SUMMER INDUSTRIAL TRAINING

PREPARED BY: SUBMITTED TO:

MAYUR PARMAR ASIAN PAINTS

(PHTHALIC DIVISION)
ANKLESHWAR, GUJRAT
 INTRODUCTION
 In 1942, Asian paints company was started by four brothers.
 The first plant of Asian plant is started in bhandup. So it is the oldest plant of the Asian paints. But now the oldest
plant of the Asian paint is Ankleshwar, Gujrat.
 In India six plants are available of Asian paints at this time.
1. Ankleshwar, Gujrat
2. Patancheru, Andhra Pradesh
3. Kasna, utter Pradesh
4. Shriperumbudur, Tamil nadu
5. Rotak, Haryana
6. Khandala, Maharastra
 Bhandup plant is not available at this time in India.
 Ankleshwar plant is second DCS plant in India.
 Two plants of Asian paint are coming soon :
1. Mysore
2. Visakhapatnam
 It is a backward integration. Phthalic plant is send phthalic anhydride to the paint division.
 Raw materials : O-xylene, oxygen.
 Main products : phthalic anhydride(PA)
 By products : melic acid, benzoic acid, light ends & heavy ends.
 Price of O-xylene - 50 Rs/kg
 Price of P.A. – 65 Rs/kg
 Yield of plant : 112%
 ASIAN PAINTS
 Paint is a colloidal mixture which used to coat on some surfaces like wall, metals, plastic, cloth, etc.
 Mainly paints are two types :
1. Water based paint
2. Solvent based paint
 For increasing the quality and make efficient paint we add some ingredients in the paint.
 Generally we add four type of ingredients in the paint :
1. Pigments : they are used for impart color on surface opaqueness.
2. Additives : it is used as anti-bacterial and to remove odour from paint after painting.
3. Binder : binder are use to bind the paint with surface
4. Solvent : solvent is used as thinner for paint.
SWOT ANALYSIS :
S W S = STRENGTH
O T O = OPPORTUNITY
W = WEAK NESS
T = THREAT
Certificates of Asian paint plant :
 ISO 9001 : for quality
 ISO 14001 : for environment safety
 OHSAS 18001 : for health and environment safety
SAFETY
 This plant is petrochemical plant. So if we not take care then the chances of accidents are increase in plant. So
before entering the plant we know about the all safety factors.
 Here the raw material o-xylene is fuel and air is present everywhere. So if it will come into the contact with any
ignition than it will fire.
 Fire triangle :
Fuel

Oxygen Ignition
 In the plant main two type of safety are considered :
1. People safety
2. Plant safety
People safety :
 Helmet, goggles, gloves, proper shoes are all personal protective equipment's.
 We should wear these equipment for our safety before entering the plant.
 Behavior of person is the main parameter of the safety. So, first we need to change our behavior.
 Many type of accidents are occur because of the behavior of people.
 Flash point of o-xylene is near around 27 ℃. so we need to remove static electric charge of o-xylene
when it send to the storage tanks.
 Here we remove the static electric charge by arcing, bonding and earthing.
 When we enter the storage tanks we also need to remove our static charge.
 Peoples who doing work in the plant are need to aware about MSDS of all the chemicals which are
reacted or produced in plant.
 Hot work permit : we should take permission of our higher authority in plant Before doing work in hot
areas like, welding, cutting etc.
 Cold work Permit : permit is not necessary in cold areas. but take permit is better for safety.
 Work at height : If we do work at any height then there should be a proper stand for standing. We
should wear the belts during work at height.
 Confined vessel entry : we should wear oxygen mask, Before entering in confined vessel. So, hazardous
gases can not enter in our body. When we enter the confined vessel we need one person whom is stand
outside the confined vessel.
Plant safety :
 In case of electrical fire we can not use water so at that time we have to use CO2 extinguisher.
 Some time dry chemical powder is also used as extinguisher material.
 In case of electric fire we can also use sand.
 Interlocks are also used for safety purpose.
 In plant, interlocks are set in every components like pump, reactor, valve, vessel etc.
 Here we set the two values. If the value parameter is increase than first value then the alarm is on. If the
value of parameter is increase than second value than the plant is automatically stop.
 Rupture disk and breather valves are set in the storage tanks and reactor for safety purpose.
 If pressure in tank/reactor will increase then it is released by rupture disk and breather valve.
 AIR Air
Air Air pre-

P
I Blower
Blower heater

n O-xylene Evaporator
o-xylene

R
p preheater
u

O
t Waste Main reactor
s Gas Switc Gas Post- with 7000 TO CUSTOMERS
Scrub h-
h
cool reac

C
ber Cond tubes
ense
enser er tor containing
s catalyst

E Crude PA tanks

S
Pure (distilled) Flaker & Phthalic Anhydride
Crude
CrudePA
PA
preheater
preheater PA tanks bagging
machine

S Treatment vessels
Main PA
recover
Heavy Ends
distillation
y
column system
Pre-distillation
column Light Ends

Maleic Acid Solution

ETPINCINERATOR
/ INCINERATOR
ETP
PROCESS DESCRIPTION
The main sections of the plants are:
 Oxidation of o-xylene
 Purification of crude PA
 Flaking and bagging of pure pa
 Effluent treatment plant
 Operations of utilities

Oxidation of O-xylene:
 Here we do partial oxidation of o-xylene.
 By air blowers we compress the atmospheric air. Process of heating air are doing in the 3 stages.
 In the first stage air is heated by 22 bar steam. Now in second stage air is heated by oil and the third stage air is
heated by 4 bar steam.
 O-xylene is pump from storage tank and pass through filter and preheated.
 O-xylene is preheated up to 6 bar steam and 145 ℃.
 now air and o-xylene are fed separately into the evaporator. O-xylene is fed from bottom and air is fed
from top.
 Here in the evaporator no reactions are occur. Only homogeneous mixture is occur.
 Now this homogeneous mixture is send to the PA rector.
 The shape of the reactor is cylindrical. Reactor is filled with 7000 tubes and the diameter of the each
tube is 3.5 mm. The length of the tube is 3.2m.
 All tubes are filled with catalyst V2O5 and TiO2 as an ingredient.
 Here in the reactor mixture flow is top to bottom.
 In the gas phase o-xylene is partially oxidized in phthalic anhydride.
 The reaction is highly exothermic.
REACTIONS IN PA REACTOR :
 O-xylene + 3O2 Phthalic Anhydride + 3H2O + 310 Kcal

 O-xylene + 7.5O2 Melic Anhydride + 4CO2 + 4H2O +760 Kcal

 O-xylene + 3O2 Benzoic Acid+ CO2 + 2H2O +320 Kcal

 O-xylene + 2O2 Phthalide + 2H2O + 206 Kcal

 O-xylene + O2 O-Toluic Acid + H2O

 O-xylene + 10.5O2 8CO2 + 5H2O + 1100 Kcal

 O-xylene + 6.5O2 8CO + 5H2O + 520 Kcal

 O-xylene + 4.5O2 Citraconic Acid + 3CO2 + 3H2O

 O-xylene + 1.5O2 O-Tolualdehyde + 4CO2 + 4H2O +760 Kcal

 In the catalyst tube there are four sections.CL1,CL2,CL3 & CL4.
 All reactions in the PA reactor are exothermic. So we need to absorb heat in reactor. So, there is salt bath material
which is made of KNO2 and NaNO2.
 Salt coming into salt bath cooler where saturated steam is produce. Then it is passed through super heater to
produce 22 bar superheated steam.
 Superheated steam is sent to turbine to generate electricity.
 Now outlet of the PA reactor is send to the post reactor where unconverted o-xylene is converted into the our main
product.
 The temperature of outlet gases are around 390-395℃.
 Now it is pass through the gas cooler where the we reduce the temperature to 165-170℃. Here 22 bar steam is
also generate.
 Now it is pass through the switch condenser to remove impurities.
 In the switch condenser there are three part loading, melting and re-cooling. The ratio of re-cooling : melting :
loading = 1 : 2 : 7.
 Here for the heating ilexal oil is used. Desublimation of gas is occur In the loading section.
MASS BALANCE
ENERGY BALANCE
 Now gas mixture is send to the scrubber. The main function of the scrubber is scrub the gases.
 Here we spread the water from the top and mixture is pass from the bottom. In the scrubber by adding
water melic anhydride is convert into the melic acid which is our by product.
 In the scrubber melic acid and some unwanted gases are removed from the gas mixture.
 Now this mixture of crude PA is stored into the crude pa tank and melic acid send into the melic acid
storage tank.
 Now from the crude PA tank mixture is send to the purification section.

Purification of crude PA :
 Here in this section first crude PA is send to the treatment vessel. Treatment vessel is the one type of the
reactor where some impurities from the crude PA is removed.
 Now this mixture is followed by pre-distillation column where therminol oil is used as the heating
medium. Here if we use natural gas as a heating medium then the chances of the fire or blast is increase.
 Boiling point of phthalic anhydride is more than benzoic acid and melic acid. So PA is stay in the
mixture at the bottom and at the top we get light ends in the pre distillation column.
 Now this phthalic anhydride is send to the main distillation column.
 Here in the main distillation column liquid PA is converted into gas and we collect PA from the top and
other heavy ends are collect from the bottom of the main distillation column.
 Now this PA is send to the PA storage tank.
 Before send to the PA storage tank it is pass through the PA gas cooler for reduce the temperature.

Flaking and bagging of pure PA :

 Now in this section our PA is converted into the form of flakes by indirect contact of cold liquid.
 Now it is pass through the hopper. We get flakes of PA from the bottom of the hopper and it is followed
by conveyor belt.
 Now here flakes of PA is packed into 25 kg and 500 kg’s bags.
Effluent treatment plant (ETP) :
 All waste water which is coming out the all sections of plant is treated in this section.
 Here in ETP by using bacteria we remove the hazardous things from the water and make clean the
water.
 Here in this section we add melic acid which is food for the bacteria.
 Now treated water is stored in the storage tanks.

Operations of utilities :
 Here using natural gas and air we heated the therminol oil and ilexal oil.
 We used activated alumina for the drying the air in air dryer.
 N2 plant is also come into this section. N2 is used as the inert which is not taking part into reaction.
 In the utility section boiler is also important section.
 DM plant is another important section which is come under the utility section.
 In the first step we send the water into the PS filter(pressure Shane filter). Here three layer are present
and in PS filter impurities from the water is removed.
 Now it is send to the AC filter(active carbon filter) where dichlorination is occur and the impurities of
chlorine from the water is removed.
 From the ac filter two outlets are there. One is send to the DM plant and second is send to the softener.
 In DM plant outlet first it is go into the cation where we add 10% HCl. Now it is followed by degasser
and then anion. In anion section we add 10% NaOH.
 Now it is followed by mix bed. So at the end we remove temporary hardness of water.
 Now second outlet of the ac filter is directly send to the softener where NaCl is used. Here we remove
permanent hardness of the water.
Thank
you