Chapter 1

INTRODUCTION

1.1 General
Camphor is a waxy, white or transparent solid with a strong, aromatic odour having the chemical formulaC10H16O. It is found in wood and of the of camphor laurel (Cinnamomumcamphora), a giant of a large evergreen tree found in Asia (particularly in Borneo and Taiwan) also Dryobalanopsaromatica, the Bornean forests. It also occurs in some other related trees in the laurel family, notably Ocoteausambarensis. Dried rosemary leaves (Rosmarinusofficinalis), in the mint family, contain up to 20% camphor. It can also be synthetically produced from oil of turpentine. It is used for its scent, as an ingredient in cooking (mainly in India), as an embalming fluid, for medicinal purposes, and in religious ceremonies. A major source of camphor in Asia is camphor basil. The word camphor derives from the French word camphre, itself from MedievalLatincamfora, from Arabickafur, from Sanskrit, karpuura. Barus was the name of an early port on a city named "Sibolga" (located in the western coast of Sumatra island - North Sumatra Province, Republic of Indonesia]. At that time, this city was initially built prior to the Indian Bataknese trade of camphor and spices. Foreign traders such as; Dravidian - Indian, East Asian and Middle east traders would call "kapurbarus" to buy the extract/dried ooze of camphor tree from the local tribesman (Bataknese), in [Bataknese language "Gorga" It is also known as kapur Barus. Until now, the local tribesman and Indonesian in general refer to naphthalene balls
1

and moth balls as kapur Barus. For the local tribesman the use of camphor are ranging from deodorant, wood - cloth finishing veneer coat, traditional ritual and non-edible preservatives as the camphor tree itself natively found on that region. The tree itself in Indonesian language called as "Kamfer" also known for it's resistance. Camphor is readily absorbed through the skin and produces a feeling of cooling similar to that of menthol and act as local anesthetic, however it is poisonous when ingested and can cause seizures, mental confusion, irritability and neuromuscular hyperactivity.

1.2 Chemical constituents of Camphor laurel

Camphor laurel contains volatile chemical compounds in all plant parts, and the wood and leaves are steam distilled for the essential oils. Camphor laurel has six different chemical variants called chemotypes, which are camphor, linalool, 1,8cineole, nerolidol, safrole, or borneol. In China field workers avoid mixing chemotypes of fake when harvesting laurel oil" the is by their in odour. China The to (or cineole fraction camphor used

manufacture

"Eucalyptus

chemical

variants

chemotypes) seem dependent upon the country of origin of the tree. The tree is native to China, Japan, and Taiwan. It has been introduced to the other countries where it has been found, and the chemical variants are identifiable by country. i.e., Cinnamomumcamphora grown in Taiwan and Japan, (often commonly called "Ho Wood") is normally very high in Linalool, often between 80 and 85%. In India and Sri Lanka the high camphor variety/chemotype remains dominant. The Cinnamomumcamphora grown in Madagascar, on the other hand, is high in 1,8 Cineole

(averaging

between

40

and

50%.

The

essential

oil

from

the

Madagascar trees is commercially known as Ravintsara.

1.3 Company Profile

Camphor & Allied Products Ltd incorporated in 1961 is Indias largest manufacturers of variety of terpene chemicals and other speciality synthetic aroma camphor, in chemicals. Its terpineols, and vast several array of vast pine product oils, range includes finding from resins, chemicals astrolide,

dihydromyrcenol, applications

other

industries

ranging

flavours&fragrances, pharmaceuticals, soaps & cosmetics, rubber &tyre, paints & varnishes and many more. It is a pioneer in the field of terpene chemistry in India since 1964, having established the first synthetic camphor plant with technology from DuPont of USA. The plant of the company is located finished at Bareilly products in West Uttar and Pradesh, 250 km the from New Delhi. It handles a volume of 20,000 tons of raw materials and annually incorporates latest technology and equipment. The operations company such carries as out all conceivable chemical oxidation,

fractionation,

esterification,

saponification,

hydrogenation,

dehydrogenation,

peroxidation, pyrolysis, etc. in the plant using equipment and technology that is constantly updated with time to keep pace with the latest advancements in chemistry and chemical engineering practices. Its grades), resins vast and product many range pine includes oils, processes
3

synthetic are

camphor by

(all well-

terpineols,

Isobornyl

acetate,

terpene

more. All

monitored

trained

technical

personnel

with

the

help

of

latest

instrumentation and quality control. The company is also having a state-of-the-art manufacturing facility that was set value up at Nandesari, Baroda in 1999, to manufacture high fragrance chemicals and fragrance

chemical intermediates based on in-house technology. Products manufactured at this plant are of international standard and are well accepted in markets abroad and at home. 1.3.1 Product Range 1.3.1.1 Fragrance Chemicals 1. Amberone It is a pale yellow viscous liquid & amber odour. 2.Astromeran It is colourless to pale yellow colour&woody, spicy, floral odour. 3.Astrone It is clear liquid colourless to pale yellow, woody, balsamic, floral, pine odour. 4.Astrolide It is colourless liquid. Clean, powerful, long lasting musk odour (Galaxolide equivalent). 5. Capinone It is colourless woody odour. to pale yellow liquid, rich, sweet and

6.Dihydroterpineol It has piney, woody odour. 7.Dihydroterpinyl Acetate It is citrus fresh & has pine needle odour. 8. Fenchone It is a pale yellow liquid.Strongcamphoraceousodour. 9.Isoborneol It is white crystalline powder.Pineycamphoraceousodour. 10. Isobornyl Acetate It is colourlessliquid.Pine needle camphoraceousodour. 11.Ketone 101 It is pale yellow liquid. Sweet, earthy, woody and slightly camphoraceousodour patchouli oil. 12.Terpineol It is pale yellow to colourlessliquid.Sweet, piney, pleasant, lilac character. 13.Terpinyl Acetate It is colourless liquid - fresh bergamot Lavender odour. 14.Citwanene It is having pleasant citrus 15.Isolongifolene Colourless to pale yellow liquid.Characteristicodour.
5

with

tobacco

suggestion,

reminiscent

of

character with woody back note.

16.Longifolene It is colourless to pale yellow liquid. Characteristic terpenic odour. 1.3.1.2 Pharmaceutical Products 1.Camphor EP/USP/BP/DAB/JP It is a white granular powder& it isanti-infective and antipruritic 2.Cerpineolbp It is colourless liquid and has sweet, pleasant, lilac odour, used as anticeptic. 1.3.1.3 Industrial Chemicals 1.AlphaPinene Epoxide It is clear colourlessliquid. 2.AlphaCampholenic Aldehyde It is light pale yellow clear liquid sweet, woody odour. 3.Camphene It is starting material for sandalwood type aroma chemicals. 4.Camphor It is white crystalline material. Characteristic penetrating odour. 5.Camphor oil It has colourless to pale yellowcolour&Camphoraceous 6.Capolene
6

odour.

It is colourless to pale yellow liquid 7.Capolyte CP Resin It is a tackifyingagents. 8.Distilled turpentine It is pale yellow liquid & used as solvent in paint and lacquer industry. 9.Dipentene It is a colourless to pale yellow liquid. 10.Para cymene It is a polymerisation initiator for synthetic rubber 11.Pinenehydroperoxide It is a polymerisation initiator for synthetic rubber 12.Pine tars It is a dark brown viscous liquid, Tackifier. 13.Pine oils It is colourless to pale yellow liquid & have Sweet, pleasant, piney, floral odour. 14.Sodium acetate trihydrate It is a colourless or white crystalline powder. 15.Phenol It is orange coloured liquid.

1.4 Objective
The main objective of the project is to gain knowledge about the manufacturing process of camphor using turpentine oil and to know about the camphor. industrial and pharmaceutical uses of

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Chapter 2 LITERATURE REVIEW

2.1 Basic Definition

2.1.1 Distillation Distillation is an unit operation in which constituents of liquid mixture (solution) are separated using thermal energy. Basically, the difference in vapour pressure of different constituents at the same temperature is responsible for such operation. The unit operation is also termed as fractional distillation or fractionation. With this technique it is possible to separate liquid mixture into its components in almost pure form and this fact has made distillation perhaps the most important of all mass transfer operation. In distillation, the phase involved are liquid and vapour or gas (vapour phase is created by supplying heat to liquid ) and mass is transferred from both the phase to one another, by vaporization from liquid phase. Distillation is a method of separating mixtures based on differences in volatilities of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction. 2.1.2 Types of distillation 2.1.2.1 Flash Distillation Flash distillation consists of vaporizing a definite

fraction of a liquid in such a way that the evolved vapour is

9

in equilibrium with the residual liquid, separating the vapour from liquid and condensing the liquid 2.1.2.2 Steam Distillation Steam distillation generally treated as a simple

evaporation without fractionation and is generally handled as a batch operation. It may be illustrated by the fractionation of crude oil, where the last trace of lighter constituents in the still bottoms are separated by the introduction of steam in the column and all side streams are drawn off the column are stripped with steam to remove same amount of volatile constituents could without the restoring oil. The to high temperature, the which to decompose steam allows column

operate at atmospheric pressure, while at same time gives the effect of a partial vacuum distillation of crude. 2.1.2.3 Vacuum Distillation In vacuum distillation feed is charged into the colum

which is under atmospheric pressure i.e. vacuum, this results in separation into different constituents of the feed. Vacuum distillation is used to separate components of high boiling points, fraction which above could 600 for not degree their be boiled readily are available to heat source or which are unstable at their atm boiling point. Thus celcius subjected because vacuum this distillation separation above

temperature, decomposition and coking occurs in the furnance tubes in which oil is reboiled. Thus it results in loss of valuable plugging. product and destruction of furnance tubes by

10

Fig.2.1- Distillation column Source-www.google.com/images/distillationtower

11

2.1.3.

Turpentine (also called spirit of turpentine, oil of

Turpentine

turpentine, and

wood turpentine) is a fluid obtained by the

distillation of resin obtained from live trees, mainly pines. It is composed of terpenes, mainly the monoterpenes alpha-pinene and beta-pinene. It is sometimes colloquially known as turps. 2.1.4. Alpha Pinene -Pinene is an organic compound of the terpene class, one of two isomers of pinene. It is an alkenes and it contains a reactive four-membered ring. It is found in the oils of many species of many coniferous trees, notably the pine. It is also found in the essential oil of rosemary. Both enantiomers are known in nature. The racemic mixture is present in some oils such as eucalyptus oil. 2.1.5. Beta Pinene Beta-Pinene (-pinene) is a colorless liquid, soluble in

alcohol, but not water. It has a woody-green pine-like smell. It occurs naturally in rosemary, parsley, dill, basil, yarrow, and rose. It is also a major constituent of hop aroma and flavor. 2.1.6 Camphene Camphene is bicyclic monoterpene. It is nearly insoluble in water, It is but a very soluble in of It the common many is organic essential produced more solvents. oils such It as by volatilizes readily at room temperature and has a pungent smell. minor and constituent valerian. of turpentine, cypress oil, camphor oil, citronella oil, neroli, ginger oil, industrially catalytic isomerization common alpha-pinene.

Camphene is used in the preparation of fragrances and as a food

12

additive for flavoring. Its mid-19th century use as a fuel for lamps was limited by its explosiveness.

2.2 Uses of Products

2.2.1 Camphor oil It is used in the preparation medicines. 2.2.2 Isobornyl acetate It finds its use in compounding pine needle odours, toilet water, bath preparation,antiseptics, theatre sprays, soaps and in manufacture of synthetic camphor. 2.2.3 Terpeneol It is used in solvents for resins, gums, waxes, oils, other products. Mutual solvents for cellulose esters and ethers ,soaps disinfectents, antioxidents,and as medicine. It is also used as denaturing fat for soap manufacture. 2.2.4 Natural camphor Camphor is the basic raw material for the manufacture of celluloid ,film and of medicinal pharmaceutical preparations such as vitacamphor.Camphor as such used as an ingridient of ammoniated camphor liniments.Camphor water,camphorated tincture of opium,ointments and balms, in halers ,counter irritants, anesthetic,and mid antiseptics. 2.2.5.Terpine hydrate It is used in medicine as well as in veterinary. In medicine it is used as raw material for pharmaceuticals firms.
13

ofinsectisides , flysprays,

soaps,and many other technical preparation as a deodrant and in

In medicine it is used as expectorant for cough. In veterinary it is used as expectorant in chronic bronchitis. 2.2.6.Pinetar Orefloatation, tarsoaps preservatives.It roofing is also compositions, general used in paints, of varnishes, rubber and

,asphaltic

compositions,

preservatives,marine

manufacture

rubber gooda as a tackyfyingagent. It is used in manufacture of cordage,insulation varnishes,and quenching oil. 2.2.7.Pine oil Pine oil is an excellent resin solvent,finds use in paints and varnishes.It is used in textile industry as a penitrant, dispersant,detergent, and as bacterial inhibitor in wet processing cotton,silk and rayon. 2.2.8.Caprez resin Caprez resin is an adhesive.It is widely used as a medicinal tape in medicinal industries.Also used in bubble gum industry, 2.2.9.Menthol Used in perfumes, as a flavour in toothpastes, mouthwash, chewinggums, syrups. incosmetics for cooling sensations and in pharmaceutical industries as pain balms,rubs,ointments,and cough

2.3 Camphor quality

2.3.1 GF Granulated flakes 2.3.2 BQ Best quality 2.3.3 ST Slab type 70% camphor and 30%ib. 2.3.4.IPIndian pharmaceutical(96%).
14

2.3.5.USPUnited state pharmaceutical.

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15

Table 2.1: Properties of Camphor

PROPERTY NAME 1. Molecular formula VALUE WITH UNITS

C10H16O 152.23 g mol1 152.120115134 g mol1AppearanceWhite, translucent crystals 0.990 g cm3 175-177 C, 448-450 K, 347-351 F

2. Molar mass

3. Exact mass 4. Density 5. Melting point

6. Boiling point

204 C, 477 K, 399 F

7.Physical Appearance
8.Solubility in water 9.Solubility in acetone~ 10.Solubility in acetic acid~

1.2gdm-3 2500 g dm3 2000 g dm 2000gdm-3 1000 g dm3 1000 g dm3 4 mmHg (at 70 C) []D+44.1

11.Solubility in diethyl ether~ 12.Solubility in chloroform~ 13.Solubility in ethanol~log P 14.Vapor pressure 15.Chiral rotation

Source- www.wikipedia.org

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Chapter-3 Process description

3.1 Manufacturing process Of natural camphor

Camphor can be naturally manufactured from natural camphor wood steam distillation process. Camphor wood is subjected to a steam distillation unit to obtain camphor. However for production purpose synthetic camphor production from turpentine oil is generally used. The entire process of camphor production from natural camphor wood is given below in the figure.

3.2 Manufacturing process of Synthetic Camphor

3.2.1 Small scale production In small batches, camphene can be converted directly into synthetic camphor by oxidizing it with ozone, oxygen, potassium permanganate or any this other readily does available not lend oxidizing itself to agent. mass Unfortunately, process

production, and additional steps are taken when large quantities of synthetic camphor are required. 3.2.2 Large scale production For large scale production, synthetic Camphor is produced from -pinene oil which is a main ingredient of turpentine oil. The production of synthetic camphor begin with the distillation of turpentine to yield -pinene. The -pinene is carefully dried and treated dry hydrochloric acid to produce bornyl chloride, also known as Synthetic Camphor.

17

Fig.4.1 Manufacturing of natural camphor Sourcewww.google.com/images/naturalcamphor

18

The patented

resultant

solid

is

then

converted by

by

several the

chemical

process

into

camphene

removing

hydrochloric acid with phenol, cresol, aniline and alkali. For large scale production of synthetic camphor, the glacial acetic acid. The isobornyl acetate is subsequently separated and treated with alcoholic sodium hydroxide to produce isoborneol. After isoborneol has been purified, it is oxidized by nitric acid and sulphuric acid to finally producing synthetic Camphor.

3.3 Specification of -Pinene

Molecular Formula- C10H16 IUPAC NAME- 2,6,6-Trimethyl bicycle(3,3,1)-2-heptane Melting Point- -65 degree celcius Boiling Point- 156 degree celcius 3.3.1 Sources of -Pinene 1. Wood turpentine 2. Gum turpentine 3. Sulphate turpentine

3.4 Production process description

1. Mixture or turpentine oil is obtained by steam distillation of oleogum from pine trees. Turpentine oil on Fractional Distillation yield alpha pinene along with few side products. About 90% of turpentine get converted into alpha pinene, 8% into careen, camphene. production 5% beta pinene is and remaining raw get converted for into Turpentine basic material camphor

19

85-90% Alpha Pinene 8-10% Carene Turpentine Oil 3-5% Beta Pinene 1-2% Camphene

2.

Alpha

Pinene

oil

obtained

by

fractional

distillation

of

turpentine oil undergo isomerisation reaction in the presence of Titanium dioxide to produce crude camphene tricycle camphene. Isomerisation Alpha Pinene TiO2 Catalyst 3. Crude Tricyclo Camphene is then sent to distillation unit where it undergo fractional distillation to produce Pure camphene along with side products. Fractional distillation Cr camphene Depentene 4. Pure Camphene of is then treated to with acetic acid in the to Pure Camphene + TarpeneD + Cr Tricyclo Camphene

presence

CXC-120

Catalyst

undergo

Esterification

produce isoborneol acetate (IBA).

20

Fig.4.2 Camphor production flowsheet Source-www.google.com/images/camphorflowsheet

21

Esterification Pure camphene IBA + (Acetic Acid + Unreacted Camphene) 5. IBA is further distilled to produce pure IBA.

IBA

IBA+(acetic acid +camphene)

6.The next step in camphor manufacture is saponification.Itis done to obtain total conversion. For total conversion the ratio of IBA:NAOH should be 1:0.22 . The reaction is as follows (160-170 C) C10H17COOCH3 +NaOH C10H18O +CH3COONa 7-8 KG/cm2 The product formed is known as isoborneol.After the isoborneol is purified, it is oxidised in presence of nitric acid and sulphuric acid into the final synthetic camphor.

3.5 Turpentine production and processing

Turpentine is an oil obtained from pine trees, and is different from the mineral turpentine that can be bought in the supermarket. It is a very important substance with many applications as a solvent, in the pharmaceutical industry and in the production ofoils, resins and varnishes. It is also used as the starting material to manufacture variety of other products, including pine oil and turpentine. Turpentine is initially separated from wood chips after

they have been "cooked" in the kraft paper-making process. It is

22

separated off as a which separate out

mixture of water and turpentine when left to separate in a

vapours, tank, as

turpentine is much lighter than water. This turpentine is then distilled into "heads" (volatile compounds with no commercial value), and - and -pinene. Of these, -pinene is sold as is and -pinene is further processed to make pine oil by reacting it with phosphoric acid. Pine oil is used as a solvent, disinfectant and deodorant, and -pinene is used to produce camphor and insecticides. A further, less valuable, solvent, dipentene, is produced as a by-product of this process.

3.6 Properties of turpentine oil

1.CST is a volatile amber liquid, with a density of 0.85g cm-3. 2.It is a mixture of - and -pinene (30 and 60% respectively) and other monoterpenes of the general formula C10H16 and various impurities and such as small quantities with of unpleasantCST and

smelling sulphurous compounds(e.g. methyl mercaptan and dimethyl sulphide) inorganics associated handling refined turpentine, both because of its volatility and because it has a low flash point. 3.6.1 Operations in camphor manufacture Basically camphor manufacture takes place in three steps. 1.Saponification 2.Washing 3.Dewatering These processes are explained in details now.
23

The processes used in each of the steps include: 1.Charging raw materials For the manufacture of camphor the raw material turpentine oil is charged first.the objective of this is to yield pinene.After that pinene is carefully dried. 1.Reactions 2.Cooling 3.Transfer and flushing 2.Dehydrogenation Dehydrogenation is the process of removal of bulk hydrogen from the raw material. The isoborneol formed is dehydrogenated at a temperature of 220-225 c to form camphor with the elimination of H2.The process include charging the catalyst and then cooling and subsequently filtering it.Inert gas is also purged into it. 3. Camphor refining & distillation Camphor refining takes place in 4 steps.These are as follows: 1.Stripping of hydreogenated benzene. 2.Removal of camphor oil. 3.Distillation of camphor from camphor +hbs mixture. 4.Reclaimingof the camphor from, residue.

4. Camphor reclaiming Camphor reclaiming is a process to obtain the maximum amount of camphor and to minimize the waste. This process is done in following way:
24

the

1.Evaporation of camphor through steam distillation. 2.Condensation of water + camphor vapours in benzene. 3.Cooling of water + benzene camphor solution. 4. Removal of water. 5.Draining of pitch. 5.Nutschefilter. IB From R-904a is taken in this filter and it is washed with benzene, vanes of this filter requires the solution and make benzene ( with impurities of IBA ) pass through the filter and get collected. Filter allow the benzene to pass thorough benzene vanes. 5.Isomerisation C10H16 reaction( batch process) C10H16 + Mixed tarpene

The mixed tarpene is a mixture of dipentane and pentane. Camphor is separated from dipentene and pentene D by fractional distillation.

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25

Chapter-4 MATERIAL BALANCE

4.1 Specification
A process design starts with the development of a process flow sheet for the development of such process flow diagram material balance calculation across each unit is necessary. There material balance follow the law of conservation of mass. According to law of conservation of mass, the total mass of a system whether it undergo unit process or unit operation remain unchanged, it can neither be created nor destroyed. When we deal the material balance, reach and they on pertain and to physical with and chemical reaction or or process and which are often referred to as material balance without chemical that chemical involve respectively. separating Physical process chemical mostly process involve mixing process

process

reaction occurring in the reactor. Now the question comes, why do we need material balance. Although we usually have the idea of the overall process, we immediately face the question of how much product can be produced from the available raw materials or how much the certain raw material need to be processed to meet a particular demand. Thus we are referring to flow of the raw materials and of product or waste materials out of process. A material balance is a careful accounting of this materials flow and is the first and essential step in the analysis of chemical process. It is here that one begin to get a feeling for overall size of the process since one is now dealing with the masses or volumes of material involved. Such considerations are of extremely important because the flow of material involved, to determine size and cost of reactor & number of unit etc.
26

Material material determine the

balance is

are of

the over raw

basis the

of

process required

design. and

balance

taken

complete

process

will the

quantities

material

product produced. Balance over individual process unit set the process steam flow and composition. Material balance are also useful for study of plant operation and trouble shooting, it can be used to check performance against design, to check instrument celebration and to locate source of material loss. Assumption made during material balance 1. No material loss is considered 2. No material is accounted for heating the process material that will be calculated in energy balance. 3. Final product is considered as hundred percent pure as per specification 4.2 calculation

Table 4.1 Calculation

Material

Formula

Density

Mol.wt

Camphor Turpentine oil Isoborneol acetate

C10H16O.990 g cm3 C10H16 C10H18O

152.23gm/mol 136gm/mol 154.25gm/mol

.87g cm3 1.54g cm3

Initial Basis = 1 ton of turpentine oil

27

1. Camphor production initial raw material Raw material are added in following proportion in

manufacturing of Camphor

Material

Weight(in ton)

Turpentine oil Wood Furnance oil Natural gas Steam

1 3.493 .053 .5 .1

Since the amount of additive are very small(in kg) hence we neglected 2. Amount it in material balance calculation. of -pinene oil formed from turpentine oil(since

conversion is 90%)

Turpentine oil -pinene formed = 1*0.9 = .90 ton

-pinene (90%) + side product(10%)

Side product formed = .1 ton

28

Alpha pinene oil (.9 ton)

1 ton turpentine oil + steam

Side product i.e Camphene Careen,betapinene (.1 ton)

3 Alpha pinene oil obtained from fractional distillation is kept in a batch reactor for about 2 hour and small amount of titanium dioxide is added as catalyst, this led to isomerization of alpha pinene to crude camphene with no loss of reactant.

TiO2

Alpha pinene(.9ton)

Crude Camphene

4. Pure Camphene Production Yeild of different product from crude camphene are as follows Pure Camphene Dipentine Pine oil 55% 10% 30%
29

Other residue

5%

Crude camphene Dipentine(10%)+ pine oil

Pure camphene(55%)+

Residue(terpine& hydrate)

Since the yield of pure camphene is 55%, so amount of pure camphene produced = .55*0.9 =.495 tons 5. Isoberneol acetate formation tank Percentage yield of IBA is 70% Acetic acid taken= .33 ton Isoberneol acetate formed = .433 ton Reacted acetic acid = .231 ton Unreacted acetic acid = .33-.231 =.099 ton Unreacted camphene = .1485 ton Unreacted acetic acid

Pure camphene Acetic acid IBAReactor

Isoborneol acetate

Unreacted camphene
30

6. Saponification reactor( Isoborneol formation) To ensure total conversion IBA: NaOH :: 1:0.22

Since the conversion is 100%, so the amount of Isoberneol formed is same as IBA produced i.e 0.3465 ton Caustic soda (NaOH) taken = .07623 ton 7. Dehydogenation Reactor (Camphor) Isoborneol produced is dehydrogenated to give Camphor

Hydrogen Isoborneol Dehydrogenation Tower Camphor

Since

isoborneol

is

totally

convert

into

hydrogen

and

camphor, so the amount of camphor produced is same as that of isoborneol formed. Amount of camphor formed = 0.3465 ton %Conversion of camphor = .3465/1*100 = 34%

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31

Chapter-5 GENERAL DESIGN CONSIDERATION 5.1

A

General
design is normally is to divided calculate into the two main of steps, a

tower

process design followed by a mechanical design. The purpose of the process design number required theoretical stages, column diameter and tower height. On the other hand, the mechanical design focuses on the tower internals and heat exchanger arrangements. Many distillation factors column have such to as be the considered safety in and designing a environmental

requirements, column performance, economics of the design and other parameters, which may constrain the work. The determine feed. few design rules for distillation column are as follows: 1) Direct sequences that remove the components one by one in the distillate are generally favored. 2) Sequences that result in a more equal-molar division of the feed between distillate and bottoms products should be favored. 3) Separations where the relative volatility of two adjacent components is close to unity should be performed in the absence of other components; ie, reserve such a separation until the last column in the sequence. first the step in distillation sequences, column which design is on to the separation depends

relative volatility and concentration of each component in the

32

4)

Separations be

involving until number

high-specified last of in the

recovery sequence. stages,

fractions Once the

should to

reserved the

separation sequence is decided, engineering calculations follow determine theoretical operating parameters and tower dimensions. In general, the steps included in distillation calculations are summarized into the following:

Performing a material balance for the column Determining temperature) Calculating the minimum number of theoretical stages using the Fenske equation Calculating the minimum reflux rate using the Underwood equations the tower operating pressure (and/or

5)

Determining

the

operating

reflux

rate

and

number

of

theoretical stages 6) Selection of column internals (tray or packings) 7) Calculating the tower diameter and height The theoretical explanation and sample calculations of each step above are discussed in detail in later sections. 5.2 Other factors Some general design rules (from Cheresources.com) that should be considered are as follows: 1. Distillation is usually the most economical method of

separating liquids.
2. For Ideal mixtures (low pressure, medium temperature, and non-

polar), relative volatility is the ratio of vapor pressures i.e. = P2/P1

33

3. Tower

operating

pressure

is

determined

most

often

by

the

temperature of the available cooling medium in the condenser or by the maximum allowable reboiler temperature. 4. Tower Sequencing Easiest separation first least trays and reflux When neither relative volatility nor feed concentrations vary

widely, remove components one by one as overhead products. When the adjacent ordered components in the feed vary widely

in relative volatility, sequence the splits in order of decreasing volatility. When the concentration in the feed varies widely but the

relative volatilities do not, remove the components in the order of decreasing concentration in the feed. 5. Economically optimum reflux ratio is about 120% to 150% of the minimum reflux ratio. 6. The economically optimum number of stages is about 200% of the minimum value. 7) A safety factor of at least 10% above the number of stages by the best method is advisable.

8) A safety factor of at least 25% about the reflux should be utilized for the reflux pumps. 9) Reflux drums are almost always horizontally mounted and designed for a 5 min holdup at half of the drum's capacity. 10) For towers that are at least 3 ft (0.9 m) in diameter, 4 ft (1.2 m) should be added to the top for vapor release and 6 ft (1.8 m) should be added to the bottom to account for the liquid level and reboiler return. 11) Limit tower heights to 175 ft (53 m) due to wind load and foundation considerations. 12) The Length/Diameter ratio of a tower should be no more than 30 and preferably below 20.
34

13) A rough estimate of reboiler duty as a function of tower diameter is given by: Q = 0.5 D2 for pressure distillation Q = 0.3 D2 for atmospheric distillation Q = 0.15 D2 for vacuum distillation Where, Q : Energy in Million Btu/hr D : Tower diameter in feet.

5.3 Selection of Column Internals

The selection of column internals has a big impact on the column performance and the maintenance cost of a distillation tower. There are several choices of column internals and the two major categories are trays and packing. The choice of which to utilize depends on the following 1) Pressure, 2) Fouling potential, 3) Liquid to vapor density ratio, 4) Liquid loading, and 5) Most importantly the life cycle cost. Trays can be divided into many categories, such as baffle trays, dual flow trays, conventional trays, high capacity trays, multiple downcomer trays and system limit trays. According to some rules of thumb, trays should be selected if: 1) The compounds contain solids or foulants 2) There are many internal transitions 3) Liquid loads are high 4) There is a lack of experience in the service 5) Vessel wall needs periodic inspection 6) There are multiple liquid phases

35

On

the

other

hand,

packing

divisions

include

grid

packing, and high

random

packing,

conventional

structured

packing,

capacity structured packing. The rules of thumb for selecting packing are: 1) The compounds are temperature sensitive 2) Pressure drop is important (vacuum service) 3) Liquid loads are low 4) Towers are small in diameter 5) Highly corrosive service (use plastic or carbon) 6) The system is foaming 7) The ratio of tower diameter to random packing is greater than 10 Some design guidelines should be considered when designing a tray tower, such as follows: 1) Constriction factor The constriction factor should not be less than 0.6. This parameter shall be checked only for the side downcomer. 2) Tray spacing Overall column heights depend on tray spacing. Tray spacing should common be from 18 to is 24 inches, inches with to accessibility allow easy in mind for (Generally, for a tower diameter of 4 feet and above, the most tray spacing 24 access maintenance. However, for a tower diameter below 4 feet, a tray spacing of 18 inches is adequate as the column wall can be reached from the man way.) 3) Peak tray efficiencies Iy usually occur at linear vapor velocities of 2 ft/s (0.6 m/s) at moderate pressures, or 6 ft/s (1.8 m/s) under vacuum conditions.
36

4) A typical pressure drop : Pressure drop per tray is 0.1 psi (0.007 bar). Max Dry pressure drop in height of hot liquid less than 16% of tray spacing. 5) Tray efficiencies: For aqueous solutions these are usually in the range of 60-90% while gas absorption and stripping typically have efficiencies closer to 10-20% 6) Sieve tray holes The generally vary are 0.25 to 0.50 in. diameter with the total hole area being about 10% of the total active tray area. Maximum efficiency is 0.5 in and 8%. That large holes are recommended for fouling and corrosive services and a spray regime. 7) Valve trays Valve tray typically has 1.5 in and 2 in. diameter holes each with a lifting cap. 12- 14 caps/square foot of tray is a good benchmark. The disk typically rises 3/16 to 7/16 in above the tray deck and 10 % open area of fully open valves. 8) Weir height The most common weir heights are 2 to 3 in and the weir length is typically 75% of the tray diameter. For vacuum operation is recommended 0.25 to 0.5 in to reduce the pressure drop. 9) Weir loading The maximum recommended weir loading is 13 gpm/inch. At high weir loadings, trays will have high pressure drop, high froth height and potential downcomer limitations. At lower weir loading, picket fencing may be required.

37

10) Downcomer clearance It is recommended 1.5 in. At low liquid loading the clearance can be reduced to secure a proper distribution of the liquid on the active area, but lower than 1 in are not recommended. At high liquid loading the clearance can be increased up to the weir height to minimize the head loss and the jetting. 11) Downcomer velocity: and residence time velocities is range from 0.1-0.7 ft/s, the maximum velocity needs to be lowenough to prevent downcomer flooding. The minimum residence time is 3 s and the best residence time is 5 s. the residence time needs to be long enough to allow adequate vapor-liquid disengagement. 12)Flow path length The flow path length is measured from the downcomer exit to the outlet weir. Minimum size is typically 16 to 18 inches. High flow path length will enhance the efficiency while the low flow path length will increase weir load. 13) Open area Open area typically 0.04 to 0.15. lower values may result hydraulic limitation and mass transfer efficiency reduced while higher value result less the tray efficiency. The packed tower design concepts are listed below: 1) Packed towers almost always have lower pressure drop compared to tray towers. 2) Packing is often retrofitted into existing tray towers to increase capacity or separation.

38

3) For gas flow rates of 500 ft3/min (14.2 m3/min), use 1 in (2.5 cm) packing, for gas flows of 2000 ft3/min (56.6 m3/min) or more, use 2 in (5 cm) packing. 4) Ratio of tower diameter to packing diameter should usually be at least 15 5) Due to the possibility of deformation, plastic packing should be limited to an unsupported depth of 10-15 ft (3-4 m) while metal packing can withstand 20-25 ft (6-7.6 m). 6) Liquid distributor should be placed every 5-10 tower

diameters (along the length) for pall rings and every 20 ft (6.5 m) for other types of random packing. 7) For redistribution, there should be 8-12 streams per sq. foot of tower area for towers larger than three feet in diameter. They should be even more numerous in smaller towers. 8) Packed columns should operate near 70% flooding. 9) Height Equivalent to Theoretical Stage (HETS) for vaporliquid contacting is 1.3- 1.8 ft (0.4-0.56 m) for 1 in pall rings and 2.5-3.0 ft (0.76-0.90 m) for 2 in pall rings. 10) Packing support is used to carry the weight of the wet packing while allowing free passage of the gas and liquid. Gas inlets are provided above the level where the liquid flows from the bed. 11) Liquid distributor is used to maintaining a uniform flow of liquid throughout the column. For small diameter columns, a

39

central open feed pipe or one fitted with a spray nozzle may well be adequate. 12)Liquid redistributors Redistributors are used to collect liquid that has migrated to the column walls and redistribute it evenly over the packing and also out any maldistribution.

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40

Chapter-6 MATERIALS OF CONSTRUCTION

While designing a chemical plants material of construction of various units must be properly selected.Once the type of equipment is selected,the materialsfor construction have to be established.The process engineer should have a general idea of the materials that are compatible with the process.The selection of materials for specific application depends upon the process requirement,purity of product,mechanical properties of materials such as knowledge brittleness, creep, ductility , fatigue,hardness,impact strength,malleability,toughness strength characteristic etc.The permits the of material strength,tensile

process engineer to select the proper material efficiency for process equipment and its supporting structure.While selecting the material economic consideration also play a major role.The cost of materials,its availability,fabrication technique,cost & strength or properties has to be specifically considered. The most economically materials that satisfies both process & mechanical requirement should be selected. This will be the materials that gives the lowest cost over the working life of the plant allowing for maintenance and replacement.Other factors such as product contamination & process safety must also be considered.All these factors mostly varies with materials and its properties.The different properties of materials are classified as.

6.1. Properties

41

6.1.1Mechanical properties 1.Strength- Tensile strength 2.Stillness-Elastic modulus 3.Toughness- Fracture resistance 4. Fatigue resistance 5. Creep resistance 6. Ductility-brittleness 6.1.2 Thermal properties These includes thermal conductivity,heat capacity, melting point etc. The mechanical properties vary with thermal properties. 6.1.3 Corrosion resistance This is the most important aspects that plays prominent role in the selection of materials of construction.Corrosion resistance depends & upon may precise greatly corrosive influence environment the resistance where of a concentration,purity level,aeration flow velocity,heat transfer temperature particular material.Usually corrosion rate is measured in terms of thickness reduction or weight loss.As in meter stream is passed through jacket therefore care it cause be high corrosion during stresses.Therefore selection. 6.1.4 Temperature This is an important as the aspect may while be selecting or low material which of will respective should taken

construction

temp

high

defiantlyshows its influence on the mechanical properties of the materials. In the Camphor plant the maximum temperature attained
42

is 150-250 C. The materials of construction for these equipment should be proportionally chosen taking into accounts the mechanical properties at such a high temperature. 6.1.5 Special properties Special properties required are thermal conductivities,

electrical resistance, magnetic resistance etc. 6.1.6 Fabrication These properties govern the case of fabrication

i.e.,forming,welding, casing. 6.1.7 Availability Materials of construction should be available in standard sizes and may be in the form plate section or tube. 6.1.8 Machinability The ease with which material may be machined or fabricated plays an important role upon the cost of the equipment.

6.2 Cost
This is the most important criteria which has to be looked. It itself depends upon number of factor,which is shown in cost estimation.The more cost rating compares the relative cost of various materials as given by. CR = C/Fs C = Cost per unit mass(Rs/kg) = Density

Fs = Design stress(N/mm2)

43

The

appropriate

values

of

relative

cost(CR)

for

the

following materials are:Carbon Steel Aluminum Stainless Steel Copper 01 18 06 27 Seeing all these factor we can say the for selection of materials,it really requires the large experience.So referring literature it is found that no special materials of construction are necessary & stainless steel is used only in those parts which are in contact with the product. For the manufacturing of Camphor,the reactor are made

from stainless steel. Stainless steel can be considered as: i. ii. Feritic stainless steel Martensitic stainless steel

iii. Austentic stainless steel

1.Feritic

stainless

steel-It

has

carbon

content

less

than

0.2%,chromium contents are between 11-18%,its tensile and impact strength is poor.It cannot be heat treated,it has good corrosion resistance.It is useful for handling strong oxidizing acids i.e. nitric acid, sulphuric acid etc. 2. Martensitic stainless contents is issued steel-It are as has carbon to content has steel upto good for

1.2%,chromium

between cladding

12-18%.It carbon

hardenability,it chemicals.

process vessels.It is resistant to water,steam & mild corrosive

44

3. its

Austenitic austenitic

stainless

steel-In at

addition impact steel

to

carbon

&

chromium,it contains 3.5-22% nickel.Nickel allows it to retain microstructure high strength,good containing ductility & corrosion resistance. It is also good for handling sulphuricacids,organicacids.Austenitic moly denum upto temperature of 3 0 C not good enough for has good resist to pitting corrosion.high above and in alkaline solution,it is reducing toxic environment & severe

susceptible to stress corrosion cracking.All these steels are corroding media. Some of the stainless steel used application are as follows: Type Application

304,304L,321,347 resistance. 308,309,309SS,310

Useful for general corrosion

Useful for high temp operation Of preheater,vessel liners &

Welding rods. 316,316L Good corrosion resistance

6.3 Lining of chemical processequipment

The purpose of lining is to provide protection to the costly metal equipment against chemical action. It also prevents wear & tear of the metal from highly abrasive material such as quarter, iron ore, limestone etc, specially in mining industry. Lining also helps to present contamination
45

of

the

liquid

being

processed adopting

specially the

in

food

&

pharmaceutical advantage

industries. of strength

In of

composite

structure,

cheaper material and corrosion resistant properties of material which may either lack in strength or may be costly beneficially utilized. Mild steel lined with lead, titanium, rubber, plastic,

glass are well known in chemical process industries. In Camphor units, camphor should be stored in epoxy lined silos

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46

Chapter-7 PLANT LOCATION AND PLANT LAYOUT

The success

proper as the

location selection for

of of

plant a up

is of

as

important Selection plant

to of

its an

process. any

appropriate

location

setting

is

quite

necessary so as to run the plant under profitable condition. It is necessary that overall outlook s taken into account and all selection factor while selecting a suitable location of the proposed plant. In this chapter a brief discussion regarding the principle factor leading to selection of location are summarized as follows.

1.

Availability of suitable land & sufficient land.

2. Sufficient raw material supply. 3. Uninterrupted supply of utilities like water, power & fuel. 4. Location with respect to market for products. 5. Good transport facilities. 6. Availability of labour. 7. Effluent disposal facilities. 8. Suitable topography and weather condition. 9. Soil condition and bearing quality of site. 10.Local community consideration. 11.Political atmosphere.
47

For the safe and economic working of a plant it is of great importance to take into account selecting the site. Camphor & Allied product limited are pioneers in the field of turpentine chemistry in India, having established the first synthetic camphor plant with technology from Dupontof USA in 1964. There Gujarat with from tons are and two plant operating Uttar in Indiai.e The The just in Vadodara, plant and away is raw so and all the above factors while

Bareilly,

Pradesh.

Bareilly products 1 k.m.

located in West Uttar Pradesh, 250 km from New Delhi on NH-24 coordinate here, of 2823'46"N railway and 7922'57"E. station is materials can be easily transported by road and rail network Bareilly transportation can be easily done. It handles a volume of 20,000 raw materials finished products annually incorporates the latest technology and equipment. It carry out all conceivable chemical operations such as

fractionation,

esterification,

saponification,

hydrogenation,

dehydrogenation, oxidation, peroxidation, pyrolysis, etc. in the plant using equipment and technology that is constantly updated with time to keep pace with the latest advancements in chemistry and chemical engineering practices. Their grades), resins vast product range Pine includes is synthetic free Camphor of air (all and

Terpineols, many

Oils, plant

Isobornyl totally

acetate,

Terpene

and

more. The

liquid pollution and maintains strict vigil all the time to protect environment and people.

7.1 Plant layout

Plant layout is the method of locating machines,process and plant services within the factory so as to achieve the greatest
48

possible ease of

output

of

high is

quality performed

at at

lowest the

possible point of

cost

of

manufacturing. It aims at discovering an optimum plan by which operation greatest convenience. Maximum productivity from plant building and equipments can be obtained only when these facilities are so integrated to provide smooth flow of materials, parts and products. Smooth flow is a result of a good plant layout. Management can obtain the desired objectives through an efficient follows. 1. Economics in material and product handling. 2. Minimizing of useful areas. 3. Avoidance bottlenecks. 4. Avoidance of unnecessary and costly charges once a layout is made. 5. Improvements in production process & methods. 6. Incorporation of safety into the physical plant as part of the layout & organization. 7. Better product control & supervision. 8. Safety. Plant layouts ideally involve the allocation of space and the arrangement of the equipment in such a way that overall operating costs are minimized. A complete layout project represents the master plan for physically integrating the factor of production which are required on the premises. Poor layout
49

plant

layout.

The

objectives

to

be

attained

as

results

in

high to

materials mention

handling only a

cost few

& of

excessive the

space

requirements

consequent

inefficiencies.

7.2 Factor influencing plant layout

1. The volume of work to be handled. 2. The products to be manufactured including their components parts and sub assemblies of each products. 3. The assembly relationship between the component parts and sub Assemblies of each products. 4. The operation needed on each part sub assembly and final assembly. 5. The condition necessary for manufacturing processs of operation. 7. The characteristics and requirements of auxiliary services. 8. Material handling equipment that may be required.

7.3 Types of layout

There are two different types of layout depending upon the type of manufacturing they are: 1. Line of product layout. 2. Functional or process layout. The line layout has been found to be suitable for continues process industries for example chemical, petroleum, sugar industries and industries which produces assembled products for consumer. The demand for such product is relatively inelastic
50

and

they

can

be

manufactured

in

stock.

The

equipments

and

machines us in such factor are therefore generally arranged in a straight line or in sequence in which they are used. The functional layout is more suitable for those which

carry out for job order production. In such factories no two job are similar and so line layout is out of questions. Machines in such factories are generally arranged according to functions. The machines performing the same process are grouped together in department. In this way a number of departments are set up each of which is responsible for a specific process and not a product as in the line layout.

7.4 Selection of a layout

It line or is necessary for the manufacturingprocess to be most to arrange for

different equipment in a certain typical sequence. Hence the product layout process suitable manufacture of camphor. One important factor to kept in is adequate space for future expansion to meet the changing demands. Again not only the processing block like boiler house, dumping yard section, canteen should be given due importance. More room should be provided near the raw material and product storage to allow easy loading and unloading operations. The general need which must considered while laying out a plant are: 1. Ensuring smooth production flow. 2. Absence of back traffic and congestion. 3. Easy control and supervision. 4. Maximum productivity.
51

5. Flexibility in operation. 6. Should consider expansion and growth potential of enterprise. The cost of construction can be minimized by adopting a layout that gives the shortest run of construction pipe between equipments. Adequate space must be provided for man, machines, raw

materials and products. Due consideration must also be given to technical requirements, waste disposal, antipollution and other legal provision. The given figure the complete plant layout for manufacture of camphor in which all above aspects have been considered. The not on layout danger should the be such that of the man movement and of man and and

materials should be in minimum possible time. The layout should security equipments consideration should be given to waste disposal arrangement and waste effect treatment.

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52

Chapter-8 SAFETY AND ENVIRONMENT ISSUES

Inspite of all skill of operation, all the precision in design inspection & equipment reviews, the process has to operate under component failure, utility imperfection & human error. In consequence each item may cause damage to the equipment, plants, public lives and to the environment. Modern some technology has been since quite successful & in developing are

failure mode chemicals. However this effort has also introduced additional problems manufacturing handling frequently found to be inadequate to deal with the question of hazards. Various types of hazard are either due to the nature and properties of the materials or due to side reactions. During processing the materials are likely to undergo fire hazards, mechanical hazards, chemical hazards, electrical hazards etc. All manufacturing processes are to some extent hazardous but in chemical process there are addition hazard associated with the process. The designer must be aware of those hazards & ensure the application of sound engineering practices so that the risk are reduced a to acceptable plant levels. Attempt must be made to provide design having maximum protection for plant

personal and minimum chance of occurring of any accident. All operating personnel in the plant should study and get themselves well acquainted and well versed in various hazardous situations. In every process industry a wide variety of preventive & protective safety measure must be provided, such measure are of two type.

53

2.

Measure

which

will

limit

the

extent

of

damage,

if

the

situation gets out of control(curative).

8.1 Hazards
8.1.1 Fire Hazard Fire can be due to inflammable fuel like petroleum product, oils, lubricants, wood etc. The objective is to minimize the chance of personnel injury, loss of life and property, damage and production discontinuity, so we must require necessary means to control fire. The properties of flammable materials must be studied &no where in process the temperature should be allowed to reach 30% auto ignition temperature or above flash point. So allied air, so flammable product, these substance camphor can must be handled with care. at to These normal dissent

catches crawl

fire along

easilyeven the ground

temperature. The vapour of flammable substance is heavier than vapour flames & spark and then flashed back to the source. All drums, container and tanks are connected to ground

electricity whenever flammable material is being transferred, this prevents build up of static electricity and the possibility of starting of spark. All flammable container are kept closed when not in operation. Fire alarm system are must to control fire, necessary and equipment like heater, supply furnances should be should there be to protected against accidental explosion. Hot surface should be insulated uninterrupted water control fire in case of emergency. 8.1.2 Mechanical Hazards All the machinery & tools must be well protected in

accordance with the instruction laid down in Indian factory act for safeguarding against mechanical hazards. Automatic control
54

systems, alarms should be provided correct structural design of the vessels, piping & steel work should be done. Some of the safety measure are: 1. Guarding or avoiding sharp ends. 2. Insulation of electrical tools. 3. Process relief jets in steam jackets or chambers. 4. Use anti spark tools in explosive and inflammable areas. 8.1.3. Electrical Hazards All the electrical appliance should be installed accordingly to Indian electricity act for safeguarding against electrical hazards. Proper insulation of valves is of utmost importance Preventive measure should be taken against shock and burns. High voltage equipment should be properly covered. There should be proper wiring and insulation, safety switches and capacitor should be used. Periodic checking should be done be maintenance department. 8.1.4 Chemical Hazards These may be due to persons coming in the contact with the corrosive chemical directly or indirectly. Inhalation of harmful fumes should be checked. These may be due to process leaks or through vents. Storing of chemicals should be as minimum as possible, it should be stored to safe places and arrangement should be made to ensure 100% safety. During handling of hazardous chemicals, normal safety equipment such as gloves & chemical splash goggles should be worn. In case of exposure to eyes, it should be

55

flushed

with

water

and

physician

should

be

contacted

immediately. Prolong contact with solution should be avoided. Some of basic preventive and protective measure that should be taken in in from consideration process spill and areadequate and supply of water for of and & protection over pressure relief device, segregation of reactive materials drainage plant lines fire all equipment, water from grounding nozzles electrical equipment, safe location of auxiliary electrical gear fighting adequate sprinkler head, insulation of hot surface, proper building and layout above advanced instruments control facilities.

8.2 Safety measure in equipment design

The design of reactor, distillation column for camphor, allied product working under 4.4 atm design pressure should be taken to 10-25% excess of operating If pressure and all equipment beyond should follow standard codes. Careful attention should be given any welded equipments. reactor pressure goes operating pressure then rupture disc should be there to release excess pressure The check list for safety is following 8.2.1 Materials 1. Flash Point 2. Autoignition Range 3. Heat of combustion 4. Toxicity 5. Corrosion 8.2.2 Reactors 1. Heat of reaction
56

2. Side reaction 3. Stability 4. Temperature 5. Pressure Control 8.2.3 Control system 1. Fail safe 2. Back up system 3. Automatic operation of valves 4. Alarms 5. Inert purging blanketing 6. Mechanical control system ( in case of failure) If fire takes place one of following should be onsite 1. DCP-Dry chemical cylinder 2. Water extinguisher 3. Foam extinguisher 4. CO2 extinguisher 5. Dry sand

8.3 Personnel safety

1. Hard hats, face asbestos shield, hand gloves & fire suits in case of high temperature zone 2. Ear plugs to be used in high noise pollution areas. 3. For handling of chemical rubber hand gloves, nose masks & goggles should be provided. 4. Safety shower are provided at various places. 5. Personnel safety is adapted to carry out periodic training program on safety mock drills and class room training. 6. Training is given to operation people in HAZOP.

57

7. Fire extinguisher are placed at various locations & fire hydrant fighting. is available throughout the plant for fire

8.4 Environment Management

To keep pace with the stringent environmental

regulations and to maintain ecological balance, zero effluent technology for camphor and allied products plants have been selected discharge Pradesh at the outset. The is quality of liquid effluent and is at from the factory control by monitored The high continuously air quality samplers

remains much lower than the norms prescribed by the Uttar pollution board. constantly monitored providing volume

different locations around the factory campus. Eighty meter wide green belt has been developed around the factory and the township to keep the environment clean. A number of trees have been planted in the plant area to check the pollution level inside plant and to control its adverse effect. 8.4.1 Methodology for environment protection Environment protection starts with identification of all the activities, which have a substantial environmental impact. These are: i) Air emission quality and quantity ii) Effluent quality and quantity iii) Hazardous waste generation iv)Non hazardous waste generation v) Consumption & conservation of Natural resources. vi) Ensure compliances with National Environmental Quality vii)Standards, Rules & Regulations covered under Environmental Protection Act, 1986. viii) Recycle and reuse of the wastes generated
58

ix) Ammonia odor in the plant x) Noise 8.4.2. Environment management system at Camphor & allied product ltd, Bareilly Camphor & allied product ltd. has sound environmental management system comprising of following features:i) Afforestation ii)Zero Effluent Technology iii)Social Forestry iv) Monitoring of ambient air and stack emissions v)Development of all-round awareness regarding environmental issues vi) ISO-14001:2004 (EMS) Accreditation

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59