottom of tower.
Carbone dioxide content of carbonate brine (c-liquor) in bottom of cleaning tower is

Kept constant (l .6 kmol / m3) by adjusting quantity of cleaning gas fed to tower.
Cleaning of carbonation tower it is important that carbon dioxide content of A-Liquor is

not high. Heat is generated by absorption of carbon dioxide; heat is removed by cooling water
at bottom part of tower. C-liquor flow via over flow top to C-liquor storage. It is pumped from
storage to top of 2 group of 4 parallel operating production tower. Carbon dioxide gas is flow
controlled supplied at bottom and at middle of production tower.
Gases flow counter current with respect to liquid to top of tower. The carbon dioxide is
dissolved in liquid followed by crystallization due to exothermal reaction; cooling of liquor is
required to reduce temperature and obtain NaHC03. Cooling take Place with cooling water and
chilled water.
In tower operating temperature control is obtain well grow NaHC03 crystals. The
escending C-liquor increase in temperature to 65 oc in tower part of column cooling bases are
installed and down temperature.
The bicarbonate slurry is cooled by both cooling water and chilled water. The upper part
of cooling section is cooled by cooling water and lower part of cooling section is cooled by
chilled water.
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Fig 3.4.1 “Section – 400, Carbonation”
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Bottom liquor (draw liquor) flow to filtration section 400 from top of carbonation tower
is separated from liquid in separator and washed with brine to remove ammonia collected liquor
in flow to C-liquor tank. The production rate of tower is controlled by gas flow to tower.
Middle gas supply offers best starting point for capacity of carbonation. The quantity of
bottom gas is depended on an amount of gas in calcinations. Other reactant C-liquor follow
automatically changed in carbon dioxide which is change heat of reaction.
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3.5 SECTION 500:- FILTRATION AND CALCINATION
3.5.1 RAW MATERIALS

 D Liquor(Draw Liquor)
3.5.2 EQUIPMENTS
 RVDF(Rotary Vacuum Drum Filter)
 Lewis Conveyor
 Calciner
 Vacuum Pump
 Scrubber
3.5.3 PROCESS
The bicarbonate slurry from carbonation tower is filtered by rotary vacuum drum filter.
And then send to calciner to remove moisture in bicarbonate.
In this section we get soda ash in form of light soda ash and dense soda ash and carbon
dioxide gas.
Carbon dioxide is send to section-400 in carbonation tower and dense soda is send to
section- 700 for bagging and light soda ash is send to section-600 for densification.
The precipitated bicarbonate separated from liquor by vacuum filter. The air is sucked
through the filter is blown off to the atmosphere. After ammonia is remove by washing the air
with brine to reduce NaCl content of soda ash. The bicarbonate filter cake is washed with
water.
The water used for filtration which combined with mother liquor which is fed to
distillation to recover ammonia. In calciner bicarbonate is decomposed into light soda ash,
carbon dioxide and water in form of vapor by heating operation. 180 ⁰C of decomposition.
3.5.4 Filtration
Rotary vacuum filter drum consists of a drum rotating in a tub of liquid to be filtered.
The technique is well suited to slurries, and liquids with a high solid, which could clog other
forms of filter. The drum is pre-coated with a filter aid, typically of diatomaceous earth (DE) or
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Perlite. After pre-coat has been applied, the liquid to be filtered is sent to the tub below the
drum. The drum rotates through the liquid and the vacuum sucks liquid and solids onto the
drum pre-coat surface, the liquid portion is “sucked” by the vacuum through the filter media to
the internal portion of the drum, and the filtrate pumped away.
The solids adhere to the outside of the drum, which then passes a knife, cutting off The
solids and a small portion of the filter media to reveal a fresh media surface that will enter the
liquid as the drum rotates. The knife advances automatically as the surface is removed.
A rotary vacuum filter consists of a large rotating drum covered by a cloth. The drum is
suspended on an axial over a trough containing liquid/solids slurry with Approximately 50-
80% of the screen area immersed in the slurry.
As the drum rotates into and out of the trough, the slurry is sucked on the surface of the
cloth and rotated out of the liquid/ solid’s suspension as a cake. When the cake is rotating out, it
is dewatered in the drying zone. The cake is dry because the vacuum drum is continuously
sucking the cake and taking the water out of it. At the final step of the separation, the cake is
discharged as solids products and the drum rotates continuously to another separation cycle.
The draw liquor is come from carbonation tower is collected in draw tank. The function
of this filter is removed impurity by 3-fold in filter.
I. To separate solid bicarbonate from mother liquor.
II. Remove Cl content by washing with the cake. Reduce moisture content of filter cake.
The surface of drum is dipping into a through filled with bicarbonate slurry. By means
of vacuum in filter drum compartment. Filtrates and air is flowing through filter cake and filter
cloth and via central output into filter separator to separate the air and liquid.
Mother liquor is flow by vacuum pump to scrubber. Cake on filter cloth is washed with
free of Ci and NH3 water. Dewatering of cake is mainly done by air displacement of liquid in
pores cake.
There are two separate connections between central discharge of filter drum and
separator.
A Mother liquor discharge provided with pressure control valve.
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B Discharge of wash water and dry air.
Moisture in cake is 17% by weight cake is discharged from drum surface by scraping
and collected in tank blow back air is applied for cleaning of filter cloth with some water. Filter
capacity is controlled by variation of drum speed and thus cake thickness. Regularly unit have
cleaned by hot water. This hot water is mixture of steam and process water. Suction pressure of
vacuum pump is controlled by recycle flow. In this some water Present is cause the fouling in
pump. This excess sprayed water is removed in separator.
Ammonia is removed by scrubber with pure brine.
To keep liquid level in scrubber is constant, is adjusted by level controller. Wash water
is fed to tank is cooled to 300C in cooler. This low temperature is decrease solubility of
bicarbonate. Mother liquor is pumped with mother liquor pump to distillation section 300.
Gases from mother liquor are fed to calciner o as condenser.
Bicarbonate slurry tank buffers temporarily unbalance between bicarbonate supply from
production tower and filter through put. Bicarbonate slurry tank is to provide with agitator To
prevent sedimentation of crystals.
The slurry tank is recycled with bicarbonate slurry pump. To prevent emission of
ammonia to environment filter is partly converted and vapor are removed by fan removed
air/vapor. Mixture is washed together with filter gases in scrubber. Spent liquor is collected in
sump pit to slop tank. By mean of slop pump this liquid is pumped to free ammonia still.
3.5.5 CALCINATION
Bicarbonate cake from filters is collected in bicarbonate buffer where temporarily some
bicarbonate can be buffered. i.e., in the case of carbonation tower change over.
From buffer bicarbonate is distributed by means of drug conveyor to calcination unit.

Three in operation and one in standby. To prevent emission of ammonia to environment Air is
sucked through storage tank and belt by means of vacuum pump. The loaded with ammonia
scrubbed in filter gas scrubber.
Crude bicarbonate is fed to calciner feeder. To avoid transport and fouling problem
inside Calciner, the crude bicarbonate is mixed with recycled light soda vs produced soda ash
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such that moisture content of product is 7% by weight.
Fig 3.5.1 “Section – 500, Filtration and Calcinations”
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Recycle soda ash is dosed by ash recycle valve and ash recycle screw in to mixture. Due
to high temperature of recycle soda ash(180 oc).
Decomposition of bicarbonate is start already in feed mixture. It is transported into

calciner. Calciner consists of rotary drum with steam tubes. In it bicarbonate is decomposed
according to reaction. Required heat for decomposition will be provided by condensing high
pressure stream (35 bar) in tubes. Condensate is collected in calciner. To assure complete
decomposition of bicarbonate temperature of soda ash leaving calciner must be minimum
1800C.
Then soda is collected in discharge box of calciner and transported with conveyor to ash
conveyor. The hot calciner gas (1200C) loaded with soda ash.
Dust will be fed via gas box into calciner cyclones. Cyclones remove dust and then gas
is sent to calciner gas scrubber to remove remaining dust. In scrubber gas is scrubbed by
circulating condensate from calciner gas.
Almost clean water from weak liquor still vacuum pump is added to dilute and cool
circulating fluid. To avoid accumulation of soda ash on cyclone wall. Scarpereds are use. Dust
is collected in cyclone transported to recycle screw.
The collected middle stream condensate in condenser receiver tank is sent level
controlled to intermediate pressure flash tank to flashed at 8bar. Flash stream is fed to 8bar
stream grid.
Hot soda ash is transported with ash conveyor via elevator to top part of conveyor in the
top building. For start-up purposes a part of the light ash can be transported from ash conveyor
to the calciner unit by means of start-up rotary valve and conveyor. In conveyor soda ash is
transported in the top part to the end of conveyor and transported back in Bottom.
First densification bunker is filled. The soda ash not consumed by densification is
transported to the light ash cooler by rotary valve. When soda ash supply to conveyor exceeds
the consumption of the downstream equipment, the excess amount soda is transported by
conveyor to screen to storage.
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The L.S cooler the soda is cooled to 80 ⁰C to prevent scaling of the cooling water tubes
in the soda cooler.
Then it is transported with conveyor and feed to screen, the oversize ash is removed and
crushed in lump crusher. To prevent damaging of crusher by metal parts, magnet is located in
the crusher inlet.
The soda dust will be removed from air in scrubber by counter current flow of diluted
soda ash solution circulation by pump. A part of circulation solution is used in hydrator. In
process water will be supplied level-controlled valve to scrubber from flash water tank.
Water used for flushing is collected in sump at wash water tank. By sump pump water is
transported to flash water tank. Where it is store together with ammonia free purge water from
the compression section. Process water is used. The water is pumped flow controlled by flash
water pump to scrubber.
Oversize is crushed by dense ash lump crusher and recycles by screw and cooling
section of fluidized bed drier to remove newly formed fines. The dense ash is conveyed by ash
belt to soda storage. For indication of actual/ total produced quality converted soda ash will be
weighed.
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3.6 SECTION-600: DENSIFICATION
3.6.1 Raw Material

 Light soda ash
3.6.2 Equipment
 Crusher
 Hydrator
 FBD (fluidized bed dryer)
 Rotary valve
3.6.3 PROCESS
Product from the section 500 is light soda is densification in the section 600. This is
done by two types. One is by hydration and other is dehydration.
Hydration
Light soda ash coming from sec-500 is mixed with water to hydrate. In the ratio of
1m³/hr of water to 3rpm of feed screw. To cool down this mixture cooling is given by cooling
water.
The mixture created in hydrator is fed to crusher to make similar size monohydrate
crystal of soda ash.
Hydrator is a horizontal type Mixer which continuously mixes and agitates the mixture
regularly.
Fluidized Bed
The cake coming from crusher is fed into FBD and it is dried to make dehydrated
crystal of dense soda ash.
In FBD there are three zones are available.
 Feeding zone
 Drying zone
 Cooling zone
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Fig 3.6.1 “Section – 600, Densification”
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 The temperature of every zone is different.
 In FBD for heating 35 bar steam is passed through tube inside the dryer.
 At the bottom side of the FBD high velocity air to be blown for drying.
 Density of inlet is about 620-680 kg/m3.
 Density about 1120-1220 kg/m³.
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3.7 SECTION-700: SODA -ASH STORAGE AND BAGGING

 Conveyor Belt
 Screw Feeder
 Vibro Feeder
 Weighing Bucket
 Bags Lifting Crane
3.7.2 PROCESS
 Section 700 is storage and bagging section for the soda ash product, light soda in section
600.
 Conveying of L.S.A from the storage facilities is done by installed conveying belts.
 There are 6 bunkers (SILO) for storage of L.S.A and four bunkers for dense soda ash.
 Material coming from belt is lifted by Silo buckets lifts to top floor by vibrato feeder.
 Then the material is sent to screen, from the screen the material is sent to packing while
 Remaining lumps are sent to hammer mill and then recycled to screen.
 The bags of light soda ash are of three size 50kg, 750kg and 1000 kg.
 It has packing capacity of 1800-2000 tons/day.
 The bags of dense soda ash are of two size 50 and 1000 kg.
 It has packing capacity of 800-1000 tons/day.
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Fig 3.7.1 “Section – 700, Soda Ash Storage and Bagging”
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CHAPTER-04: REVERSE OSMOSIS AND
DE-MINERALISATION PLANT
The Reverse Osmosis and De-mineralization plant aims at purifying the water free of minerals.
4.1 Raw Materials
 Sea water
4.2 Equipment used

 Tube settler
 Pressure Sand Filter
 Dual Media Filter
 Cartridge Filter
 Reverse-Osmosis unit
 Ultra filtration unit
 Mixed Bed Filter
4.3 Process
The sea water is pumped and taken into stilling chamber. The conductivity of sea water
is around 45000-80000 μS.
In stilling chamber, FeCl3 and Poly-E-chloride are added from the dosing tank. FeCl3
acts as a flux agent, while Poly-E-chloride acts as a coagulating agent. The flocculation takes
place and the feed is taken into the tube settler.
In tube settler, further chlorine is added so as to remove the bacteria from the Water.
Finally the water is separated from the slurry.
Sodium Meta bi-sulphite is added to recover the flocculants. Now, after recovering the
flocculants, the feed water is sent to Pressure Sand Filters. It consists of a multiple layer of sand
with a variety in size and specific gravity.
These filters are designed to remove turbidity and suspended particles present in feed
water with minimum pressure drop. These are designed as per process requirement.
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The feed water is further filtered in a Dual Media Filter. It utilizes the combination of
Filter media and anthracite. It is extensively used for the removal of suspended solids, turbidity
and some part of color and odor from feed water.
During the filtration cycle, largest particle are strained out by the anthracite, then the
sand traps the rest of the particulate matter. As a certain depth is achieved, the filter requires
cleaning. There are seven layers of dual media filter including anthracite.
There are seven pairs of DMF and PSF. The water is taken to Cartridge Filter. When the
liquid is passed through the cylinder into the basket, the solid impurities are blocked in the filter
basket, and clean fluid is discharged through the filter basket.
Then, the water is pumped through booster pump, and then to vacuum pump. Now, the
pumped water is sent to Reverse Osmosis unit. Here, the spiral wound membrane module is
used. The feed water is sent to the RO unit. The permeate is collected at the centre and a
common header is there to collect the permeate of all the R.O. units.
Every 2-3 months, cleaning is required. Cleaning is performed through chemical

cleaning. Back flushing is performed to obtain cleaning with hot water. Chemical agents like
STPP (Sodium Tri Poly Phosphate), EDTA (Ethylene Diamine Tetra Acetic acid), and SLS
(Sodium Lire Sulphate) are added during chemical cleaning. To treat bio fouling, biolite is
added. For low pH, citric acid is preferred.
In new RODM plant, instead of PSF, ultra filtration unit is present. After the R.O.
treatment, it is sent to drinking water unit. It is also sent to Fire unit, process water unit.
Next, the R.O. purified water is sent to mixed bed filter. Mixed bed filter consists of
anion and cat ion exchange resin. The feed water consists ionic impurities like calcium and
magnesium ions. These minerals are collected by anion and cat ion resins.
The important characteristic of mixed bed filter is that the resins can be regenerated. Cat
ion can be regenerated using acid wash like HCl. Anion can be regenerated using base wash
such as NaOH.
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Fig 4.1 “RODM Plant”
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293064 Pure Water Plant
CHAPTER-05: PURE WATER PLANT
5.1 RAW MATERIAL

 Brine
 Steam
5.2 EQUIPMENT
 Shell and tube heat exchanger
 Settling tank
 Insulated vessel
 Settling tank
 Centrifuge
 FBD
5.3 PROCESS
Saturated brine from the condenser of the salt works is preheated, degassed and fed to a
threestage evaporation unit. The resulting water to water vapor is condensed and transported to
water treatment section at the soda ash plant. The resulting salt is separated washed, dried and
transported to storage bin.
In the evaporation process anhydrite is formed as second solid phase in order to

minimize the crystallization on heating surface of anhydrite crystals are recovered and used as
seeds.
In this section main product is pure water and by product is salt. Here different types of
salt are produced like plane, pure, printed and iodized salt. Sea water is taking into the pond
through pump and solar evaporation is occur.
We will get raw brine with density 1200kg/m3 from pond is stored in the storage tank.
Raw brine is preheated in shell and tube heat exchanger and then feed into every evaporator
from washing leg. In first evaporator brine is flow through tube while 2.5 bar steam is passed
by shell side. Steam is condensed which is collected from the bott0ln of heat exchanger then
utility section.
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293064 Pure Water Plant
Vapor formed in first evaporator is using as a heating medium for 2 nd evaporator and
slurry have a density of 1230-1280 kg/m3 is discharge from leg. Condensate from second effect
shell side is pure water which is stored in storage tank. Vapor from 2 nd effect is used as a
heating medium for 3rd evaporator and condensate is pure water which is stored into storage
tank.
Here steam used in first effect is having temp. of 130°C output will have t of about
120°C. Vapors coming from first effect will have temp of 940 ⁰C and the outcome ling vapors
of second effect will have temp of 750⁰C which will act as a heating medium for third effect
and output of third effect vapors will have temp of 58 °C.
Slurry from these three effects is feed into salt slurry tank and then washed with brine in
washing tank. After this process slurry is sent to thickener from which heavy slurry from
bottom is sent to the centrifuge and over flow clear liquor is stored into brine tank which is
recycled to process again.
This centrifuge is rotating pusher type having 40 MT/hr capacity. Solid from centrifuge
contain 1.7% moisture and Mother liquor is send to raw brine tank and cake is conveyed into
FBD.
Before feed to FBD an anti-caking agent is mixed with it’ll Nirma they are using
Fe(CN)6 as an anti cocking agent for salt. The aqueous solution of Fe(CN) 6 is sprayed on
conveying belts in the limits of 6ppm.
After addition of anti cacking agent salt is sent to FBD for removing remaining
moisture. The output salt is stored on silo and packed as per requirements with fully automatic
packing unit.
5.4 FINAL PRODUCTS

 4480 m³/day pure water as main product.
 160 TPD vacuum salt as by product.
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293064 Refined Sodium Bicarbonate
CHAPTER-06: REFINED SODIUM BICARBONATE
6.1 Raw Material

 CO2
 Soda Ash
6.2 Equipment
 Weight feeder
 Carbonation Tower
 Leaf Filter
 Centrifuge
 Fluidized Bad Dryer
6.3 Process
Crude bicarb from the new section 500 is feed to storage tank. Crud bicarb is directly
not used for food safety purpose so that in this section refined crude bicarb. Crude bicarb
containing many impurities like NH3, CO2, H2O.
Crude bicarb is feed into Lewis conveyer via rotary valve. After that it is feed into
slurry Preparation Tank were Mother liquor add. In this tank slurry is prepare.
This slurry is feed in de-carbonation tower. For heating medium to steam is injected
(2.5bar) de-carbonation tower. The ammonia, CO2 and water vapor is remove from the top of
the tower and soda solution is obtained. Here carbonation tower top part temperature is Above
the 90°C and bottom part temperature is 103-104°C.
NaHCO3→ Na2CO3 + CO2 + H2O
After soda solution is coming a leaf filter. Leaf filter contain 8 leaf. Leaf filter obtain
purified soda solution.
Purified soda solution is send to carbonation tower by pump. In carbonation tower

added CO2 (40% by Volume) and it is temperature is around 40°C. After carbonation process
we get obtained Draw liquor.
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293064 Refined Sodium Bicarbonate
Na2CO3 + CO2 + H2O→NaHCO3
D liquor is send to thickener. After thickener process slurry is sent to Centrifuge were
mother liquor is separate from slurry and cake is send to FBD were 5% moisture is remove
from the cake. After that is feed into silo. It is capacity is 100T.
6.4 Product
 Refined Bicarbonate
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293064 Material & Energy Balance
CHAPTER-07: MATERIAL & ENERGY BALANCE

MATERIAL & ENERGY BALANCE FOR SODA ASH PROCESS
(i) For the Brine refinery of a 2000 TPD Soda ash plant, how much Soda ash and
quick lime will be required for brine purification per month? Raw water is used.
(Salt – 94% NaCl, Ca 0.2%, Mg 0.17%)
Salt required per ton Soda Ash = 1.8 T

For 2000 TPD Salt required = 2000 x 1.8 = 3600 TPD
Mg Content = 3600 x (0.17/100) = 6.12 TPD
Mg”Cl2 + Ca(OH)2 → Mg(OH)2 + CaCl2
Mg” + CaO → MgO + Ca”
24.3 56 40
Daily CaO required = (56/24.3) x 6.12 TPD = 14.1 TPD

Calcium in salt = 3600 x (0.2/100) = 7.2 T
Calcium generated = 6.2 x (40/24.3) = 10.2 T
Total Calcium = 7.2 + 10.2 = 17.2 T
CaCl2 + Na2CO3 → CaCO3 + 2NaCl

Ca” + Na2CO3 → CaCO3 + 2Na
40 106
Daily Soda required = 17.2 x (106/40) = 113.93 T

Monthly requirement
CaO 14.1 x 30 = 423 TPM
Soda Ash 113.95 x 30 = 3418.5 TPM
(ii) How much CO2 in m3/Hr (39%) does a Kiln of 300 TPD quicklime capacity
produce?
CaCO3 → CaO + CO2

300 TPD
56 44
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300 TPD CaO = (44/56) x 300 TPD

= 235.7 TPD CO2
235700 Kg/day = 9820 Kg/Hr

= (9820/44) Kg mole/Hr
= 223 Kg mole/Hr (100%)
= 223 x 22.4 m3 /Hr (100%)
= 4995 m3/Hr (100%)
= (4995/0.39)
= 12808 m3 /Hr (39%)
FROM COKE
C + O2 → CO2
12 44
Coke required = 75 Kg/T LS
= 75 x 300 x (100/56) Kg
= 75 x 300 x (100/56) x 0.8 Kg Carbon
CO2 = 75 x 300 x (100/56) x 0.8 x (44/12)
= 117857 Kg/Day
= 4911 Kg/Hr
= 111.6 Kg mole/HR
= 2500 m3/Hr (100%)
= 6410 m3/Hr (39%)
Total CO2 from Kiln = 12808 + 6410
= 19218 m3 /Hr (39%)
(iii) How much CO2 do Calciners produce (95%) at 2000 TPD? (m3/Hr)
2NaHCO3 → Na2CO3 + CO2 + H2O
106 44
Na2CO3 produced = (2000000/24) Kg/Hr
= 83333 Kg/Hr
CO2 = 83333 x (44/106)
= 34591 Kg/Hr
= 786 Kg Mole/Hr
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= 786 x 22.4 m3 /Hr
= 17610 m3 /Hr (100%)
= (17610/0.95)
= 18537 m3 /Hr (95%)
(iv) How much air is required in m3/Hr for one kiln of 300 TPD (CaO) capacity?
The reaction is
C + O2 → CO2
L.S. required = (300000/24) x (100/56)

= 22321 Kg/Hr
Coke required = 22321 x (75/1000) Kg/Hr
= 1674 Kg/Hr
Carbon in Coke = 1674 x 0.8
= 1340 Kg/Hr
O2 required = (32/12) x 1340 Kg/Hr
= 3573 Kg/Hr
Air required = 3573 x (100/25)
= 14292 Kg/Hr
With 15% excess air,

Air required = 14292 x 1.15
= 16436 Kg/Hr
= (16436/29) Kg Mole/Hr
= (16436/29) x 22.4 m3/Hr
= 12695 m3 /Hr
(v) Heat of Calcination of CaCO3 is 43350 K Cal/Kilo mole. If LS contains 95%

CaCO3 and if CV of Coke is 7500 K Cal/Kg and thermal efficiency of the kiln is
85%, how much coke is required in Tons/Hr for a kiln of 350 TPD lime stone
capacity?
Kiln capacity = 350 TPD LS

CaCO3 = 350 x 0.95
= 332.5 TPD
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Heat required = (332500/100) x 43350 KCal
C.V. Coke = 7500 K Cal/Kg
Coke required (100% Eff.) = (332500/100) x (43350/7500) Kg/day
Coke required at 85% Eff. = (332500/100) x (43350/7500) x (1/0.85) x (1/1000) x (1/24)
=0.942Tons/ Hr
(vi) Steam tube calciner - Heat Balance :

Chemical Reactions
NaHCO3 + NH4Cl → NH3 + CO2 + H2O + NaCl
7.0 4.5 1.4 3.7 1.5 4.9 Kg/T
= 0.0841 Kmole
HR = +25230 x 0.0841
= +2420 Kcal
NH4HCO3 → NH3 + CO2 + H2O
79.5 17.1 44.3 18.1 Kg/T
= 1.006 Kmole
HR = +27300 x 1.006
= +27460 Kcal
2NaHCO3 → Na2CO3 + CO2 + H2O
1585 1000 415.2 169.9 Kg
= 9.433 K Mol
HR = +19960 x 9.433
= 188280 Kcal
Total HR = 218160 Kcal
 STD Heat Balance

Heat in Heat out
From steam (28 Bar, 300°C) From Condensate
1000 x 1.4 x 717 = 100 3800 Kcl 1000 x 1.4 x 235 329000
From Product
1000 x 0.25 x 200 50000
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 STD Heat Balance
Heat in Heat out
From Filter moisture as vapor of
117°C
1680 x 0.20 x 640 215040
From Reaction water vapor
88 x 640 120320
From CO2
415 x 0.2 x 117 9711
From Heat of read 218160
942231 Heat loss 61569
(vii) Ammonia Inventory calculation:

V - 412 A/B/C V - 413 A/B/C V - 504 A/B/C Tower - 14 V - 503 A/B
Vol - 450 m3 Vol - 250 m3 V - 450 m3 V - 150 m3 V - 80 m3
Ammonia Inventory MT = Level x Volume x NH3 concentration x Mol. Wt.

A-liquor tank = (0.30 x 3 x 450 x 5.1 x 17)/1000
= 35.1 MT
C-liquor tank = (0.45 x 3 x 250 x 5.0 x 17)/1000

= 28.7 MT
Mother liquor = (0.5 x 3 x 450 x 4.35 x 17)1000

= 49.9 MT
Carbonation Tower = (14 x 150 x 4.75 x 17)/1000

= 169.5 MT
Bicarbonate slurry tank = (0.6 x 2 x 80 x 4.75 x 17)/1000

= 7.7 MT
Total ammonia Inventory = 35.1 + 28.7 + 49.9 + 169.5 + 7.7

= 290.9 MT
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(viii) PHE–303 Heat load calculation / Stream:
A-liquor flow rate - 810 m3/hr

A-liquor inlet temp. - 60 degC
A-liquor outlet temp. - 40 degC
A-liqour density - 1170 kg / m3
A-liquor Specific heat - 0.78
Heat load Q = m x Cp x ∆T
= 810 x 1170 x 0.78 x (60 – 40)
= 14784120 kcal / hr = (14784120/860) = 17190 kw / hr
= (14784120/30)
= 492804 kcal/ton of soda ash
Sea Water required

492804 = m x 1 x (38-30)
M = (492804/8) x1025
= 60.1 x 29
= 1743 m3 /hr.
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293064 Design of Equipment
CHAPTER-08: DESIGN OF EQUIPMENT
8.1 Find out Rate of Reaction:

In the industry, basically reaction occur between Dimethyl sulphate and salicylic acid in the
stage-1. By the use of that reaction & material balance by them, Calculation of Rate of
Reaction for this stage is as per below:
 Input of Raw Material to the Reactor = Output of ‘A’ from the reactor + disappearance
of A by reaction within the reactor + Accumulation of A within the reactor
 Di-methyl Sulphate = 500 kg, Temp. - 25 °C, Time - 1:00 hr
 Salicylic Acid = 546 kg, Temp. - 5-12 °C, Time - 1:00 hr
 DMS Molecular Weight = 126.13 gm/mol
 Density of DMS = 1.33 g/cm3 = 1330 kg/m3
 Volume of Reactor = 5 KL = 5000 L = 5 m3
V0 = (𝑀𝑎𝑠𝑠 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒/𝐷𝑒𝑛𝑠𝑖𝑡𝑦) = 500/1300 = 0.376 m3/ hr
 Now, In Case of Batch Reactor, No Fluid enters & leaves during the reactor.
Inflow of A = Outflow of A = 0.
 Rate of Disappearance of A by reaction in moles/time in the reactor of volume,

V =(-rA)*v.
 Moles of A fed = NA0 = 500×1000126.13 = 3964.16 mol

 Conversation of A at any time t = XA
 Moles of A consumed/reacted/disappeared = NA0 * XA
 Moles of A remained in the reactor at time t = NA
Remained NA = NA0 - NA0*XA = NA0*(1- XA)
 Rate of accumulation of A within the reactor in moles/time = 𝑑𝑁𝑎𝑑𝑡⁄

d [ NA0 (1-XA)] / dt = -NA0 * dXA/dt
(-rA)*v = -(-NA0 * dXA/dt)
(-rA)*v = NA0 * dXA/dt
dt = NA0 * dXA/ (-rA)*v
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Integrating, At t=0, XA=0 & At t=t, XA= XA

t = NA0 ∫(𝑑𝑋𝑎/(−𝑟𝑎)∗𝑣)
 for constant density system,

t = (NA0/V0) ∫(𝑑𝑋𝑎/(−𝑟𝑎))
Where, NA0 = 3964.16 mol & V0 = 0.376 m3
Suppose conversation nearly 100% then XA = 1.
 Our reaction time is 1 hr then -rA = ?

1 = 3964.160.376 ∫(𝑑𝑋𝑎/(−𝑟𝑎))
-rA = (1 x 3964.16/0.376 )-1
-rA = 110542.978
-rA = 9.484 * 10-5 mol/m3h
-rA = 0.09484 kmol/m3h
8.2 Find the Height & Diameter of Reactor:

 Usually, one thumb rule is used for calculation.
 Length to diameter ratio is considered in between 1.2 to 1.6
L/D = 1.3 (suppose we choose)
Data:
 Batch Reactor Volume = 5000 L (5 KL)
 Reactor volume compromises of one cylindrical middle part and a torispherical bottom
(ASME)
 Volume of Reactor = Cylindrical Volume + Torispherical Dish Volume
= πr2l + (π/24)* D3 where r = D/2,
= π (D/2)(D/2)(1.3D) + π/24 * (D)(D)(D)
5 = [1.022 + 0.1311] (D)(D)(D)
D3 = 4.3361
Diameter = 1.6306 m
L/D = 1.3 then, Length = 2.119 = 2.12 m
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Fig 8.1 “Glass Lined Reactor Mechanical Design”
8.3 Find the Heat Transfer Area of Reactor:

 Now, we know that reactor vessel is a combination of cylindrical part and torispherical
dish. So, we can calculate first heat transfer area of cylinder and torispherical dish and
then add it.
 Heat Transfer area of Cylinder :
= Perimeter of the rectangle * Length of Cylinder
= (2*π*r)* L
= 2*3.14*(1.6306/2)*2.12
=10.85 m2
 Area of a torispherical dish :
= π/4 * (1.147) * D2
= 3.14/4 *(1.147) * (1.6306)2
= 2.394 m2
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 Total heat transfer area of the reactor:

= Area of Cylindrical part + Area of torispherical dish
= 10.85 + 2.394
= 13.244 m2
 Total Heat Transfer Area of Reactor is 13.244 m2
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293064 Waste Handling
Chapter-9: Waste Handling

9.1 Water Handling: -
 As per the report of EIA in this proposed unit total 32KLD fresh water will be required
for domestic activities, greenbelt development. Manufacturing process and utility
operation.
 Source of fresh water will be bore well.
 Total 4 KLD sewage (domestic waste water) will be generated, total industrial waste
water generation will be 44 KLD.
 Among of industrial waste water, 3KLD waste water from process containing
Ammoniacal nitrogen will be treated in ammonia stripper and then will be mixed with
other low COD streams.
 Total 40.8KLD waste water is taken to ETP. After treatment, it will be passed to RO.
And recycled back for the process.
9.2 Air Pollution Handling: -

 In this proposed unit, flue gas emission will be the main source of air pollution. HCL
gas and NH3 will be liberated from glimepiride and pregabalin respectively. The
ducting will be taken to caustic scrubber and HCL scrubber.
 HCL gas and Ammonia will be liberated from REACTOR-1 and REACTOR-2
respectively. The ducting will be taken to caustic scrubber followed by stack and HCL
scrubber followed by stack. There will be chances of VOC emission during the
production of pharmaceutical products reactors will be provided with scrubber system
followed by column of activated charcoal for adsorption of VOC.
9.3 Noise Pollution Control: -

 Noise may be generated due to the operation of D.G. set after the proposed project.
Latest technology based low noise D.G. set with a caustic enclosure will be installed.
 All the vibrating parts were checked periodically and serviced to reduce the noise
generation.
50
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293064 Safety
CHAPTER-10: SAFETY.
10.1 Safety policy:
 Provide, maintain and upgrade facilities and working condition which are safe for
all employees, visitors, contractor, and public.
 Integration of safety, health and environmental aspects in planning operation. Protect
the health of employees and encourage them to adopt practices for maintenance of
good health.
 Provide necessary information and training to all for conducting operation effectively
and responsibility.
 Design and maintain appropriate emergency response procedure and business
continuity capabilities.
10.2 Personal Protective Equipment (PPE’S):

 Employers have duties concerning the provision and use of personal protective
equipment at work. PPE is equipment that will protect the user against health or
safety risks at work. It can include items such as safety helmet, gloves, eye
protection, high visibility clothing, and safety footwear and safety harness.
10.3 Types of PPE’s:
(1) Safety helmet and Safety shoes:
Fig 10.3.1 “Safety shoes”
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293064 Safety
Fig 10.3.2 “Safety helmet”
(2) Protection and Goggles:
Fig 10.3.3 “Safety gloves”
Fig 10.3.4 “Safety goggles”
Fig 10.3.5 “Safety mask”
52
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293064 Conclusion and Discussion
CHAPTER-11: CONCLUSION AND DISCUSSION.
11.1 Overall Analysis of Internship:

I would like to say that this training program is a marvellous opportunity for us to get
to the ground and experience the things that we would have never got by getting straight in to
job. We are grateful to Drive & Control System for this opportunity.
The core objective of this internship program is to equip the under graduate students
with practical, leadership, and ground phenomenon. Apart from our workshop class this is the
only chance to witness practical knowledge.
This program is not only about the professional skills, but it helps the student on
settling and working with different peoples. It helps us not only as an engineer as human being
to. So by any means this opportunity should never be overlooked.
The main thing I learnt from the internship is that chemical engineering is all about
challenge. It is about how to solve the problems during site or any other department works.
11.2 Problem encountered and possible solution:

When I am working in the industry, there are some new things that I faced and by the
knowledge of chemical engineering of 4 years I am tried to give best possible solution to the
workers and head of that department as per below.
11.2.1 Problem:
When my internship is going on there had some problem created in dust collection
system. Due to some problem in dust collector dust is not collect perfectly. This is one
of the problem when I was in internship.
11.2.2 Solution:
The work of dust collector is to remove or collect dust. Due to not perfect cleaning of
system and also in problem in blower which required pressure is not maintain because of these
no dust collection take place. Then this problem was solved by the PM and other team
manager of company.
53
University Morbi
293064 Conclusion and Discussion
11.2.3 Summary of internship:

There is great experience with Dharmaj crop guard limited. Here staff is so interactive
and helpful and also GET gives depth of each technical term. We gain so much industrial
knowledge from it. Also know how to behave as a chemical engineer in company. What is
different role of chemical engineer in company. Like a production, designing, commissioning
of new plant. Also what PPE’s are required from plant.
How to react when any other condition take place. This internship is give me great
experience for my bright future
54
University Morbi
293064 Reference
REFERENCE
1. https://sustainability.tatachemicals.com/assets/environment_doc/20200801025605.pd
f
2. https://www.tatachemicals.com/
3. https://www.tatachemicals.com/Asia/Products/Basic-chemistry/Soda-ash/light-soda-
ash
4. https://www.thehindubusinessline.com/portfolio/stock-fundamental-analysis-
india/why-you-should-accumulate-tata-chemicals-stock/article65063102.ece
5. https://www.tatachemicals.com/investors/financial-reports/Yearly-reports
6. https://s3-ap-southeast-
1. amazonaws.com/gtusitecirculars/uploads/Internship _Project_Report_Guidelines_
_3180701__661242.pdf
7. https://www.sciencedirect.com/science/article/abs/pii/S1570794607801155
8. Aresta, M., A. Dibenedetto, and E. Quaranta. 2016. “State of the Art and
Perspectives in Catalytic Processes for CO2 Conversion into Chemicals and Fuels:
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Catalysis 343: 2– 45.10.1016/j.jcat.2016.04.003Search in Google Scholar
9. Bichel, J., and S. Schaaf. 2008. “Recovering Purified Sodium Bicarbonate and
Ammonium Sulfate from a Sodium Sulfate Solution.” Patent No.
US/2008/7,393,378.Search in Google Scholar
10. Bonaventura, D., R. Chacartegui, J. M. Valverde, J. A. Becerra, C. Ortiz, and J.

Lizana. 2018. “Dry Carbonate Process for CO2 Capture and Storage: Integration with
Solar Thermal Power.” Renewable and Sustainable Energy Reviews 82: 1796–
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Esteller. 2018. “Multi-objective Design of a New Sustainable Scenario for Bio-
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Jang. 2003. “Interpretation of Gas-liquid Reactive Crystallization Data Using a
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of Trona to Sodium Bicarbonate.” Powder Technology 184: 58–
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INPLANT TRAINING AT NIRMA PRIVATE LIMITED.

VAGHAMASHI DHAVAL BHAVESHBHAI

In partial fulfilment for the award of the degree of

Lukhdhirji Engineering College, Morbi

Dr. A. D. BALDANIA Dr. R. K. MEWADA

Gujrat Technological University, Ahmedabad

This is to certify that the internship entitled “In-Plant Training at NIRMA

Dr. A. D. BALDANIA Dr. R. K. MEWADA

Internal guide Head of department

Name of Student Sign of Student

Mr. Dhaval Bhaveshbhai Vaghamashi

VAGHAMASHI DHAVAL BHAVESHBHAI SIGNATURE

An internship - a vital part of the engineering curriculum provides engineers a

Fig 1.1 Nirma private limited..................................................................................................6

Table 1.7 List of product.......................................................................................................3

Table 1.8 Equipment used by company….............................................................................8

1.1 Company Overview:

Fig 1.1 “NIRMA PVT LTD, BHAVNAGAR”

The company mission to provide

1.3 Different Plants in our company:

1.4 Different Department in Soda ash Plant:

1.5 Classification of our product:

1.6 List of Raw Material:

Sr Name Chemical State Molecular Weight

1.7 List of Product:

Sr. Product Name Capacity Tones/Day

1.8 Equipment used in our Company:

Table 1.8 “Equipment used by company”

CHAPTER-02: PROCESS FLOW DIAGRAM (PFD)

2.1 Different Sections in Soda Ash Plant

2.2 MAIN RAW MATERIAL:-

2.3 MAIN PRODUCT: -

Fig 2.1 “Process Flow Diagram of Soda ash”

Process take place in each and every section is...

CHAPTER-03: UNIT PROCESS AND UNIT OPERATION

3.1 SECTION 100: - BRINE PREPARATION AND PURIFICATION

3.1.2 EQUIPMENTS USED

Fig 3.1.1 “Section - 100, Demag Plant Flow Diagram”

3.2.2 EQUIPMENT USED

3.2.4 STEPS FOR IDEAL OPERATIONS OF KILN ARE

3.2.5 FINAL PRODUCT

Fig 3.2.1 “Section – 200, Lime Kiln”

3.3.1 RAW MATERIAL

3.3.3 CHEMICAL REACTIONS

This whole system is operated under vacuum.

Fig 3.3.1 “Section – 300, Absorption, Distillation”

3.4.1 RAW MATERIALS

3.4.2 EQUIPMENTS USED

3.4.3 COMPRESSION PROCESS

In the suction of compressor process water in injected to prevent fouling of Compressor

Carbone dioxide content of carbonate brine (c-liquor) in bottom of cleaning tower is

Cleaning of carbonation tower it is important that carbon dioxide content of A-Liquor is

Fig 3.4.1 “Section – 400, Carbonation”

3.5.1 RAW MATERIALS

Ammonia is removed by scrubber with pure brine.

From buffer bicarbonate is distributed by means of drug conveyor to calcination unit.

Fig 3.5.1 “Section – 500, Filtration and Calcinations”

Decomposition of bicarbonate is start already in feed mixture. It is transported into

3.6.1 Raw Material