Project Report

0n
Design a Plant to manufacture 15 Tonnes/day of FORMALIN

Submitted to

Indian Institute of Chemical Engineers

Dr H L Roy Building Jadavpur University Campus
188 Raja Subodh Chandra Mullick Road Kolkata 700 032 India

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF

ASSOCIATE MEMBER OF INDIAN INSTITUTE OF CHEMICAL ENGINEERS

Submitted by

Vishal Vilvas
Roll No 10/S-10/474
Registration No - S/111/14/34

TABLE OF CONTENTS
Title
CANDIDATES DECLARATION
CERTIFICATE
ACKNOWLEDGEMENT
STATEMENT OF THE PROBLEM
INTRODUCTION
CHAPTER-1 LITERATURE SURVEY
CHAPTER-2 DETAILED FLOW SHEET
CHAPTER-3 MATERIAL AND ENERGY BALANCE
CHAPTER-4 DESIGN OF PACKED BED CATALYTIC REACTOR

Page No.

1
2
5
20
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41

INCLUDING MECHANICAL DETAILS

CHAPTER-5 DESIGN OF FRACTIONATION COLUMN TO SEPARATE

54

37% PURE FORMALINE

CHAPTER-6 INSTRUMENTATION AND PROCESS CONTROL OF THE

72

REACTOR
CHAPTER-7 PLANT LAYOUT
CHAPTER-8 SAFETY AND POLLUTION ABATEMENT ASPECTS
CHAPTER-9 COST ESTIMATION
CHAPTER-10 DETAILED ENGINEERING DRAWING OF THE
REACTOR AND SEPARATION COLUMN
NOMENCLATURE
BIBLIOGRAPHY
DETAILED DRAWING SHEET

75
84
96
104
107
109
POCKET

FIGURE
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Figure No.
Figure1.1. Gibbs free energy v/s T for the mechanism of reaction

2.
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7.
8.
9.

proposed Cozzolino et al
Figure 3.1 Reactor Streams
Figure 3.2 Absorption Column Stream
Figure 3.3 Fractionating Column Stream
Figure 5.1. Csb, f V/S Fp graph
Figure 5.2.Gilliland Chart
Figure 5.3.Relative volatility of key component
Figure 6.1 PID of Reactor
Figure 7.1 Plant Layout

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83

Table
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Title
Table1.1. Properties of Monomeric Formaldehyde
Table 1.2 Typical Analyses and Physical properties of
Formaldehyde solutions
Table 1.3 Formaldehyde specifications
Table 3.1 Evaporator stream
Table 3.2Air Blower Stream
Table 3.3 Mixer Stream
Table 3.4 Reactor Stream
Table 3.5Absorber Liquid stream entering
Table 3.6Absorber Gases stream entering
Table 3.7 Absorber Material output (Vent gas leaving)
Table 3.8 Material Output (Solution leaving)
Table 3.9 Fractionating column Feed Stream
Table 3.10 Fractionating Column Distillate Stream
Table 3.11 Fractionating Column Residue Stream
Table 3.12 Heat for cooling the reactants from 923K to 373K
Table 3.13 Heat entering in the Absorber by gases
Table 8.1, Information about Formaldehyde
Table 10.1, Reactor Specification
Table 10.2, Catalyst Details
Table 10.3, Mechanical Design Details of Reactor
Table 10.4, Fractionating column specification

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CANDIDATES DECLARATION

I hereby certify that the work which is being presented in this project titled Design a
Plant to manufacture 15 Tonnes/day of FORMALIN in fulfillment of the requirement
for the degree of Associate Member of Indian Institute of Chemical Engineers and
submitted to Indian Institute of Chemical Engineers, Dr H L Roy Building Jadavpur
University Campus 188 Raja Subodh Chandra Mullick Road Kolkata 700 032 India,
is an authentic record of my own work carried out under the supervision of Dr. D.P. Tiwari.
The work contained in this project has not been submitted to any other University or
Institute for the award of any other degree or diploma

VISHAL VILVAS
ROLL NO. - 10/S-10/474
REGISTRATION NO.S/111/14/34

CERTIFICATE

This is to certify that the project titled Design a Plant to manufacture 15 Tonnes/day of
FORMALIN submitted by VISHAL VILVAS to Indian Institute of Chemical
Engineers, Kolkata, for the award of the degree of Associate Member of Indian
Institute of Chemical Engineers in Chemical Engineering is a record of bonafide work
carried out by him to the best of my knowledge. In my opinion, the project has reached the
standards of fulfilling the requirements of the regulations to the degree. The work
contained in this project has not been submitted to any other University or Institute for the
award of any other degree or diploma.

Dr. D.P. Tiwari

Professor & Chairman
Department of Chemical Engineering
Deenbandhu Chhotu Ram University of Science & Technology
Murthal (Sonipat)
Haryana
MIIChE No-31215

ACKNOWLEDGEMENT

It is with deep sense of gratitude and reverence that I express my sincere thanks to my
supervisor Dr. D.P. Tiwari for their guidance, encouragement, help and useful suggestions
throughout. Their untiring and painstaking efforts, methodical approach and individual
help made it possible for me to complete this work in time. I consider myself very
fortunate for having been associated with the scholar like them. Their affection, guidance
and scientific approach served a veritable incentive for completion of this work.
I am greatly thankful to Dr. D.P. Tiwari, Professor and Chairman of Chemical Engineering,
DCRUST, Murthal, (Sonipat) for his constant encouragement, valuable suggestions and
moral support. This acknowledgement will remain incomplete if I fail to express my deep
sense of obligation to my family members for their consistent help and encouragement. I
greatly appreciate support, motivation and inspiration of my Colleague during the
preparation of this project.

VISHAL VILVAS
ROLL NO. - 10/S-10/474
REGISTRATION NO.S/111/14/34