Report of Industrial Training

At

BASF India LTDThane site

Submitted by

Kartik Kulkarni110903014

In partial fulfillment of the requirements for the award of the degree of

BACHELOR OF ENGINEERINGIN

CHEMICAL ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY(A Constituent College of Manipal University)MANIPAL – 576104, KARNATAKA, INDIA

June 2014Index Page

Declaration 3

Acknowledgement 4

Abstract 5

Chapter 1 Introduction

1.1 PU System house 6

1.2 Training objectives 6

Chapter 2 Training Highlights

2.1 Pesol 7-12

2.2 Pre-Polymers 13-19

2.3 Blended polyol 20-24

2.4 Safety 25-27

2.5 Material safety 28-29

2.6 Hazard identification and prevention 30

2.7 Effluent treatment plant 31-32

2.8 Reactor effectiveness 33

2.9 Suggestions 34

Chapter 3 Conclusions

3.1 Conclusions 35

Chapter 4 Company Profile

4.1 History of BASF 36-37

4.2 History in India 38

2

References

DECLARATION

An Engineer is one who converts the theories of the textbooks into practical working models and

processes. We learn many things more perfectly and accurately through observations and

applications.

Learning in classes just gives us the basic idea about any process, while at the same time

industrial training helps us to understand the detailed and thorough working of that particular

process. Hence we can clearly understand the practical application of the theoretical study.

Industrial training is implemented by our college for imparting knowledge about real operations

and processes, and also to learn about working equipment.

This report contains the various unit operations and operational details of the plant. This report

has been prepared on the basis of information collected and provided during the training I

underwent at BASF India Pvt. Ltd., Thane, Navi Mumbai. The information given in the report is

true as per my knowledge and data provided by the industry.

I take immense pleasure in presenting this report and sincerely apologize for any wrong

information printed in it.

3

ACKNOWLEDGEMENT

To begin with, it is my pleasure in showing gratitude to my mentor Mr.Rajesh Shetty, without

whom this project would never have been so informative. In reference to my field work at BASF,

I am thankful to the production manager Mr. Gopinath Ganesan and my H.R. guide Mr. Sunil

Singh for providing me their immense support and precious time. I am grateful to them for

providing me excellent guidance, practical insights and valuable material that have been very

useful in my field work activities. Above all their encouragement and motivation was a driving

force which helped me perform to the best of our potential.

I would like to thank Mr. Viraj Nayak, Mr. M.K. Gupta, Mr. D.S. Sonawane, Mr. B.B. Desai,

Mr. K.D. Bhawalkar, Mr. P.J.Varghese and all other employees of BASF for providing me

opportunity to become a part of their esteemed organization and to learn various skills that will

be useful in shaping my career as a Chemical Engineer.

4

ABSTRACT

Industrial exposure is an integral part of a student’s overall education program. Most employers

rank interpersonal communication and teamwork skills, and practical experience above technical

aptitude. There’s no better way to acquire these skills than to jump into an industrial

environment.

Industrial internships are a proven way to gain relevant knowledge, skills, and experience while

establishing important connections in the field. This term work provides us with valuable

insights into the professional and industrial side of classroom skills.

This report documents all the activities and learning during my four week industrial internship at

BASF India Pvt. Ltd., Thane site. The report shall give an overview of the company’s history

and products produced in the plant assigned to me. It contains various unit operations, process

details and also equipment details of all the equipments needed in the manufacturing. The report

also provides details about the quality assurance tests, safety procedures followed in the industry

along with the different suggestions that I could give to reduce the present batch time of the

products.

5

CH 1. INTRODUCTION

1. PU SYSTEM HOUSE

BASF is the leading supplier of polyurethanes solutions for systems. The plant setup in

Thane is operational since 2007.

BASF offers a comprehensive polyurethanes product portfolio from basic products such as

polyether polyols, polyester polyols, MDI and TDI to polyurethane systems. The major

product manufactured include various grades of polyester polyol and blended polyols. The

blended polyols are further divided into rigid and flexible type.

MDI is used to manufacture both the grades of blended polyols whereas TDI is used to

manufacture only the flexible grade.

All the products are marketed under different names only known to BASF employees and the

customers.

2. TRAINIG OBJECTIVES

- To experience and understand real life situations in industrial organizations.

- To understand the process involved in manufacture of the products.

- To provide suggestions to reduce the current batch time for production process.

- To perceive safety practices and regulations in the industry.

- To understand hazard identification.

- To keep track of trends of reactors for studying asset effectiveness.

CH 2.TRAINING HIGHLIGHTS

6

1. PESOL

PRODUCTION PROCESS

Raw Materials:

Adipic Acid: available in powder form in 1000 kg Bags

1,4-Butanediol: available in liquid state in200L drums

Catalyst: stored in 50 L drums or jerry cans

Mono Ethylene Glycol (MEG): stored in storage tank in liquid form

Diethylene Glycol (DEG): stored in storage tank in liquid form

Process Description:

PESOLs are a result of condensation reaction of carboxylic acids and poly alcohols (glycols).

Water as by-product must be removed in order to shift the equilibrium towards the product.

Side reactions might occur to small Degree producing Cyclic ester, 1, 4-dioxane,

aldehydes, ether, etc.

Step-wise Procedure:

Step1: Recipe selection and Batch start phase

-Depending on schedule batch size is decided and recipe is taken from the recipe book.

-The required raw materials are brought from warehouse and kept in plant.

-The liquid raw material is loaded into storage tanks.

Step 2: Raw material pre-charging phase

7

MEG Adipic Polyester Polyol

The Adipic acid is unloaded into the silo and MEG and DEG is pumped into storage

tanks.

Step 3: Utility start-up and checking phase

-Cooling water pumps, thermic oil heater unit, chilled water unit, nitrogen supply, steam

supply, instrument air supply are started and checked.

-Vent scrubber pump is switched on and water level is checked.

Step 4: Raw material charging phase

-Reactor must be empty and bottom valve is closed and vent through scrubber is kept

open.

- The hot oil internal helical coil and external limpet are started. Stirrer is set at 50rpm.

-Reactor and silo both are inertized using nitrogen. Then MEG and DEG are charged into

the reactor. Check the silo weight.

-The jacket temperature is set at 1200C. When reactor reaches 750C then adipic acid is

added from silo.

- The jacket temperature is then increased.

Step 5: Atmospheric distillation phase

-At 1500C atmospheric distillation phase starts. Vapour temperature and reflux flow must

be checked.

- The level of water collected in water tank is monitored. If distillation column

temperature exceeds 1050C, the reflux is started. The column temperature must be

maintained at 1000C to prevent any glycol from coming into the column.

Step 6: Partial vacuum phase

-At 2000C when 80% of water generated in reactor is removed, the vacuum pump is

started. The catalyst is charged.

- Jacket temperature is increased, the vent valve is closed and bleed valve is opened when

pressure reaches around 1000-100 mbar.

Step 7: Full vacuum phase

8

-Reflux to vessel is closed. Pressure reaches 30mbar. The set temperature is reduced

according to steam table.

-After reactor reaches 2450C wait for 1hr.

Step 8: Sample checking phase

-sample from reactor is withdrawn and checked for the specifications. It undergoes tests

for viscosity, hydroxyl value and acid value.

- If sample is not within specifications then required adjustments are made.

- Excess glycol is removed.

Step 9: Cooling and vacuum breaking phase

-The vacuum pump is stopped and vacuum is broken with nitrogen gas.

- The thermic oil which is cooled using a heat exchanger is used for cooling the product.

Step 10: Transfer, cooling and packing

-The product is transferred from one reactor to other where it is allowed to cool down till

800C using cold thermic oil.

-The cooled product is then packed into drums or tankers.

Utilities:

Water cooling tower:

Counter flow induced draft water cooling towers are used to cool the hot water from heat

exchanger to a temperature of 270C. Hot water from the system enters the water cooling

tower and is distributed over the film type fills. Air is induced through the fill causing a

small portion of water to evaporate. This evaporation removes heat from water thus

cooling it. The cooled water is collected in the basin. Make-up water is added to adjust

the evaporated water.

Water chilling unit:

It is used to bring the water temperature down to 5 to 60C. It consists of a hot water well,

cold water well, compressor, condenser and a shell and tube heat exchanger for cooling

of water. The refrigerant gas is first compressed and condensed which then flows through

the tube side of heat exchanger. Hot water enters the shell side. Liquid refrigerant absorbs

9

heat gets converted to gas thus cooling the water. The chilled water is then sent for

cooling the thermic oil and also for condensing water vapour at distillation column.

Thermic fluid heater:

The thermic fluid used for heating and cooling of reaction is Hytherm 600. The thermic

fluid circulates in a coil heated by PNG inside the heater. The automatic control of the

PNG is done using a solenoid valve. Hytherm 600 is heated to 2400C by keeping the set

point at 2800C. This heated oil is then used for heating the PESOL reaction.

Vacuum:

Vacuum is necessary for the distillation and stripping operations. Vacuum is created by

water ring vacuum pump and steam jet ejector. Vacuum as low as 30 mbar is achieved.

Instrument air and Nitrogen gas:

Instrument air is required for various on/off valves, pneumatic valves etc. It is also used

to control the function of centrifugal pump in charging of raw materials. The nitrogen gas

is used for inertization of the reactors and silo before and during the reaction.

10

EQUIPMENTS DETAILS

Reaction Vessel: the plant consists of 8 reactors of varing sizes for different batch size

and product.

PESOL: two reactors (one for reaction and mixing and other for cooling)

Its capacity is 12.45 m3 and is made up of stainless steel. It has a half coil jacket and an

internal helical coil and 4 baffles. The first reactor has a pitched blade type agitator and

the second reactor has a paddle type agitator. It can withstand from 3kg/cm2 pressure to

full vacuum and a temperature of 3000C. The reactor has undergone hydrotest and

radiography test, and has a joint efficiency factor of 0.85. No corrosion allowance is

provided.

11

Distillation column:

It is a packed column type and has structured packings. The packings are of rasching

ring type. Dimension: 600x7600(mm)

Silo:

The adipic acid silo consists of unloader with nitrogen aerator. It consists of a lump

breaker having a motor of 1hp and a dust extraction system with a blower having

capacity of 200 m3/hr.

Heat Exchanger:

The plant has three heat exchangers. All are shell and tube type heat exchanger made of

stainless steel. Two of them are used as condensers to condense water vapour from

distillation tower and third one is used to cool the thermic fluid for cooling of the

product.

Tests for PESOL quality:

Viscosity test:

Sample is taken out from the reactor, cooled and some of it is placed in the viscometer.

The viscometer spindle then rotates at 60 rpm and temperature is maintained at 750C. The

viscometer displays the measured viscosity.

Acid value test:

Equipments required - analytical balance, plastic cup, measuring cylinder, magnetic

stirrer, burette, pipette

Reagents- ethyl alcohol (96%), acetone, distilled water, 0.1 N KOH, phenolphthalein

Procedure- the sample of PESOL is cooled and then mixed with a mixture of ethyl

alcohol and acetone (1:1). This mixture is titrated against 0.1 N KOH solution, in

presence of indicator phenolphthalein. Colour change marks the end point of the titration.

12

2. PRE-POLYMER

CHEMISTRY

Pre-polymer reaction –

Pre-polymers are manufactured by the conversion of a stoichiometric excess of

isocyanate with polyols and possibly further OH components according to the

following reaction equation.

R1-OH + R2-NCO R1-O-CO-NH- R2

The large scale production of Pre-polymers takes place in discontinuous mixing

vessels , whereby the isocyanate is added followed by a temperature controlled

addition of polyol. To minimize secondary reactions the temperature is kept

below 100 ⁰C.

During the Pre-polymer reaction, undesired reactions of the isocyanate can occur

under certain conditions.

i. Dimerisation of isocyanate with the formation of uretdions –

Isocyanates can interact with dimer formation. This is a balanced reaction

which is almost completely on the side of monomers at high temperatures.

These reactions are only slightly exothermic.

2 R-NCO Uretdions

ii. Interaction of isocyanates with the formation of carbodiimides –

Isocyanates can also form carbodiimides. The reaction takes place with the

splitting of CO2 and without catalyst only at high temperatures which

leads to the build-up of pressure in the reactor.

R-NCO + OCN-R R-N=C=N-R + CO2

iii. Reaction of carbodiimides with isocyanates with the formation of

uretoimines –

A further reaction of the carbodiimides with isocyanates gives rise to the

formation of uretonimines, which then causes cross-linkage. As with

dimer formation, uretone formation possesses no safety problems due to

the low reaction enthalpy.

R-N=C=N-R + R-N=C=O Uretonimines

13

iv. Trimerisation of isocyanates with the formation of isocyanurates –

Isocyanates are subject to trimerisation to produce isocyanurates. The

reaction takes place at high temperatures. It can occur at low temperatures

if the reaction is catalysed by bases such as KOH or potassium

carboxylate. The trimerisation reaction of multifunctional isocyanates

gives rise to the production of highly branched and insoluble products.

3 R-N=C=O Isocyanurates

v. Allophanate formation through reaction of isocyanates with urethane

groups –

Isocyanates can form allophanates with already formed urethane groups.

This reaction takes place in the absence of catalyst at high temperature.

Allophanate formation is catalysed by the same nucleophiles that also

accelerate the isocyanurate reaction. additionally, allophanates can react

with further isocyanate groups with ring closure whereby an isocyanurate

and an alcohol are produced.

R-NH-COOR’ + R-N=C=O Allophanate

PROCESS DESCRIPTION

RAW MATERIAL MODE OF CHARGING REMARKS

Methy Diphenyl Isocynate

(MDI)

Vacuum charging from drums

to reactor

Stored as a solid at -5 ⁰C in

cold storage. Melted at 100 ⁰C

in oven and charged under

vacuum of 500 mbar & 50-55

⁰C

Benzyl Chloride Charged through funnel on top

of the reactor

Charged under atmospheric

pressure

Polyols + Dipropyleneglycol Vacuum charging from drums

to reactor

Premixing of polyols and

dipropyeleneglycol required

before charging material at a

particular flow rate

14

(undisclosed)

Catalyst Vacuum charging from drums

to reactor

Reactor temperature to be

maintained at 50-55 ⁰C

Triphenyl Phosphate Charged through funnel on top

of the reactor

Material to be charged at a

particular flow rate

(undisclosed)

Diiso nonyl phthalate Charged through funnel on top

of the reactor

Material to be charged at a

particular flow rate

(undisclosed)

2,6-di-tert-butyl-p-cresol Charged through funnel on top

of the reactor

Material to be charged at a

particular flow rate

(undisclosed)

Raw Material testing and making ready for charging –

i. Raw Materials are tested for quality as per the requirements.

ii. Raw Materials are issued from the Warehouse and brought to reactor

using forklift and hand trolley. MDI is issued from cold storage separately.

Start up check –

i. Reactor must be clean, dry and empty.

ii. Bottom valve must be closed.

iii. Ensure that limpet circulation heating inlet and outlet and cooling inlet and

outlet valves are closed.

iv. Ensure manhole is tightly closed.

v. Isocynate quality is thoroughly checked for various parameters before

charging it since it is very toxic and hazardous.

Operating Procedure –

15

i. Vessel is purged with 30 mbar Nitrogen for maintaining inert atmosphere

for reaction.

ii. Reactor is preheated to 50 ⁰C.

iii. Reactants are charged as per the table above.

iv. Once charging is completed vacuum is broken by stopping the vacuum

pump.

v. As reaction proceeds temperature of reactor increases due to exothermic

nature of majority of Pre-polymer reactions. Optimum temperature and

pressure for all the Pre-polymer reactions was experimentally estimated as

70 – 75 ⁰C and 30 mbar. This is maintained by operating cooling

water/chilled water supply valves.

vi. Samples are taken at intervals and checked for NCO content. If found

within the specified limit, the pressure of the blender reactor is increased

to 1.5 kg/cm2 and discharging of the product is started.

Procedure followed in case of failures –

i. In case of runaway reaction – During glycol charging the rate of rise of

temperature of the reactor as well as the current flowing through the motor

of the stirrer are monitored. If the temperature rises by 5 ⁰C/minute or the

current increases rapidly charging of polyol must be stopped. Inhibitor

solution of Benzyl Chloride is added to the reactor. If the temperature or

current continues to increase the material in the reactor must be discharged

immediately while keeping the safety vent open.

ii. In case of failure of ventilation system – Charging of MDI or discharging

of Pre-polymer products must be halted while keeping the stirrer on.

iii. In case of failure of cold storage – MDI is highly toxic and its leakage in

the form of vapours can cause deadly damage. Thus, it is instantaneously

shifted to an adjacent cold storage location.

iv. In case of choking of carbon filter – If the differential pressure across the

carbon filter increases to more than 150 mbar, the carbon inside the filter

16

must be changed and replenished. The exhausted activated carbon is then

disposed as per MPCB regulations.

PRODUCTS

COSYPUR – Used for Vehicle Seats, Car Dashboards and Pillows.

ELASTOFOAM – Used for Insulations, Cushions, Car Upholstery and Pillows.

ELASTOPAN – Used in Footwear (Uses Polyether as raw material).

LUPRANATE – Used in Footwear (Uses Pesol, that is, Polyester as raw

material).

QUALITY CONTROL

Test for NCO Content:

i. 2 grams of sample is added to toluene (acts as a solvent) and a known

quantity of dibutylamine.

ii. The above solution is stirred for 15 to 30 minutes to make it

homogeneous.

17

iii. sSome dibutylamine is consumed in the above reaction. The quantity

remaining is found by titration with an acid of known concentration.

iv. Potentiometric Titration is performed using an Electronic Auto Titrator

apparatus.

v. End point of Titration is reached when there is a sudden jump in the value

of the potential measured.

vi. The software displays the values of the volume of acid utilized and the

%NCO content in the sample.

Other Tests performed for Pre-polymers include the OH test and the Amine Test.

However, these tests are performed for very selective grades and hence were not

studied in depth.

EQUIPMENTS

Reaction Vessel –

It is made up of stainless steel. It has a geometric volume of 13.75 m3 and an

operating capacity of 10 m3. It has 2 baffles and is designed to withstand from 5

barg pressure to full vacuum and a temperature of 190 0C. The operating pressure

ranges from 1 barg to 5 barg and the operating temperature ranges from 80 - 90 0C. The reactor has undergone hydrotest and radiography test. It has a joint

efficiency factor of 1.00. No corrosion allowance is provided.

Stirrer/Agitator –

Pitched/bolted blade stirrer with variable frequency drive is used in the reactor. It

has 4 impellers at the top and 2 impellers at the bottom. It operates at an RPM of

87.

Limpet Heating Coils –

They are designed to withstand a pressure of 5 bar(g) while the working pressure

is 3.5 bar(g). They have a pitch of 300 mm. They have a joint efficiency of 0.7

and are not provided with any corrosion allowance. They have a total heat transfer

area of 11.7 m2.

18

Valves –

There are six types of valves used in this process. They are Globe Valve

(example), Gate Valve (example), On-Off Valve (example), Three Way Valve

(example), Pneumatic Valve (example) and the Diaphragm Type Valve

(example).

Temperature and Pressure indicators –

There are various temperature and pressure indicators in the system which

transmits the values of the temperature and pressure at different points via PLC

(programmable logic controller) to the PC in the control room. This permits more

efficient monitoring of the temperature and pressure in the system.

19

3. BLENDED POLYOL

PROCESS

- There are four blenders in the PU plant. The blenders are used to carry out blending for various

polyol systems.

- Raw materials are used in various combinations to obtain various blended products which are

customer specific .

Raw Material Used Mode of Charging Remarks

Polyol Shuttle block pump for tanks/

AODD pump for drums

Requires heating before

charging

Catalysts Through charging funnel at 10

meter level

Pre-weighing is done in

carboys in the room

Additives Through charging funnel at 10

meter level

Pre-weighing is done in

carboys in the room

Blowing Agents From the bottom of the reactor

with AODD pump

Requires low temperature in

the reactor

Flame Retardants From the bottom of the reactor

with AODD pump

Requires low temperature in

the reactor

DM Water From DM water tank N/A

Steps Of Reaction-

1. Raw material is tested and then is made ready for charging.

2. Raw material charging and blending

- Polyol is charged from tanks or drums.

- Flame retardant adition(Product Specific)

- Catalyst additive charging.

- Blowing agent charging.

20

- DM water addition.

3. Sampling and corrections. Quality assurance is done to check if the product is consumer

specific.

4. Filling and packing. The product is packed and transported to the customers.

PRODUCTS

Type Application

Elastocool Appliances

21

Elastoflex Cushions and Insulations

Elastofoam Insulations

Elastopan Footwear

Elastopor Construction

Elastopir Construction

QUALITY CONTROL

* Blended Polyol Rigid Type

1. Moisture Test

- The sample collected is titrated with Karl Fischer reagent and dried methanol.

- The reaction is handled by an automated computer programme..

- Moisture content is showed and is verified for the specific sample.

2. Cup Test

- Sample is cooled and mixed with cyclopentane and is stirred till formation of foam.

Cyclopentane acts as a blowing agent.

- Blend is cooled and methyl diphenyl isocyanite is added. This mixture is agitated.

22

- The foam starts rising and poked with a sharp object to notice thread formation.

- Foam is left to harden and rise time and gel time are noted down.

* Blended Polyol Flexible Type

1. Cup Test

- Blended polyol is cooled and isocyanide is added. The mixture is agitated and foam is formed.

- The foam initially rises and when co2 escapes the foam settles back.

- The rising time/settling time/height are measured using ultrasonic sensors connected to the

computer. The specifications are verified.

2. Cushion Test

- Blended polyol and isocynaide is agitated for 6 sec at 1000-1500 RPM.

- It is immediately transferred into a pneumatic mould which is pre heated to 58oc.

- The mould is sealed for 5mins. After the cushion is removed it is tested using a compression

machine which gives the compression for a specific force.

EQUIPMENT SPECIFICATIONS

- Reaction is done in a agitated reactor with torispherical head

- Coil jacketed type.

- MOC: Stainless Steel.

23

- No corrosion allowance. Joint efficiency is 0.85

- Can withstand pressure of 3kgf/cm2 and temperature of 100oc.

- Tests applied are Vacuum test, Radiography and Hydro test.

- Agitator used is (2x3) anchor type. It has 2 turbofoil and 1 pitched blade at the bottom. The

wetted parts are made of stainless steel and the non-wetted parts are made of carbon steel.

- Empty weight is 4000kg.

- Reaction temperature is 70oc.

4. SAFETY

*SAFETY AND POLLUTION CONTROL

24

Safety cannot be compromised by any of the employees. BASF is having a Full-flegged Saftey

Department with qualified safety officers in a safety committee . Meetings are held regularly and

various problems are discussed. Recommendations are circulated to the concerned departments.

- Adequate safety budgets are made and company has a constant pattern of expenditure on

safety related issues.

- Accidents and incidents are investigated and records are kept. All the employees are

informed about the cause of the accident

- Internal safety inspections and external safety audits are done frequently.

- Safety education and training are given to each employee in detail.

- Awareness of safety is displayed through notice boards and pamphlets and also accident

free days are displayed.

- Hazard identification and control measures are carried out once a month.

- Work permit system exists in the factory. Hot work, confined space entry, digging snd

general permits are available and are followed strictly.

- Waste disposal system of various type of water is also available.

- Mock drills are conducted once in six months

- Fire prevention equipments like hydrant water systems and fire water pumps has been

used to ensure safety of every corner of the plant.

- BASF has set an occupational health center (OHC) in the premises and also houses full

time doctors and an ambulance is always kept on stand by.

25

- As a part of safety program all the pipe lines are color coded as per international norms.

Fluid Color Code

Cooling water Green

Nitrogen Yellow

Instrument Air Sky blue with blue band

Vacuum Sky blue

Fire Hydrant Red

Process Air Sky blue with silver band

Waste Water Green with blue and orange band

Process Water Green with white band

Vent Light brown

- DCC(Disaster Control Centre) is a special program initiated by the chairperson of BASF,

For the safety of its employees at any time and hour of the day. It is a special team spread

confined to only Mumbai currently but aims at every part of the country where BASF has

its mark. Let it be a mass riot or a major accident, the DCC panel would get you out of it

once you inform them about the situation.

26

*PERSONAL PROTECTIVE EQUIPMENT

SR.NO PROTECTION TYPE OF APPLIANCES

1 Head Safety helmets

2 Eye Safety goggles, Welder’s

goggles, Chipper’s goggles

3 Face Face shields, Face masks

4 Hands Specific hand gloves

5 Body Full body aprons, Boiler suit

6 Ear Ear plug

7 Foot and Leg Safety shoes

8 Respiratory Face masks with filter, Gas

masks with canisters.

9 Protection from falling Safety belt

5. MATERIAL SAFETY

Chemical Hazards Protection

Diethylene Glycol Acute oral toxicity, acute

dermal toxicity, slightly

flammable in presence of

Use adequate PPE, in case of fire use

dry chemical powder or foam but not

water jet.

27

open flames and sparks

Monoethylene Glycol Acute toxicity of vapour,

carcinogenic effects,

mutagenic effects, acute oral

toxicity

Adequate PPE required while

handling, must be kept away from

strong acids and bases, water jet

extinguisher must not be used to put

out fire

Adipic Acid May cause eye irritation,

coughing, sneezing. On

ingestion may cause

diarrhoea

Proper PPE must be used

Tetrahydrofurane (by

product of reaction)

Highly flammable,

hazardous if ingested or

comes in direct contact with

skin

It is removed as a distillate during

vacuum phase

1, 4- dioxane Hazardous to aquatic life,

poses problem in water

treatment

Removed as distillate in ambient

pressure phase

Benzoyl Chloride Harmful if inhaled, irritant to

eyes, toxic to aquatic

animals

Adequate PPE must be used, extreme

heat must be avoided

2,6-ditert butyl-p-

cresol

Toxic to aquatic animals Avoid heat and accidental leakage or

spillage into drains

Di-propylene glycol No hazard PPE is necessary

Triphenyl phosphate Toxic to aquatic organisms,

irritant to skin and

respiratory system

Adequate PPE, avoid spillage and

leakage

28

Elastopan/ Elastocool Harmful is inhaled or

ingested

PPE necessary

Elastopor Dangerous for ozone layer Do not let spillage or leakage to

enter drains

Elastoflex Harmful to aquatic

organisms

High spillage precautions must be

taken

Lupraphen No hazard General PPE necessary

6. HAZARD IDENTIFICATION AND PREVENTION:

Hazard Identification is the process of identifying hazards in order to plan for, avoid, or

mitigate their impacts. Hazard identification is an important step in risk assessment and risk

management. BASF with the aim of ensuring and continuing to develop safe working conditions

strictly follows issuing of safety work permit and concept of yellow card.

Certain safeguards that normally protect the worker may have to be removed when repair or

maintenance work is performed. When this occurs, the hazards involved need to be identified

and a safe work system developed to eliminate or control these hazards. A safe work permit is a

written record that authorizes specific work, at a specific work location, for a specific time

period. Permits are used for controlling and co-ordinating work to establish and maintain safe

working conditions. They ensure that all foreseeable hazards have been considered and that the

29

appropriate precautions are defined and carried out in the correct sequence. There are four basic

type of work permit available in the plant: general work permit, confined Space work permit,

height work permit and hot work permit.

During the internship I learnt to fill, document and maintain the safe work permits, thus gaining

knowledge about hazard identification and prevention.

SAFETY MEETING:

Safety meetings are organized every month to discuss the production issues, reported yellow

cards and action taken against the complaint and follow ups, safety trainings conducted, changes

(addition/ deletion) in the plant equipments, etc.

The meeting I attended started with the declaration of remarkable production achieved in the

month of May. The workers were motivated and everyone was thanked for their contribution.

The meeting proceeded to discuss two major issues, lack of man power and space limitation for

storage of materials. Next all the yellow cards reported were discussed along with the

appropriate action taken. Pending issues of previous meeting were addressed and their status was

discussed. The emergency numbers, assembly point details and safety pledge were revised.

7. ETP-EFFULENT TREATMENT PLANT

Effluent generated from the plants is collected in the effluent collection pits placed across the

site and then pumped to the ETP for treatment.

Effluent is treated in three stages

1. Primary treatment (physio- chemical treatment)

2. Secondary treatment ( Biological treatment)

- Anaerobic treatment.

- Aerobic treatment.

3. Tertiary treatment.

30

Primary Treatment

- Removal of oil and grease is done.

- The suspended solids are removed.

- The equalization and neutralization of effluent is done.

Secondary Treatment

- Removal of COD and BOD and ammonical nitrogen is done.

- Aeration tanks are provided.

- Microbes decompose organic matter in presence of air.

- Excess sludge is wasted and thickened in the decanter.

Anaerobic Treatment

- Effluent water of high COD comes here.

- Soda ash is used for neutralization.

- PH is maintained at 11.

- Anaerobic reactor is a fluidized bed of sand.

- Sand is supported by rock at bottom.

- Feed enters from the bottom.

- The filtrate is fed to the aerobic reactor.

Aerobic Treatment

- The treatment takes place due to the activity of bacteria in presence of oxygen.

- PH is maintained at 9-10.

- There are two tanks used for the process. In the first tank batch is made ready by

adding chemicals and in other tank only effluent water is present.

- The effluent is pumped to a first stage clarifier.

- Solid waste will settle down and clear water will pass through.

- Clear liquid is fed to the aeration tank.

- Here the COD decreases from 8000 to 800.

31

- Following materials are added to the aeration tank for developing bacteria. Food, Di

ammonium Phosphate, Urea and Starch.

- Water is now fed to second stage clarifier.

- In this clarifier there is one agitator present which keeps moving slowly.

- The pure product is fed to the Poly Aluminum Tank.

Tertiary treatment

- Fenton treatment is given to the effluent from secondary treatment.

- Ferrous sulphate and hydrogen peroxide are added.

- Effluent is then treated with lime.

- Clarified effluent is then sent to sand and activated carbon filter.

- Carbon and sand acts as an absorbent and absorb impurities.

- The Treated effluent is finally drained into the MIDC drain through V-notch

chamber.

8. REACTOR EFFECTIVENESS

ABOUT THE SOFTWARE

The Software was developed using MS Excel.

A database of possible reasons for delay in batch time of the reactor was created.

Each possible reason in the database created above had a rate of loss of tonnage

(of product) associated with it.

32

Another database containing all the products manufactured in every reactor and

the theoretically calculated batch time for each of these products was maintained.

APPLICATION

Weight indicators on each reactor continuously transmitted the measured values

to a PC in the Control Room of the Plant.

A plot of Weight v/s Time was generated by the PC.

This plot was carefully monitored and the actual batch time was noted along with

all those time periods wherein the reactor was not utilized (indicated by constant

weight of the reactor).

By referring to the company logbook, the aforementioned delays were attributed

to the pre-decided reasons from the database.

Thus, for every product (every new batch) the departure of actual batch time from

the estimated batch time was accounted for and the Reactor Effectiveness was

obtained.

A bar chart of %Effectiveness v/s Batch Number and %Effectiveness v/s Month

were then simulated for company records.

9. SUGGESTIONS

- Conveyor Belts can be used to transport drums for charging and discharging

thus reducing the time required and increasing the efficiency. Automated filling

33

machines can be used instead of manual charging. Fork lift related accidents will

reduce because of lesser frequency of its usage

- In pesol production, MEG and DEG are first charged into a smaller vessel and

then charged into the reactor. Time is wasted because the amount of DEG and

MEG required for a single batch far exceeds than what the tank can store. Thus

increasing the capacity of the tank or introducing another tank to meet the

requirements of the reaction.

- Pesol required for pre-polymers and blending is imported externally. The pesol

produced in the plant is directly sold. Pesol can be produced in the plant and

directly charged into reactors or stored in the storage tanks. By doing so the time

taken for charging will be lesser than that of charging through drums. Constant

supply of pesol will also be available at all times. Cost and batch effectiveness

increases.

- Delay due to manpower is the biggest issue for blending polyols. So keeping 2-

3 contractors only for charging and discharging of polyols will increase the

effectiveness of the procress. Thus more batches can be produced and the revenue

of the company will increase.

CH 3.CONCLUSION

34

In conclusion, there were many things that I learned and experienced during the

four weeks of my industrial training at BASF India LTD, Thane site. The whole

industrial training was interesting, challenging and application oriented. Through

this training I was able to gain more insight and more comprehensive

understanding about the real industrial working conditions and practices. This

training period has also provided me with opportunities to develop and improve

my soft and functional skills. All of this valuable information and knowledge

were not only acquired through the direct involvements in the tasks given but also

by other aspects of training such as work observation of seniors and also through

logical and instructive interaction with them. It is known for a fact that the

industrial training program is the best way to prepare a student for facing a real

working life and I completely agree with it. As a result of this, I have gained

immense confidence to enter the employment world and build my future career.

35

CH 4.COMPANY PROFILE

1. HISTORY OF BASF

BASF GROUP:AT A GLANCE

We are the world’s leading chemical company: The Chemical Company. Nearly 111,000

employees work at the BASF Group. Our broad portfolio is arranged into six segments:

Chemicals, Plastics , Performance Products, Functional Solutions, Agricultural Solutions

and Oil & Gas.

-Markets and sites

BASF has subsidiaries in almost eighty countries and supplies products to a large number of

business partners in every part of the world. In 2011, we achieved 53% of our sales with

customers in Europe, of which 30% were in oil&gas. In addition 19% sales were generated in

North America and 20% sales in Asia Pacific. Our Verbund site in Ludwigshafen is the largest

integrated chemical complex in the world.

Organization of the BASF Group

- BASF’s six business segments contain 15 divisions which bears the operational

responsibility and manage our 70 global and regional business units. The divisions

develop strategies for the business units and are organized according to products.

36

- The regional divisions contribute to the local development of our business and help to

exploit market potential. They are also responsible for optimization of infrastructure for

our business. For financial reporting purposes, our divisions are grouped into regions.

- Three central division and 5 corporate departments provide group wide services such as

finance, investor relations, communications, human resource, research, engineering and

management.

BASF Group- Strategy and Values.

- BASF aims to strengthen it’s position in the world as the world’s leading chemical

company. We describe this in our” We create chemistry” strategy, which we presented in

November 2011. This strategy is based on our success in recent years and define

ambitious goals for our future.

BASF Purpose- ‘ We create chemistry for a sustainable future’.

BASF- Strategic Principle. -We add value as one company.

- We innovate to make our customers more successful.

- We derive sustainable solutions.

- We form the best team

37

2. HISTORY IN INDIA.

Establishing a strong India presence.

BASF India Ltd was first incorporated as R.A. Cole Private Limited. It was first involved in the

production of Expandable Polystyrene. With this BASF took first step into the manufacturing .

Over the years BASF India’s product portfolio steadily grew. Because of this the first production

site was opened in Thane, India. In 1986 BASF was listed on the Bombay Stock Exchange &

was listed on the National Stock Exchange in 1995.

The Manglore site which was opened in 1996 is currently the largest manufacturing site on India

and South Asia.

Thane site- Plastic Chemicals.

- BASF India Limited started operations at the Thane site in Navi Mumbai 1967. It is the

first production site of the company in India and currently focuses on the production of

engineering plastics, Polyurethanes , Performance chemicals, care chemicals,

construction chemicals, dispersions, pigments and styropor.

- This site houses five plants and technical application centre’s for textile, leather , pharma,

engineering plastics and polyurethanes.

38

REFRENECES

- www.india.basf.com

- Process manuals from the plants

- www.google.com

- Material safety data sheet

39