Chapter: 1

Introduction

Diploma Chemical Engineering Project Entitled “ANILINE’’ 1

1.1 History

Aniline is an organic compound (C6H5NH2) that comes from coal and oil. The history of
aniline is complicated, as it was identified by various scientists and given a variety of
different names, all within a relatively short period of time. Aniline was first isolated
from indigo by Otto Unverdorben, who called it Crystalline, in 1826. Not long afterwards, in
1834, Friendlier Range isolated a substance from coal tar that he called kyanol or cyanol. The
substance turned a bright blue colour when treated with chloride of lime. Range’s discovery
was followed in 1840 by Carl Julius Fritsch (1808-1871), who treated indigo with caustic
potash and obtained an oil that he called aniline. It was later recognised that all of these
substances were the same and they became known under the general heading, aniline. The
most important discovery in the early history of aniline took place in 1856 when the British
scientist, William Perkin (1838-1907), identified in coal-tar benzene a related product that he
called mauveine, which produced purple. Perkin then went on to identify a process to
consistently produce the first synthetic dyes. Shortly afterwards the French scientist, Antoine
be champ, developed a new method of producing a range of aniline dyes on an industrial
scale. These dyes literally changed the nature of colour production (techniques, economics,
and social structures) within the textile industry throughout the world. In particular,
production of aniline dyes led to the creation of a massive dye industry in Germany under the
name of BASF (Badeshi Aniline- und Soda-Fabric), which supplied aniline dyes to many
countries around the world.

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 1.2 DIFFERENT PROCESS FOR MANUFACTURING ANILINE:

1. Manufacture of aniline from Nitrobenzene by bechamp reduction.

4C6H5NO2 + 9Fe + 4H2O → 4C6H5NH3 + 3FeO4

90 – 95%Yield

2. Manufacture of Aniline from chlorobenzene by ammonolysis.

C6H5Cl + 2NH3 (aq) → C6H5NH2 + NH4Cl

96%
Yield

3. Aniline from phenol by Ammonolysis

C6H5OH +NH3 → C6H5NH2 + H2O

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 Chapter: 2
Properties of Aniline

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 2.1 Properties of Raw Material & Product

Molecular Weight 93.12 gm/mole

Boiling Point 184 - 186 0C
Melting Point -6.3 0C (solidifies)
Flash Point 76 0C (169 0F) closed cup
Vapour Density 3.22 (air = 1)
Density/Specific Gravity 1.022 at 20/20 oC (water = 1)
Vapour Pressure 0.489 mm Hg at 25 oC
Conversion Factor 1 ppm = 3.8 mg/m3
Storage Temp. 2-8 C
Water Solubility 36 g/L (20 ºC)
Structure formula

Table 1:- Physical Properties of Aniline

 Chemical Properties Aniline

 Aniline reacts with Benzaldehyde forming Benzylidene Aniline

NH2 CHO N=CH

 Aniline reacts with hydrochloric acid forming aniline hydrochloride

NH2 NH2HCL

HCL

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  Raw Material
 Nitro-Benzene,,
 Phenol

 Properties of Nitrobenzene

Chemical Formula C6H5NO2

Molecular weight 123.06 g/mol
Appeasence Yellowish , oily liquid
Odour Like paste shoes polish
Flash Point 88 oC
Melting Point 6 oC
Boiling Point 210 - 211 oC
3
Density 1.119 gm/cm

Table 2:- Properties of Nitrobenzene

 Chemical properties Nitrobenzene

 Reduction of Nitrobenzene Produce Aniline

 Reaction of nitrobenzene and hydrogen produce aniline and water

C6HNO2+3H2 C6H5NH2+2H2O

 Properties of Phenol

Chemical Formula C6H6O

Molecular weight 94.11 g/mol
Appearance Transparent crystalline solid
Odour Sweet and tarry
Density 1.07 g/cm3
Melting point 40.5oc
Boiling point 181.7oc

Table 3:- Properties of Phenol

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  Chemical properties Phenol

 Phenol is easily neutralized by sodium hydroxide forming sodium

phenolate

C6H5OH + NAOH C6H5ONA + H2O

 Phenol and benzoyl chloride are shaken in presence of dilute sodium

hydroxide solution phenyl benzoate is formed

C6H5OH + C6H5COCL C6H5OCOC6H5 +HCL

2.2 Applications of Aniline

1. Rubber chemical: Antioxidant, accelerators, vulcanizing agent

2. Photography chemical: Hydroquinone.
3. Dyes and dye intermediates: Acetanilide, diethoxy aniline, P-A Mino
Azo benzene, diethyl aniline, diethyl aniline.
4. Pharmaceutical: Anlagen, isopropyl anti pyrine, sulpha drugs, vitamin B2.
5. IsocyanatesMethelene: Diphenylene Di-isocyanate

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 2.3 List of Manufacturing of India

Manufactures Capacity
(ton/annum)
Hindustan Organic Chemicals 15000
Ltd. (Maharashtra)
Mardia Chemicals Ltd. 6000
(Gujarat)
Priya Organics & Chemical Ltd. 1500
(Bihar)

Table 4:- List of Manufacturing of India

Sales

1500

6000
Maharashta
Gujarat
15000
Bihar

Fig: 2.1 India Consumption of Aniline

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 Chapter: 3
Various Manufacturing Process

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3.1Manufacture of Aniline from nitrobenzene by bechamp Reduction

Raw materials

Nitrobenzene

Iron borings

Hydrochloric acid

Reaction

HCL

4C6H5NO2 + 9Fe + 4H2O → 4C6H5NH3 + 3FeO4

90 – 95%Yield

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 Figure

Nitrobenzene Cooler

Aniline

Catalyst HCL

C
O Vacuum
Reactor Cooler
L Decanter Column
&
Separator U
M
N
Sludge

Aniline water Water

Fig 3.1 Aniline from nitrobenzene by bechamp Reduction

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Process:

Nitrobenzene is charge into a reactor fitted with an efficient reflux condenser. Water and
catalyst are added gradually, in small quantities, to the nitrobenzene. The mixture is heated
by steam to reflux temperature (200°C).

The water required for the reaction is generally in the form of aniline water recovered from
the separator or column and is added to the reactor in bulk at the start or in small quantities
along with the iron additions. Dilute (30%) HCL acid is added along with the water as
catalyst. The acid reacts with the iron borings. Forming catalytically active iron salts.

At the end of the reduction (about 10 hrs. for 2250 kg charge), the aniline is separated from
the reducer charge by one or more of several methods, The liquid water aniline mixture may
be separated from the solid iron oxide, iron hydroxide sludge by steam distillation, vacuum
distillation, filtration, centrifugation or siphoning.

The water aniline mixture from the reducer is run to a separator where the lighter aniline
separates and is withdrawn from the upper. The top layer, which contains 3 to 5% aniline, is
partially distilled until the aniline content in the water is low.

The residual aniline water is returned to the reducer for subsequent runs. The aniline in the
distillate is separated by decantation and the water layer is redistilled to obtain the remaining
aniline. An alternate procedure is to extract aniline from the aniline water with nitrobenzene.

The aniline streams from the separator and decanter are united and vacuum distilled to yield
purified aniline. The yield based on nitrobenzene is approximately 95% by weight.

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 3.2 Manufacture of Aniline from chlorobenzene by Ammonolysis

Raw materials

Basis

Chlorobenzene

Ammonia solution (28%)

Cuprous oxide

Chemical Reaction

C6H5Cl + 2NH3 (aq) →C6H5NH2 + NH4Cl

96% yield

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Figure:

Absorber
Chloro Benzene Ammonia (aq)

Cu2O

Coo
Reactor ler
&
sepa
rator
Neutralizer Col Separat
um or
n

Aniline

Filter

NaOH

Neutralizer Acid
Column
Acidifier

Aniline

Diphenyl aniline Phenol

Fig 3.2Aniline from chlorobenzene by Ammonolysis

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Process:

The reaction products are cooled below 100°C and run to a separator. The free ammonia
continues to absorption and condensing system for recovery. The settled reaction mass
separates into two layers: aniline rich lower and an aqueous upper layer. The
approximate distribution of reaction products not including unreached chlorobenzene in
the two layers is as follows: aniline layer 82% aniline, 5% phenol, and 1%
diphenylamine; water layer 5 % aniline, 0.5% phenol, 9% chlorine ion (NH4Cl), 3%
cuprous oxide and 14% ammonia.

The aqueous layer is drawn from the top of the separator and is run to a neutralizer,
where it is treated with sodium hydroxide or lime. A sufficient amount of alkali is used
to react with the ammonium chloride and phenol. The solution is fractionally distilled,
and the liberated ammonia expelled first is recovered in an absorption system. The
second fraction consists of aniline and water, which are separated by decantation. The
residual solution of sodium phenate and sodium chloride is filtered to remove the
precipitated copper oxides, which are reused in subsequent runs.

The aniline layer is withdrawn from the bottom of the separator and treated with 50%
sodium hydroxide solution. Approximately 0.2 percent of the volume of the aniline
layer is used. The solution is fractionally distilled, yielding first aniline -water mixture,
which is further treated as described previously. The second fraction is technically pure
(97 to 90%) aniline, the residue is steam distilled, yielding diphenylamine. The phenol
is recovered by acidifying the residue mostly sodium phenate and distilling. The yield of
aniline is 96% based on chlorobenzene

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 3.3Aniline from phenol by Ammonolysis

Raw Material:

Phenol

Ammonia

Water

Chemical Reaction:

C6H5OH +NH3 → C6H5NH2 + H2O

Figure:

Fig 3.3 Aniline from phenol by Ammonolysis

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Process:

In the process of aniline from phenol. Ammonia and phenol preheated by preheater and

Gone to the catalytic reactor where reaction occure and aniline form.

Aniline produce from the catalytic reactor passed from ammonia recovery column. Where

The ammonia recovery at the top of the column and recycle by catalytic reactor.

Fed to the dehydrating column in the dehydrating column water is removing from the top.

And aniline product gone to the purification column with 8 kpa pressure.

In the purification column aniline get at the top of the column and the ammonia and to the

Bottoms removal column where a zoetrope is recover at the top of the column and recycle.

And the bottom of the column we get diphenylamine etc.

 

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

Chapter: 4
Selection of Process

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 4.1Aniline from phenol by Ammonolysis

Raw Material:

Phenol

Ammonia

Water

Chemical Reaction:

C6H5OH +NH3 → C6H5NH2 + H2O

Figure:

Fig 4.1 Aniline from phenol by Ammonolysis

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Process:

In the process of aniline from phenol. Ammonia and phenol preheated by preheated and

Gone to the catalytic reactor where reaction occur and aniline form.

Aniline produce from the catalytic reactor passed from ammonia recovery column. Where

The ammonia recovery at the top of the column and recycle by catalytic reactor.

Fed to the dehydrating column in the dehydrating column water is removing from the top.

And aniline product gone to the purification column with 8 kpa pressure.

In the purification column aniline get at the top of the column and the ammonia and to the

Bottoms removal column where a zoetrope is recover at the top of the column and recycle.

And the bottom of the column we get diphenylamine etc.

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 Chapter: 5
Major Equipment

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5.1 Types of Major Equipment:

1. Fluidization bed reactor

2. Nitrobenzene Vaporizer
3. Catalytic reactor
4. Cooling tube
5. Water Settler
6. Decanter
7. Condenser
8. Distillation Column
9. Dehydrating Column

1. Fluidization bed reactor

A fluidized bed reactor is a type of reactor device that can be used to carry out a variety of multi phase
chemical reaction this process known as Fluidization bed reactor.

Fig 5.1: Fluidization bed reactor

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Advantages

 Due to the internsic fluid like behaviour of the solid material fluidized bed do not
experience poor mixing as in packed beds.
 Many chemical reaction require the addition or removal of heat
 Thus FBRs are well suited to exothermic reactor.
 The fluidized bed nature of these reactors allows for the ability to continuously
withdraw product and introduce new reactants into the reaction vessel.

Disadvantages

 Higher energy and pumping power

 Lager vessel is often require for bed reactor
 If fluidization pressure is suddenly lost the surface area of the bed may be suddenly
reduced

Application

 Fluidized bed reactors are still used to produce gasoline and other fuels.
 Used in rubber, vinyl chloride, Polyethylene, Styrene, aniline.

2. Catalytic Bed Reactor

A variety of reactors for use with liquid s gases or solids with stationary spinning or falling
catalyst baskets.

Corrosion resistant gradient less reactor is basic equipment for advancing the science of gas
phase solid phase heterogeneous catalyst technology.

In a manufacturing process of aniline it is used for reaction between a phenol and ammonia

Fig: 5.2 Catalytic Bed Reactor

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Advantages

 High heat capacity to provide to good tempreture control.

 Easy heat recovery.
 High intraparticle diffusion rate, small particle can be used.

Disadvantages

 Generation of fine particles by abrasion of the catalyst.

 Higher catalyst consumption than that of fixed- bed reactor.
 Back mixed flow and the volume of the reactor are not fully utilized.

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 Chapter: 6

Material Balance

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6.1 MATERIAL BALANCE OF ANILINE

 A process design starts with the development of process flow diagram, for the
development of such a diagram material balance calculation are necessary. This balance
will follow the law of conservation of mass, which states that,

Input – Accumulation = Output

 Under steady state condition, there will be no accumulation, therefore in such a case,

Input = Output

 Process design of a plant is based on material balance. It is the basis of process design,
economic process evaluation and optimization. Even the material balance data is used for
process operating decisions and can be integrated for revealing picture of process
operation.

 Material balance is an exact accounting of all the materials that enter, leave or accumulate
or are depleted during given time interval of process. So material balance of a process
flow sheet is very important part of industrial process. This follows the laws of
conservation of mass, which is “mass is neither created nor destroyed” or “mass of a
isolated system is constant” or “mass of the universe is constant”.

From the law of mass conservation, for any process:

Input + Generation – Consumption – Accumulation = Output.

 Material balance can refer to a balance on a system for total mass or volume or moles of
chemical compound or atomic species.

 In any flow or batch process, a definite mass of material is charged into equipment. When
the accumulation of charged material is constant or nil and ignoring the generation and
consumption of material, then we have, Input=Output. This is the case of steady-state
process.

A balance equation can be written for each separately elements, compounds, radicals and
identifiable species; and also for the total material. Material Balances are also useful tool
for the study of plant operation and trouble shooting. They can be used to check
performance against design; to extend the often limited data available from the plant
instrumentation; to check instrumentation calibrations; and to locate sources of material
loss.

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 Reaction :-

C6H5OH +NH3 → C6H5NH2 + H2O

 Basis :-

1 Ton Per day C6H5NH2= 1000 Kg

 Material Balance of Reaction :-

 Molecular Weight of C6H5OH= 94 Kg /mole

 Molecular Weight of NH3 = 17 Kg / mole

 Molecular Weight of C6H5NH2 = 93 Kg / mole

 Molecular Weight of H2O = 18 Kg / mole

93 Kg of C6H5NH2 = 94 Kg of C6H5OH
So, 1000 Kg of C6H5NH2 = (?)

= 100 × 94
93

= 1010.75 Kg C6H5OH

94 Kg of C6H5OH= 93 Kg of C6H5NH2
So, 1000 Kg of C6H5OH= (? )

= 1010.75 × 93
94

=
999.99 Kg C6H5NH2

93 Kg of C6H5NH2 = 17 Kg of NH3
So, 1000 Kg of C6H5NH2 = (?)

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 = 1000 × 17
93

= 182.79 Kg NH3

94Kg of C6H5OH = 18 Kg of H2O

So, 1010.75 Kg of C6H5OH = (?)

= 1010.75 × 18
94

= 193.40 Kg H2O

Reactant Product
( Kg ) ( Kg )
 C6H5OH = 1010.75 Kg  C6H5NH2= 1000 Kg

 NH3= 182.79 Kg  H2O = 193.40Kg

Total = 1193.94 Total = 1193.40

Kg Kg
Reactant Product

Unreacted = 0.14 Kg

Table 5 Total reactant and Total product of Aniline Manufacturing

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 Chapter: 7
Utility & Instrumentation

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 MAJOR INSTRUMENTATION REQUIRED

7.1 Pressure Measurement :

 Pressure Gauge:

 The bourdon tube is most frequently used in the pressure gauge. A bourdon tube
consist of a long think walled cylinder of non circular cross section sealed at the end,
made from materials such as phosphor bronze, steel & beryllium copper, and attached
by a light line work to the mechanism which operates the pointer. The other and of
tube is fixed and is open for the application of the pressure which is to be measured.

 The tube is soldered or wended to a socket at the based, through which pressure
connection is made. Bourdon tube is available in many shapes like, c type, spiral, &
helical.

 Advantages:-
 Cost is low
 Construction is simple
 Life is long
 Efficiency is high
 Tubes are in different range

 Disadvantages:-
 Spring gradient is low (50psig)
 Shock and vibration effect

Diploma Chemical Engineering Project Entitled “ANILINE’’ 30

 Fig 7.1: Bourdon Tube Pressure Gauge

 Temperature Measurement:-

 Temperature has been defined in a variety of ways. One example defines temperature
as the measure of heat associated with the movement of the molecules of a substance.
This definition is based on the fact that the molecules of all matter are in continuous
motion that is sensed as heat.

 Another definition is based on the concept of thermodynamics. Thermal energy

always flows from a warmer body to a cooler body. In this case, temperature is
defined as an intrinsic property of matter that quantifies the ability of the one body to
transfer thermal energy to another body. If two bodies are in thermal equilibrium and
no energy is exchanged, the bodies are at the same temperature.

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  In simplest terms, the temperature is the measurement of the hotness or coldness of
the body.

 Temperature Measuring Devices:-

 Consistent measurement of the temperature is an important part of the process control.

Therefore, it is essential that the temperature measuring device must be reliable.

 While there are many types of temperature sensing devices, they can be classified into
two major groups – temperature sensors and absolute thermometer. Three of the most
common types of the temperature sensors are thermocouples, resistance temperature
devices, and filled systems.

 Temperature depends on the properties of some of the particular material, such as a

gas, liquid, metal and alloy for their temperature indications. Typically, temperature
indications are based on the material properties such as the coefficient of expansion,
temperature dependence of electrical resistance, thermoelectric power and velocity of
sound.

 Flow Measurement:

 Flow is one of the most difficult process variables to measure accurately. One of the
simplest methods for determining the flow rate is the fluid per unit time method,
which assumes a basic premise of the fluid mechanics that mass is a conserved
quantity. The mass entering a system is equal to the mass leaving the system and both
are measured over the same time interval.

 This method for accurate flow measurement takes into consideration two basic
properties of fluid, which are density and viscosity and their effect on the accuracy of
flow measurement. The instruments used are Differential pressure meter and orifice
plates

Diploma Chemical Engineering Project Entitled “ANILINE’’ 32

 Level Measurement:

 Level is measured at the position of the interface between phases, where the phases
are liquid/gas, solid/gas, or immiscible liquid/liquid. Level is simply a measure of
height defining the position of the interface that is the surface where the two phases
meet with respect to a reference point. This measurement is often converted to a
volumetric or gravimetric quantity. So level may be measured directly by defining the
position of the interface or indirectly by measuring another quantity, such as volume
and interfacing the level measurement by converting the quantity to a level
measurement.

 Level is a vertical measurement taken from the surface or interface to a fixed point.
Normally the reference point is the bottom of the vessel holding the substance. As
with most process variables, level can be measured by both direct and indirect
methods.

 The level measurement is done by Level Gauge, Differential pressure level detector,
Displacer Level detector, Ultrasonic Level detector.

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 VARIOUS UTILITIES OF ANILINE PLANT

 Every plant / industries / human being requires certain necessities without which it
would be impossible to function. Necessities like water, air, energy (power), raw
water, etc, are just these and full under the category called UTILITIES. It is no
wonder that the utility section is called the heart of the plant
 In the manufacturing plant of SSP following utilities are created and consumed such
that various other plants producing various products are major consumer of this
utility. These utilities are mainly

1. Raw water
2. Air
3. Electricity

 Raw water

 The requirement of water at all over company is 60000 m3/day.

 Raw water reservoir has capacity of 75000 m3/day.

The following are the specification of raw water quality water.

Ph 8.8
Turbidity 1500 ppm
Calcium hardness as CaCO3 70 ppm
Chlorides as Cl 24 ppm
Silica as SiO2 40 ppm

Table 6:- Specification of Raw Water

After treatment of Raw water Filter water contains following qualities

Ph 7.3
Turbidity 2.0 ppm
Calcium hardness as CaCO3 90 ppm
Chlorides as Cl 80 ppm
Silica as SiO2 38 ppm

Table 7:- Specification of Filter Water

Diploma Chemical Engineering Project Entitled “ANILINE’’ 34

This water will supplied through different suction by pipe line. Like Industrial water, DM
water, services, Township and factory drinking.

 Air
 Air should be dust free and moisture free.
 Plant air can also be used for flushing the vessel purpose.
 Temperature of air is atmospheric temperature.

 Electricity (power)
The utilities is required and is often considered as the bloodline of the plant

Diploma Chemical Engineering Project Entitled “ANILINE’’ 35

 Chapter: 8
Plant Location & Plant Layout

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 When it has been decided to start a factory it is most important to select a suitable site or
location to house the factory. This is not an easy problem, because of the site selected may
not be proper, and then all the money expanded on factory building, equipments and
layout etc. Will go in waste. Therefore while selecting a site, owner must consider
technical, commercial and financial aspects and then to select a site that will produce a
maximum advantage.

 Factors in planning layout :-

1. Operational convenience and accessibility.

2. New site development or addition to previously developed site.

3. Type and quantity ph products to be produced.

4. Economic distribution of utilities and services.

5. Type of process and product control.

6. Health and safety problems.

7. Type of building and building code requirement.

8. Auxiliary equipment.

9. Waste disposal problems.

10. Roads and railroads.

11. Space available and space required.

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The geographical location of the final plant can have strong influence on the success of the industrial
venture. Considerable care must be exercised in selecting the plant site, and many different factors
must be considered. Primarily the plant must be located where the minimum cost of production and
distribution can be obtained but, other factors such as room for expansion and safe giving conditions
for plant operation as well as the surrounding community are also important. The location of
the plant can also have a crucial effect on the profitability of a project.

The choice of the rural site should first of all based on a complete survey of the advantages
and disadvantages of various geographical areas and ultimately, oil the advantages and
disadvantages of the available real estate. The various principal factors that must be
considered while selecting a suitable plant site are briefly discussed in this section. Tile
factors to be considered are:

1. raw material availability

2. location (with respect to the marketing area)
3. availability of suitable land
4. transport facilities
5. availability of labors
6. availability of utilities (water, electricity)
7. environmental impact and effluent disposal
8. local community considerations
9. climate
10. political strategic considerations
11. taxations and legal restrictions

Diploma Chemical Engineering Project Entitled “ANILINE’’ 38

Raw material availability:

The source of raw materials is one of the most important factors influence site selection of a
plant site. This is particularly true for the sulfuric acid plant because large volumes of sulfur
are consumed in the process which will result the reduction of the transportation and the
storage charges. Attention should be given to the purchased price of the raw materials,
distance from the source of supply, freight and transportation expenses, availability and
reliability of supply, purity of raw materials and storage requirements.

Location:

The location of markets or intermediate distribution centres affects tile cost of product
distribution and time required for shipping. Proximity to the major markets is an important
consideration in the selection of the plant site, because the buyer usually finds advantageous
to purchase from nearby sources. In case of sulphuric acid plant, the major consumers are
fertilizer industries and hence the plant should be erected in close proximity to those units.

Availability of suitable land:

The characteristics of the land at the proposed plant site should be examined carefully. The
topography of the tract of land structure must be considered; since either of both may have a
pronounced effect on the construction costs. The cost of the land is important, as well as local
building costs and living conditions. Future changes may make it desirable or necessary to
expand the plant facilities. The land should be ideally flat, well drained and have load-bearing
characteristics. A full site evaluation should be made to determine the need for piling or other
special foundations.

Transport:

The transport of materials and products to and from plant will be an overriding consideration
in site selection. If practicable, a site should be selected so that it is close to at least two major
forms of transport: road, rail, waterway or a seaport. Road transport is being increasingly
used, and is suitable for local distribution from a central warehouse. Rail transport will be

Diploma Chemical Engineering Project Entitled “ANILINE’’ 39

cheaper for the long distance transport. If possible the plant site should have access to all
three types of transportations. There is usually need for convenient rail and air transportation
facilities between the plant and the main company head quarters, and the effective
transportation facilities for the plant personnel are necessary.

Availability of labours:

Labours will be needed for construction of the plant and its operation. Skilled construction
workers will usually be brought him from outside the site, but there should be ail adequate
pool of unskilled labours available locality, and labours suitable for training to operate the
plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs and
restrictive practices will have to be considered when assessing tile availability and suitability
of the labours for recruitment and training.

Availability of utilities:

The “utilities” is generally used for the ancillary services needed in the operation of any
production process. These services will normally be supplied from a central facility and
includes water, fuel and electricity which are briefly described as follows:

Water:-

Tile water is required for large industrial as well as general purposes, starting with water for
cooling washing, steam generation and as a raw material ]it the production of sulfuric acid.
The plant therefore must be located where a dependable water supply is available namely
lakes, rivers, wells, seas. It the water supply shows seasonal fluctuations, it’s desirable to
construct a reservoir or to drill several standby wells. Tile temperature, mineral content, slit
and sand content, bacteriological content, and cost for supply and purifications treatment
must also be considered when choosing a water supply. Demineralized water, from which all
the minerals have been removed is used where pure water is needed for the process use, in
boiler feed. Natural and forced draft cooling towers are generally used to provide the cooling
water required on site.

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Electricity:

Power and steam requirements are high in most industrial plants and fuel is ordinarily
required to supply these utilities. Power, fuel and stem are required for running, the various
equipments like generators, motors, turbines, plant lighting and general use and thus be
considered as one major factor is choice of plant site.

Environmental impact and effluent disposal:

Facilities must be provided for the effective disposal of the effluent without any public
nuisance. In choosing a plant site, the permissible tolerance levels for various effluents
should be considered and attention should be given to potential requirements for additional
waste treatment facilities. As all industrial processes produce waste products, full
consideration must be given to the difficulties and coat of their disposal. The disposal of toxic
and harmful effluents will be covered by local regulations, and the appropriate authorities
must be consulted during the initial site survey to determine the standards that must be met.

Local community considerations:

The proposed plant must fit 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

Climate:

Adverse climatic conditions at site will increase costs. Extremes of low temperatures will
require the provision of additional insulation and special heating for equipment and piping.
Similarly, excessive humidity and hot temperatures pose serious problems must be
considered for selection a site for the plant. Stronger structures will be needed at locations
subject to high wind loads or earthquakes.

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Political and strategic consideration:

Capital grants tax concessions, and other inducements are often given by governments to
direct new investments to preferred locations, such as areas of high unemployment. The
availability of such grants can be the overriding considerations in site selection.

Taxation and legal restrictions:

State and local tax rates on property income, unemployment insurance, and similarly items
vary from one location to another. Similarly, local regulations on zoning, building codes,
nuisance aspects and other facilities can have influence in the final choice of the plant site.

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 Chapter: 9
Material Safety Data Sheet

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 Section 1: Chemical Product and Company Identification
Product Name: Aniline Contact Information:
Catalog Codes: SLA1735
Synonym: Amino benzene; Benzenamine; Company: Gujarat Narmada Valley
Aminophenol Fertilizer& Chemical Limited, Bharuch
Chemical Name: Aniline Chemical
Formula: C6H5NH2 Pin: 392001

Section 2: Composition and Information on Ingredients

Composition:
Name CAS # % by Weight

Aniline 62-53-3 96
Toxicological Data on Ingredients: Aniline: ORAL (LD50): Acute: 250 mg/kg [Rat.].
464 mg/kg [Mouse]. DERMAL (LD50)
Acute: 820 mg/kg [Rabbit.]. 1400 mg/kg [Rat].

Section 3: Hazards Identification

Potential Acute Health Effects:

Hazardous in case of skin contact (irritant, parameters), of eye contact (irritant), of
ingestion, of inhalation. Severe overexposure can result in death.

Potential Chronic Health Effects:

Slightly hazardous in case of skin contact (sensitizer). CARCINOGENIC
EFFECTS: Classified A3 (Proven for animal.) by ACGIH. 3 (Not classifiable for
human.) by IARC. DEVELOPMENTAL TOXICITY: Not available. The substance
may be toxic to blood, kidneys, liver, bladder, spleen, cardiovascular system, central
nervous system (CNS).

Section 4: First Aid Measures

Eye Contact:
Check for and remove any contact lenses. Immediately flush eyes with running water
for at least 15 minutes, keeping eyelids open. Cold water may be used. Get medical
attention. Finish by rinsing thoroughly with running water to avoid a possible
infection.

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Skin Contact:
In case of contact, immediately flush skin with plenty of water. Cover the irritated skin
with an emollient. Remove contaminated clothing and shoes. Cold water may be used.
Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention.

Serious Skin Contact:

Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream.
Seek immediate medical attention.

Serious Inhalation:
Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar,
tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is not
breathing, perform mouth-to-mouth resuscitation.
Ingestion:
Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything
by mouth to an unconscious person. If large quantities of this material are swallowed, call a
physician immediately. Loosen tight clothing such as a collar, tie, belt or waistband.

Serious Ingestion: Not available.

Section 5: Fire and Explosion Data
Flammability of the Product: Combustible.

Auto-Ignition Temperature: 615°C (1139°F)

Flash Points: CLOSED CUP: 70°C (158°F)

Flammable Limits: LOWER: 1.3% UPPER: 23%

Products of Combustion: These products are carbon oxides (CO, CO2), nitrogen
oxides (NO, NO2...)

Fire Hazards in Presence of Various Substances:

Flammable in presence of open flames and sparks, of heat. Non-flammable in presence of
shocks.

Explosion Hazards in Presence of Various Substances:

Risks of explosion of the product in presence of mechanical impact: Not available. Risks of
Explosion of the product in presence of static discharge: Not available.

Fire Fighting Media and Instructions:

SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam.
Do not use water jet.

Special Remarks on Fire Hazards:

Ignites on contact with sodium peroxide + water. Aniline ignites spontaneously in presence of
red fuming nitric acid. Sodium peroxide or potassium peroxide is spontaneously flammable
with aniline. When heated to decomposition it emits toxic fumes.

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 Section 6: Accidental Release Measures
Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container. If necessary: Neutralize the residue with a
dilute solution of acetic acid.

Large Spill:
Combustible material. Keep away from heat. Keep away from sources of ignition. Stop leak
if without risk. Neutralize the residue with a dilute solution of acetic acid. Be careful that
the product is not present at a concentration level above TLV. Check TLV on the MSDS
and with local authorities.

Section 7: Handling and Storage

Precautions:
Keep locked up... Keep away from heat. Keep away from sources of ignition. Ground all
equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapour /spray.
Wear suitable protective clothing. In case of insufficient ventilation, wear suitable respiratory
equipment. If ingested, seek medical advice immediately and show the container or the label.
Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents,
metals, acids, alkalis.

Storage:
Air and light sensitive. Store in light-resistance container. Keep container in a cool, well-
ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all
possible sources of ignition (spark or flame).

Section 8: Exposure Controls/Personal Protection

Engineering Controls:
Provide exhaust ventilation or other engineering controls to keep the airborne concentrations
of vapours below their respective threshold limit value. Ensure that eyewash stations and
safety showers are proximal to the work-station location.

Personal Protection:
Splash goggles. Lab coat. Vapour respirator. Be sure to use an approved/certified respirator
or equivalent. Gloves.

Personal Protection in Case of a Large Spill:

Splash goggles. Full suit. Vapour respirator. Boots. Gloves. A self contained breathing
apparatus should be used to avoid inhalation of the product. Suggested protective
clothing might not be sufficient; consult a specialist BEFORE handling this product.

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 Section 9: Physical and Chemical Properties
Physical state and appearance: Liquid (Oily liquid.)

Oder: Aromatic Amine like.

Taste: Burning.

Molecular Weight: 93.13 g/mole

Colour: Colourless.
n
PH (1% sol /water): Basic.

Boiling Point: 184.1°C (363.4°F)

Melting Point: -6°C (21.2°F)

Critical Temperature: 425.6°C (798.1°F)

Volatility: Not available.

Oder Threshold: 2.4 ppm

Dispersion Properties: See solubility in water, methanol, and diethyl ether.

Solubility: Soluble in cold water, hot water, methanol, diethyl ether.

Section 10: Toxicological Information

Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion.

Toxicity to Animals: Acute oral toxicity (LD50): 250 mg/kg [Rat.]

Acute dermal toxicity (LD50): 820 mg/kg [Rabbit.]
Acute toxicity of the vapour (LC50): 175 7 hours [Mouse]

Chronic Effects on Humans:

CARCINOGENIC EFFECTS: Classified A3 (Proven for animal.) by ACGIH. 3 (Not
classifiable for human.) by IARC. MUTAGENIC EFFECTS: Mutagenic for mammalian
somatic cells. Mutagenic for bacteria and/or yeast. May cause damage to the following
organs: blood, kidneys, liver, bladder, spleen, cardiovascular system, central nervous system.

Other Toxic Effects on Humans:

Hazardous in case of skin contact (irritant, permeate), of ingestion, of inhalation.

Special Remarks on Toxicity to Animals: Not available.

Special Remarks on Chronic Effects on Humans:

May affect genetic materials. May cause adverse reproductive effects. It may cause cancer.
However, IARC has found inadequate evidence in humans. Human: passes through the
placenta.

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 Section 11: Ecological Information

Ecotoxicity: - Not available.

BOD5 and COD: - Not available.
Products of Biodegradation: - Possibly hazardous short term degradation products are not
likely. However, long term degradation products may arise.
Toxicity of the Products of Biodegradation: - The products of degradation are less toxic
than the product itself.
Special Remarks on the Products of Biodegradation:- Not available.
Section 12: Disposal Considerations
Waste Disposal:
Waste must be disposed of in accordance with federal, state and local environmental control
regulations.

INTRODUCTION TO INDUSTRIAL SAFETY:

 Safety is becoming very important with every management as it has come to play
a very vital role in the modern development.


 Before many years, accidents were considered as acts of God and nature. Scientific
minded people have analyzed accidents and developed a separate engineering
branch of accident prevention. This analysis was required due to:

1. Rising trend of accident

2. Increased use of machinery

3. Increased material handling

4. Lack of safety standard

5. Lack of training

6. Better reporting of accidents

SAFETY:

Safe use of man, material and machine by safe system method of work is to achieve
zero accidents which results in higher productivity.

ACCIDENT:

An accident is unplanned and unexpected events which interfere or interrupts the planned
process of work and results in personal injury.

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ACCIDENT FACTOR:

1. A personal accident injury occurs as a result of an accident

2. An accident due to unsafe act or unsafe condition

3. Unsafe act/unsafe condition exists due to fault of persons

4. Fault of persons is due to negligence.

Thus, if we can remove fault of persons we can prevent 98% accidents.

SAFETY PRECAUTIONS:

 Goggles and rubber gloves, If any part of the skin has been exposed to ammonia,
 wash immediately and thoroughly with water.

 The location of fire hydrants. Safety showers, eye wash fountain ammonia canisters gas
 mask, emergency air breathing apparatus should be well known to all personnel.

 Heavy, leakage of ammonia can be dealt by spraying large quantity of water

with spray nozzles.

FIRE HAZARDS:

The general types of fire are encountered in the process plants. One involves common
combustible material such as wood. Rags. Paper. etc. (class A fires), the next flammable
liquids and gases such as lubrication oils and solvents, ammonia vapour etc. (Class B
fires) and the third involve electrical equipment (Class C fires)

In general three things are required to make a fire

  Something which will burn e.g. a combustible material

 Oxygen-air

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PRINCIPLE OF FIRE EXTINGUISHING:

 Fire may be extinguishing by withdrawing of flammable contents, interrupting

flammable flow, isolating fuel from air, heat removal to below reaction temperature
or by dispersal.

 Carbon tetrachloride extinguishers and Carbon dioxide extinguishers are intended
mostly for use on electrical fires and may be used on energized electrical equipment
without danger to operator provides. They are properly maintaining no moisture.

 In case of fire, it is the duty of the operating personnel to protect life and property
and to extinguish the fire as quickly as possible.

PRINCIPLE OF PROTECTION & PREVENTION:

Industrial accidents are caused by negligence of employer, the worker or the both. Employers
efforts to reduce the accidents are generally motivated by four considerations.

a) To lessen human suffering

b) To prevent damage to plant and machinery

c) To reduce the amount of time lost as a result

d) To hold the expenses of workman’s compensation to a minimum.

SAFETY MEASURE IN PLANTS:

General rules for safety are as follows:

  Unauthorized entry into the plant premises is prohibited.

  Smoking and carrying matchbox or lighter should be avoided in plant.

  Before repairing machines switch off power supplies.

 Before unloading chemicals from car ortrucks check that to container to see if
 any cracked, broken or leakage is there.
  Do not operate any switch that is protected with danger board.
  More than one person should be presents while dealing with leaks or toxic gases.
  Remove sources of fire or sparks from areas where chemicals are stored or used.
 Immediately flash your eyes with large amount of water when contacted with some
 toxic chemicals.

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  Always is required safety application when you are doing a job. These are safety
helmets, chippers goggles, chemical gloves, rubber apron acid proof suit,
gumboots, safety shoes, and mask and flame mask.



DIFFERENT SAFETY EQUIPMENTS:

Head Protection: Head protectors are hard hats, cap, helmets made of aluminium, PVC,
fibreglass, laminated plastic or vulcanized rubber. They may be fitted with breakers for
fixing welding marks, protective faces screen or lamp. The hats and caps which provides
sufficient clearance between the top of the head and shell. Soft caps and hoods are also used
for protection against heat, sparks and other dangerous material and are made up of
appropriate material.

Eye and Face Protection: Eye injuries can be caused by dust, flying particle, splashes
and harmful reactions. Eye protectors are safety spectacles, mono goggles, impact goggles,
wilding goggles, foundry goggles, chemical goggles and gas tight goggles, face shield etc.

Ear protection: Noise level above 90 db is hazards if human body is expose to it for
more than 8 hrs/day or 48 hrs/week. It may cause deafness, loss of efficiency, irritation
and also loss of hearing, noise level can measure by a Noise Average Meter or a Noise
Dose Meter, ear plug or ear muffs reduce to at 25 to 49 db ear plug is made of plastic,
rubber of polyurethane from. Ear muffs covers external ear and provides better attenuation
then earplug.

Body Protection: Body protectors are coats, aprons, overall jackets and complete head to toe
protective suits. Nature of potential hazard, degree of hazard involved and nature of activities
of the earner are important in the selection of safety clothing.

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 Chapter: 10
Pollution Control

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10.1 Environmental management
Company has developed and implemented Environment Management System (EMS) as per
ISO: 14001-1996 for its Fertilizers, Chemicals and Printed Circuit Board units and
supporting services at Bharuch, Gujarat with expert guidance from M/S EQMS Indian Pvt.
Ltd, Delhi. It is now “ An ISO: 14001 Company” certified by the renowned certifying body
RWTUV Anlagentechbik GmbH, Germany through their Indian arms, M/s TUV Indian Pvt.
Ltd. The certificate was presented at its corporate office at Bharuch on 31st January 2002

Company has been following a three pronged strategy for environment preservation.

 Reduce pollutants at source by adopting LOW POLLUTION or NO POLLUTION

alternatives wherever feasible.
 Develop fruitful utilization for pollutants, whether solids, liquids or gaseous.
 Treat balance effluents/wastes to achieve acceptable discharge quality norms.

Some major benefits achieved so far through EMS implementation are listed below:

 Conservation in energy consumption.

 Reduction in water consumption.
 Reduction in lube oil consumption.
 Increase in recovery of used lube oil.
 Increase in revenue from scrap sale due to better segregation.
 Improved housekeeping in the complex.

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 Chapter: 11
Conclusion

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 Conclusion

  Now a day, chemical engineers have to survive in the global environment. To

Development all these skills which are required for success in the filled in the,
th
university have made project work – a part of 6 semester. In this regard, we have
done our project work on “Aniline”.

 Up till now we are studying theoretical concept of chemical mechanism and standards
but doing project work we are using our theoretical knowledge and but into on paper
to become practical one. By this work we know design of equipment and how to work
if different parameters, safety aspect and material requirement and also energy
consumption required for the new plant for particular product.

 A good and well engineer has good skill for designing any plant with different modes,
this is only and only possible when one have to first primarily project work and then
scale up there project.

 Ultimately from this project report I conclude that from technical and economical
point of view this project of aniline is viable.

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 Chapter 12
References

Diploma Chemical Engineering Project Entitled “ANILINE’’ 56

 References
 References Book
1. Chemical and Process technology encyclopaedia urban
2. Industrial safety health and environment management
3. Process instrumentation and control, S.K.SINGH
4. Shreve’s chemical process industries fifth edition George T. Austin
5. Process calculation

 References website
6. http://www.chemengonline.com/aniline-production-nitrobenzene-liquid-phase-
intratec-solutions/
7. https://en.wikipedia.org/wiki/Bechamp_reduction

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