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CUMENE
PROJECT REPORT
Submitted by
OF
DIPLOMA
IN
CHEMICAL ENGINEERING.
CUMENE 2
SHREE KJ POLYTECHNIC, BHARUCH
CERTIFICATE
This is to certify that SAVALIYA DIVYAM B., PATEL TIRTH., PATEL SHREYAS.,
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PREFACE
• Teaching is the important knowledge, but training develops habits. It assures that technical skills cannot be
perfect without practical training. Hence, the practical training is grate valuable for engineering student the
actual aim of in plant training is to get all operation and process which are carried out in the industries and
• Practical makes a man perfect in practical training a person deals with many technical problems. In real
operation and process another aim of I plant training is to learn industrial management and discipline.
• This project describes the manufacture of “ISOPROPYL ALCOHOL” is prepared fulfillment in chemical
engineering. It is purely academic in nature though attempts have been made to incorporate faculty data
available from journals, books and other sources. Reasonable assumption have been made for data those
• This report includes the information based on theoretical backgrounds. So this report cannot applicable to
industrial scale to tally . but for actual setting up of a new chemical plant and expansion or revision of
• The report provides preliminary information and gives an idea and in sign into the process design aspects.
• The report also includes safety consideration, instrumentation, and process control. The reference section at
the end lists the source of information. A detailed market surveys and plant set up design factor has to be
studied before setting up a plant end. A number of pilot trials should be conducted before starting. No such
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ACKNOWLEDGEMENT
We extend our sincere gratitude to our guide Shri K .J Panchal sir and Head of
department in Chemical Engineering. Shri. T. P. Chowdhury sir in SHREE K. J.
POLYTECHNIC, BHARUCH for sharing his knowledge and resources and also for his
availability.
We are also thankful to Shri K.J. Panchal sir our project group guider in Chemical
Engineering Department.
For extending his help in the course, we are also thanks to all the authors and
editors of various reference books, research paper that helped us through his report.
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INDEX
SR.no Topic Page no.
From. To.
1 Introduction
1.1 Introduction
1.2 Structural formula
1.3 Market analysis
1.4 List manufacturers of cumene
1.5 Properties
1.6 Uses & Application
1.7 Raw materials
1.8 Catalyst used
3.1 Equipment
3.3 Instrumentation
4 Material balance
6 Plant location
7 Economic evaluation
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7.2 Estimation of capital investment costs
8.1 Safety
8.2 Pollution
10 Conclusion
11 Preference
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Chapter 1
INTRODUCTION
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Chapter : 1
Introduction
hydrocarbon with an aliphatic substitution. It is a constituent of crude oil and refined fuels. It is a
flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is produced as a
the synthesis of other industrially important chemicals, primarily phenol and acetone.
• The alkylation of benzene with propylene gives CUMENE a very important petrochemical C3
compound.
• The cumene molecular have can be visualize as straight chain propylene group have benzene
• The cumene production capacity of the world is about 7 million Ton/day distribute over 40 plant.
Kieselguhr(skpa).
• Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum
• Cumene producers account for approximately 20% of the global demand for benzene.
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Structure.
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1.2. PRESENT STATUS AND MARKET ANALYSIS.
Essentially, all world cumene is consumed for the production of phenol and acetone. As a
result, demand for cumene is strongly tied to the phenol market. Trade In cumene accounts for only 4%
of world production. The largest exporter of cumene are the United States & Japan. Taiwan also import
As of early 2011, the U.S. cumene market was tight-primarily as a result of a shortage of
feedstock propylene. Schedule plant maintenance by several large cumene manufacturer was also
planned for early to mid 2011. Because of the cumene shortage, phenol and acetone plant operations rate
have been reduced significantly, which in turn has restricted phenol export to Europe and higher demand
Increased demand for bisphenol A and phenolic resin will result in strong Demand for phenol,
particularly in Asia (excluding Japan). As a result, consumption of cumene for phenol is forecast to
grow at approximately 8% per year in the region China alone is expected to add a million metric ton of
cumene capacity during stream in 2013) to supply its phenol/ acetone plants that are slated to come on
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stream during that period. Overall, world wide cumene consumption for the production of
phenol/acetone is forecast to grow at an average annual rate of about 4.5% during 2010–2015.
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1.3.2 LIST GLOBAL MANUFACTURER
Table 2, Global manufacturer of cumene and capacity of cumene
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1.5 PROPERTIES
• Color :- colorless
• Odor. :- odorless
• Purity :- 99%
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• Insoluble in. :- Alcohol, Ether, Carbotetrachloride & etc.
oxygen.
✓ C6H5CH(CH3)2 + O2 = C6H5(CH3)2COOH.
• By catalytic actions of dilute sulphuric acid, cumene hydroperoxide is Split into phenol
& acetone.
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1.6 USES OF CUMENE
1. Cumene is a natural component of coal tar and crude oil, and also can be used as Blanding
component in gasoline.
chemical intermediate in the production of phenol & acetone, two chemicals that are widely use
plastic .
3. Additional, cumene I’m minor amounts is used as a solvent during the manufacturing of paints,
6. Cumene in minor amounts is used as a thinner for paints, enamels and lacquers and to
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1.7 RAW MATERIALS USED.
➢ 1.Benzene
➢ 2.Propane
➢ 3.Propylene.
➢ QZ-2000™
&
➢ QZ-2001™
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Chapter :- 2
DIAGRAMS.
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2.1 Various process of manufacturing.
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1) Q-MAX™ CUMENE manufacturing process flow diagram.
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2)CD-TECH CUMENE manufacturing process flow diagram.
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3) MONSANTO – LUMMUS crest cumene process.
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4) UOP cumene manufacturing process .
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5) Badger Cumene Manufacturing Process.
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2.3 SELECTION OF CUMENE MANUFACTURING PROCESS
manufacturing.
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2.4 Process description on Q-MAX ™ cumene manufacturing process.
1. Raw material propylene and benzene are used for the production of cumene.
2. These are stored in the respective storage tanks of 500MT capacity in the storage yard pumped
3. Benzene pumped to the feed vessel which mixes with the recycled benzene. Benzene stream
is pumped through the vaporizer with 25 atmospheric pressure and vaporized to the
temperature of 243℃, mixed with the propylene which is of same and temperature and pressure
of benzene stream.
4. This reactant mixture passed through a fired super heater where reaction temperature 350℃
is obtained.
5. The vapor mixture is sent to the reactor tube side which is packed with the solid phosphoric
acid catalyst supported on the the exothermal heat is removed by the pressurized water which
is used for steam production and the effluent from the reactor i.e. cumene, p-DIPB, unreacted
benzene, propylene and propane with temperature 350℃ is used as the heating media in the
vaporizer which used for the benzene vaporizing and cooled to 40℃ in a water cooler,
propylene and propane are separated from the liquid mixture of cumene, p-DIPB, benzene in
a separator operating slightly above atmospheric and the pressure is controlled by the vapor
control value of the separator, the fuel gas is used as fuel for the furnace also.
6. The liquid mixture is sent to the benzene distillation column which operates at 1 atmospheric
pressure, 98.1% of benzene is obtained as the distillate and used as recycle and the bottom
liquid mixture is pumped at bubble point to the cumene distillation column where distillate
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7. The heat of bottom product p-DIPB is used for preheating the benzene column feed, All the
utility as cooling water, electricity, steam from the boiler, pneumatic air are supplied from the
utility section.
8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso propyl
9. This high yield of cumene is achieved without of diiso propyl benzene and is unique to the
10. The cumene product is 99.9 Wt. % pure and the heavy aromatics, which have an octane
number of 109, can either be used as high octane gasoline blending components or combined
with additional benzene and sent to a trans alkylation section of the plant where diiso propyl
11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans alkylation
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2.5 Manufacturing process description of Cumene.
A representative Q-Max flow diagram is shown. The alkylation reactor is typically divided
The fresh benzene is routed through the upper midsection of the depropanizer
column to remove excess water and then sent to the alkylation reactor via a side draw.
The recycle benzene to both the alkylation and trans alkylation reactors comes from
A mixture of fresh and recycle benzene is charged down flow through the alkylation reactor.
The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid
Because the reaction is exothermic, the temperature rise in the reactor is controlled by
recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the
inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed inlet
Effluent from the alkylation reactor is sent to the depropanizer column, which
removes any propane and water that may have entered with the propylene feed.
The bottoms from the depropanizer column are sent to the benzene column, where excess
benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column,
where the cumene product is recovered overhead. The Cumene column bottom which contains most d-
isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to
the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which are
normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation section.
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A portion of the recycle benzene from the top of the benzene column is combined with the
recycle DIPB from the side cut of the DIPB column and sent to the trans alkylation reactor.
In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The
effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst
At the end of each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn by
a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst
regeneration.
Mild operating conditions and a corrosion-free process environment permit the use of carbon-
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2.4 PROCESS FLOW DIAGRAM WITH INSTRUMENTATION AND EQUIPMENT OF Q-MAX
Fig.9, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed locations,
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Chapter:- 3
IN MANUFACTURING OF CUMENE
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.
1. Alkylation reactors.
3. Depropanizer column.
4. Benzene column.
5. Cumen column.
6. DIPB column.
1. Feed drum.
2. Feed pump.
3. Feed vaporizer.
4. Feed heater.
5. Effluent coolers.
6. Phase separator.
7. Condenser.
8. Reflux pump.
9. Reboiler.
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1. Alkylation reactors.
The alkylation reactor is typically divided into four catalyst beds contained in a single reactor
shell. The fresh benzene is routed through the upper midsection of the depropanizer column to remove
excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the
alkylation and trans alkylation reactors comes from the overhead of the benzene column.
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Fig. 10, Alkylation Reactor of Q-MAX ™ Cumene manufacturing process.
A mixture of fresh and recycle benzene is charged down flow through the alkylation reactor.
The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid
Because the reaction is exothermic, the temperature rise in the reactor is controlled by
recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the
inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed inlet
Effluent from the alkylation reactor is sent to the depropanizer column, which
removes any propane and water that may have entered with the propylene feed.
In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The
effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst
utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of each cycle, the
catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration contractor.
However, the unit can also be designed for in-situ catalyst regeneration. Mild operating conditions and
a corrosion-free process environment permit the use of carbon-steel construction and conventional
process equipment.
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3. Depropanizer Reactors.
Depropanizer Reactors is reactors which removes propane, water, and other impurities
present in the propylene feed. The depropanizer has a total condenser, partial reboiler, 20 equilibrium
stages , and operates at 17 bar. The feed streams, a saturated liquid at 101.6°C, enter at stage 11 at a flow
rate of 100Kmol/hr.
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4. Benzene column.
The bottoms from the depropanizer column are sent to the benzene column, where excess
benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column,
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5. Cumene Column.
Benzene column bottoms are sent to the cumene column, where the cumene product is recovered
overhead. The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB
stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor.
The bottom liquid mixture is pumped at bubble point to the cumene distillation column where
CUMENE 37
6. DIPB COLUMN.
The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB
stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB
column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam or
hot oil provide the heat for the product, fractionation section.
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3.2 Instrumentation Required In Cumene Manufacturing Process.
• Vortex flowmeters.
• Coriolis flowmeter.
• Electro pyrometer.
6. Ph measuring instruments.
• Ph meter.
• Ph indicator.
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Chapter :- 4
MATERIAL BALANCE
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4.1 Overall Material Balance.
C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7)
= 1050.50 Kgmole/hr
=1071.94 Kgmoles/hr
= 128836.32 Kg/hr
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Propylene required =1071.94/.97
= 1105.09 Kgmole
= 1381.3625 Kgmole/hr
= 107746.27 Kg/hr
Propane acts as an inert in the whole process . It is used for quenching purpose in the reactor. It
does not take part in the chemical reaction . Also It is inevitably associated with the propylene as
Being an inert we are neglecting propane balance in the material balance to avoid complexity.
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1.) Material balance around reactor :
Products:
Propylene = 1105.09-1071.94
Reactor
= 33.15/2 kmoles/hr
= 16.575 kmoles/hr
= 2685.15 Kg/hr
= 292.85 kmoles/hr
= 22820.85 kg/hr
Input = output
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2) Depropanising column.
Assuming almost all the propane is removed in depropanising column and sent to reactor for
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3.) Distillation column 1: (Benzene column)
Feed,
D = Benzene = 15969.41Kg/hr
Benzene
F=D+W
154160 = D +W
F XF = DXD +WX w
Taking XF = 0.9999
, XD = 0.05
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D = 15969.41 Kg/hr
= Benzene
W = 154160 – 15969.41
= 138190.5 Kg/hr
= cumene + DIPB
= 154160 kg/hr
Input = Output
Assuming all the Benzene present in benzene column is recycled to the feed . Hence considering
negligible amount of benzene to be part of residue. This will avoid the complexity of multicomponent
= 170129.5 Kg/hr.
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4.).Distillation column 3: (Cumene column) .
XF = 128836.3/138190.5 = 0.932
Cumene = D = 17065.2Kg/hr
Cumene
F = D +W
138190.6 = D +W
Taking XD = 0.995
XW = 0.01
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D = 129051 kg/hr
= 138190.5 Kg/hr.
Input = output
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Chapter: 5
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5.1 Design Basis.
Capacity,(kmol/h),110
Catalyst, Zeolite -Y
Catalystregenerationfrequency,years2
Catalystlife,years6
Pressure,bar14
Conversion,%:
Propylene%100
Benzene%55
Catalyst Zeolite-Y
Catalystlife,years6
Temperature,°C140-150
ConversionofDIPB,%50
Separations Units:
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• Benzene column:
Operational pressure:0.3bar.
• Cumene column:
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Chapter no 6
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6.1 Economic Evaluation Of Project.
a) Manufacturing cost.
▪ Variable costs.
▪ Fixed charges.
b) General expenses.
▪ Administrative expenses.
4. Cash flow.
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1.TOTAL CAPITAL INVESTMENT COST.
Total Capital Investment is sum of fixed capital investment and working capital investment.
1 Alkylation Reactor 1
2 Trans Alkylation Reactor 1
3 Benzene column 1
4 Cumene column 1
5 Depropanizer 1
6 DIPB column 1
7 Flash tank 3
8 Cooler 2
9 Heater 3
10 Compressors 1
11 Reflux drum 2
12 Reboiler 3
Total Equipment cost. 152800000.0
I. Direct Costs: material and labour involved in actual installation of complete facility (70-85% of
fixed-capital investment)
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Consider purchased equipment cost = 25% of Fixed-capital investment
= 0.25 × 6.113×10^8
= Rs. 1.528×10^8
= 40% of 1.528×10^8
= 0.40 ×1.528×10^8
= Rs.0.6112×10^8
= 20% of ×1.528x10^8
= 0.20 ×1.528×10^8
= Rs. 0.3056×10^8
= 0.40 ×1.528×10^8
= Rs. 0.6112×10^8
= 0.25 ×1.528×10^8
= Rs.0.382×10^8
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B. Buildings, process and Auxiliary: (10-70% of Purchased equipment cost
= 40% of PEC
= 0.40 ×1.528×10^8
= Rs. 0.6112×10^8
= 60% of PEC
= 0.60 ×1.528×10^8
= Rs. 0.9168×10^8
= 6% of 1.528 ×10^8
= 0.06 ×1.528×10^8
= Rs. 0.09168×10^8
II. Indirect costs: expenses which are not directly involved with material and labour of actual
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Consider the cost of engineering and supervision,
= Rs.0.5058×10^8
= 10% of 5.058×10^8
= 0.5058×10^8
= 12% of 6.113×10^8
= 0.12 × 6.113×10^8
= Rs. 0.7336×10^8
= (5.058×108) + (1.7452×108)
= Rs. 6.803×108
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Consider the Working Capital = 15% of Fixed-capital investment.
= 15% of 6.803×10^8
= 0.15 × 6.803×10^8
= Rs. 1.0205×10^8
= (6.803×10^8) + (1.0205×10^8)
= Rs. 7.8235×10^8
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2. ESTIMATION OF TOTAL PRODUCT COST:
I. Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.
i. Depreciation: (13% of FCI for machinery and equipment and 2-3% for Building Value for)
= Rs. 0.9027×108
= 0.03×6.803×10^8
= Rs. 0.2041×10^8
= 0.007×6.803×10^8
= Rs. 0.0476×10^8
= Rs. 0.0703x10^8
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B. Direct Production Cost: (about 60% of total product cost)
= 1.2247×108/15%
= 1.2247×108/0.15
= Rs. 8.1647×10^8
= 0.25×8.1647×10^8
= Rs. 2.0412×10^8
= 12% of 8.1647×10^8
= 0.12×8.1647×10^8
= Rs. 0.9797×10^8
iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL)
= 12% of OL
= 12% of 0.9797×10^8
= 0.12×0.9797×10^8
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= Rs. 0.1176×10^8
= 12% of 8.1647×10^8
= 0.12×8.1647×10^8
= Rs. 0.9797×10^8
= 0.05×6.803×10^8
= Rs. 0.3402×10^8
= 15% of M & R
= 15% of 0.3402×10^8
= 0.15 ×0.3402×10^8
= Rs. 0.05103×10^8
= 15% of OL
= 15% of 0.9797×10^8
= 0.15×0.9797×10^8
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= Rs. 0.1469×10^8
= 4% of 8.1647×10^8
= 0.04×8.1647×10^8
= Rs. 0.3266×10^8
C. Plant overhead Costs (50-70% of Operating labour, supervision, and maintenance or 5-15% of total
product cost); includes for the following: general plant upkeep and overhead, payroll overhead,
packaging, medical services, safety and protection, restaurants, recreation, salvage, laboratories, and
storage facilities.
= Rs. 0.8625×10^8
Thus, Manufacture cost = Direct production cost + Fixed charges + Plant overhead costs.
II. General Expenses = Administrative costs + distribution and selling costs + research and
development costs
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Consider the Administrative costs ,
= 0.05 ×8.1647×10^8
= Rs. 0.4082×10^8
B. Distribution and Selling costs: (2-20% of total product cost); includes costs for sales
= 15% of 8.1647×10^8
= 0.15 ×8.1647×10^8
= Rs. 1.2247×10^8
= 5% of 8.1647×10^8
= 0.05 × 8.1647×10^8
= Rs. 0.4082×108
= 5% of 7.8235×10^8
= 0.05×7.8235×10^8
= Rs. 0.3912×10^8
= Rs. 2.4323×10^8
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2. Total Product cost = Manufacture cost + General Expenses
= (12.6485×10^8) + (2.4323×10^8)
= Rs. 15.0808×10^8
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3. Gross Earnings/Income:
= 53 x 30000000
= Rs. 15.9×10^8
= (15.9×108) – (8.1647×108)
= Rs. 7.7353×10^8
= Rs. 4.2544×10^8
=(4.2544*10^8/15.9*10^8)/100
=26.756%
= 6.803*10^8/4.2544*10^8
= 1.6.
= 4.2544*10^8*100 / 7.8235*10^8
= 54.38 %
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4. Cash Flow :
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Chapter. 7
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7.1 Utilities.
The word utilities is not generally used for the ancillary services needed in the operation of any
production process. These services will normally be supplied from a central site facility, and will
include:
(1) Electricity.
(8) Refrigeration.
Electricity:
.The power required for electrochemical processes, motor drives, lighting, and general use
maybe generated on site, but will more usually be purchased from the local supply company. The
voltage at which the supply is taken or generated will depend on the demand. For a large site the supply
will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will be used to step
down the supply voltage to the voltages used on the site. In the United Kingdom a three phase 415V
system is used for general industrial purposes, and 240V single phase for lighting and other low power
requirements. If a number of large motors is used, a supply at an intermediate high voltage will also be
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Steam:
The steam for heating is usually generated in water tube boilers using the most economical
fuel level available. The process temperatures required can usually be obtained with low temperature
steam typically 2.5 bar and steam distributed at a relatively low pressure, typically around 8 bar (100
psig). Higher steam pressures, or proprietary heat transfer fluids, such as dowtherm will be needed for
The energy costs on a large site can be reduced if the electrical power required is generated on
the site and the exhaust steam from the turbines used for process heating. The overall thermal efficiency
of such systems can be in the range 70-80 %, compared with the 30-40 % obtained from a conventional
power station, where the heat in the exhaust steam is wasted in the condenser. Whether a combined heat
and power system scheme is worth considering for a particular site will depend on the size of the site,
the cost of fuel, the balance between the power and heating demands, and particularly on the availability
of and cost of, stand by supplies and the price paid for any surplus power electricity generated.
Cooling Water:
Natural and forced draft cooling towers are generally used to provide the cooling water required
in a site; unless water can be drawn from a convenient river or lake in sufficient
quantity.
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The water required for general purposes on a site will usually be taken from the local mains
supply, unless a cheaper source of suitable quantity water is available from a river, lake or well.
Demineralized Water:
Demineralized water from which all the minerals have been removed by ion exchange, is used
where pure water is needed for process use, and as boiler feed water. Mixed and multiple bed ion
exchange units are used, one resin converting the cations to hydrogen and the other removing the acid
radicals. Water with less than one ppm of dissolved solids can be produced.
Refrigeration:
It will be needed for processes that require temperatures below those that can be economically
obtained with cooling water. For temperatures down to around 10 o C chilled water can be used. For
lower temperatures, down to -30oC, salt brines are used to distribute the “refrigeration” round the site
Compressed Air:
It will be needed for general use, and for the pneumatic controllers that are usually used for
Inert Gases:
Where large quantities of inert gas are required for the inert blanketing of tanks and for purging
is usually supplied from a central facility. Nitrogen is normally used and is manufactured on site in an
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Chapter:8
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8.1 Plant location and site selection.
The location of the plant can have a crucial effect on the profitability of a project and the scope
for future expansion. Many factors must be considered when selecting a suitable site. The factors
to be considered are:
3. Transport facilities.
4. Availability of labour.
9. Climate.
1. Marketing Area:
For materials that are produced in bulk quantities such as cement, mineral acids and fertilizers
where the cost of the product per ton is relatively low and the cost of transport a significant
fraction of the sales price, the plant should be located close to the primary market. This
consideration will be less important for low volume production, high-priced products, such as
pharmaceuticals.
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2. Raw Materials:
The availability and price of suitable raw materials will often determine the plant location. Plant
producing bulk chemicals are best located close to the source of the major raw material: where
3. Transport:
The transport of materials & products to & from the plant will be an overriding consideration in
site selection. If practicable, site should be selected that is close to at least two major forms of
transport road, rail, waterway (canal or river) or a sea port. Road transport is being increasingly
efficient for the movement of personnel &essential equipment & supplies & the proximity of the
4. Availability of labour:
Labour will be needed for construction of the plant & its operation. Skilled construction workers
will usually be brought in from outside the site area, but there should be an adequate pool of
unskilled labour available locally ; & labour suitable for training to operate the plant. Skilled
tradesmen will be needed for plant maintenance. Local trade union customs & restrictive
practices will have to be considered when assessing the availability & suitability of the local
5. Utilities(Services)
Chemical processes invariably require large quantities of water for cooling & general process
use, & the plant must be located near a source of water of suitable quantity. Process water may
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be drawn from a river, from wells, or purchased from a local authority. At some sites the cooling
water required can be taken from a river or lake , or from the sea; at other locations cooling
tower will be needed. Electrical power will be needed at all sites. Electrochemical processes that
require large quantities of power; for example, aluminium smelters need to be located close to a
cheap source of power. A competitive priced fuel must be available on site for steam & power
generation.
All industrial processes produce waste products & full consideration must be given to the
difficulties & cost of their disposal. The disposal of toxic & harmful effluents will be
Type equation here.coverd by local regulations & the appropriate authorities must be consulted
during the initial site survey to determine the standards that must be met. An environmental
impact assessment should be made for each new project or major modification or addition to an
existing process.
The proposed plant must fit in with & 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: school, banks, housing & recreational & cultural facilities
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Sufficient suitable land must be available for the proposed plant & for future expansion. The land
should ideally be flat, well drained & have suitable load bearing characteristics. A full site
evaluation should be made to determine the need of piling or other special formations.
9. Climate:
Adverse climate conditions at a site will increase cost. Abnormally low temperatures will require
the provisition of additional insulation & special heating for equipment & pipe runs. Stronger
structures will be needed at locations subject to high winds (cyclone hurricane areas) or
earthquakes.
Capital grants tax concessions & other inducements are often given by the government to direct
renew investments to preferred locations, such as areas of high unemployment. The availability
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8.2 plant layout
The economic construction & efficient operation of a process unit will depend on how well he
plant & equipment specified on the process flow-sheet is laid out. The principal factors to be
considered are:
3. Convenience of operation
4. Convenience of maintenance
5. Safety
6. Future expansion
7. Modular construction
1. Costs:
The cost of construction can be minimized by adopting a layout that gives the shortest run of
connecting pipe between equipment & the least amount of structural steel work. However this
will not necessarily be the best arrangement for operation & maintenance.
Process Requirements:
An example of the need to take into account process considerations is the need to clevate the
base of columns to provide the necessary net positive suction head to a pump or the operating
5. Process Requirements:
Equipment that needs to have frequent operator attention should be located convenient to the
control room. Valves, sample points, and instruments should be located at convenient positions
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and heights. Sufficient working space and head room must be provided to allow easy access to
equipment.
6. Maintenance:
Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for cleaning
and tube replacement. Vessels that require frequent replacement of catalyst or packing should be
located on the outside of buildings. Equipment that requires dismantling for maintenance, such
7. Safety:
Blast walls maybe needed to isolate potentially hazardous equipment, and confine the effects of
an explosion. At least two escape routes for operators must be provided from each level in the
process buildings.
8. Plant Expansion:
Equipments should be located so that it can be conveniently tied in with any future expansion of
the process. Space should be left on pipe alleys for future needs, and services pipes over-sized to
9. Modular Constructions:
In resent years there has been a move to assemble sections of plant at the plant manufacturers
site. These modules will include the equipment, structural steel, piping and instrumentation. The
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8.3 Plant layout.
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CHAPTER. 9
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10.1 MSDS of Raw materials and product.
HAZARDS IDENTIFICATION
Inhalation -
Breathing high concentrations may be harmful. Mist or vapor can irritate the throat and lungs.
Breathing this material may cause central nervous system depression with symptoms including nausea,
Eye Contact -
This material can cause eye irritation with tearing, redness, or a stinging or burning feeling.
Further, it can cause swelling of the eyes with blurred vision. Effects may become more serious with
Skin Contact
May cause mild skin irritation with redness and/or an itching or burning feeling. Effects may
become more serious with repeated or prolonged contact. It is likely that some components of this
material are able to pass into the body through the skin and may cause similar effects as from breathing
or swallowing it.
Ingestion –
Swallowing this material may be harmful. Swallowing this material may cause stomach or
intestinal upset with pain, nausea, and/or diarrhea. This material can get into the lungs during
swallowing or vomiting. Small amounts in the lungs can cause lung damage, possibly leading to chronic
Secondary effects of ingestion and subsequent aspiration into the lungs may cause pneumatically
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Conditions Aggravated by Exposure -
Disorders of the following organs or organ systems that may be aggravated by significant
exposure to this material or its components include: Skin, Respiratory System, Central Nervous System
(CNS).
Target Organs –
May cause damage to the following organs: kidneys, liver, mucous membranes, spleen, upper
respiratory tract, skin, adrenal, central nervous system (CNS), eye, lens or cornea.
Carcinogenic Potential –
This product is not known to contain any components at concentrations above 0.1% which are
Take proper precautions to ensure your own health and safety before attempting rescue or
Inhalation –
Move victim to fresh air. If victim is not breathing, immediately begin rescue breathing. If
breathing is difficult, 100 percent humidified oxygen should be administered by a qualified individual.
Seek medical attention immediately. Keep the affected individual warm and at rest.
Eye Contact –
Check for and remove contact lenses. Flush eyes with cool, clean, low-pressure water for at least
15 minutes while occasionally lifting and lowering eyelids. Do not use eye ointment unless directed to
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Skin Contact –
Remove contaminated shoes and clothing. Flush affected area with large amounts of water. If skin
surface is damaged, apply a clean dressing and seek medical attention. Do not use ointments. If skin
surface is not damaged, clean affected area thoroughly with mild soap and water. Seek medical attention
Ingestion –
Do not induce vomiting. If spontaneous vomiting is about to occur, place victim’s head below
knees. If victim is drowsy or unconscious, place on the left side with head down. Never give anything by
mouth to a person who is not fully conscious. Do not leave victim unattended. Seek medical attention
immediately.
Hazardous Combustion Products - Carbon dioxide, carbon monoxide, smoke, fumes, and/or
unburned hydrocarbons.
Special Properties –
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This material releases vapors at or below ambient temperatures. When mixed with air in certain
proportions and exposed to an ignition source, its vapor can cause a flash fire. Use only with adequate
ventilation. Vapors are heavier than air and may travel long distances along the ground to an ignition
source and flash back. A vapor and air mixture can create an explosion hazard in confined spaces such as
sewers. If container is not properly cooled, it can rupture in the heat of a fire.
Extinguishing Media –
SMALL FIRE: Use dry chemicals, carbon dioxide, foam, water fog, or inert gas (nitrogen).
LARGE FIRE: Use foam, water fog, or water spray. Water fog and spray are effective in
cooling containers and adjacent structures. However, water can cause frothing and/or may not extinguish
the fire. Water can be used to cool the external walls of vessels to prevent excessive pressure, auto
ignition or explosion. Do not use a solid stream of water directly on the fire as the water may spread the
Firefighters must use full bunker gear including NIOSH-approved positive pressure self-
products and oxygen deficiencies. Evacuate area and fight the fire from a maximum distance or use
unmanned hose holders or monitor nozzles. Cover pooling liquid with foam. Containers can build
pressure if exposed to radiant heat; cool adjacent containers with flooding quantities of water until well
after the fire is out. Withdraw immediately from the area if there is a rising sound from a venting safety
pipelines. Be aware that burning liquid will float on water. Notify appropriate authorities of
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3. ACCIDENTAL RELEASE MEASURES
Flammable Liquid! Release causes an immediate fire or explosion hazard. Evacuate all non-
essential personnel from immediate area and establish a "regulated zone" with site control and security.
A vapor-suppressing foam may be used to reduce vapors. Eliminate all ignition sources. All equipment
used when handling this material must be grounded. Stop the leak if it can done without risk. Do not
touch or walk through spilled material. Remove spillage immediately from hard, smooth walking areas.
Prevent spilled material from entering waterways, sewers, basements, or confined areas. Absorb or cover
with dry earth, sand, or other non-combustible material and transfer to appropriate waste containers. Use
clean, non-sparking tools to collect Absorbed material. For large spills, secure the area and control
access. Prevent spilled material from entering sewers, storm drains, other drainage systems, and natural
waterways. Dike far ahead of a liquid spill to ensure complete collection. Water mist or spray may be
used to reduce or disperse vapors; but, it may not prevent ignition in closed spaces. This material will
float on water and its run-off may create an explosion or fire hazard. Verify that responders are properly
clothing during cleanup operations. In an urban area, cleanup spill as soon as possible; in natural
environments, cleanup on advice from specialists. Pick up freeliquid for recycle and/or disposal if it can
be accomplished safely with explosion-proof equipment. Collect any excess material with absorbent
pads, sand, or other inert non-combustible absorbent materials. Place into appropriate waste containers
for later disposal. Comply with all applicable local, state and federal laws and regulations.
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Handling
A spill or leak can cause an immediate fire or explosion hazard. Keep containers closed and do
not handle or store near heat, sparks, or any other potential ignition sources. Avoid contact with
oxidizing agents. Do not breathe vapor. Use only with adequate ventilation and personal protection.
Never siphon by mouth. Avoid contact with eyes, skin, and clothing. Prevent contact with food and
tobacco products. Do not take internally. When performing repairs and maintenance on contaminated
equipment, keep unnecessary persons away from the area. Eliminate all potential ignition sources. Drain
and purge equipment, as necessary, to remove material residues. Follow proper entry procedures,
including compliance with 29 CFR 1910.146 prior to entering confined spaces such as tanks or pits. Use
gloves constructed of impervious materials and protective clothing if direct contact is anticipated. Use
appropriate respiratory protection when concentrations exceed any established occupational exposure
level Promptly remove contaminated clothing. Wash exposed skin thoroughly with soap and water after
handling. Non-equilibrium conditions may increase the fire hazard associated with this product. A static
electrical charge can accumulate when this material is flowing through pipes, nozzles or filters and when
it is agitated. A static spark discharge can ignite accumulated vapors particularly during dry weather
conditions. Always bond receiving containers to the fill pipe before and during loading. Always confirm
Bonding and grounding alone may be inadequate to eliminate fire and explosion hazards associated with
electrostatic charges. Carefully review operations that may increase the risks
associated with static electricity such as tank and container filling, tank cleaning, sampling,
gauging, loading, filtering, mixing, agitation, etc. In addition to bonding and grounding, efforts
to mitigate the hazards of an electrostatic discharge may include, but are not limited to, ventilation,
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may be improved with the use of conductivity additives when used with other mitigation efforts,
including bonding and grounding. Always keep nozzle in contact with the container throughout the
loading process. Do not fill any portable container in or on a vehicle. Do not use compressed air for
filling, discharging or other handling operations. Product container is not designed for elevated pressure.
Do not pressurize, cut, weld, braze solder, drill, or grind oncontainers. Do not expose product containers
to flames, sparks, heat or other potential ignition sources. Empty containers may contain material
residues which can ignite with explosive force. Observe label precautions.
Storage
Keep container tightly closed. Store in a cool, dry, well-ventilated area. Store only in approved
containers. Do not store with oxidizing agents. Do not store at elevated temperatures or in direct
sunlight. Protect containers against physical damage. Head spaces in tanks and other containers may
contain a mixture of air and vapor in the flammable range. Vapor may be ignited by static discharge.
Storage area must meet OSHA requirements and applicable fire codes. Additional information regarding
the design and control of hazards associated with the handling and storage of flammable and
combustible liquids may be found in professional and industrial documents including, but not limited to,
the National Fire Protection Association (NFPA) publications NFPA 30 ("Flammable and Combustible
Liquid Code"), NFPA 77 ("Recommended Practice on Static Electricity") and the American Petroleum
Institute (API) Recommended Practice 2003, (“Protection Against Ignitions Arising Out of Static,
Lightning, and Stray Currents"). Consult appropriate federal, state and local authorities before reusing,
reconditioning, reclaiming, recycling or disposing of empty containers or waste residues of this product.
Engineering Controls
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Provide ventilation or other engineering controls to keep the airborne concentrations of vapor or
mists below the applicable workplace exposure limits indicated below. All electrical equipment should
comply with the National Electrical Code. An emergency eye wash station and safety shower should be
Personal protective equipment should be selected based upon the conditions under which this
material is used. A hazard assessment of the work area for PPE requirements should be conducted by a
qualified professional pursuant to OSHA regulations. The following pictograms represent the minimum
requirements for personal protective equipment. For certain operations, additional PPE may be required.
Eye Protection
Safety glasses equipped with side shields are recommended as minimum protection in industrial
settings. Chemical goggles should be worn during transfer operations or when there is a likelihood of
misting, splashing, or spraying of this material. A suitable emergency eye wash water and safety shower
Hand Protection
Avoid skin contact. Use heavy duty gloves constructed of chemical resistant materials such as
Viton® or heavy nitrile rubber. Wash hands with plenty of mild soap and water before eating, drinking,
smoking, use of toilet facilities or leaving work. Do not use gasoline, kerosene, solvents or harsh
Body Protection
Avoid skin contact. Wear long-sleeved fire-retardant garments (e.g., Nomex®) while working
with flammable and combustible liquids. Additional chemical-resistant protective gear may be required
if splashing or spraying conditions exist. This may include an apron, boots and additional facial
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protection. If product comes in contact with clothing, immediately remove soaked clothing and shower.
Respiratory Protection
For known vapor concentrations above the occupational exposure guidelines (see below), use a
NIOSH-approved organic vapor respirator if adequate protection is provided. Protection factors vary
depending upon the type of respirator used. Respirators should be used in accordance with OSHA
Use of this material in spaces without adequate ventilation may result in generation of hazardous levels
of combustion products and/or inadequate oxygen levels forbreathing. Odor is an inadequate warning for
hazardous conditions
Chemical Stability - Normally stable but may form peroxides when stored for prolonged time
Conditions to Avoid - Keep away from heat, sparks and flame. Forms peroxides with
prolonged storage.
7. TOXICOLOGICAL INFORMATION
Toxicity Data –
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Overexposure to cumene may cause upper respiratory tract irritation and severe CNS depression.
High-level exposure to cumene vapors significantly increases renal tubule adenoma in male rats.
Furthermore this exposure is associated with increased alveolar/broncheolar adenoma and carcinoma in
mice and with increased hepatocellular carcinoma in female mice. At this time the relevance of these
8. ECOLOGICAL INFORMATION
Eco toxicity - LC50 (fish): 1- 10 mg/l. This product is potentially toxic to freshwater and
saltwater ecosystems.
Environmental Fate - This product will normally float on water. Components will evaporate
rapidly. Aquatic toxicity values are expected to be in the range of 1 - 10 mg/l based upon data from
components and similar products. This material may be harmful to aquatic organisms and may cause
long term adverse effects in the aquatic environment. The log Kow value for this product is 3.66.
9. DISPOSAL CONSIDERATIONS
Hazard characteristic and regulatory waste stream classification can change with product use.
Accordingly, it is the responsibility of the user to determine the proper storage, transportation, treatment
and/or disposal methodologies for spent materials and residues at the time of disposition. If discarded,
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and disposal of waste material must be conducted in accordance with RCRA regulations (see 40 CFR
260 through 40 CFR 271). State and/or local regulations may be more restrictive. Contact the
RCRA/Superfund Hotline at (800) 424-9346 or your regional US EPA office for guidance concerning
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10.2 Gaseous/Liquid/Solid Waste Treatment.
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1. Screen chamber:
2. Collection tank:
The collection tank collects the effluent water from the screening chamber,
3. Equalization tank:
• The effluents do not have similar concentrations at all the time; the pH will vary
• time to timetan Effluents are stored from 8 to 12 hours in the equalization tank resulting in a
• Continuous mixing also eliminates settling of solids within the equalization tank.
• Retention time depends upon the capacity of treatment plant. (Generally 8-16 hours)
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4. Flash mixer:
3. Poly electrolyte: (0.2 ppm) To settle the suspended matters & reduce SS, TSS.
5. Clarriflocculator:
• The solid particles are settled down, and collected separately and dried; this reduces SS, TSS.
• Flocculation provides slow mixing that leads to the formation of macro flocs, which then settles
• The settled solids i.e. primary sludge are pumped into sludge drying beds.
6. Aeration tank:
• The water is passed like a thin film over the different arrangements like staircase shape.
• Water gets direct contact with the air to dissolve the oxygen into water.
• Aerobic bacteria is used to stabilize and remove organic material presents in waste.
7. Clarifier:
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• The clarifier collects the biological sludge.
• The outlet water quality is checked to be within the accepted limit as delineated in the norms of
• Through pipelines, the treated water is disposed into the environment river water barren land,
etc.
8. Sludge thickener:
• The sludge thickener reduces the water content in the effluent to 40% water + 60% solids.
• The effluent is then reprocessed and the sludge collected at the bottom.
• Partial amount of sludge is returned back to the aeration tank from thickening unit through
9. Drying beds:
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