SUMMER INTERNSHIP

JUBILANT LIFE SCIENCES LTD.

Sagar Arora
2011CH10110
Group-2

ubilant Bhartia Group

Jubilant Bhartia Group is a global company encompassing a spectrum of business areas
and with a strong presence across the world.
The group operates in various sectors:-

Agro and Consumer Products- Latex, Adhesives, Emulsions

Energy- Oil and Gas Exploration
Food Works-India's largest and fastest growing
Multinational food service Company
Automobiles- Collaboration with Audi cars
Life Sciences- Pharmaceuticals and Fine Chemicals

Global positions

Jubilant Life
Sciences

1st in pyridine and its

derivatives
2nd in API of Citalopram and
Risperidone
3rd in Niacin & Niacinamide,
Allergenic Extracts

Active Pharmaceutical Ingredients, Solid Dosage

Formulations, Radiopharmaceuticals, Allergy Therapy
Products and Life Sciences ingredient.

Sales in 100 countries (mainly India, Europe China & NAmerica)

Partner of choice 19 of top 20 pharmaceutical companies

& 6 of 10 agrochemical companies recommend this group.

7 world class manufacturing facilities in India & 3 in NAmerica

Multi-location presence, best in class products.

2013-14 Turnover Rs 4600 Crore

ABOUT THE PUNE PLANT

Location- Nira Village, Maharashtra
Products Ethyl Acetate
Acetic Anhydride
Ethanol(Sold commercially
under Officers Choice
brand)
Carbon Dioxide
Biogas(Distributed to the
residents of the village for
free)
Period of Training : 12th May to 12th July
2014 (51 working days)

About the Internship

Ethyl Acetate Plant

Analysis of Material Balance

Loss calculations
Suggestions for improvement of Efficiency
Thorough study of the process details.

Acetic Anhydride Plant

Analysis of Material Balance
Process description in Brief
Suggestions to use the waste material from this plant in other plants.

ETHYL ACETATE
Produced via the Fischer Esterification of Ethanol and Acetic Acid

CH3CH2OH + CH3COOH CH3COOCH2CH3 + H2O

Ethanol used in the reaction is mainly provided by the ethanol plant in

the factory itself. However, if the usage exceeds the production,
ethanol is bought from external sources
Acetic Acid is almost totally bought from external sources and it
contributes to a major part of the expenditure of the plant.

FISCHER ESTERIFICATION

Fischer esterification is a special type of esterification by refluxing a carboxylic

acid and an alcohol in the presence of an acid catalyst.

CH3CH2OH + CH3COOH CH3COOCH2CH3 + H2O

The reaction mechanism for this reaction has several steps.

The equilibrium can be shifted to the right by removal of water.
Hence, the reaction can be accelerated by acid catalysis which acts as a
dehydrating agent.
The catalyst used was PTSA(p-Toluenesulfonic acid)
It is a strong organic acid, with the formula CH3C6H4SO3H, and is about a million
times stronger than benzoic acid.

PFD for the process

PFD:-

KETTLE REACTOR
Most of the reaction takes place
inside the kettle. The vapour
stream (A) which leaves from
the top of the kettle already
consists of 80% ester by weight.
A constant level is maintained in
the kettle(usually 70% of the
total capacity) by adjusting the
feed stream (C).
The feed consists of ethanol
and acetic acid with the
concentration of the alcohol
slightly higher than the acid,
along with the catalyst, PTSA.

MATERIAL BALANCE ON THE KETTLE

Stream
C (Feed)

Acetate
%
----

Ethanol
%

Acid %

Total
(kg/hr)

55

45

4700

A(Kettle
to Vapour
Column)

80

11

22100

D(Reflux
from
Vapor
Column)

78

12

10

19400

B(Kettle
to Liquid
Column)

15

50

35

25000

E(Reflux
from
Liquid
Column)

10

53

37

23000

MATERIAL BALANCE ON THE KETTLE

Stream

Ethanol
(Kg/hr)

Acid
(Kg/hr)

Total
(Kg/hr)

----

2585

2115

4700

A(Kettle
to Vapour
Column)

17680

2431

1989

22100

D(Reflux
from
Vapor
Column)

15142

2328

1940

19400

B(Kettle
to Liquid
Column)

3750

12500

8750

25000

C (Feed)

Acetate
(Kg/hr)

E(Reflux
2300
12200
8500
23000
from
Liquid
Column)
By calculations, it was found that:
Ethyl Acetate produced in kettle=3988 kg/hr (Total capacity of the plant=4220 kg/hr)
Ethanol consumed in kettle=2182 kg/hr
Acid consumed in kettle=1816 kg/hr

OVERALL MATERIAL BALANCE

C. Feed
The overall mass balance becomes fairly simple as there is only
one feed and one output and we do not need to take the reflux
streams into account

System

I. Back to feed

J. To Storage Tank

OVERALL MATERIAL BALANCE

Acetat Ethanol
e(Kg/h (Kg/hr)
r)

Acid
(Kg/hr)

Total
(Kg/hr)

C(Feed)

--

2585

2115

4700

I(Back to
feed)

720

56

24

800

J(To
Storage
Tank)

3500

--

--

3500

C. Feed

System

I. Back to feed

Total mass exiting the system is less than the mass entering. This is accounted by a
primer tank that stores material at around 400 kg/hr and is drained at regular
intervals.

J. To Storage Tank

OVERALL DATA
Ethanol consumed in the whole process= 2585-56 =2529 kg/hr
Acetic acid consumed in the whole process= 2115-24=2091 kg/hr
Ethyl acetate formed in the whole process= 3500+720=4220 kg/hr
OR
101.2 MT/day

PART-II OF THE TRAINING

Acetic Anhydride Plant

ACETIC ANHYDRIDE
Acetic anhydride is an organic compound with the formula (CHCO)O. This
colorless liquid has a characteristic very pungent, penetrating, vinegar-like
smell.
Acetic anhydride is prepared commercially by KETENE PROCESS.
Ketene or Ethanone is a very reactive organic compound that is formed by
dehydrating the hot vapours of acetic acid in a furnace.

CH3COOH

CH2=CO + H2O

The catalyst used is TEP(Tri-Ethyl Phosphate)

This Ketene gas is then made to flow against a liquid stream of
almost pure acetic acid for the following reaction to happen:CH3COOH + CH2=CO
CH3CO-O-OCCH3
As in the ethyl acetate plant, the main raw material that needs to be
purchased here is Acetic Acid as well.

THE FURNACE
Vapours of Acetic Acid are decomposed to form Ketene in the presence of TEP under 750 deg
Celsius.
B(To chillers)
A(96% Acetic Acid)
Furnace
Acetic Acid Water

Ketene

Total

A(In)

3483.89

145.16

-----

3629.05

B(Out)

1045.17

876.78

1707.1

3629.05

Ketene

Total

Acetic Acid Water

A(In)

96

B(Out)

28.8

24.16

-----

100

47.04

100

(All figures are in

kg/hour)

90% of the heat in the furnace is supplied by the burning of coal.

The rest is supplied by a combination of Tar, Biogas and Light-Diesel Oils.

SEPARATOR
The product of the furnace is sent to the Separator after passing
through a series of coolers and brine water chillers. The product
stream exiting the separator contains almost 100% Ketene.
B(From Chillers)

Separator

C(To Absorption Tower)

D(Recycle)

Acetic Acid Water

Ketene
1707.1

Total

B(In)

1045.17

876.78

3629.05

C(Out)

----

----

1707.1

1707.1

D(Out)

1045.17

876.78

----

1921.95

Acetic Acid Water

Ketene

Total

B(In)

28.8

24.16

47.04

100

C(Out)

----

----

100

100

D(Out)

54.38

45.62

----

100

(All figures are in

kg/hour)

ABSORPTION TOWER
C(From Separator)

E(99.8% Acid)

Absorption Tower

F(To Distillation)

The Ketene gas from the separator is made to flow against a liquid stream of
almost pure acetic acid for the following reaction to take place.
CH3COOH + CH2=CO

Acetic
Water
Acid

CH3CO-O-OCCH3
Ketene
Acetic
Total
Anhydrid
e

E(In)

2893.58

5.8

-----

C(In)

----

----

1707.1

F(Out)

454.85
Acetic
Acid

5.80
Water

---Ketene

E(In)

99.8

0.2

C(In)

----

----

----100

-----

2899.37
1707.1

4145.83
4606.48
Acetic
Total
Anhydrid
e
-----

100
100

(All figures are in

kg/hour)

DISTILLATION
COLUMN
This is usually the final stage of the process as it ends up in giving us 99.5%
Acetic Anhydride as the final product. Anhydride being the least volatile in the
mixture, is collected at the bottom.
However, if more purity is desired, further stages like separating using a third
liquid can be used(Liquid-Liquid Equilibrium), although it is not often practised.
G(Top Product)
F(From Absorber)
Distillation Column
H(Bottom Product)
Acetic
Acid

Water

F(In)

454.85

5.80

G(Out)

434.02

5.8

H(Out)

20.833
Acetic
Acid

---Water

F(In)

9.87

0.13

G(Out)

98.67

1.33

Ketene

-----

Acetic
Total
Anhydrid
e
4145.83

4606.48

---

---

439.81

---Ketene

4145.83
4166.67
Acetic
Total
Anhydrid
e

-------

90

100

---

100

(All figures are in

kg/hour)

OVERALL DATA
Total Acetic Acid entered=
Total Acid recovered=

6377kg/hr
1464kg/hr

Net amount of acid consumed=

4913kg/hr

Total amount of Acetic Anhydride formed=

4146 kg/hr
or
99.5

MT/day

Q/A
1) Which catalyst is used in the Fischer Esterification and why?

2) Why tertiary alcohols are not suitable for use in Fischer Esterification?

3)Why is a reflux of vapour used in the kettle reactor in the production of Ethyl
Acetate?
4) Which catalyst is used in the production of Acetic Anhydride?

5) Why is Acetic Anhydride chemically stable despite the dipole-dipole repulsion

between the two carbonyl oxygens?

Q/A
1) Which catalyst is used in the Fischer Esterification and why?
Ans- PTSA(p-Toluenesulfonic acid),because it acts as a dehydrating agent by providing a hydronium ion.
2) Why tertiary alcohols are not suitable for use in Fischer Esterification?
Ans- Tertiary alcohols are prone to elimination, leading to the formation of an alkene.
3)Why is a reflux of vapour used in the kettle reactor in the production of Ethyl
Acetate?
Ans- To prevent the loss of volatile compounds.
4) Which catalyst is used in the production of Acetic Anhydride?
Ans- TEP (Tri Ethyl Phosphate)
5) Why is Acetic Anhydride chemically stable despite the dipole-dipole repulsion
between the two carbonyl oxygens?
Ans- Due to the resonance stabilization by pi system linkage through the central oxygen.

THANK YOU