A

INTERNSHIP PROJECT AT

ELANTAS BECK INDIA LTD.

Submitted by

LUHARIYA ANJALI J.

In partial fulfilment for the award of the degree of

BACHELOR OF TECHNOLOGY
In

CHEMICAL ENGINEERING

DHARMSINH DESAI UNIVERSITY, NADIAD

 INTRODUCTION Chapter 1

1.1 About Elantas

With a worldwide network of production facilities, we can supply

customers locally wherever they are. The ELANTAS group comprises 7
companies and 12 production sites over the globe. ELANTAS Beck India
Limited.

ELANTAS BECK INDIA LIMITED is a Public Company, who was

incorporated 66 Year(s) 9 Month(s) 1 Day(s) ago on dated 15-Mar-1956 .
ELANTAS BECK INDIA LIMITED is classified as Non-govt company
and is registered at Registrar of Companies located in ROC-PUNE.
Ankleshwar Unit manufactures a wide range of specialty chemicals in the
electrical insulation and construction industries.

1.2 History of Elantas

Incorporated in Mar.'56 Dr Beck & Company (India) was promoted by

Mahindra & Mahindra in collaboration with Dr Beck & Company
Germany. It went public in 1961. The company has collaboration with
BASF Lacke and Farben Germany to manufacture paints at Satara.
BASF Germany which had the controlling interest in the company with a
stake of 51% sold its stake to Schenectady International Inc. USA. on 1st
Jan.'98. The company has it manufacturing facilities at Pune Ankleshwar
and also has its regional offices located at Bangalore, Kolkata, New Delhi
& Mumbai etc.
Dr Beck & Company (India) has developed over the years one of the
finest and widest ranges of synthetic insulations for the Indian industry.
These ranges include wire enamels varnishes epoxy and unsaturated
polyester resins to meet the needs of various sectors like the private
government and PSUs such as defence railways telecommunications heavy
electricals etc.

Company has requisite permission from the Govt. of India & RBI for
Schenectady (India) Holding Ltd (SIHL) a wholly own subsidiary of
Schenectady International Inc USA acquired 51% of the Equity Capital of
the Company from BASF Group. SIHL made an offer to acquired further
6.16% f the equity of the Company the total holding of SIHL to 57.16%.

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 Company has received the ISO-14001 Environment Management System
Certification from RWTUV Germany.
With the Acquisition of majority shareholding of the Company by the
Schenectady Group the name of the company has changed to
'Schenectady-Beck India Ltd'. The Hon'ble High Court Mumbai has
approved scheme of amalgamation of Schenectady India Ltd. with the
company. The name of the company has been changed during the year
2003 from Schenectady-Beck India Ltd to Beck India Ltd. During 2005
the companies production capacity of Wire enamels & Impregnating
varnishes expanded from 8000 MT to 9500 MT. Synthetic Resins capacity
stood at 4500 MT.

1.3 Objectives & Principles of Elantas

Elantas aim to act on their own responsibility to ensure that their

products and working methods do not harm people or the environment.
The need to strive for economic success must not under any circumstances
prevent action in this direction which is prescribed by law or which they
consider to be important. Hence they want to create secure jobs and good
working conditions for the employees. To this end ALTANA Electrical
Insulation has defined group-wide environmental and safety standards.
These standards are based mainly on the Responsible Care initiative of the
chemical industry.

ELANTAS attaches great importance to uniform, group-wide

compliance with environmental and safety standards. To this end all
companies and subsidiaries worldwide are committed to comply with the
general principles contained in our Principles and Objectives and those
arising from the Responsible Care initiative.

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1.4 Company Product

Elantas customers benefit from their comprehensive product portfolio and

appreciate reliability and strong technical expertise.

1. Wire Enamels,

2. Impregnating Materials,

3. Casting & Potting Materials,

4. Flexible Electrical Insulation Materials,

5. Materials for Electronic Protection,

6. Materials for Tooling & Composites,

7. Specialty & Industrial Coatings,

8. Printed Electronic Products.

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DEPARTMENT

Elantas Beck India, Ankleshwar site work with many different departments. The
Admin block (Management), Environment, Occupational Health & Safety department,
Production/manufacturing department, Corporate Social responsibility Initiatives,
QC/QM department, Logistics Department, etc.

Quality, Environment, Occupational Health & Safety Department

ELANTAS Beck India Ltd, manufacturer of speciality chemicals is committed to

continually improve its customer satisfaction, environment, health and safety
performance and comply with all its legal obligations. It is the responsibility of
both management and its employees to achieve a high level of QEHS
performance through instituting adequate processes and measurement systems:

In pursuit of our belief and commitment, we shall strive to:

• Incorporate QEHS considerations at all key stages of our business operations.

• Achieve consistent quality of our products and services

• Conserve natural resources and protect the environment

• Provide all employees with a safe and healthy workplace by implementing

measures to prevent work related injury and ill health

• Provide our employees, distributors and customers with the information

necessary to handle and manage our products safely and thereby reduce hazards
and OH&S risks

• Increase employees and contractors’ awareness of this policy and provide

necessary training for improving QEHS performance

• Build a strong culture of team work through consultation and participation

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 PRODUCT

1. Wire Enamel
Electrical motors, generators and transformers function on the basis of
electromagnetic induction. The rotational or linear movement of such electrical
rotary equipment is caused by electromagnetic fields induced by current flow
through copper/aluminum wires and coils, and their mutual repulsion forces.

For a safe and stable operation of such rotary equipment, the copper or aluminum
wire is concentrically coated with multiple insulating layers of a so-called wire
enamel varnish, prior to the winding process. This wire coat prevents short circuits
and other electrical failures potentially resulting in the loss of the electromagnetic
fields and machine breakdowns.

Depending on the end-use application, wire enamels provide high thermal

resistance, strong mechanical stability, superior flexibility and chemical/moisture
resistance, which all supports a long service life of the insulation.

ELANTAS is offering a high-performing range of enamels for the use as magnet

wire coatings. Our chemistries include Polyester, THEIC-modified Polyester (PE),
Polyesterimide (PEI), Polyamideimide (PAI), Polyimid (PI), Polyamide (PA),
Polyurethanes (PU), Polyvinylformal (PVF) and Nylon.

The ELANTAS portfolio comprises enamels especially designed for various wire
grades such as copper and aluminum wires, fine wires, medium wires, heavy round
wires and shaped wires. We provide solutions for both horizontal and vertical
enameling technologies, as well as different coating builds from single layer to
multiple layer application. Our product range covers varnishes delivering special
requirements such as corona resistance properties, solder ability and oil resistance,
among many others. In addition, we guarantee superior compatibility with most
impregnation varnishes, in particular, the ELANTAS impregnation varnishes.

Through the global ELANTAS production infrastructure, with eight

manufacturing sites across the globe, we stand for the highest quality and most stable
supply chains. We offer a broad product portfolio globally fulfilling the international
standards of the industries but also provide regional qualities that meet local
demands.

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 2. Insulating Varnish
Excellent insulation material performance is critical wherever electrical
components have to operate and it is even more so under extreme conditions.

The application conditions for any piece of electrical equipment can be

extreme. It is therefore vitally important that insulation systems for motors,
generators and transformers are designed around the most critical conditions.
The right selection of insulating components including Flexible Electrical
Insulation for the various voltages and temperature classes is paramount to
the integrity of the electrical equipment.

Flexible Electrical Insulation layers protect insulated wires from coming

into contact with steel cores, hold wires in place, and provide a phase-tophase
barrier. To protect the conductor and insulation structure against mechanical,
electrical, environmental and thermal stress, the whole winding is then
consolidated using a compatible resin system. Typical Flexible Electrical
Insulation applications are slot liners, phase insulations, wedges and slot
closures.

Withstanding extreme constant stresses – mechanical, thermal, chemical

and electrical – is a fundamental prerequisite that every insulation material
must meet. However, when it comes to Flexible Electrical Insulation,
ELANTAS goes beyond that and utilizes its extensive knowledge in
applications and its patented foundation for polyamideimide wire enamels to
develop an entirely new technology: advanced PAI layer technology.

2.1. Product Capacity

Product capacity: 9500 MT (9500000 Kg) / Year

&
1500-1600 Ton/Month (Ankleshwar Unit)

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2.2. Flow Diagram Of Process

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2.3. Thermodynamics & Physiochemical Properties of Major Raw Materials

2.3.1. Glycerin

Formula: C3H8O3
Molecular weight: 92.0938
Chemical structure: C3H8O3
Glycerin is colorless or pale yellow liquid; odorless and syrupy; sweet and warm taste. It is
hygroscopic and its solutions are neutral. Miscible with water and alcohol. Insoluble in
chloroform, ether and in volatile oils
Composition:
Glycerine, Glycerin, Glycerol, 1,2,3-Propanetriol
Glycerin
Livestock
Identification
Recommendation
National List:
Allowed (Consensus)
Suggested
Annotation:
Glycerin, Allowed. Must be USP grade and produced through hydrolysis of fats and oils. For use
as a livestock teat dip. (Consensus)
Characterization
C8H8O2. Glycerine 99.7% and water.
Properties:
Glycerin is colorless or pale yellow liquid; odorless and syrupy; sweet and warm taste. It is
hygroscopic and its solutions are neutral. Miscible with water and alcohol. Insoluble in
chloroform, ether and in volatile oils.
How Made:
Glycerin is a by-product of the soap manufacturing process. Oldest method of manufacture is by
hydrolysis of natural fats & oils (either animal or vegetable): heat, steam, and pressure “split” the
glycerin from the oil. The glycerin is concentrated in multistage evaporators and refined.
Purification is achieved through either an ion exchange process or a distillation system. It can
be produced synthetically from propylene.
Specific Uses:
Glycerin has over 1,000 uses; however for purposes of this review, glycerin is used as an
ingredient in teat dips. It is often described as an inert ingredient used in topical medications as
a vehicle. In teat dips it prevents teat irritation and improves skin conditioning. Glycerin has
some germicidal activity (Fox et al., 1990).
Action:
The means by which it inhibits bacterial growth is not entirely known. Serves as a humectant
and emollient.
Combinations:
Iodine, chlorohexidine.

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2.3.2. MEG

Mono ethylene glycol (also known as MEG, EG, 1,2-ethanediol or 1,2-Dihydroxyethane) is an

organic compound with the formula C2H6O2. It is a slightly viscous liquid with a clear, colourless
appearance and a sweet taste that emits virtually no odour. It’s miscible with water, alcohols,
and many other organic compounds and is primarily used in the industry for manufacturing
polyester fibres and as a component in the production of antifreeze, coolants, aircraft anti-icers
and de-icers.
Mono Ethylene Glycol
Technical Properties
Technical properties of Mono Ethylene Glycol:
Molecular Formula: C2H6O2 / (CH2OH)2 / HOCH2CH2OH
Synonyms: monoethyleneglycol, mono ethyl glycol, meg glycol, ethylene glycol, 1,2-ethanediol,
Ethane-1,2-diol, EG, industrial glycol, 1,2-Dihydroxyethane, glycol alcohol.
Cas Number: 107-21-1
Molecular Mass: 62.07 g/mol
Exact Mass: 62.036779 g/mol
Flashpoint: 232 °F/ 111.11 °C
Autoignition temperature: 770 °F / 410 °C
Boiling Point: 387.7 °F / 197.6 °C at 760 mm Hg
Melting Point: 9 ° F / -12.8 °C
Vapour Pressure: 0.06 mm Hg at 68 °F / 20 °C
Density: 1.115 at 68 °F

How is Mono Ethylene Glycol Produced?

The intermediate ethylene oxide is used to convert ethylene (ethene) into ethylene glycol.
Ethylene oxide is obtained through oxidation and is then reacted with water to give mono
ethylene glycol with di and tri ethylene glycols as co-products:
C2H4O + H2O → HOCH2CH2OH
Acids and bases can catalyse this reaction, or it can occur at neutral pH under elevated
temperatures. Yields of up to 90% can be achieved with acidic or neutral pH with a large excess
of water.
Mono ethylene glycol is also manufactured via the hydrogenation of dimethyl oxalate in the
presence of a copper catalyst or via the acetoxylation of ethylene.
Global demand for Monoethylene Ethylene Glycol (MEG) is strong with the market worth $25
billion and expected to grow 6% annually to 2024. This is especially due to the increased
production of polyethene terephthalate (PET) and the demand for polyesters in the Asia Pacific.
Demand is strongest in China where approximately 70% of the world’s MEG output is
consumed.
How is Mono Ethylene Glycol Stored and Distributed?
Storage & Handling
Under the NFPA 704, mono ethylene glycol is rated as a 0 for instability, indicating that mono
ethylene glycol is usually stable. Mono ethylene glycol’s vapours are heavier than air and will
travel to surrounding areas. Due to its high flashpoint of 111.11°C, the chemical has a
flammability rating of 1, indicating that it requires considerable preheating for ignition and
combustion to occur. However, in storage, MEG should be kept away from heat, sparks, and
open flames. If a fire was to occur, alcoholresistant foam or water spray should be used to fight
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fires with a focus on preventing the spillage from reaching water sources or sewers.
Mono Ethylene Glycol Health Hazards
The chemical has high toxicity when ingested with the major danger being a result of the sweet
taste encouraging further consumption; this increases the danger posed to animals and
children. Ingestion of sufficient amounts is fatal if left untreated with the ethylene glycol being
oxidised in the body to glycolic acid and then the toxic chemical, oxalic acid. MEG ingestion
impacts the central nervous system, heart and can cause acute kidney failure.
Eye exposure to mono ethylene glycol vapours can irritate, and therefore it is suggested
goggles should be worn while handling the chemical. Exposure to ethylene glycol in liquid form
has the potential to cause more serious eye damage. If contact is made with the eyes,
immediately wash with plenty of water and seek medical attention.
Skin exposure with MEG can also irritate and so gloves should be worn. If the skin does
become contaminated, all wet clothing should be removed, and the skin washed with water.
Inhalation exposure to high levels of ethylene glycol can cause irritation, and potentially
intolerable respiratory discomfort and coughs. If excessive inhalation occurs, the individual
should be removed from the environment, breathe fresh air, and seek medical attention.

2.3.3. Phenol
Phenols are the organic compounds containing benzene ring bonded to a hydroxyl group. They
are also known as carbolic acids. They exhibit unique physical and chemical properties in
comparison to alcohol. These physical and chemical properties of phenols are mainly due to the
presence of the hydroxyl group.
Some prominent physical and chemical properties of phenols are given below.

1. Boiling Point of Phenols

Phenols generally have higher boiling points in comparison to other hydrocarbons having equal
molecular masses. This is due to the presence of intermolecular hydrogen bonding between
hydroxyl groups of phenol molecules. In general, the boiling point of phenols increases with an
increase in the number of carbon atoms.Boiling point of Phenols

2. Solubility of Phenols

The solubility of phenol in water is governed by the hydroxyl group present.

The hydroxyl group in phenol is involved in the formation of intermolecular hydrogen bonding.
Thus, hydrogen bonds are formed between water and phenol molecules which make phenol
soluble in water.
However, the aryl group attached to the hydroxyl group is hydrophobic in nature.
Thus, the solubility of phenol decreases with the increase in the size of the aryl group.

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3. Acidity of Phenols

Phenols react with active metals such as sodium, potassium, etc. to form the corresponding
phenoxide. These reactions of phenols indicate its acidic nature. In phenol, the sp2 hybridized
carbon of the benzene ring attached directly to the hydroxyl group acts as an
electron-withdrawing group. Thus, it decreases the electron density on oxygen.
Due to the delocalization of negative charge in the benzene ring, phenoxide ions are more
stable than alkoxide ions. As a result, phenols are more acidic than alcohols. In the case of
substituted phenols, the acidity decreases if an electron-donating group is attached to the ring
while the acidity increases in the case of an electron-withdrawing group.

4. Chirality of Phenols

Phenols exhibit chirality within their molecules, for example, catechin. This chirality is due to the
absence of planar and axial symmetry in the phenol molecule.

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2.4. MSDS
Each and every material have their own MSDS. All the component MSDS
has 16 sections. Common Sections of MSDS are as follows.

Section 1: Identification of the substance/mixture and of the

company/undertaking.

Section 2: Hazardous identifications

Section 3: Composition/information on ingredients.

Section 4: First aid measures.

Section 5: Firefighting measures.

Section 6: Accidental release measures

Section 7: Handling and storage

Section 8: Exposure control/personal protection

Section 9: Physical and chemical properties

Section 10: Stability and reactivity

Section 11: toxicological information

Section 12: Ecological information

Section 13: Disposal consideration

Section 14: Transport information

Section 15: Regulatory information

Section 16: Other information

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SAFETY, HEALTH AND ENVIRONMENT

3.1. Introduction

a) Safety is the state of being “safe”, the condition of being protected against
physical, social, spiritual, financial, political, emotional, occupational,
psychological, education, or other types of consequences of failure, damage,
error, accident, harm or any other event which could be considered non desirable.
This can take the form of being protected from the event or from exposure to
something that causes health or economical loss. It can include protection of
people or of possessions.

b) No industry can afford to neglect the fundamentals of safety in design and

operation of its plant and machinery. It is important that all the people
responsible for management and operation of any industry should have a good
knowledge of industrial safety.

c) “Safe use of man, material and, machine by safe systems and method of work so
as to achieve zero accidents which results in higher productivity.

d) Accident: An accident is unplanned/ unexpected events which interfere or

interrupts with the planned process of work and results in personal injury.
3.2. Basic Rules

• No smoking
• No electronic items allowed in the industry without special permission
• Photography is strictly prohibited
• Personal protective equipments are compulsory.
• Only walk on the showed footpath
• Watch out for big vehicles in the blind spot convex mirrors. Let them pass
and then cross the road
• Speed limit 10km/hr • Do not enter in restricted area.

3.3. Emergency siren code

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Testing Siren rings till 1 minutes continuously

Plant Alert Siren rings until plant safety

representative arrives on the lace.

On site emergency Siren rings continuously 10s to 2min

Off-site emergency Siren rings 10s to 15 min

All clear (on site) Siren rings continuously for 2 min

All clear (off site) Siren rings continuously for 3min

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 3.4. Pre-start-up Safety review

• One of the fundamental tolls for managing change is the pre start-up safety
review (PSSR). A PSSR consists of a checklist of items to be thoroughly
verified before a process begins or restart in order to ensure that potential
hazards have been properly addressed.

• The aim of PSSR is to prevent serious injury from the hazard of stored
energy as a result of the failure of a pressure system or one off its
component parts.

• The team required for PSSR consists of representatives from the following
departments:

e) Process
f) Mechanical
g) Electrical
h) Project
i) Instrumentation
j) Safety
It consists of verification of:

• Fire and explosion safety

• Electrical safety
• Machine and equipment safety
• Industrial hygiene
• Safety training
• Interlocks and alarms
• Field safety
• Relief devices
3.5. Fire and Fire triangle
Generally, in industries explosions and fires have more possibility to happen
because sometimes untrained workers are allowed to operate or else the event is
simultaneous like increase of pressure inside the boiler.

I. Flash point: The minimum temperature at which fluid gets converted

t into vapor is called flashpoint.

II. Lower explosive limit (LEL): The lower explosive limit (LEL) is the
lowest concentration of a gas or vapor that will burn in the air.
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 III. Upper explosive limit (UEL): The highest concentration of a gas or
vapor above which a flame will nor spread in the presence of an ignition
source.

IV. Flammable range: The concentration of gas between lower and upper
explosive limit.

V. Permissible Explosive limit (PEL): PEL is a regulatory limit on the

amount or concentration of a substance in the air.

VI. Threshold limit value (TLV): PEL is a regulatory limit on the amount
or concentration of a substance in the air.

VII. Short term exposure limit (STEL): A short term explosive limit is the
acceptable average exposure over a short period time, usually 15 min
as long as the time weighted average is not exceeded.

VIII. Acute toxicity: Acute toxicity describes the adverse effects of a

substance that result either from a single exposure or from multiple
exposures in a short period of time.

IX. Chronic toxicity: Chronic toxicity is the development of adverse

effects as the result of long-term exposure to a toxicant or other stressor.

X. Excursion limit: The OSHA standard fibre per cubic centimetre

worker exposure limit to asbestos, averaged over a sampling period of
thirty minutes.

Fire Triangle:
The fire triangle or combustion triangle is a simple model for understanding the
necessary for most fires.

The triangle illustrates the three elements a fire needs to ignite: heat, fuel and an
oxidizing agent (usually oxygen). A fire naturally occurs when the elements are present
and combined in the right mixture. A fire can be prevented or extinguished by removing
any one of the elements in the fire triangle.

• Oxygen is approximately 20% of the atmosphere.

• There has to be an initial source of heat to ignite the fire
• Fuel such as paper, wood or flammable substances.

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 Fig: 3.5.1 Fire triangle
Types of fires:

CLASS MATERIAL EXTINGUISHERS

A Wood, paper, fabric Water

B Flammable liquids Foam

C Burning gases Carbon dioxide

D Combustible metal Dry chemical powder

E Electrical equipment Carbon dioxide

F Unsaturated cooling oil Carbon dioxide

Table: 3.5 Types of fire

Techniques to stop fire:

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 • Cooling: By reducing temperature of surrounding
• Smothering: By removing oxygen from fire.
• Starving: By removing the fuel in the vicinity of fire.
NFPA Diamond

Fig: 3.5.2 NFPA Diamond

3.6. Plant safety
• Electrical safety: High voltage electricity is required to automize a chemical
plant. So electrical safety should be given priority.

• Some methods of shock protection are:

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 a. Isolation: To limit the forces transmitted to the surroundings of the
equipment in which shock originates.

b. Limitation: To stop providing power to the origin of shock.

c. Low voltage: Use earth leakage circuit breakers to avoid high voltage.

d. Double insulation: For thick wires use highly durable insulation

material.

e. Earthing: Earthing is used to protect you from an electric shock. It does

this by providing a path for a fault current to flow to earth.

Fig: 3.7.1 Site safety

PERSONAL PROTECTIVE EQUIPMENT (PPE):

• Personal protective equipment, commonly referred to as “PPE”, is

equipment worn to minimize exposure to hazard that cause serious
workplace injuries and illnesses. These injuries and illnesses may result from
contact with chemical, radiological, physical, electrical, mechanical, or
another workplace hazard.

• PPE ma include items such as gloves, safety glasses and shoes, earplugs or
muffs, hard hats, respirators or coveralls.

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 Fig: 3.7.2 PPE

List of PPE used in an industry:

Non-Respiratory Respiratory
Safety Helmet Dust mask
Safety goggles ½ mask
Ear plug Bubble hood mask
Hand gloves: Powdered Air purifying Respirator
Sharp object-Kevlar gloves
Solvent handling-Neoprene
Normal work-Rubber gloves
Hot work-Leather gloves

Safety shoes Supplied Airline Respirator

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Safety Harness Self-controlled breathing apparatus
(SCBA):
1. Open circuit
2. Closed circuit

Protective clothes

Table: 3.7 PPE

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