BTP 2

A Report on
Production of Phenol from 99.9% pure

Cumene from Naptha Cracker
Production of 99.9% pure Bisphenol A from
99.9% pure Phenol
February-14-2015
Major Project Report Submitted by

Gopal Singh Charan
Department of Chemical Engineering
IIT Roorkee
Index
1. Material and Energy Balance
1.1 Material Balance
1.2 Energy Balance
2. Environmental Protection & Energy Conservation
2.1 Air Pollution
2.2 Liquid Effluents
2.3 Solids disposal
2.4 Noise Pollution
2.5 Energy conservation
3. Organizational Structure and Manpower Requirement
3.1 Organizational Principles and Basics
3.2 Hierarchy
3.3 Manpower Requirement
4. SITE SELECTION & PROJECT LAYOUT
4.1 Plant Location
4.2 Plant Layout
1|Page
1. MATERIAL AND ENERGY BALANCE

1.1
Material Balance
BASIS: 21833 kg/hr production of phenol

1.1.1 Overall reactions:
1. Oxidation of Cumene:
NaOH
C6H5CH(CH3)2
(120)
O2
C6H5C (CH3)2OOH
(32)
(152)
2. Decomposition of Cumene hydroperoxide:

C6H5C (CH3)2OOH
H2S04
C6H5OH
(152)
(94)
1.1.2 Molecular weights of components:

Cumene (Isopropyl benzene) = 120 kg moles
Cumene Hydroperoxide
= 152 kg moles
Oxygen
= 32 kg moles
Phenol
= 94 kg moles
Acetone
= 58 kg moles
Mass of inlet of Cumene and oxygen
= 120+32=152 kg moles
Mass of outlet of phenol and acetone

INLET
= 94+52= 152 kg moles
1.1.3 Feed:
Cumene = 1650 kg (For 1000 kg of Phenol)
Required oxygen = 440 kg
1 kg of air contains 0.23 kg of O2
X kg of air contains 440 kg of O2
Amount of air supplied = 1913 kg of air
25% excess air supplied = 478 kg of air
Actual amount of air supplied = 2319 kg of air
1.1.4 Balances:
2|Page
OUTLET
CH3COCH3
(58)
OXIDIZER:
COMPONENTS
INLET kg/hr
OUTLET kg/hr
Cumene
35786.025
9065.793
Air
51857.2035
---
Cumene hydroperoxide
----
36263.172
Off gases
----
42314.2635
Total
87643.2285
87643.2285
COMPONENTS
INLET kg/hr
OUTLET kg/hr
36263.172
9067.96185
Cleavage
9065.793
---
H2SO4
---
36271.8474
Total
10.84425
---
COMPONENTS
INLET kg/hr
OUTLET kg/hr
36271.8474
9067.96185
Carryover Cleavage
---
906.5793
Cleavage
9067.96185
35365.2681
Total
45339.80925
45339.80925
ACIDIFIER:
Cumene
SEPARATOR:
WASH TOWER:
3|Page
COMPONENTS
INLET kg/hr
OUTLET kg/hr
Cleavage
35365.2681
---
Water
520.524
---
Acid free Cleavage
---
35256.8256
Acidified wash water
---
628.9665
Total
35885.7921
35885.7921
ACETONE COLUMN:
COMPONENTS
INLET kg/hr
OUTLET kg/hr
OVERHEAD
BOTTOM
Cleavage
35256.8256
---
---
Acetone
---
10818.2238
---
Carryover cleavage
---
108.4425
---
---
---
108.4425
Residue
---
---
24221.7168
Total
35256.8256
10926.6663
24330.1593
INLET kg/hr
OUTLET kg/hr
OVERHEAD
Carryover acetone in
residue
CUMENE COLUMN:
COMPONENTS
BOTTOM
Feed
24330.1593
---
---
Cumene
---
1763.27505
---
---
108.4425
---
Residue
---
---
22458.44175
Total
24330.1593
1871.71755
22458.44175
Carryover acetone in
Cumene
- METHYL STYRENE COLUMN:
4|Page
COMPONENTS
INLET kg/hr
OUTLET kg/hr
OVERHEAD
BOTTOM
Feed
22458.44175
---
---
- methyl styrene
---
494.4978
---
Residue
---
---
21963.94395
Total
22458.44175
494.4978
21963.94395
INLET kg/hr
OUTLET kg/hr
OVERHEAD
PHENOL COLUMN:
COMPONENTS
BOTTOM
Feed
21963.94395
---
---
Phenol
---
21751.39665
---
Carryover acetophenone
---
82.4163
---
Acetophenone
---
---
108.4425
Total
21963.94395
21833.81295
108.4425
The amount product phenol =21833 kg/hr

Purity of the product phenol = 99.9%
5|Page
1.2
Energy Balance
OXIDIZER:
A) Inlet heat@ 70C:
1. Cumene @ 30C
mass 1
35786.025
Cp1
0.415
T1
Q1
kg
kcal/kg C
C
74256.00188
Kcal
310761.3678
KJ
2. Air @ 30C
mass 2
Cp2
T2
Q2
51857.2035
1.005
5
260582.4476
kg
kJ/kg C
C
KJ
3. Total heat inlet

Q = Q1+ Q2= 74256.00188+260582.4476
Q = 571343.8154 kJ
B) Outlet heat@ 110C:
1. Cumene Hydroperoxide @ 110C
mass 1
Cp1
T1
Q1
36263.172
0.45
85
1387066.329
5804872.587
6|Page
kg
kcal/kg C
C
Kcal
KJ
2. Cumene @ 110C
9065.793
mass 1
Cp1
kg
0.455
kcal/kg C
85
T1
350619.5443
Q1
1467342.793
C
Kcal
KJ
3. Off gases @ 110C

a) Oxygen
2385.735
mass 3
Cp3
0.936
25
T3
55826.199
Q3
kg
kJ/kg C
C
KJ
b) Nitrogen
39928.5285
mass 4
Cp4
1.035
25
T4
Q4
1033150.675
kg
kJ/kg C
C
KJ
4. Total heat outlet Q= Q1+ Q2+ Q3+ Q4

Q = 8361192.254 KJ
Heat of reaction of Cumene Hydroperoxide = 736 KJ/kg
For 1672 kg of Cumene Hydroperoxide
=26689694.59 KJ
7|Page
COMPONENTS
INLET HEAT kJ
OUTLET HEAT kJ
Cumene
310761.3678
1467342.793
Air
260582.4476
---
26689694.59
---
---
5804872.587
Off gases
---
1088976.874
Heat removed by water
---
19894575
Total
27261038.41
28255767.25
COOLER:
A) Inlet heat @ 110C:
Heat taken by Cumene Hydroperoxide =5804872.587KJ
Heat taken by Cumene = 1467342.793KJ
Total heat inlet = 7272215.38 KJ
B) Outlet heat @70C:

1. Cumene hydroperoxide @ 70C:
mass 1
Cp1
T1
Q1
36263.172
0.45
45
734329.233
3073167.84
kg
kcal/kg C
C
Kcal
KJ
2. Cumene @ 70C:
mass 2
Cp2
T2
Q2
9065.793
0.435
45
177462.898
742682.228
3.
Total heat outlet
8|Page
kg
kcal/kg C
C
Kcal
KJ
Q= Q1+ Q2 = 3073167.84 + 742682.228

Q = 3815850.068KJ
COMPONENTS
INLET HEAT kJ
OUTLET HEAT kJ
5804872.587
3073167.84
Cumene
1467342.793
742682.228
---
3638279
Total
7272215.38
7454129.068
ACIDIFIER:
Heat taken by Cumene Hydroperoxide = 3073167.84KJ
Heat taken by Cumene = 742682.228 KJ
Total heat inlet in product (Q1) = 3815850.068 KJ
1. H2SO4 @ 30C:
10.84425
mass 2
Cp2
1.44
45
T2
702.7074
Q2
Kg
kJ/kg C
C
KJ
Total heat inlet Q = Q1+Q2 = 3816552.776 KJ
B) Outlet heat @ 80C:

Mass of cleavage = 36271.8474 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
22488.80565
2.29
Acetone
11243.3184
1.481
9|Page
Cumene
1813.1586
1.842
- methyl styrene
509.67975
1.406
Acetophenone
221.2227
1.97
Q1=((23672.42.29)+( 11835.0721.481)+( 1908.581.842)+( 536.501.406)+( 232.8661.97))

(80-25)
Q1= 3995363.684 kJ
1. Cumene hydroperoxide@ 80C:
9067.96185
mass 2
Cp2
0.45
55
T2
224432.0558
Q2
939248.1535
kg
kcal/kg C
C
Kcal
KJ
Total heat outlet

Q = Q1+Q2 = 4934611.838 kJ
Heat of reaction of cleavage = 2983 KJ/kg

For 38180.9 kg of cleavage =113893624.7 KJ
COMPONENTS
10 | P a g e
Cumene Hydroperoxide
INLET HEAT KJ
3073167.84
OUTLET HEAT KJ
939248.1535
Cumene
742682.228
---
H2SO4
702.7074
---
Heat of reaction of
cleavage
113893624.7
---
Cleavage
---
3995363.684
---
112716720.4
Total
117710177.5
117651332.2
SEPARATOR:
A) Inlet heat @80C:
Heat in Cumene Hydroperoxide = 939248.1535 kJ
Heat in Cumene = 3995363.684 kJ
Total heat inlet = 4934611.838 kJ

Heat in Cumene Hydroperoxide = 939248.1535 kJ
Heat in cleavage = 3995363.684 kJ
Total heat outlet = 4934611.838 kJ
WASH TOWER:
A) Inlet heat @80C:
Mass of Cleavage =35365.2681 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21927.0735
2.29
Acetone
10963.53675
1.481
Cumene
1767.61275
1.842
- methyl styrene
494.4978
1.406
Acetophenone
212.5473
1.97
Q1=3895095.656 kJ
1. Water @ 30C
mass 2
Cp2
T2
Q2
11 | P a g e
520.524
4.18
5
10878.9516
kg
kJ/kg C
C
KJ
Total heat inlet Q = Q1+Q2 =3905974.607 kJ

Acid free cleavage = 35256.8256 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21857.6703
2.29
Acetone
10926.6663
1.462
Cumene
1763.27505
1.821
- methyl styrene
494.4978
1.367
Acetophenone
212.5473
1.97
Q1=3868395.941 kJ
1. Acidified wash water @ 40C

520.524
mass 2
Cp2
4.18
15
T2
32636.8548
Q2
kg
kJ/kg C
C
KJ
Heat taken by carryover cleavage Q3=5201.9 KJ
Total heat outlet

Q= Q1+Q2+ Q3= 3906234.696 kJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Cleavage
3895095.656
---
Water
10878.9516
---
Acid free cleavage
---
3868395.941
Acidified wash water
---
32636.8548
12 | P a g e
Carryover cleavage
---
5201.9
Total
3905974.607
3906234.696
HEATER:
A) Inlet heat @75C:
Cleavage
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
10926.6663
1.462
Acetone
1763.27505
1.821
Cumene
494.4978
1.367
- methyl styrene
212.5473
1.97
Acetophenone
10926.6663
1.462
Q = 3868395.941 kJ

COMPONENTS
MASS kg
Phenol
21857.6703
2.29
Acetone
10926.6663
1.509
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
Q = 3902835.934 kJ
13 | P a g e
SPECFIC HEAT KJ/KgC
COMPONENTS
Cleavage
INLET HEAT KJ
3868395.941
Heat added by steam
36252.62
Total
3904648.561
OUTLET HEAT KJ
3902835.934
--3902835.934
ACETONE COLUMN:
A) Inlet heat @90C:
Mass of cleavage =35256.8256 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21857.6703
2.29
Acetone
10926.6663
1.509
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
Q = 4612442.468 KJ
B) Outlet heat:
1. Acetone vapours @ 56C
Mass 1
1
Q1
10818.2238
212.3
2296708.913
kg
kJ/kg C
KJ
2. Cleavage vapours @ 56C
Mass 2
2
Q2
14 | P a g e
108.4425
109.96
11924.3373
kg
kJ/kg C
KJ
3. Total heat outlet as vapour

= 2308633.25
4. Bottom residue @90C
Mass of residue= 2533.2168 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21792.6048
2.32
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
Q3= 1924198.222 kJ
5. Carryover acetone @90C

108.4425
mass 4
Cp4
1.509
65
T4
10636.58261
Q4
kg
kJ/kg C
C
KJ
6. Total heat outlet

Q = Q1+Q2+ Q3+ Q4
Q =4243468.055 kJ
COMPONENTS
INLET HEAT KJ
Cleavage
4612442.468
Vapour acetone
---
2296708.913
Vapour cleavage
---
11924.3373
Bottom residue
---
1924198.222
Carryover acetone in residue
---
10636.58261
Total
4612442.468
4855203
15 | P a g e
OUTLET HEAT KJ
---
OVERHEAD ACETONE CONDENSER:

10818.2238
Mass 1
212.3
2296708.913
Q1
kg
kJ/kg C
KJ
2. Cleavage vapours @ 56C

108.4425
Mass 2
109.96
11924.3373
Q2
kg
kJ/kg C
KJ
3. Total heat inlet as vapour Q = Q1+Q2

Q= 2308633.25 KJ
B) Outlet heat@50C:
1. Acetone
10818.2238
mass1
Cp1
1.397
25
T1
377826.4662
Q1
kg
kJ/kg C
C
KJ
Heat produced by Cleavage Q2 = 4837.75 kJ
2. Total heat outlet Q = Q1+Q2

Q = 382664.2162 KJ
COMPONENTS
INLET HEAT KJ
Vapour acetone
2296708.913
---
Vapour cleavage
11924.3373
---
---
16 | P a g e
OUTLET HEAT KJ
2027590.4
Condensed acetone
---
377826.4662
Condensed cleavage
---
4837.75
Total
2308633.25
2410254.616
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21792.6048
2.32
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
HEATER:
A) Inlet heat @90C:
Q1 = 1924198.222 kJ
1. Acetone
108.4425
mass2
Cp2
1.509
65
T2
Q2
10636.58261
kg
kJ/kg C
C
KJ
2. Total heat inlet Q = Q1+Q2

Q =1934834.805 kJ
COMPONENTS
MASS kg
Phenol
21792.6048
17 | P a g e
SPECFIC HEAT KJ/KgC

2.32
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
Q1=1924198.222 kJ
1. Acetone
108.4425
mass2
Cp2
1.51
70
T2
11462.37225
Q2
kg
kJ/kg C
C
KJ
2. Total heat outlet

Q = Q1+Q2 =2037537.468 kJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Residue
1924198.222
1924198.222
Carryover acetone
10636.58261
11462.37225
Heat added by steam
869.25
Total
1935704.055
--1935660.594
CUMENE COLUMN:
A) Inlet heat @95C:
Mass of feed= 2533.2168kg
COMPONENTS
MASS kg
Phenol
21792.6048
2.32
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
18 | P a g e
SPECFIC HEAT KJ/KgC
Q1=3848396.444 KJ
1. Acetone
108.4425
mass2
Cp2
1.51
70
T2
Q2
11462.37225
kg
kJ/kg C
C
KJ
Total heat inlet

Q = Q1+Q2 = 3859858.816 kJ
B) Outlet heat:
1. Cumene vapours @ 90C
Mass 1
1763.27505
343.9
1
Q1
606390.2897
kg
kJ/kg C
KJ

108.4425
Mass 2
212.3
2
Q2
23022.34275
kg
kJ/kg C
KJ
3. Residue @ 95C
Mass = 22458.44175 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21792.6048
2.32
Cumene
1763.27505
1.863
- methyl styrene
494.4978
1.445
19 | P a g e
Q3 = 3848396.444 kJ
Total heat outlet
Q = Q1+Q2+Q3=4477809.076 kJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Feed
3848396.444
---
Vapour Cumene
---
606390.2897
Vapour acetone
---
23022.34275
Residue
---
3848396.444
Carryover acetone in feed
11462.37225
---
Total
4713483
4477809.076
CUMENE VAPOUR CONDENSER:

A) Inlet heat:
1. Cumene vapours @ 90C
Mass 1
1
Q1
1763.27505
343.9
606390.2897
kg
kJ/kg C
KJ
Mass 2
2
Q2
Total heat inlet Q
Q1+Q2 = 629412.6324 kJ
20 | P a g e
108.4425
212.3
23022.34275
kg
kJ/kg C
KJ
B) Outlet heat@80C:
1. Cumene
1763.27505
mass1
Cp1
1.842
55
T1
178637.3953
Q1
kg
kJ/kg C
C
KJ
2. Acetone
108.4425
mass1
Cp1
1.51
55
T1
9006.149625
Q1
kg
kJ/kg C
C
KJ
Total heat outlet

Q = Q1+Q2 = 187643.5449 kJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Vapour Cumene
606390.2897
---
Vapour acetone
23022.34275
---
---
465020.1
Condensed Cumene
---
178637.3953
Condensed acetone
---
9006.149625
Total
629412.6324
652663.6449
HEATER:
Mass = 22458.44175 kg
COMPONENTS
21 | P a g e
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21792.6048
2.32
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
Q = 3618447.745 kJ
B) Outlet heat @ 110C:

Mass = 22458.44175 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21792.6048
- methyl styrene
494.4978
1.445
Acetophenone
212.5473
1.97
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Residue
3618447.745
4393829.404
Heat added by steam
816191
Total
4434638.745
2.32
Q=4393829.404 kJ
--4393829.404
- METHYL STYRENE COLUMN:

Mass =22458.44175 kg
COMPONENTS
MASS kg
Phenol
21792.6048
- methyl styrene
494.4978
1.523
Acetophenone
212.5473
1.97
22 | P a g e
SPECFIC HEAT KJ/KgC

2.32
Q=4397107.925KJ
B) Outlet heat:
1. - methyl styrene vapours @ 100C
494.4978
Mass 1
449.1
222078.962
Q1
kg
kJ/kg C
KJ
2. Residue @110C
Mass = 21963.94395Kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21751.39665
2.32
Acetophenone
212.5473
1.97
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Residue
4397107.925
Vapour - methyl styrene
---
222078.962
Bottom residue
---
4324966.465
Total
4397107.925
4628534.5
Q2 = 4324966.465 KJ
Total heat outlet
Q = Q1+Q2 = 4547045.427 KJ
- METHYL STYRENE CONDENSER:

A) Inlet heat:
1. - methyl styrene vapours @ 100C
23 | P a g e
---
494.4978
Mass 1
449.1
222078.962
Q1
kg
kJ/kg C
KJ
B) Outlet heat:
1. - methyl styrene condensed @ 95C
494.4978
mass 1
Cp1
1.445
70
T1
50018.45247
Q1
kg
kJ/kg C
C
KJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Vapour - methyl styrene
222078.962
---
181116.3
Condensed - methyl styrene
---
50018.45247
Total
222078.962
231134.7525
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21751.39665
Acetophenone
212.5473
---
HEATER:
A) Inlet @110C
Mass =21963.94395Kg
Q=4324966.465 kJ
B) Outlet @130C
Mass =21963.94395 Kg
24 | P a g e
2.32
1.97
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21751.39665
Acetophenone
212.5473
1.97
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Residue
4324966.465
5342605.633
Heat added by steam
1071199
Total
5396165.465
2.32
Q=5342605.633 KJ
--5342605.633
PHENOL COLUMN:
A) Inlet @130C
Mass =21963.94395 Kg
COMPONENTS
MASS kg
Phenol
21751.39665
Acetophenone
212.5473
SPECFIC HEAT KJ/KgC

2.32
1.97
Q=5342605.633 KJ
B) Outlet heat
1. Phenol vapours @ 120C
21751.39665
Mass 1
296.7
6453639.386
Q1
kg
kJ/kg C
KJ
2. Acetophenone vapours @ 120C
Mass 2
2
25 | P a g e
82.4163
116.1
kg
kJ/kg C
Q2
9568.53243
KJ
3. Bottom acetophenone @130C

108.4425
mass 3
Cp3
1.97
105
T3
22431.33113
Q3
kg
kJ/kg C
C
KJ
Total heat outlet

Q= Q1+Q2+ Q3= 6485639.25kJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Feed
6826988.5
Vapour phenol
---
6453639.386
Vapour Acetophenone
---
9568.53243
Acetophenone
---
22431.33113
Total
6826988.5
6485639.25
---
PHENOL VAPOUR CONDENSER:

A) Inlet heat
1. Phenol vapours @ 120C
Mass 1
1
Q1
21751.39665
296.7
6453639.386
kg
kJ/kg C
KJ
2. Acetophenone vapours @ 120C
Mass 2
2
Q2
26 | P a g e
82.4163
116.1
9568.53243
kg
kJ/kg C
KJ
Total heat inlet

Q= Q1+Q2=6463207.918 kJ
B) Outlet heat@ 100C

Mass = 21833.81295 kg
COMPONENTS
MASS kg
SPECFIC HEAT KJ/KgC
Phenol
21751.39665
2.32
Acetophenone
82.4163
1.97
Q=3796920.025KJ
COMPONENTS
INLET HEAT KJ
OUTLET HEAT KJ
Vapour phenol
6453639.386
---
Vapour Acetophenone
9568.53243
---
---
2806618
Condensed phenol &

acetophenone
---
3796920.025
Total
6463207.918
6603538.025
27 | P a g e
2. Environmental Protection & Energy conservation

2.1 AIR POLLUTION
In this section, air emissions are characterized by location, effective emission heights, and emission
factors for criteria pollutants and selected pollutants; the hazard potential of each pollutant is
quantified, and the affected population is determined; the national and state emission burdens are
calculated; and the growth factor of the industrys emissions is determined. The data in this section
were obtained through industry cooperation.
SELECTED POLLUTANTS
Compounds identified as potential emissions from the manufacture of acetone and phenol from
cumene are listed in Table 12. A sampling program was undertaken to quantify these compounds
plus others which may not previously have been known to be present.
TABLE 12. SUSPECTED EMISSIONS FROM ACETONE AND PHENOL MANUFACTURE FROM CUMENE
PRIOR TO SAMPLING
Acetaldehyde
Acetic acid
Acetone
-Hydroxyacetone
Diacetone alcohol
Acetophenone
Benzene
Ethylbenzene
n-Propylbenzene
Methyl isobutyl carbinol
Cumene
Dicumyl peroxide
1,1,2, 2Tetramethyll,2diphenylethane
Formaldehyde
Formic acid
2-Methylbenzofuran
Methylgioxal
Heavy tars
2, 6Dimethyl-2, 5heptadiene4-one
l-Hydroxyethyl methyl ketone
Methyl isobutyl ketone
Lactic acid
Methanol
-Methylstyrene
Dimers of -methylstyrene
2-Methyl-3, 4-pentanediol
28 | P a g e
4-Hydroxy-4-methyl- 2-pentanone
Phenol
2,4,6-Tris (2-phenyl-2-propyl)phenol
Toluene
2-Phenyl-2- (4-hydroxyphenyl) propane
TABLE 13. CHARACTERISTICS OF EMISSIONS IDENTIFIED DURING SAMPLING OR REPORTED FROM
ACETONE AND PHENOL PLANTS USING CUMENE PEROXIDATION
MATERIAL EMITTED
Acetaldehyde
Acetone
Acetophenone
Benzene
Cumene
Ethyl benzene
Formaldehyde
methyl styrene
Naphthalene
Phenol
HEALTH EFFECTS
Local irritant; central nervous system narcotic
Skin irritant, narcotic in high concentrations
Narcotic in high concentrations
Carcinogen
Narcotic ; toxic
Skin and mucous membrane irritant
Irritant ; toxic
Toxic
Moderate irritant
Toxic & irritant
TABLE 14. EMISSION SOURCES BY PROCESS TYPE AT A PLANT MANUFACTURING ACETONE AND
PHENOL FROM CUMENE
Process
technology
Allied
Hercules
29 | P a g e
Emission source
Cumene peroxidation.
Cumene hydroperoxide concentration vent.
Separation column vent.
Acetone concentration column vent.
Cumene column vent.
Methylstyrene column vent.
Refined -methylstyrene column vent.
Phenol column vent.
Acetophenone column vent.
Cumene tank vent.
Acetone tank vent.
Catalyst tank vent.
Acetone transport loading vent.
-Methylstyrene transport loading vent
Phenol transport loading vent.
Acetophenone transport loading vent.
Acetophenone transport loading vent.
Cumene peroxidation vent.
Cumene hydroperoxide wash vent.
Cumene hydroperoxide concentration vent.
Vent of cuxnene hydroperoxide cleavage and product wash operations
combined.
Acetone column vent.
Dewatering column vent
Hydrogenation column vent
Acetone tank vent
-Methylstyrene tank vent
Phenol tank vent
Buffer tank vent
TABLE 15. EMISSION SOURCES AT A REPRESENTATIVE PLANT MANUFACTURING ACETONE AND

PHENOL FROM CUMENE
1. Cumene Peroxidation Vent
The cumene feed is contacted with air in a reaction vessel to peroxidize the cumene. Air is
continuously introduced and removed. The offgas stream carries vaporized hydrocarbons and
some volatile trace elements. Cumene is recovered from the spent gas for recycle by condensation.
The emission control equipment is the last piece of equipment before the gas is emitted to the
atmosphere. That is, any prior equipment is process equipment, and the control of any material
released to the atmosphere is performed by the last piece of equipment prior to release. For
example, in the Allied process the emission control equipment is the carbon bed system, and in the
Hercules process it is the refrigerated condenser, unless another piece of equipment is added on.
1. Cleavage Section Vents, Combined
The composite emission factors, Table 18, are determined by aggregation of the emission factors
available from sampling and industry communication. These emission factors combine values for
the cumene hydroperoxide concentration vent (Allied process technology) and the cumene
hydroperoxide wash vent, the cumene hydroperoxide concentration vent, and the combined cunene
hydrperoxide cleavage and product wash vent (Hercules process technology).
TABLE 18. AVERAGE EMISSION FACTORS FOR THE CLEAVAGE SECTION
Material emitted
Total nonmethane hydrocarbon
Acetone
Acetophenone
Benzene
2Butanone 0.0000018
2Butenal
tButylbenzene
Cumene
Ethylbenzene
30 | P a g e
g/kg phenol produced

0.17
0.0000060
0.0000044
0.000031
0.0000018
0.000000085
0.000023
0.14
0.0000050
Formaldehyde
2Hydroxy-2phenylpropane
Isopentanal
<0.00000026
0.0000034
0.00000085
Briefly, in the cleavage section the CUMENE hydroperoxide stream is Washed (Hercules process
only) and concentrated to 80% or more cumene hydroperoxide, the cumene removed is recycled,
the cumene hydroperoxide is cleaved to products using an acid catalyst, and the catalyst is removed
from the product stream.
2. Storage Tank Vents, Combined
The emission factor for the Phenol tanks in an average of the calculated value 0.06g phenol/kg
phenol produced and an estimate of 0.012 g phenol/
phenol produced. However, based upon plant experience, he used other data for some of the
input variables Such as storage temperature, vapor pressure, etc. The two estimates were
determined using the same procedure but different input variables; therefore, the estimates
were averaged.
3. Product Transport Loading Vent; Combined
The emissions from product transport loading are caused by displacement of hydrocarboncontaining vapors in the compartment being filled. One source reports emissions of 0.061 g
acetone/kg phenol produced from the acetone loading area and 0.20g Phenol/kg phenol
produced from the phenol loading and shipping area.
4. Fugitive emissions
Fugitive emissions occur from pressure relief valves, pump seals, compressor seals, pipeline
valves and flanges, equipment purges, Process drains, wastewater separators, and laboratory
analysis Sampling. An estimate of the total non-methane hydrocarbons (as methane
equivalents) from pumps and sewers has been reported to 0.022 g/kg phenol produced. Pump
and sewer caused emissions are not the total fugitive emissions, nor are they necessarily the
most significant.
CONTROL TECHNOLOGY
Air emissions from the manufacture of acetone and phenol from cumene Consist of hydrocarbons.
Existing emission control technologies for the industry are described in this section. These control
methods include condensation, absorption, adsorption, floating roof tanks, and incineration. Future
considerations in emissions control technology are also discussed in this section.
Adsorption is the most commonly used method to control emissions from the cumene peroxidation
vent. Condensation, absorption and incineration are also used.
31 | P a g e
Emissions in the cleavage section are most often controlled by condensation. Absorption and
incineration are also used.
Emissions in the product purification section are controlled by condensation, adsorption,
absorption, and incineration.
Floating roofs are used to control emissions from tanks, particularly acetone and cumene storage
tanks. Condensation, sealed dome roofs, and conservation vents are also used for this purpose, but
not as commonly as floating roofs.
Product transport loading emissions are controlled by absorption or vapor recovery. Not all plants
control this emission source.
The Scope of fugitive emissions and control methods are under study by EPA.
VARIOUS EMISSION CONTROL METHODS IN USE AT CUMENE PEROXIDATION PLANTS
VAPOUR CONDENSATION
Organic compounds can be removed from an air stream by condensation. A vapor will condense
when, at a given temperature, the partial pressure of the compound is equal to or greater than its
vapor pressure. Similarly, if the temperature of a gaseous mixture is reduced to the saturation
temperature (i.e., the temperature at which the vapor pressure equals the partial pressure of one of
the constituents), the material will condense. Thus, either increasing the system pressure or
lowering the temperature can cause condensation. In most air pollution control applications,
decreased temperature is used to condense organic materials, since increased pressure is usually
impractical. Equilibrium partial pressure limits the control of organic emissions by condensation. As
condensation occurs, the partial pressure of material remaining in the gas decreases rapidly,
preventing complete condensation.
ACTIVATED CARBON ADSORPTION
Adsorption is a phenomenon in which molecules become attached to the surface of a solid. The
process is highly selective, and a given adsorbent, or adsorbing agent, will adsorb only certain types
of molecules. The material adhering to the adsorbent is called the adsorbate. Adsorption involves
three steps.
First, the adsorbent comes in contact with the stream containing the adsorbate, and separation due
to adsorption results. Next, the unadsorbed portion of the stream is separated from the adsorbent.
Finally, the adsorbent is regenerated by removing the adsorbate.
Activated carbon is the most suitable adsorbent for organic vapors. Carbon adsorbs 95% to 98% of
all organic vapor from air at ambient temperature regardless of variations in concentration and
humidity given a sufficient quantity of carbon. The adsorption of a mixture of organic vapors in air
by carbon is not uniform, however, higher boiling point components are preferentially adsorbed.
When a contaminated gas stream is passed over an activated carbon bed, the organic vapor is
adsorbed and the purified stream passes through. Initially, adsorption is rapid and complete, but as
32 | P a g e
the carbon bed approaches its capacity to retain vapor, traces of vapor appear in the exit air. This is
the breakpoint of the activated carbon. If gas flow is continued, additional amounts Of Organic
material are adsorbed, but at a decreasing rate.
SOLVENT ABSORPTION
Absorption is a process for removing one or more soluble component from a gas mixture by
dissolving them in a solvent. Absorption equipment is designed to insure maximum contact
between the gas and the liquid solvent to permit interphase diffusion between the materials.
Absorption rate is affected by factors such as the solubility of gas in the particular solvent and the
degree of chemical reaction; however, the most important factor is the solvent surface exposed.
A vent gas scrubber-cooler system used on a cumene peroxidation vent is illustrated in figure. In this
system off gases are scrubbed in a tray tower to absorb hydrocarbons into the scrubbing liquid,
which is an aqueous Na2CO3 solution. Some of the scrubbing liquid is sent to the oxidation section,
and some is recycled through the scrubber with makeup solution. The scrubbed gas is cooled,
condensate is removed and sent to the oxidation section, and the gas is released to the atmosphere.
INCINERATION
Complete combustion of the hydrocarbons present in the emissions from a cumene peroxidation
phenol plant produces carbon dioxide and water. NOx may be produced depending on the method
of combustion the temperature. SOx production depends on the sulphur content of the auxiliary
fuel, if any. The types of incinerators (i.e., direct flame afterburners, catalytic after burners, or flares),
used to combust hydrocarbons at plants manufacturing acetone and phenol from cumene were not
reported.
STORAGE TANKS
Six kinds of evaporation loss from storage of organic materials occur: breathing, standing storage,
filling, emptying, wetting, boiling. Vapors expelled from a tank because of thermal expansion,
barometric expansion, or additional vaporization are breathing losses. Vapor loss from such areas
as seals, hatches, other openings (but not due to breathing or level changes) constitute standing
storage loss. Vapors expelled from a tank is filled constitute filling loss. Vapors expelled from tank
during emptying (due to the fact that vaporization occurs slowly, air enters to equalize pressure,
vaporization stabilizes, and there is excess vapor in the tank) are emptying loss. Wetting loss is the
vaporization of liquid from wetted exposed wall in a floating roof tank when the roof is lowered.
Vapors expelled because of boiling are boiling loss.
FLOATING ROOF TANKS
Floating roof tanks are of various designs but the basic concept is that the roof floats on the surface
of the stored material. A seal provides intimate contact between the roof and the tank wall. These
tanks reduce breathing and filling losses by reducing the space available for vapor accumulation.
Wetting losses are small and not a problem.
33 | P a g e
SEALED DOME ROOF TANKS

This type of tank can withstand relatively large pressure variations without incurring a loss. There is
little or no breathing loss. Filling loss will depend on the tank design.
CONSERVATION VENT FOR TANKS
The conservation vent is a device to inhibit evaporation loss while protecting the tank from possible
damage due to under pressure or overpressure. The vent has two set points, an upper a lower
pressure. If the pressure is outside this range the vent opens to allow pressure equalization with the
atmosphere. This reduces evaporation losses.
VAPOR RECOVERY SYSTEM ON PRODUCT LOADING FACILITIES
This control device collects the vapors produced from product loading and disposes of them by one
of the control methods previously described, such as condensation, adsorption, etc. Vapor recovery
is a general term for emission control practices.
2.2 Liquid effluents

Acetophenone
Acetophenone is a colorless liquid with a sweet, pungent odor that is sparingly soluble (0.55 wt % at
20C) in water. Acetophenone is used as a chemical Intermediate for resins, pharmaceuticals,
corrosion Inhibitors and dyestuffs; as a solvent for gums, resin dyestuffs and highmelting aromatic
chemicals; as a polymerization catalyst and photosensitizer. In organic synthesis; as a flavoring
agent for tobacco and in perfumery. If acetophenone is released to water, microbial degradation
and volatilization are expected to be the major environmental fate and transport processes.
Biodegradation studies have shown that acetophenone is significantly biodegradable. The
volatilization halflife from a river 1m deep flowing at 1 m/sec with a wind velocity of 3 m/sec was
estimated to be 3.7 days. Hydrolysis, oxidation, adsorption to sediments and bioconcentration are
not expected to be significant. When acetophenone is released to the ambient atmosphere, reaction
with photochemical)yproduced hydroxyl radicals is expected to be the dominant removal
mechanism; the halflife for this reaction has been estimated to be 2 days (U.S. EPA. 1981). In the
atmosphere, acetophenone will exist almost entirely in the vapor phase.
If
acetophenone
is
released
to
soil,
microbial
degradation
is
likely
to
be
the major degradation process. Based on various adsorption studies
acetophenone is expected to be mobile in soil and susceptible to significant leaching. Acetophenone
is also expected to evaporate from dry soil surfaces. Acetophenone occurs naturally. In varius plant
oils, in the buds of balsam poplar and In Concord grapes (Dorsky et al., 1963; NIcholas, 1973). It has
been detected in drinking waters, surface waters, groundwaters and waste effluent waters. The
presence of acetophenone in environmental waters is most likely the result of discharges from
industrial sources. Metabolism and toxicity data indicate that acetophenone is absorbed by both
gastrointestinal and respiratory tracts. Studies using rabbits indicate that acetophenone Is
metabolized to ()1phenylethanol, which is excreted in the urine as glucuronide and sulfate
conjugates.
34 | P a g e
Health Hazard Information

Acute Effects:
Acute exposure of humans to acetophenone vapor may produce skin irritation and
transient corneal injury. One study noted a decrease in light sensitivity in exposed
humans.
Acute oral exposure has been observed to cause hypnotic or sedative effects,
hematological effects, and a weakened pulse in humans.
Congestion of the lungs, kidneys, and liver were reported in rats acutely exposed to
high levels of acetophenone via inhalation.
Tests involving acute exposure of rats, mice, and rabbits have demonstrated
acetophenone to have moderate acute toxicity from oral or dermal exposure.
Reproductive/Developmental Effects:
No information is available on the reproductive or developmental effects of
acetophenone in humans.
In one study of pregnant rats exposed dermally, no effects on reproduction or
development were noted.
Cancer Risk:
No information is available on the carcinogenic effects of acetophenone in humans or
animals.
EPA has classified acetophenone as a Group D, not classifiable as to human
carcinogenicity.
Potential Health Effects
Inhalation:
May cause irritation to the respiratory tract; symptoms may include sore throat, coughing,
headache, and dizziness. Higher concentrations may cause narcosis.
Ingestion:
May cause sore throat, abdominal pain, nausea, coughing, headache, dizziness, anesthetic
effects, and central nervous system effects.
Skin Contact:
May cause irritation with redness and pain.
Eye Contact:
May cause severe irritation, redness, pain, and transient corneal injury.
Chronic Exposure:
Prolonged or repeated skin exposure may cause dermatitis.
Aggravation of Pre-existing Conditions:
No information found.
35 | P a g e
First Aid Measures

Inhalation:
Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give
oxygen. Call a physician.
Ingestion:
Induce vomiting immediately as directed by medical personnel. Never give anything by
mouth to an unconscious person. Call a physician.
Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes.
Remove contaminated clothing and shoes. Wash clothing before reuse. Call a physician.
Eye Contact:
Immediately flush eyes with plenty of water for at least 15 minutes, lifting lower and upper
eyelids occasionally. Get medical attention immediately.
Fire Fighting Measures
As in any fire, wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH
(approved or equivalent), and full protective gear. During a fire, irritating and highly toxic gases may
be generated by thermal decomposition or combustion. Use water spray to keep fire-exposed
containers cool. Combustible liquid and vapor.
Extinguishing Media: Use water spray, dry chemical, carbon dioxide, or appropriate foam.
Flash Point: 77 deg C ( 170.60 deg F)
Autoignition Temperature: 570 deg C ( 1,058.00 deg F)
Explosion Limits, Lower:1.1%
Upper: 6.7%
Accidental Release Measures
Ventilate area of leak or spill. Remove all sources of ignition. Wear appropriate personal protective
equipment as specified in Section 8. Isolate hazard area. Keep unnecessary and unprotected
personnel from entering. Contain and recover liquid when possible. Use non-sparking tools and
equipment. Collect liquid in an appropriate container or absorb with an inert material (e. g.,
vermiculite, dry sand, earth), and place in a chemical waste container. Do not use combustible
materials, such as saw dust. Do not flush to sewer! Environmental Regulations require reporting
spills and releases to soil, water and air in excess of reportable quantities.
Handling and Storage
Keep in a tightly closed container, stored in a cool, dry, ventilated area. Protect against physical
damage. Isolate from any source of heat or ignition. Isolate from oxidizing materials. Containers of
this material may be hazardous when empty since they retain product residues (vapors, liquid);
36 | P a g e
observe all warnings and precautions listed for the product. Keep away from heat and flame. Keep
away from sources of ignition. Store in a tightly closed container. Store in a cool, dry, well-ventilated
area away from incompatible substances.
Exposure Controls/Personal Protection
Airborne Exposure Limits:
- Threshold Limit Value (TLV): 10 ppm (TWA)
Ventilation System:
A system of local and/or general exhaust is recommended to keep employee exposures below the
Airborne Exposure Limits. Local exhaust ventilation is generally preferred because it can control the
emissions of the contaminant at its source, preventing dispersion of it into the general work area.
Please refer to the ACGIH document, Industrial Ventilation, A Manual of Recommended Practices,
most recent edition, for details.
Personal Respirators (NIOSH Approved):
If the exposure limit is exceeded, a respirator with an organic vapor cartridge may be worn for up to
ten times the exposure limit. Since this compound has been identified as possibly existing in both
vapor and particulate phase, a dust/mist prefilter is recommended. For emergencies or instances
where the exposure levels are not known, use a positive-pressure, air-supplied respirator.
WARNING: Air-purifying respirators do not protect workers in oxygen-deficient atmospheres.
Skin Protection:
Wear protective gloves and clean body-covering clothing.
Eye Protection:
Use chemical safety goggles and/or a full face shield where splashing is possible. Maintain eye wash
fountain and quick-drench facilities in work area.
Stability:
Stable under ordinary conditions of use and storage.
Hazardous Decomposition Products:
Carbon dioxide and carbon monoxide may form when heated to decomposition.
Hazardous Polymerization:
Will not occur.
Incompatibilities:
Strong oxidizers.
37 | P a g e
Conditions to Avoid:
Heat, flame, other sources of ignition.
Maharashtra Pollution Control board Standards under Water Act
The daily quantity of trade effluent from the factory shall not exceed 18 m3.
The daily quantity of sewage effluent from the factory shall not exceed 7 m 3.
(i) Trade Effluent Treatment: The applicant shall provide comprehensive treatment system consisting
of Primary / secondary and / or tertiary treatment and is warranted with reference to influent quality
and operate and maintain the same continuously so as to achieve the quality of the treated effluent
to the following standards:
pH
Suspended Solids
BOD
COD
Oil & Grease
TDS
Chlorides
Sulphates
Chromium
Total Chromium
Total metal
Iron
Between
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
Not to Exceed
5.5 to 9.0
100 mg/l.
100 mg/l.
250 mg/l
10 mg/1.
2100 mg/1.
600 mg/1.
1000 mg/1.
0.1 mg/l
2.0 mg/l
10 mg/l
5.0 mg/l
(ii) Trade Effluent Disposal: The treated effluent shall be used in the process to the maximum extent
and remaining shall be used on land for green belt development.
(iii) Sewage Effluent Treatment: The applicant shall provide comprehensive treatment system as is
warranted with reference to influent quality and operate and maintain the same continuously so as
to achieve the quality of treated effluent to the following standards.
(1) Suspended Solids - Not to exceed 100 mg/I.
(2) BOD 3 days 27 C - Not to exceed 100 mg/I.
(iv) Sewage Effluent Disposal: The treated domestic effluent shall be soaked in a soak pit, which shall
be got cleaned periodically. Overflow, if any, shall be used on land for gardening / plantation only.
(v) Non-Hazardous Solid Wastes:
Sr. No.
1
2
38 | P a g e
Type of waste
Slag
Machine returns
Quantity
158267MT/Yr
10000 MT/Yr
Disposal
Landfill
By reuse in own sinter
plant
Flue Dust
24000 MT/Yr
Fly ash
12000 MT/Yr
By reuse in own sinter

plant
Sale to brick & cement
mfg. & landfill
(vi) Other conditions: The industry shall monitor effluent quality regularly. The applicant shall comply
with the provisions of the Water (Prevention & Control of Pollution) Class Act, 1977 (to be referred as
Class Act) and Rules there under: The daily water consumption for the following categories is as
under:
(i) Domestic -80 CMD
(ii) Industrial Processing CMD
(iii) Industrial Cooling - 3135 CMD
(iv) Agriculture/Gardening - 16 CMD
The applicant shall regularly submit to the Board the returns of water consumption in the
prescribed form and pay the Class as specified under Section 3 of the said Act.
2.3 Solid Waste Disposal

There is no substantial solid waste in the plant; the only solid waste will be dried sludge from the
effluent treatment plant, canteen wastes, worn office equipment and tools, stationery, cleaning rags,
packing boxes, broken pallets and broken office chairs. Solid waste disposal is done by thermal
incineration or by tipping. The design of a solid waste incinerator is difficult to do due to the wide
variety of feed to be disposed. It is important to determine the burning characteristics of the solid
waste material. A major problem with the solid incinerator is fly ash control. Various methods
employed for this purpose ate two-stage combustion, filter baffle and provision of large secondary
chambers where velocities are low and settling takes place. If the fly ash problem is chronic, special
separation devices like electrostatic precipitators can be employed. The flash produced can be used
as a land fill.
2.4 Noise Pollution

The major sources of noise pollution in our plant are:
Pumps
Burners
Electric motors
Valves
Steam Vents
Various equipments noise levels and control measures are listed in the table below:
Equipment
39 | P a g e
Sound level at 3ft(dB)
Possible
measures
Noise
Control
Electric motors
90-110
Pumps
Vane(Industrial)
Vane(mobile)
Axial position
Screw type
Gear
Heaters and furnaces
75-82
84-92
76-85
72-78
78-88
90-110
Valves
80-108
Piping
90-105
Acoustically lined fan

enclosures and motor
absorbent mounts.
Acoustically lined fan
enclosures and motor
absorbent mutes.
covers,
mutes,
covers,
mutes,
Acoustic
plenums,
intake
mufflers, lined/ damped ducts
Avoid sonic velocities, limit
pressure drop and mass
flow,and replace with special
low noise valves.
Isolation and lagging, in liner
silencers, vibration isolators.
Apart from the listed noise sources, minor sources of the noise pollution may be pipes and
hoses hitting the floor, panels etc. i.e. rattling noises, which can be stabilized with adsorbent
mounts. All the bolts should be tightened to prevent vibration and clatter. Venting of process gas
out the condensers may result in serious noise pollutions. This is due to turbulent mixing of high
velocity gas with the stationary gas. Steam leaks and another common noise problem with the
sound level are reaching sometimes 100 dB at the distance of 25 feet of the leak. All steam leaks
should be timely repaired. Where noise levels cannot be reduced to acceptable levels of a
person, ear protection equipment should be used. The industry shall take adequate measures
for control of noise levels from its own sources within the premises so as to maintain ambient
air quality standard in respect of noise to less than 75 dB(A) during day time and 70 dB(A) during
night time. Day time is reckoned in between 6 a.m. and 10 p.m. and night time is reckoned
between 10 p.m. and 6 a.m.
Maharashtra Pollution Control Board Standards for Noise Pollution:

1) The industry should not cause any nuisance in surrounding area.
2) The industry should monitor stack emissions and ambient air quality regularly.
Conditions for D.G. Set:1] Noise from the D.G. Set should be controlled by providing an acoustic enclosure or by treating
the room acoustically.
2] Industry should provide acoustic enclosure for control of noise. The acoustic
enclosure/acoustic treatment of the room should be designed for minimum 25 dB(A) insertion
loss or for meeting the ambient noise standards, whichever is on higher side. A suitable exhaust
40 | P a g e
muffler with insertion loss of 25 dB(A) shall also be provided. The measurement of insertion loss
will be done at different points at 0.5 m from acoustic enclosure/room and then average.
3] The industry shall take adequate measures for control of noise levels from its own sources
within the premises in respect of noise to less than 55 dB(A) during day time and 45 dB(A) during
the night time. Day time is reckoned between 6 a.m. to 10 p.m and night time is reckoned
between 10 p.m. to 6 a.m.
4] Industry should make efforts to bring down noise level due to DG set, outside industrial
premises, within ambient noise requirements by proper siting and control measures.
5] Installation of DG Set much be strictly in compliance with recommendations of DG Set
manufacturer.
6] A proper routine and preventive maintenance procedure for DG set should be set and
followed in consultation with the DG manufacturer which would help to prevent noise levels of
DG set from deteriorating with use.
7] D.G. Set shall be operated only in case of power failure.
8] The applicant should not cause any nuisance in the surrounding area due to operation of D.G.
Set.
2.5 Energy Conservation

Chemical plants have always been designed to operate economically due to product competition.
However before 1970, the objectives of building a low cost plant was generally considered more
important than low operating cost. This concept changed due to the oil crisis of 1973 and the
subsequent action at several environment protection agencies in promoting the use of non-low
polluting attention has been paid to such topics such as energy conservation schemes, process
integration, heat exchanger network design, cogeneration etc. This attention is evident by the large
number of books and journals published on these topics in the recent years. The design engineer
must consider appropriate energy conservation schemes that are designed to:
(i) Utilize as much of the energy available within the plant.
(ii) Minimize the energy requirements for the plant.
The energy balances performed for the plant items provide the initial key to identify areas of high
energy availability or demand. An attempt can then be made to utilize excess energy in those areas
where energy must be provided. However, this is not always possible because:
(i) A high energy load may constitute a large volume of liquid at relatively low temperature,
exchanging this energy may require large and expensive equipment.
(ii) This energy source may be distant from the sink and piping and insulating costs may make
utilization uneconomic, sometimes a rearrangement of the plant lay out required.
(iii) The energy source may be corrosive.
41 | P a g e
Any energy conservation scheme must also consider the costs involved in removing or transferring
the excess energy i.e. capital cost of heat exchangers, piping, valves, pumps, insulation and
operating costs of pumping and maintenance. Energy conservation is only worthwhile if the
reduction in energy costs exceed the cost of implementation. A scheme maybe devised for a plant
and then held over until energy prices make the proposal attractive. This type of forward planning
requires that the plant layout adopted can be easily modified. Energy conservation can be achieved
at three levels:
(i) Correct plan and operation and maintenance
(ii) Major changes to existing plant and processes.
(iii) New plants and new processes.
The time required to implement energy conservation measures, the capital cost required, and the
potential savings, all increase from level (i) to (iii) above. The cost of downtime for level.(ii) can be
significant, and the level (iii) offers the greatest long term potential for energy conservation. This
latter objective can be achieved either by designing new, energy efficient plants for established
process routes, or adopting new and less energy- intensive process routes. The basic approach
towards conservation of energy should be taken into account:
i. Operational modification
ii. Research and development
iii. Design modification
iv. Insulation
v. Maintenance
vi. Process integration
vii. Process modification
viii. Waste utilization
In the near future all industrial operations that have reacted to the energy crisis must be organized
to institute a systematic approach towards conserving energy in all forms through more efficient
utilization of existing processes and carefully studied reduction of losses and wastes. The following
examples illustrate some application of the basic engineering principles t the design of equipment
for improved energy efficiency.
(i) Plant Operation:
Energy savings can be achieved by good engineering practice and the application of established
principles. These measures may be termed as good housekeeping and include correct plant
operation and regular maintenance. The overall energy savings are usually small and may not be
easy to achieve and significant time may be required for regulate maintenance and checking.
However, such measures do help to establish commitment of a company to a policy of energy
conservation.
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(ii) Heat Recovery:

Heat recovery is an important and fundamental method of energy conservation. The main
limitations of this method are:
(a) Inadequate scope for using recovered waste heat because it is too low grade for existing heat
requirements, and because the quantity of waste heat available exceeds existing requirements for
low- grade heat.
(b) Inadequate heat transfer equipment. Developments and improvements are continuing in design
and operation of different types of heat exchangers including the use of extended heat transfer
surfaces, optimizing heat exchanger networks, heat recovery from waste fuels, heat exchanger
fouling and the use of heat pumps.
(iii) Combined Heat and Power Systems:
Significant energy conservation is achieved by well-established method of combined heat and
power generation. This is often referred to as CHP or COGEN. The heat is usually in the form of
intermediate or low pressure steam and the power as direct mechanical drives or as electricity
generated with the turbo alternators. The choice of system is usually between back pressure steam
turbines or gas turbines with waste heat boilers for the process streams. The amount of power
generated is usually determined by the demand of heat. It is not usually possible to balance exactly
the heat and power loads in a system .The best method of achieving this aim is to generate excess
electricity for subsequent sale, other balancing methods tend to be less efficient. Therefore it is
important to forecast the heat to power ratio accurately at the design stage to avoid large
imbalances and reduced system efficiency.
(iv)Power recovery systems:
A power recovery turbine can recover heat from an exchanger gas and then use this heat to provide
a part of the energy required to drive the shaft of a motor driven process air compressor. Other
examples are the use of the steam turbine drive and a two stage expansion turbine with reheating
between the stages.
A hydraulic turbine can be incorporated on the same shaft as a steam turbine. This arrangement can
be used to provide about 50% of the energy needed to recompress the spent liquor in a high
pressure absorption /low pressure stripping system. Power generation using steam or gas turbine is
now well established; however power recovery by the pressure reduction of process fluids is more
difficult and less common. In general the equipment is not considered to be particularly
reliable.Rankine cycle heat engines have been developed to use relatively low grade waste heat
sources to generate power in the form in the form of electricity or direct drives. They tend to be
used when the heat source would otherwise be completely wasted, the low efficiencies do not
represent a significant disadvantage.
(v) Furnace efficiency
Incorporating an air heater can be more economic than using a hot oil system which is designed for
high level heat only.
43 | P a g e
(vi) Air cooler v/s water cooler:

Air coolers have higher installed cost but lower operating cost water coolers.
(vii) Low pressure steam:
Energy savings can be achieved by the efficient use of low pressure steam.
(viii) Heat integration:
Energy can be saved by optimum balance of heat sources and sinks in a process plant so as to
maximize recycling of energy input .thus however has to be done carefully as it leads to loss of
operational independence.
(ix) Thermal insulation:
Owing to the great size of the distillation column large amount of heat is dissipated from the
surface .This necessitates thermal insulation of distillation column reboiler and other piping
attached to it so that minimum heat is dissipated.Multi-layer energy saving insulation should be
used which provide protection from fire, liquid spillage and result in energy savings. Usually, inner
insulation layers are made from alumina silica fibers to reduce the heat loss from the valves and
joints to keep the system heat constant and prevent heat loss.
Instrumentation:
Use of efficient instrumentation in the plant can result in consistent high quality of product and
lesser no. of rejections. In a plant design utmost care must be taken to conserve energy. The
reboiler and the heat exchanger should be set up after a long analysis
Energy conservation in the design of complete process may be achieved in four ways:
(i) Major modifications to the existing plants.
(ii) New plant using an existing process route.
(iii) New process routes and alternative raw materials.
(iv) New processes for new products that are less energy intensive.
Items (i) and (iii) represent short term and medium term energy conservation measures. Item (iv)
requiring the use of new products or processes is more appropriate for new technology in the
chemical industry. Although energy conservation is an obvious objective of all equipment
manufacturers and plant designers, more attention iis necessary in relation to education , training
and the application of new and existing technology to ensure significant medium term and long
term savings.
Energy conservation must be considered at various stages of the project, e.g. feasibility study,
process selection, plant layout, energy balances and in conjunction with the detailed equipment
design. If he energy utilization is not only an afterthought, either unnecessary or costly modifications
may be required to the design work, or the plant may not be economically feasible as it originally
appeared.
44 | P a g e
ENERGY MANAGEMENT:
The high value of energy should be acknowledged in plant operation by treating it as a product with
monetary value than can be sold or traded, just like the chemical product. This should be the basis
for operational policies concerned with the energy management or energy conservation. These
duties can be incorporated by the process engineer. EAM&T is a means to efficient operation in this
area, but there must be a commitment from all operational and managerial personnel to the
importance of these tasks if they are to be successful. The reaction and product recovery areas have
been identified as critical units from an energy perspective. Detailed monitoring and targeting
should be established in these areas.
ALTERNATE ENERGY RESOURCES
The fuel resources of the world are fast depleting and there is an urgent need to explore the
possibility of the alternate sources of energy. Although rapid breakthrough has been
achieved in the use of nuclear energy for the distillation of the steam, which in turn is used
for the generation of electricity, it is not used widely due to the lack of the flexibility in its
utilization and because of the non-feasibility of its operation on the smaller scale. Some of
the alternate energy sources being developed nowadays have been briefly discussed below:
Solar energy
Solar energy is the most important form of renewable energy for plant. The energy incident
on the solar panel installed in the roof and other areas of the plants are highly useful in
heating up the water and converting to steam. This is one renewable source of the energy
which is now slowly finding wide acceptance in the process industry. In the process industry
it is being used widely for heating the process water and in some cases for the production of
the low pressure steam. Energy conservation is not only concerned with the process
industries but is also concerned with other small household purposes carried out in the
industrial areas. It can also be used for the heating and providing warm water in the canteen
and the other non-production areas in the process plant.
Energy from biomass conversion
Biomass in todays Chemical Industries is going to play a vital role in the production of
energy as well as in different chemical products. The biomass have been widely used
however major considerations include:
Which raw materials will be needed in the new situation?

How will biomass be processed?
How will feedstock be made available at the appropriate location?
What kind of storage facilities is needed?
How can the production of bio-based bulk chemicals be integrated?
How will products be shipped to the (geographic) area covered by the Port?
Which are the most likely companies to produce new bio-based bulk chemicals?
Two extremes can be envisioned by which the transformation to a biomass based chemical
industry may take place:
45 | P a g e
1. Biomass will be refined and cracked into the familiar platform chemicals (i.e. ethylene,
propylene, C4-olefines and BTX) and synthesis gas (syngas, a mixture of mainly carbon
monoxide and hydrogen gas). From these one- to six-carbon building blocks, all other
chemicals and materials can be produced. Provided that efficient processes will become
available by which oxygen-rich biomass of a varying composition can be transformed into
basic hydrocarbon building blocks, the big advantage is that the current petrochemicals
infrastructure and processes can be used. The fossil feedstock refining companies of today
may then become the biorefineries of tomorrow.
2. A wide range of bio-based building blocks, in which as much of the functionality of
biomass as possible has been retained, become the raw materials from which all other
chemicals and materials are made. Not a few refineries that produce a limited number of
platform chemicals will be present, but a large number of (smaller scale) bio-refineries that
produce a whole array of building blocks.
Between these two extremes lies a whole spectrum of non-exclusive scenarios that are
perhaps more realistic. As a less extreme example of the first scenario: ethylene, one of the
current platform chemicals, can be produced from (bio) ethanol. In fact, the Brazilian
company Braskem and US based Dow Chemical will each start commercial production of
polyethylene from bio-ethanol. Bio-ethanol is currently made from sugar or starch. In the
future, it is expected that ethanol will be made from the more abundant lignocellulosic or
woody biomass.
The Gobar gas concept has found wide acceptance in the rural India. Although bioconversion
technology has been very successful in the waste treatment, the technology to generate
energy for the industrial uses is in early stages of the development. However, this
technology holdsgreat promise as its fundamental advantage is that apart from being a
clean source of the fuel, it is a renewable source of energy.
Ocean thermal energy:
The Ocean energy is one of the contributors in renewable energy. The temperature of the
water in the ocean varies drastically with the depth. The principal here is to run a heat
engine to retract heat energy from ocean by utilizing the difference in temperature of the
ocean at various depths.
This technology is in the very early stages of the development and can only be utilized if the
plant is situated close to the coastlines.
Wind energy:
The unequal heating of the earth by the sun causes winds. This effect is particularly
pronounced in the coastal areas with a difference between the temperature for the land and
the sea. The force of the wind is used to rotate windmills, which are rotating blades to collect
the force of the wind. This mechanical energy produced can be used directly on it can be
converted into electrical energy. These have been used with partial success in the process
46 | P a g e
industry, mainly to pump water both process water and the water to effluent treatment
plants.
3. Organizational Structure and Manpower Requirement

3.1 Organizational Principles and Basics
According to one of the prominent scholars, organizations are social units (or human
groupings) deliberately constructed and reconstructed to seek specific goals. (Etzioni, 1964).
Organization is a prescribed pattern of relations among the various tasks and the individuals who
perform the tasks. Organizations are characterized by explicit, common parts which require the coordination of individuals and group efforts towards their attainment. The co-ordination is achieved
by the establishment of vertical and horizontal network of relationships among various components
of the organization. The basic goals of the organization are three-folds:
1. To produce the best quality product at the lowest cost
2. To sell the product to the consumer in a manner that maximizes profit, both in the short as well
as long term.
3. To do these in a manner that is sustainable and is in the interest of the society.
In order to achieve these goals, an effective organizational structure is required both at the
management and operational levels. There are various steps involved in specifying the kind of
organization and the total labour requirement of the plant complex, before beginning the
construction and commissioning of the plant. We briefly take some of the important points.
Consideration of objectives: One should be very clear as to what are the objectives of the
enterprise. Objectives determine the various activities, which need to be performed and the type of
organization, which needs to be built for the purpose.
Grouping of activities into departments: Identify the activities necessary to achieve the objectives
and group the similar or related activities into well-defined groups or departments.
Deciding key departments: Key departments are those which render activities that are essential
for the achievement of goals. These are primary departments; the others exist merely to serve
these.
Determine decision levels: The levels at which all the major and minor decisions in each
department are to be made must be determined. The amount of decentralization and spread of
authority are at the discretion of each firm.
Span of Management: The next step to be taken in designing a structure is the number of subordinates who will report to each executive.
47 | P a g e
Coordination mechanism: The whole structure should be like a well-oiled machine, with cohesion
and co-ordination at all levels.
Duties of organization and administration:
Principles of work administration and control, labour organization and control, raw material
and their storage
Selection of site, layout of works, building and plants
Problem of internal transport and material handling
Construction work
Proper equipment selection
Minimization of labour
Office administration and finance
Marketing and distribution of products.
There are sixteen principles of organization:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Unity of objectives
Specialization
Coordination
Chain of command
Authority responsibility
Delegation
Unity of command
Span of Control
Balance
Communication
Efficiency
Personal ability
Decision making and control by exception
Flexibility
Departmentalization
Goal centered and purposeful activities
But an organization that works well in one type of environment (environment being defined as
combination of markets, customers, producers and technology) may fail in another. The failure may
arise due to contingency factors such as:
1. Task uncertainty, technology and environment
2. Power and conflict
3. Growth and size
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Here task uncertainty is the degree to which the task necessary for the performance is
unpredictable. Technology and environment are the sources of unpredictability.
Organizational structure should manage conflict so that it helps the company. It is helpful to
understand the basic determinants of power in an organization and how conflicts are related
Organization effectiveness includes the following criteria
1. Organizational efficiencies
2. Adaptability to external changes
3. Satisfaction of individual needs
3.2 Hierarchy
I.
Board of Directors
i.
Establishes objectives
ii.
Overall accountability to stock holders
II.
Chief Executive Officer

i.
Operates business to accomplish objectives
ii.
Accountable to board of directors.
III.
Operating management
i.
Overall coordination and activities necessary to accomplish objectives
ii.
Accountable to CEO
IV.
Operating supervision
i.
Supervision of non-supervisory employs
ii.
Accountable to operating Management
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ORGANIZATION HIERARCHY CHART
Keeping the above factors in mind, we have divided the organization of our plant into the following
categories
General administration
Production division
Maintenance division
Commercial and inventory division
Human recourses division
Marketing division
Research and development division
A. Finance Sector
When it comes to the overall scope and duties of a finance department, there are many functions to
be fulfilled. For the most part, the duties include all things related to budgeting.
From appropriations to control of expenditure and auditing duties, the finance department of any
given company has an array of duties.
A finance department basically has three main functions:
To provide strategic financial support regarding operational and general business planning
To provide daily financial services functions
To meet and surpass the internal and external needs and financial reporting requirements
of the company at large
The finance department generally focuses on providing relevant information necessary for upper
level management. Such information is crucial in determining how a company can make better
financial decisions.
Services and Duties of a Finance Department
In order to implement these functions, there are a number of services that need to be performed.
For example, the proper preparations of the annual budget as well as compliance of regulatory
codes are both important services of a finance department.
Key Positions in a Finance Department
A finance department is comprised of several key positions that bear the burden of responsibility
when it comes to maintaining the cohesiveness and overall productivity of the department as a unit
of the company.
When you think about the overall structure of the finance department, there are four key point
people that may come to mind:
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The finance director
Deputy finance director
Accountant
Finance specialist
Finance Director
The finance director is the head of the finance department. This individual will have the supreme
responsibility to ensure that all financial reports are accurate and up to date. The finance director is
tasked with giving a financial forecast for the company and disclosing certain financial information
about the company to the shareholders.
Deputy Finance Director
The deputy finance director is usually responsible for putting together the companys annual
budget. In this position, the deputy finance director will be responsible for developing an overall
financial strategy. Sometimes referred to as the finance manager, the deputy finance director is also
responsible for managing the finance departments team of employees.
Accountant
The next position of importance in the department of finance is the accountant. The accountant is
responsible for handling the accounts payable and accounts receivable.
Accountants also process payroll. Other duties include putting together financial-related documents
such as reports, auditing, and closing out accounting books.
Finance Specialist
The finance specialist basically handles capital investments. This position may also require a bit of
analytical work such as reconciliations, maintaining the general ledger and keeping a close eye on
the funds of the company.
Evolution of the Finance Department
With each passing year the company evolves into an entity that is responsible for increasing the
company (and shareholders value). This shall be done by increasing the number of employees of
the department according to requirement and including other employees like clerical staff and intersection commuters.
B. Personnel & Administration department
Human resources is the business administration function responsible for finding, hiring, managing
and retaining employees, and for ensuring that the right employees, in the right numbers, are
deployed throughout the organization to achieve its goals. Human resources are a function that
exists in every business regardless of size, industry or geographic location. In fact, even though small
businesses may not have a formal human resource department or an employee with a title that
includes "human resources," the function is performed when employees are hired, training,
supervised and, hopefully, retained.
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Administrators, broadly speaking, engage in a common set of functions to meet the organizations
goals. These "functions" of the administrator were described by Henri Fayol as the 5 elements of
administration" (in italic below).
Planning - is deciding in advance what to do, how to do it, when to do it, and who should do it. It
maps the path from where the organization is to where it wants to be. The planning function
involves establishing goals and arranging them in a logical order. Administrators engage in both
short-range and long-range planning.
Organizing - involves identifying responsibilities to be performed, grouping responsibilities into
departments or divisions, and specifying organizational relationships. The purpose is to achieve
coordinated effort among all the elements in the organization (Coordinating).
Organizing must take into account delegation of authority and responsibility and span of control
within supervisory units.
Staffing - means filling job positions with the right people at the right time. It involves determining
staffing needs, writing job descriptions, recruiting and screening people to fill the positions.
Directing (Commanding) - is leading people in a manner that achieves the goals of the organization.
This involves proper allocation of resources and providing an effective support system. Directing
requires exceptional interpersonal skills and the ability to motivate people.
One of the crucial issues in directing is to find the correct balance between emphasis on staff needs
and emphasis on economic production.
Controlling - is a function that evaluates quality in all areas and detects potential or actual deviations
from the organization's plan. This ensures high-quality performance and satisfactory results while
maintaining an orderly and problem-free environment. Controlling includes information
management, measurement of performance, and institution of corrective actions.
Budgeting - exempted from the list above, incorporates most of the administrative functions,
beginning with the implementation of a budget plan through the application of budget controls.
C. Research and development

A research and development department is responsible for innovations in design, products, and
style. This department will be responsible for creating innovative new products to keep the company
a step ahead of the competition. R&D Department will work on improving existing consumer
products, and to explore new ways of producing them.
Often, a Research and Development Department works closely with the Marketing Department. The
Marketing Department studies consumer trends by surveying and researching consumer demands,
purchasing methods, product sales, and the existence and development of technology across the
relevant market. The marketing department gathers all the data, and makes this information
available to the R&D department, which will take action in response to the findings and proceed to
keep the company on top of current market needs.
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D. Operations
Operations management is an area of management concerned with overseeing, designing, and
redesigning business operations in the production of goods and/or services. It involves the
responsibility of ensuring that business operations are efficient in terms of using as few resources
as needed, and effective in terms of meeting customer requirements. It is concerned with managing
the process that converts inputs (in the forms of materials, labour, and energy) into outputs (in the
form of goods and/or services). The relationship of operations management to senior management
in commercial contexts can be compared to the relationship of line officers the highest-level senior
officers in military science. The highest level officer shapes the strategy and designs it over time,
while the line officer makes tactical decisions in support of carrying out the strategy.
According to the U.S. Department of Education, operations management is the field concerned with
managing and directing the physical and/or technical functions of a firm or organization, particularly
those relating to development, production, and manufacturing.
Operations management programs typically include instruction in principles of general
management, manufacturing and production systems, plant management, equipment maintenance
management, production control, industrial labour relations and skilled trades supervision, strategic
manufacturing policy, systems analysis, productivity analysis and cost control, and materials
planning. Management, including operations management, is like engineering in that it blends art
with applied science. People skills, creativity, rational analysis, and knowledge of technology are all
required for success.
E. Product Marketing & Sales
In a manufacturing company the production function may be split into four sub-functions:
Production and planning department
The production and planning department will set standards and targets for each section of the
production process. The quantity and quality of products coming off a production line will be closely
monitored. In businesses focusing on lean production, quality will be monitored by all employees at
every stage of production, rather than at the end as is the case for businesses using a quality control
approach.
Purchasing department
The purchasing department will be responsible for providing the materials, components and
equipment required to keep the production process running smoothly. A vital aspect of this role is
ensuring stocks arrive on time and to the right quality.
Stores department
The stores department will be responsible for stocking all the necessary tools, spares, raw materials
and equipment required to service the manufacturing process. Where sourcing is unreliable, buffer
stocks will need to be kept and the use of computerized stock control systems helps keep stocks at a
minimal but necessary level for production to continue unhindered.
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Works Department
The works department will be concerned with the manufacture of products. This will include the
maintenance of the production line and other necessary repairs. The works department may also
have responsibility for quality control and inspection.
3.3 Manpower Requirement

Designation
Number Required
Annual
Salary
i
n Qualification
rupees
Lacs/annum
MD/Chairperson
40
Engineer
with
cum
15
experience.
Board Of Directors
Designation
Number Required
Annual
Salary
i
n Qualification
rupees
Lacs/annum
CEO
30
Engineer cum MBA

with 10 years
Experience
COO
30
Engineer cum MBA

with 10 years
Experience
CFO
30
Engineer cum MBA

with 10 years
Experience
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MBA
years
Operation
Vice President
20
Chemical Engineer
(for production) with
10
year experience
Production Engineer
12
Chemical
Engineer
with
year
Experience
Maintenance
11
Engineer
Mechanical
with
Engineer
4
year
experience
Instrumentation
Engineer
Instrumentation
Engineer with 4 year
experience
Shift Engineer
5.5
Chemical
with
engineer
4
year
Experience
Shift Operator
12
Diploma in Chemical
Engineering
Labor(permanent)
12
Labor(temporary)
Quantity
depending
upon work required
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High School
High School
Administration
Vice President
15
MBA with 10 year

experience
Manager
12
MBA with 6 year

experience
Security Officer
5.5
Retired
Army or
police
official
Fire & Safety Officer
5.5
8 years experience in
fire and safety
management
Medical Officer
5.5
MBBS
with 4
of
experience
e
Medical Staff
Diploma
Graduate with 5 year
Public
Officer
Relation
experience in public
relations
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years
Finance:
Vice President
20
C.A. with 10 years

experience
Manager
15
MBA
(finance)
with
8
years experience
Account Officer
10
C.A. with 4 year

experience
Clerical Staff
B.Com with some or

no experience
Marketing;
Vice President
20
MBA
(marketing)
with
12
years
experience
Manager
15
MBA (marketing)
with 8 years
Marketing Officer
10
MBA (marketing)
with 5 years
experience
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of
Research & Development

Vice President
20
C.A. with 10 years

experience
Manager
15
MBA (finance) with

10
years experience
Research Assistor
10
C.A. with 4 year

experience
Clerical Staff
B.Com with some or

no experience
Total manpower requirement (permanent staff) = 95

This is the number of higher order permanent staff and highly skilled labour. The number of total
employed worker, either skilled or semi-skilled varies with the project being carried out.
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4. SITE SELECTION & PROJECT LAYOUT

4.1 Plant Location
One of the key features of a transformation system is the efficiency with which the output is
transferred to the recipients. Any consideration of this will include the determination of where to
place the plant.
The selection of appropriate location can be done in two stages:
1. Evaluation of various geographic areas and the selection of an optimum area.
2. Within each area there is a choice of proper site which can be urban, suburban or rural.
The fundamental object of location analysis is to maximize the profits by minimizing the
total cost
of production associated with the production process.
Total costs = Fixed costs + Operational costs

Fixed costs include expenditure on land, building, machines and other equipments etc. Operational
costs are the expenditure incurred on inputs, transformation process and the distribution of output
etc.
Plant location plays an important role in determining the sources of a process plant. Plant location
refers to the various parameters, which governs the operation of the plant. The following are the
major parameters which have to be carefully considered.
Also there has to be a good scope for plant expansion and a conductive environment, safe living
condition for easy plant operation. But other factor, such as safe living condition for plant personnel
as well as the surrounding community is also important. The choice of the final site should first be
based on complete survey of the advantage and disadvantage of various geographical areas and,
ultimately, on the advantage and disadvantage of real estates.
The following factors were considered in selecting the plant site:
1. Raw material:
The raw materials must be available without any interruption to the reach of the plant. It can
cause urgent shut down or reducing the production when there is a lack of raw material. This
must be considered to be important.
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2. Availability of power:
The electricity source must be available to the plant, because it is the prime source for the
process plants. This electricity is used in agitated vessels, pumps, compressors and etc.
continuous and uninterrupted power supply is essential for the continuous operation of the
plant.
3. Water:
Water is an essential material majorly used in the process plants and it is necessary to the
labours. The water can be used for cleaning the equipments and plant. The water is also used in
the wash towers, coolers and condensers. In the plant location the ground water source should
be available. Water should also available in neighborhood at low cost.
The process industries use large quantities of water for cooling, washing, steam generation and
as a raw material in process. Hence, the plant must be located where a dependable supply of
water is available. A large river or lake is preferable, although deep wells or artesian well may be
satisfactory if the amount of water required is not too great. The level of the existing water table
can be checked by consulting the state geological survey and information on the constancy of
the water table and the year round capacity of local rivers or lakes should be obtained. If the
water supply shows seasonal fluctuation, it may be desirable to construct a reservoir or to drill
several standby wells. The temperature, mineral content, slit or sand content, bacteriological
content, and cost for supply and purification must also be considered when choosing the water
supply.
4. Transport facility:
The raw material and the products want to be transported in and out of the plant. So that the
road transport facilities should be good and easily available. If the harbor is nearby means, its
best to easy shipping.
The transportation of material to or from the plant will be significant cost to us, hence it should
be located at places well connected by road, railways and waterways. For the production of
PHENOL main raw material is Cumene which we can bring our through well developed road and
railway facilities from reliance hazira plant (310 KM) or from IPCL (430 KM) Vadodara plant thus,
transportation problems will not be there. We also can import cumene through sea
transportation (Nhava Sheva Sea).
5. Skilled labours and their facilities:
60 | P a g e
The plant must require skilled labours. They should know about the process and they want the
knowledge of the safe working and hard working. They want to be available at nearby location.
Those labours must get their facilities like bus transportation, hospitals, canteens and shelter at
nearby to the plant.
The type and the supply of labor available in vicinity of a proposed plant site must be examined.
Consideration should be given to prevailing pay scales, restriction on number of hours worked
per week, competing industries that can cause dissatisfaction or high turnover rates among the
workers, and variations in skills and productivity of the workers. As Maharashtra is a prominent
industrial state labor force from all parts of India flows in there. So getting the right labor force
here will not be a problem.
6. Markets:
It is essential that the plant must be closed to the market or else, unreasonable amount will be
spending for transporting the products to the market.
7. Climate condition:
Climate and environment affect the operational efficiency of workers; excess cold may cause
tiredness, fatigue or disease among the workers. Decreased humidity and climate temperature
is high can cause dehydration to the employees while working. So that, plant must be located in
such a place where the climate is conductive to efficient operation of the plant.
8. Meteorological data:
If plant is located in cold climate, cost may be increased by the necessity for construction of
protective shelters around the process equipment, and specially cooling towers or airconditioning equipment may be required if the prevailing temperatures are high. Excessive
humidity or extremes of hot and cold weather can have serious effect on the economic
operation of the plant, and these factors should be examined when selecting the site. In
Maharashtra extremities are not experienced. Temperature ranges between 12 to 39oC.
9. Plant sewage and waste disposal:
The primary source of sewage and waste in a process plants are sanitary waste, process drains
and surface drainage. The sewage system is designed to conduct these to disposal without
logged with solid or filled with dangerous concentration of explosive gases.
10. Local community consideration:
61 | P a g e
The process plant must fit in with and be acceptable to the local community. Full consideration
must be given to the safe location of the plant, so that it does not impose a significant additional
risk to the community. On a new site, the local community must be able to provide adequate
facilities for the plant personnel like school, banks, housing and faculties.
11. Taxation and legal restriction:
State and local tax rates on property, income, unemployment insurance and similar items
vary from one location to another. Similarly, local regulations on zoning, building codes,
nuisance aspects, and transportation facilities can have a major influence on the final choice
of a plant site. In fact, zoning difficulties and obtaining the many required permits can often
be much more important in terms of cost and time delays then many of the factors
discussed in the preceding sections.
12. Tax benefits:
The incentives and facilities offered to SEZs are: (detailed instructions available at:
http://www.sezindia.nic.in/index.asp )
Duty free import/domestic procurement of goods for development, operation and
maintenance of SEZ units
100% Income Tax exemption on export income for SEZ units under Section 10AA of the
Income Tax Act for first 5 years, 50% for next 5 years thereafter and 50% of the ploughed
back export profit for next 5 years.
Exemption from minimum alternate tax under section 115JB of the Income Tax Act.
External commercial borrowing by SEZ units upto US $ 500 million in a year without any
maturity restriction through recognized banking channels.
Exemption from Central Sales Tax.
Exemption from Service Tax.
Single window clearance for Central and State level approvals.
Exemption from State sales tax and other levies as extended by the respective State
Governments.
13. Clearances
Clearances between adjacent plants should at least those for primary access roads. The
space between edge of any road and nearest equipment must not be less than 1.5 meters.
Adequate road access with properly formed roads must be provided for known maintenance
purposes: e.g. compressor house, large machine areas, reactors or convertors. Minimal
concrete paving should be supplied for walkways interconnecting major items of equipment,
platforms, stairways and buildings. Paving should be supplied around pumps or other
machinery located in the open, underneath furnaces, and any other areas where spillage is
likely to occur during normal operation. Areas containing acids or other chemicals or toxic
62 | P a g e
materials should be paved and bounded to prevent spillage spreading. Other areas of the
plant are to be graded and surfaced with granite chips or similar material.
14. Economic considerations

Apart from the process restrictions, position equipment for maximum economy of pipework and supporting steel. As compact a layout as possible with all equipment at grade,
consistent with standard clearances, construction and safety requirements. Minimize runs of
alloy pipe work and large bore pipe without the introduction of expensive expansion
equipments. Optimize use of supporting structures in concrete or steel by duplicating their
application to more than one item of equipment and ensuring that access ways, platforms
etc. have more than one function.
15. SEZ ADVANTAGES
Income tax incentives: 10 year corporate tax holiday on export profit, 100% for the initial five
years and 50% for the next five years.
Other benefits:
Exemption of electricity duty 10 years.
Duty-free procurement of capital goods (including second hand capital goods), raw
material and consumable spares from domestic market.
Full freedom for subcontracting.
Facility to realize and repatriate export proceeds within 12 months.
Facility to retain 100% foreign exchange recipient in the export earns foreign
currency amount.
Indirect tax incentives (for both SEZ units and developers).
Nil customs duty.
Nil excise duty.
Exemption from central sales tax.
Exemption from service tax.
Exemption from securities transaction tax.
Exemption from tax on sale of electricity for self-generated and purchased power.
Economic scope of SEZ is:
63 | P a g e
The SEZ has advantage of all types of transportation system such as roadways,
seaport, air and railways so the special economic zone should have a good export
link with the other countries in the world.
The trend in the unorganized industries sectors such as information technology,
jewelry and gem, toys, biotech, and leather is to come under one common roof in
order to have an access to the general infrastructure facilities.
The increasing in the demand for the integration of the industrial sector in India.
SEZ has the following political and strategically advantage:

a) Policy framework:
Such kind of promotion activities is a designated duty free enclave and treated as
foreign territory for trade operations, duties and tariffs. Units can be set up for
manufacturing, trading or service activity.
Most of the times lucrative offers are given such as exemption from customs and
central excise duty on import of capital goods, raw materials, consumables,
spares etc.
Readymade infrastructure is provided.
Exemption from payment of central sales tax could also be given.
Such industrial zone could dispose of rejects, waste, scrap in domestic market on
payment of duties.
b) Procedural ease: No routine examination of import and export cargo by
custom/central excise authorities. Goods can be brought to or removed from
industrial zone premises on self-certification basis. Performance of the units to be
monitored by a committee headed by the development commissioner and consisting
of customs officials.
c) Benefits available to developers:
Industrialization zone allows private individuals or firms to participate by way of
creating infrastructure in the zone.
The developer infrastructure is allowed duty free (customs and central excise)
import/procurement of goods for its development, operations and maintenance.
Income tax exemption for 10 years in first 15 years is allowed.
Full freedom in allocation of development plots to approve units on purely
commercial basis.
Full authority to provide services like water, electricity, security, restaurant,
recreation etc., on commercial lines.
Facility to develop township within SEZ with residential areas, market, play
grounds, club, recreation center etc.
d) Infrastructure and other facilities offered:
Built up space of any size is readily available in the standard design factory (SDF)
complexes.
Backup power supply as standby arrangement.
Good quality power and water at reasonable rates.
Telephone, fax facilities on out of turn basis.
Bank, post office, courier, travels, Xerox and other support services are available
within the zone premises.
Units exempted from payment of installing charges, local loop charges.
Certification of softex forms, free of cost.
Video conferencing facility at nominal cost.
Infrastructure:
The SEZ is self-sufficient in terms of internal roads, power, water, desalination plant,
drainage system and modern effluent treatment plants under construction.
64 | P a g e
The Maharashtra Special Economic Zone is the most strategically placed SEZ in the country.
Being the most industrialized state in India, Maharashtra has undergone rapid infrastructure
development such as roads, railways, airport, and seaports. These assistances have helped
the industries further.
The Special Economic Zones in Maharashtra have the advantages of close proximity to
seaport and airfreight services that would increase India's industrial exports.
Maharashtra Special Economic Zone comprises of
Santa Cruz Electronics Export Processing Zone

Navi Mumbai Special Economic Zone
Maha Mumbai Special Economic Zone
1. SEEPZ
Santa Cruz Electronics Export Processing Zone (SEEPZ) was set up in the year 1974 for
the purpose of manufacturing and exporting electronic products. Set up in an area
measuring 100 acres it has become watershed project of the Maharashtra Industrial
Development Corporation. The gem and jewellery industry was introduced in the year
1988 in SEEPZ.
Facilities of SEEPZ are
The imports are license free

Tax exemption on import of basic element, capital goods, etc
Tax exemption on central sales tax pertaining to national purchases
The SEEPZ can be involved in any type of activities among trading, manufacturing and
service
The SEEPZ is entitled for 100% foreign direct investments apart from a few of the sectors
2. NMSEZ
The Navi Mumbai Special Economic Zone (NMSEZ) is located in the satellite township
near Mumbai known as Navi Mumbai in the state of Maharashtra. Navi Mumbai Special
Economic Zone (NMSEZ) is situated in the most industrialized part of India. NMSEZ is
regarded to be the best SEZ in India as sea, rail, air and road and a state of the art transshipment hub connect it.
Facilities of NMSEZ are
65 | P a g e
The NMSEZ has well developed transportation system including wide main roads and
services roads
The commercial units have the option of choosing between technologically equipped
state of the art factories, land plots with proper amenities, and well-built and equipped
office space
The NMSEZ has adequate supply of power and also has back up provisions in case of
shut downs
The NMSEZ has adequate supply of water through the dams operated by the CIDCO
The NMSEZ has a very well-constructed system of disposal for solid waste and sewer
water
3. MMSEZ
The Maha Mumbai Special Economic Zone (MMSEZ) is proposed to be setup in Navi
Mumbai area, as a standard international business center. The area where the MMSEZ
would be set up is situated near Mumbai in Maharashtra. Maha Mumbai Special
Economic Zone would be acquiring 10,000 hectares of land in three different stages,
within a time span of ten years.
Facilities of MMSEZ are
Continuous power supply and provisions of standby power service

The manufacturing units have the option of office space, technologically equipped
factory space, land plots
A fully developed facility of transportation system which would have wide main roads
and services roads
Adequate water supply and well-constructed network of pipelines and water pumps
Government of Maharashtra SEZ Policy The main purpose Government of Maharashtra

SEZ Policy is the growth of the industries in the State of Maharashtra.
Area of focus of Government of Maharashtra SEZ Policy
66 | P a g e
The provision of granting permits and approvals pertaining to issues such as

environment and human resources by the means of a single window system
The exemptions of different kinds local and state duties, tariffs, and taxes pertaining
to the transactions with the special economic zones
The exemptions from registration fees and stamp duties
The time saving procedures for the acquisition of lands in order to establish the
special economic zone
67 | P a g e
Maharastra Railway Map
Maharastra Road Map
68 | P a g e
4.2 Plant Layout

Plant Layout is the physical arrangement of equipment and facilities within a Plant. Optimizing the
Layout of a Plant can improve productivity, safety and quality of Products. Un-necessary efforts of
materials handling can be avoided when the Plant Layout is optimized.
Plant layout techniques apply to the case where several physical means have to be located in a
certain area, either industrial processes or services.
The basic objective is to ensure a smooth flow of work, material, people and information.
There are probably two levels at which layouts are required. In one, the various departments have
to be sited, and in other the items of equipment within a department need to be located.
Criteria for a good layout

1. Maximum flexibility: A good layout will be one which can be rapidly modified to meet changing
circumstances.
2. Maximum co-ordination: Entry into, and disposal from, any department or functional area should
be in such a manner that it is must convenient to the issuing or receiving departments. Layout
requires to be considered as a whole and not partially.
3. Maximum use of volume: Facilities should be considered as cubic devices and maximum use
made of the volume available. This principle is particularly useful in stores, where goods can be
stacked at considerable heights without inconvenience, especially if modern lifting devices are used.
In offices, racking can be installed to minimize use of floor space.
4. Maximum visibility: All the people and materials should be readily observable at all the time; there
should be no hidden places into which goods or information can get mislaid.
5. Maximum accessibility: All servicing and maintenance points should be readily accessible. For
example, equipment should not be placed against a wall in such a manner that necessary
maintenance cannot easily be carried out.
6. Minimum distance: All movements should be both necessary and direct. Handling work adds to
cost but does not increase value; consequently any unnecessary or indirect movements should be
avoided.
7. Minimum handling: The best handling of material and information is no handling, but where it is
unavoidable it should be reduced to a minimum by the use of whatever devices are most
appropriate.
69 | P a g e
8. Minimum discomfort: poor lighting, excessive sunlight, heat, noise, vibration and smells should be
minimized and if possible counteracted.
9. Inherent safety
10. Maximum security
11. Efficient process flow
Inputs to the Layout Decision

1. Specification of objectives of the system in terms of output and flexibility.
2. Estimation of product or service demand on the system.
3. Processing requirements in terms of number of operations and amount of flow between
departments and work centers.
4. Space requirements for the elements in the layout.
5. Space availability within the facility itself.
Advantages of a good layout

The overall process time and cost will be minimized by reducing unnecessary handling and
movement.
Supervision and control will be simplified by the elimination of hidden corners
Changes in the programmers will be most readily accommodated.
Total output from a given facility will be as high as possible by making the maximum effective use
of available space and resources.
A feeling of unity among employees will be encouraged by avoiding unnecessary segregation.
Quality of the products or service will be sustained by safer and more effective methods of
operation.
70 | P a g e
71 | P a g e
Tank Farm
Plant
Area 1
Plant Layout
Roads
Plant
Utilities
Expanion
EXIT
GREEN
AREA
Plant
Area
2
Offices
Change
Rooms
Canteen
Laboratry
Workshops
FIRE
STATION
Stores
Emergency
water supply
Expansion
EXIT
GATE
Parking Area
PIPE BRIDGES
GATE
References
I.
II.
http://www.essentialchemicalindustry.org/chemicals/phenol.html
http://www.sciencedirect.com/science/article/pii/S0926860X04007562
III.
https://www.google.com/patents/US5371305
IV.
https://fenix.tecnico.ulisboa.pt/downloadFile/395139430146/Cumene%20oxidation%20to%20cu
mene%20hydroperoxide.pdf
V.
VI.
VII.
VIII.
http://www.infodriveindia.com/india-import-data/cumene-import-data.aspx
http://sezindia.nic.in/writereaddata/statePolicies/maharashtrapolicy.pdf
https://mohdazizan.files.wordpress.com/2011/12/production-of-phenol.pdf
http://www.doingbusinessinmaharashtra.org/SEZ_in_Maharashtra.aspx
72 | P a g e

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A Report on

Production of Phenol from 99.9% pure

Major Project Report Submitted by

1. MATERIAL AND ENERGY BALANCE

BASIS: 21833 kg/hr production of phenol

2. Decomposition of Cumene hydroperoxide:

1.1.2 Molecular weights of components:

Mass of inlet of Cumene and oxygen

Mass of outlet of phenol and acetone

= 94+52= 152 kg moles

Acid free Cleavage

Acidified wash water

- METHYL STYRENE COLUMN:

The amount product phenol =21833 kg/hr

3. Total heat inlet

3. Off gases @ 110C

4. Total heat outlet Q= Q1+ Q2+ Q3+ Q4

Heat removed by water

B) Outlet heat @70C:

Total heat outlet

Q= Q1+ Q2 = 3073167.84 + 742682.228

Heat removed by water

Total heat inlet Q = Q1+Q2 = 3816552.776 KJ

B) Outlet heat @ 80C:

SPECFIC HEAT KJ/KgC

Q1=((23672.42.29)+( 11835.0721.481)+( 1908.581.842)+( 536.501.406)+( 232.8661.97))

Total heat outlet

Heat of reaction of cleavage = 2983 KJ/kg

Heat removed by water

B) Outlet heat @80C:

SPECFIC HEAT KJ/KgC

Total heat inlet Q = Q1+Q2 =3905974.607 kJ

B) Outlet heat @75C:

SPECFIC HEAT KJ/KgC

1. Acidified wash water @ 40C

Heat taken by carryover cleavage Q3=5201.9 KJ

Total heat outlet

Acid free cleavage

Acidified wash water

SPECFIC HEAT KJ/KgC

B) Outlet heat @90C:

SPECFIC HEAT KJ/KgC

Heat added by steam

SPECFIC HEAT KJ/KgC

2. Cleavage vapours @ 56C

3. Total heat outlet as vapour

SPECFIC HEAT KJ/KgC

5. Carryover acetone @90C

6. Total heat outlet

Carryover acetone in residue

OVERHEAD ACETONE CONDENSER:

2. Cleavage vapours @ 56C

3. Total heat inlet as vapour Q = Q1+Q2

Heat produced by Cleavage Q2 = 4837.75 kJ

2. Total heat outlet Q = Q1+Q2

Heat removed by water

SPECFIC HEAT KJ/KgC

2. Total heat inlet Q = Q1+Q2

SPECFIC HEAT KJ/KgC

2. Total heat outlet

Heat added by steam

SPECFIC HEAT KJ/KgC

Total heat inlet

2. Acetone vapours @ 90C