ACKNOWLEDGEMENT

I have taken efforts in this In-plant training. However, it would not have been possible without
the kind support and help of many individuals in the pharmaceutical company Jubilant Generics
Life Sciences. I want to take this opportunity to thank you for your guidance and supervision
during my internship experience with Jubilant Generics Life Sciences. Your guidance assisted me
to gain hands on work experience that you just can’t get in the classroom, as well as my ability to
implement individual assignments and hence built my confidence. The experience was more than
I could have expected and allowed me the freedom to develop.

I am highly indebted to Mr. Anantha Gowda (Head Human Resource), for believing in my ability
and gave his full support by accepting my request in doing internship at Jubilant Generics Life
Sciences, Nanjangud, Mysore.

I want to express my deepest gratitude to Mr. S. Lakshminarayanan (Technology Transfer

Head) , for considering me an eligible candidate for this internship & for allowing me to visit the
plant and for seeing that all the necessities are explained to me by providing me an excellent
guide.

I express my sincere and heartfelt thanks to Mr. Vivin Fernandes (Senior Manager-Pilot Plant) &
K.Narendra Prabhu (Senior Manager-Pilot Plant), who put their faith and confidence in me
giving me an opportunity to attribute the level of this training to their encouragement and effort.
Thank you again for your guidance and constant supervision as well as for providing necessary
information regarding the plant & also for your support in completing the training.

And most importantly I would like to thank Mr.Santhosh Kshirsagar (Manager-Technology

Transfer) for this invaluable experience and without his support this training would not have
been completed or written .Thank you again for your suggestions regarding my future education
and career. I am truly grateful for the opportunity you provided me .As I move forward in my
professional endeavors, I will take with me all that I learned under your guidance. I can only
hope that I find full time employment with a firm that is as competent and experienced as
Jubilant Generics.

I also want to thank the entire staff in the Pilot plant for taking the time to share their expertise
and knowledge of the field. It was through these times that I felt I was able to learn and grow the
most in developing my skills. The staff was most responsive to my requests and always made me
feel like a full-time member of the group. I would like to express my special gratitude and thanks
to industry persons for giving me such attention and time.

I would also like to express a deep sense of gratitude to prof. Dr. M.P. Rajesh, Head of the
Department, Chemical Engineering, SRM University, for his support.
 TABLE OF CONTENT

1. Introduction

2. Jubilant Generics Life Sciences-The Pharmaceutical Company

3. Utilization of Resources in the Plant

3.1. Plant Layout

3.2. Process Description

3.3. Utilities used in Pilot plant

4. The Safety Data Sheet

5. Generation and Control of Static Electricity

6. Determination of UA for Different Reactors

6.1 Stainless Steel Reactor

6.1.1 Cooling water

6.1.2 Hot water

6.2 Glass Lined Reactor

6.2.1 Cooling water

6.2.2 Steam

6. Conclusion

7. Bibliography
 INTRODUCTION

Sustainability is at the core of our business. Jubilant Life Sciences believes that addressing the
challenges of the future rests on the Triple bottom line of Sustainability. Long term sustainability
can be achieved by reducing environmental footprint and increasing economic as well as
community development footprint.

At Jubilant Life Sciences, they uncompromisingly adopt an approach which defines

sustainability as ’Business as usual‘ Their promise of Caring, Sharing, Growing along with our
stakeholders, is the essence of all their activities that are directed towards sustainable growth.
Pilot plants are used to reduce the risk associated with construction of large process plants. They
do this in several ways:

A. Computer simulations and semi-empirical methods are used to determine the limitations of
the pilot scale system. These mathematical models are then tested in a physical pilot-scale plant.
Various modeling methods are used for scale-up. These methods include:

1. Chemical similitude studies

2. Mathematical modeling

3. Aspen/Hysys modeling

4. Finite Elemental Analysis (FEA)

B. They are substantially less expensive to build than full-scale plants. The business does not put
as much capital at risk on a project that may be inefficient or unfeasible. Further, design changes
can be made more cheaply at the pilot scale and kinks in the process can be worked out before
the large plant is constructed.

C. They provide valuable data for design of the full-scale plant. Scientific data about reactions,
material properties, corrosiveness, for instance, may be available, but it is difficult to predict the
behavior of a process of any complexity. Engineering data from other process may be available,
but this data cannot always be clearly applied to the process of interest. Designers use data from
the pilot plant to refine their design of the production scale facility.
 JUBILANT GENERICS LIFE SCIENCES -PHARMACUETICAL
COMPANY

Jubilant Life Sciences Limited is an integrated global pharmaceutical and life sciences company
engaged in manufacture and supply of APIs, Solid Dosage Formulations, Radiopharmaceuticals,
Allergy Therapy Products and Life Science Ingredients. It also provides services in Contract
Manufacturing of Sterile injectables and Drug Discovery Solutions. The Company’s strength lies
in its unique offerings of Pharmaceutical and Life Sciences products and services across the
value chain

Their success is an outcome of strategic focus on the pharmaceuticals and life sciences industry,
moving up the pharmaceutical value chain for products and services across geographies,
constantly investing in various growth platforms and promoting a culture of innovation.

They are engaged in continuous improvement of products and processes to enhance the quality
of production and cost competitiveness in order to build value for our customers. Jubilant Life
Sciences serves its customers globally with sales in over 100 countries and ground presence in
India, North America, Europe and China. We are well recognized as a ‘Partner of Choice’ by
leading life sciences companies worldwide. Jubilant has relationship with 19 of Top 20
pharmaceutical companies and 6 amongst top 10 agrochemical companies across the globe.

Over the years, Jubilant Life Sciences has extended its footprint beyond India in the USA,
Canada, Europe, and other countries across the globe. We have also expanded the business by
building capabilities internally, through strategic expansions and acquisitions This resulted in a
network of 7 world class manufacturing facilities in India and 3 in North America and a team of
around 6200 multicultural people across the globe with ~ 1300 in North America and ~1000 in
R&D.

Their multi-location presence helps them in getting closer to customers and serving them better
with the best in class products developed most efficiently, economically with speed to market.

Jubilant Life Sciences' progress in diverse businesses has been made possible through the
contribution of R&D; for quality, non-infringing process for product development and cost
reduction through process innovation. Innovation at Jubilant is backed by strong chemistry, bio
science expertise and the knowledge bank created over the years. They have harnessed our
strengths – a strong R&D team, modern R&D facilities, command over cheap technologies and
economies of scale into a synergistic organic entity, continuously creating and nurturing high
quality products and technologies.

In line with Jubilant Life Sciences continued focus on sustainability of business, we aim at
improving stakeholder value through improved eco efficient use of capital and natural resources.
Jubilant’s approach to sustainable development focuses on the triple bottom line of Economics,
Environment and Social performance. They are committed and working on various areas for
energy conservation and climate change mitigation. Their sustainability efforts have been
reported through a Corporate Sustainability Report since 2003 and this report has been receiving
GRI G3.1 A+ level & GRI Check, since 2007 from Global Reporting Initiative (GRI). This
reflects Jubilant Life Sciences commitment towards sustainable development and continued
efforts directed towards protecting the environment wherever we operate.

Corporate Social Responsibility is an integral part of how Jubilant Life Sciences conducts
business and how the efforts are directed towards community development through focus on
primary education, basic healthcare service, and livelihood generation programs focused on
improving the employability of women and local youth.

They have been recognized with several awards and recognitions, which bear testimony to their
commitment towards operational excellence, innovation, corporate governance and social
responsibility.

Jubilant Life Sciences is committed to leverage innovation and scale of operations at every step
of the pharmaceutical value chain to deliver value to our stakeholders.

Global leadership position:

Globalposition#1
l. Carbamazepine (Nanjangud)
2. Oxcarbazepine (Nanjangud)
3. Lamotrigine (Nanjangud)
GlobalPosition#2
l. Citalopram (Nanjangud)
2. Risperidone (Nanjangud)

GlobalPosition#3
l. Niacin & Niacinamide (Bharuch)

Global Manufacturing Footprints:

Cadista: Generic Formulations-Salisbury, Maryland
HollisterStier:CMO-Sterilelnjectablesandnonsterile-
Ointments,creanrs,liquids,AllergenicProducts-Spokane,Washington
Draxis: Kirkland, Quebec
CMO—Sterile lnjectables and non-sterile products
Specialty Pharma :Radiopharma

Jubilant Nanjangud Plant is APl manufacturing facility that plays important role in ensuring our
cherished Goal of Health to all.

Six Production Blocks

Plant-1 Plant-2
Plant-3 Plant-4
Plant-5 Plant-6 Pilot Plant

Jubilant Nanjangud site

 PLANT LAYOUT

PILOT PLANT PLANT-3 PLANT-2

Plant-3
STORES

PLANT-5
PLANT-1

PLANT -4
OHC

PLANT-6 ENGG
STORES ADMINISTRATION

ROLE OF A PILOT PLANT

This report focuses on the relatively small-scale development operations found in the
pharmaceutical and fine chemical industries. These usually entail manual batch operation of
processes that are often not fully defined, in standard chemical reactors from, say, 20 liters to 200
gallons. Even with the increasing role of automated bench-scale reactors in process development,
most processes will be tested in the pilot plant before reaching commercial scale.

Here are some important functions that a pilot plant can perform in process development:
1. Produce raw materials and intermediates to supply further development work.
2. Produce developmental quantities of new compounds for evaluation, toxicity testing,
safety and stability studies, clinical trials, and introduction into the market. Often the first
few kilograms of a new compound are the most difficult to make, since an optimized
route has not yet been developed.
 3. Demonstrate that processes can be successfully scaled up and that there are no
unexpected ramifications of extended operating times, slower rates of addition or mixing
effects at larger scale.
4. Ensure that no important details have been overlooked.
5. Test the effects of using commercial-grade raw materials and solvents.
6. Identify the best ways to handle and analyze reactants, intermediates, products, waste
streams and off-gases.
7. Check the effect of the buildup of impurities in recycle streams and other long-term effects.
8. Test materials of construction.
9. Complete a more detailed mass balance, and obtain better estimates of yield and effluent
stream generation.
10. Help to better estimate process costs and increase management confidence in investing for
full-scale production.
11. Obtain design data and optimum operating parameters for specifying larger-scale
equipment.
12. Train members of the technology transfer team preparing for commercial production.
13. Help develop a comprehensive and detailed operating procedure for transfer to
manufacturing.

Often, using large-scale glassware is the first scale-up step, but this can be extremely dangerous
if mixing is not reliable and if the glassware must be handled manually. It is not easy to cool such
equipment, and a spill can be a disaster resulting in exposure to flammable solvents or toxic
gases. These issues are much more easily controlled using properly designed glass or stainless
reactors in an explosion-proof environment.

Scaling up a chemical process early in its lifetime can be helpful in identifying potential scale
issues that may require engineering assistance or special equipment to handle, in identifying the
rate limiting steps, and in giving a feel for the overall workability of the process. Scaling up too
early, of course, risks process changes and wasted time and resources. Involving team members
of various disciplines early reduces the likelihood that process changes will be needed later.
For countless reasons, investment in proper pilot facilities is well worth it. Often, the pilot plant
will soon prove itself so useful that it won't be able to keep up with the demand. Flexibility is
one of the keys to success. Priorities shift, projects are added or dropped and synthetic routes are
often altered on the fly. The pilot plant must be able to adapt. The facility should be able to
handle a variety of processes safely with a minimum of special equipment. Equipment should
offer wide corrosion resistance, and should be easy to clean to prevent cross-contamination
between batches and products. Space should be available for experimental setups. And
pharmaceutical pilot plants need to accomplish all this within the added constraints of GMP
operation (see page 1-16). The following pages explore some important thoughts and concepts
that will help you maximize the utility of your pilot plant and take full advantage of its
tremendous value.

Notes on GMP:
Good Manufacturing Practice (GMP) is a detailed set of guidelines and procedures used by
pharmaceutical manufacturers to ensure that they can consistently make active pharmaceutical
product (API) that meets its purported quality specifications. It is sometimes called "cGMP" for
current GMP to reflect its state of ongoing revision. Thus there is considerable flexibility in how
the goals of GMP are accomplished. To help meet FDA requirements, the industry has adopted a
set of guidelines established by the Pharmaceutical Manufacturers Association (PMA). These
guidelines advise manufacturers on the many aspects of drug development, testing,
manufacture, quality assurance, quality control and documentation.
It is not possible to present all the details of the PMA guidelines here, but a brief listing of the
key areas regulated by GMP may be useful. Note that written, approved Standard Operating
Procedures (SOPs) must be in place for all operations, no matter how minor, in order to help
ensure consistency and minimize differences in approach between personnel. In general,
complete documentation must show that the following systems are in place.
Personnel and Training - All personnel involved in the manufacture, testing, packaging and
labeling of drug products have the education, experience, qualifications and training to
perform their functions and follow applicable SOPs; personnel training program with
regularly scheduled sessions and training records retention system are in place.
Buildings and Facilities - Buildings and facilities designed and qualified for the manufacture
of drug substances; layout minimizes cross contamination and mix-ups; air handling and dust
control systems, temperature and humidity controls, microbial and pest control systems,
sanitation and housekeeping programs are in place.
Research, Development and Scale-Up - Experimental design, data collection, notebooks and
reports support the selection of the process; all major process changes are supported by a
reasonable rationale; process control implementation program is justified; critical process
parameters and quality attributes are identified; data demonstrate equivalence in purity at various
scales.
Material Control - Procedures for ordering, receiving, labeling, quarantine, sampling, testing,
release, storage, expiration dating and disposition of all raw materials, product, and other items
used in the process; suppliers are qualified.
Equipment Qualification - Documentation of completed Installation and Operational
Qualification; procedures for equipment change control, maintenance and repair; validated
cleaning protocols and results; Instrument calibration schedule in place and calibration
records available.
Manufacture Control - Approved batch records and procedures for documenting deviations;
in-process testing, including validated test methods and criteria for acceptable results;
procedures for investigating and documenting failed batches and yield discrepancies;
justification for reprocessing and 2nd-crops; computerized control systems validated.
Quality Control - Validated analytical test methods; system suitability tests, determination of
sensitivity and limits of detection; primary and secondary reference standards established;
sample retention; stability testing program, including accelerated stability testing, forced
degradation studies, isolation and characterization of degradation products.
Raw Material and Intermediate Specifications - Sampling protocols; establishment of
criteria for identity, purity and strength with validated test methods; supplier approval; release
and reject procedures; expiration dating system; testing schedule, sampling methods and
quality standards for purified water systems.
Product Specifications - Written rationale for all specifications; identification of relevant
physical characteristics, including crystalline form, impurities, homogeneity and microbial
contamination; stability studies; expiration dating; labeling; validated analytical and test
methods; identification and characterization of major impurities.
Process Validation - Approved validation protocols for all key processing steps (the process
does what is purported); raw materials and conditions clearly defined; sources of process
variation identified and minimized; key process parameters monitored and challenged to
ensure conformance to specifications; effect of operating condition changes evaluated; repeat
validation batches completed; revalidation performed if there are significant process changes.
Documentation - SOP and production record approvals; revision and change control;
manufacturing records, deviation

FACILITY DETAILS IN PILOT PLANT

 Reaction : Different variety of the Reaction vessels, capacity & MOCs

 Distillation : Batch Distillation: Atmospheric, Azeotropic High vacuum distillation &

Packed column

 Crystallization

 Filtration : All variety of filtration equipments like (Centrifuge/Nutsche Filter/Pressure

Nutsche filter/Agitated Nutsche filter & dryer)

 Drying : Vacuum Tray Dryer/Agitated Nutsche filter & dryer/RCVD/FBD

 Milling & Size Reduction : Air Jet Mill/Multi mill/Sifter

 Absorption : Scrubber for the hazardous fumes

 Hydrogenation : A separate area for hydrogenation

 Freezer: Lyophilizer for Rabeprazole

 API Manufacturing facility with 22 reactor system

Capacity is 3.6 KL

Capacity to handle different variety of Unit Operation

18 different products with outputs ranging from 3-10 Kg/batch Cgmp Plant.

 Two Streams of clean rooms:

 The facility is Two tier for the ease of the unit operation / process.

Class 100000 in the clean room area.

 Independent Utilities except steam/water & power.

PROCESS DESCRIPTION

1. Product Preparation

In the first stage in the manufacture of X, the solvent is charged to the reactor tank R-6110 &
mixed with a hygroscopic compound along with the intermediate.

The ingredients are agitated as they are charged to the reactor tank to produce a homogenous
solution.

The conditions inside a reactor tank are ambient temperature and pressure , continuous agitation
during feed is a good practice.

2. Reaction

The reactor is charged with specific quantities of the solvent & possible additives. The reactor
agitation is started & kept of constant speeds throughout the complete reactor cycle.

The reactor is reached a temperature higher to room temperature due to agitation. The reactor is
furthur heated to higher temperature using hot water through a reactor jacket upto 2-3 hours &
the temperature is maintained .

Most reactions are controlled at temperatures ranging from 50-60 degree C, depending on the
product requirement. Maintaining the temperature in the required range is a critical aspect of the
process. Reaction is carried out at atmospheric pressure as temperature is the driving force.

We could analyse that the slurry which had initially formed during agitation has become more
soluble in the solvent.

After filtration in the sparkler filter using filtration head hyflosupercell the aqueous layer
undergoes water wash in the reactor .The aqueous layer has to be further separated from the
hygroscopic compound so it is reacted with another reagent that is soluble in the intermediate-1,
thus we can separate it from the hygroscopic compound . After agitation the immiscible mix is
allowed to rest and later the two layers undergoes layer separation .Thus the layer other than the
aqueous layer is evaporated & the solid product is obtained and this is intermediate-2.

After sampling the intermediate-2, the next reaction is done in reactor by charging the solvents
and reagents required. The heating is done in maintained for a particular temperature .A
heterogeneous mixture is obtained containing solid phase , liquid phase & unreacted intermediate
phase.

After this process the Ph of the mixture is adjusted using an acid who separates the layers .There
after the solvent washing is done, the aqueous layers Ph is adjusted by washing it using a base.
The produced organic layer undergoes water washing twice for better purity.

The layers are furthur separated and is charged with an alcohol and distillated under vaccum, this
mix is heated and it undergoes stirring for 15-20 min. Thereafter activated charcoal is charged
into the distillated alcohol the mass is filtered through hyflo bed for a particular temperature.
Hereafter cooling and stirring for 2-3 hours, further cooling for 4-5 hours to 0-10 degrees. The
alcohol is separated from the mother liquor through sparkler filtration and dried under vacuum
till the solid product is obtained. The product obtained is Intermediate-3 which is our desired
product.
 DETERMINATION OF UA FOR SS316 USING COOLING WATER
Time Batch Temp Avg temp jacket ln((TJ-TO)/(TJ-T))
(min
) (hour) degree C degree C  
0 0 68 34 0
5 0.08 62 31 0.177
10 0.17 57 28.5 0.326
15 0.25 53 28.5 0.478
20 0.33 49.4 26.5 0.595
25 0.42 46.7 26.5 0.720
30 0.5 44.2 25 0.806
35 0.58 42.2 25.5 0.934
40 0.67 40.4 24.5 1.006
45 0.75 38.9 24.5 1.106
50 0.83 37.6 24.5 1.200
55 0.92 36.5 23.5 1.231
60 1 35.5 23 1.281
65 1.08 34.6 23 1.356
70 1.17 33.9 23 1.418
75 1.25 33.2 23 1.484

Capacity 250 L
Area 0.75 m2

UA/
SLOPE MCp 1.142240971
Cp 1 Kcal/ Kg °C
M 187 Kg
 UA 213.60 Kcal / hr °C
Kcal / hr m2
284.7987488 °C
330.3665486 W/m2 °C

DETERMINATION OF UA FOR R-6106 SS-316 USING HOT WATER

Time Batch Temp Avg temp jacket ln((TJ-TO)/(TJ-T))
(min) (hour) degree C degree C  
0 0 30.6 75 0
5 0.08333333 37.8 75.5 0.175
10 0.16666667 39.5 76 0.218
15 0.25 46.1 76 0.418
20 0.33333333 51.7 77 0.606
25 0.41666667 56.2 76.5 0.816
30 0.5 60 78 0.968
35 0.58333333 63.3 77.5 1.195
40 0.66666667 65.8 78 1.357

Capacity 250 L
Area 0.75 m2
SLOPE UA/MCp 2.0774062
Cp 1 Kcal/ Kg °C
M 187 Kg
UA 388.47 Kcal / hr °C
517.9666125 Kcal / hr m2 °C
600.8412705 W/m2 °C
 DETERMINATION OF UA -GLASS LINED USING COOLING WATER
Time Time Batch Temp Average Jacket Temperature ln((TJ-TO)/(TJ-T))
min hour degree c degree c  
0 0 84.5 38 0
5 0.08 79.3 41 0.127311042
10 0.17 73.8 39 0.268094939
15 0.25 68.8 37 0.401263421
20 0.33 64.5 35 0.517582406
25 0.42 60.7 34 0.637309771
30 0.5 57.2 33 0.755229175
35 0.58 54.3 32 0.856226491
40 0.67 51.6 31 0.954390578
45 0.75 49.4 31 1.067330989
50 0.83 47.1 30 1.159122238
55 0.92 45.4 29.5 1.241014076
60 1 43.6 29 1.335361492
65 1.08 42.1 28.5 1.415281898
70 1.17 40.7 28.5 1.523915739
75 1.25 39 27 1.566878298
80 1.33 38 27 1.653889675
85 1.42 37.4 26 1.635413399
90 1.5 36.3 26 1.736882859
95 1.58 35.5 26 1.817734956
100 1.67 34.8 26 1.894275033

Capacit
y 100 l
Area 0.8 m2
UA/ 1.11692298
Slope MCP 7
M 74 Kg
CP 1 Kcal/ Kg °C
 82.6523010
UA 3 Kcal / hr °C
103.315376
3 Kcal / hr m2°C
119.845836
5 W/m2°C
DETERMINATION OF UA -GLASS LINED USING STEAM
Time Time Batch Temp Pressure Average Jacket Temperature ln((TJ-TO)/(TJ-T))
min hour degree c kg/cm2 Degree c  
0 0 29.2 0 99.51 0
2 0.03 29.2 0 99.51 0
4 0.06 29.3 0.1 101.91 0.001376229
6 0.1 31 0.2 104.15 0.024307952
8 0.13 33 0 99.51 0.05555953
10 0.17 37.4 0 99.51 0.124001961
12 0.2 42.4 0.2 104.15 0.193717301
14 0.23 47.1 0.3 106.26 0.264343952
16 0.27 51.8 0.2 104.15 0.358849196
18 0.3 55.5 0.2 104.15 0.432144257
20 0.33 59.5 0.25 105.22 0.508444332
22 0.37 63.3 0.3 106.26 0.584328663
24 0.4 66.8 0.2 104.15 0.696441464
26 0.43 70 0.2 104.15 0.786003039
28 0.47 72.9 0.25 105.22 0.85527699
30 0.5 75.5 0.3 106.26 0.918395315
32 0.53 78 0.35 107.27 0.981128905
34 0.57 80.4 0.4 108.25 1.0433484

Capacit
y 100 l
Area 0.8 m2
 2.05790
Slope 5
M 75 Kg
CP 1 Kcal/Kg°C
UA 154.342 Kcal / hr
9 °C
192.928 Kcal/
6 hrm2°C
223.797 W/m2°C
2
 STATIC ELECTRICITY
Static electricity is one of the most insidious sources of fire and explosion encountered in
modern industry. It is by nature unpredictable and therefore difficult to detect. ln some industry
sectors it is viewed almost as a black art.
Uncontrolled static electricity is a problem in many sectors of manufacturing industry but is of
particular concern in operations where sensitive flammable materials are present Fires and
explosions attributable to static may actually be increasing in frequency due increased product
purity and faster process speeds. With the right approach electrostatic ignition
hazards can be identified and controlled This fact sheet looks at the steps taken in a hazard
assessment and the key parameters that need to
be determined.

There are five general conditions necessary for

an electrostatic ignition hazard to be present:
1l. Sensitive flammable atmosphere
2. Generation of electrostatic change
3. Accumulation of change
4. Electrostatic discharge (ESD)
5. Sufficient discharge energy
If all of the above conditions exist, an ignition hazard will be present . If any of the conditions
are removed the hazard is obviated. As a belt and braces approach attempts are often made to
remove more than one of these conditions, however the extent to which any mitigating measures
can be applied in practice often involve other considerations which may include cost and
practicality.
In any investigation. it is usually straightforward to identify the presence of flammable media.
From the point of view of electrostatic ignition hazard it is only necessary to restrict the
investigation of flammable atmospheres to those sensitive enough to be ignited by an
electrostatic discharge. In most industrial situations these are flammable gases, solvent vapours,
aerosols and fine combustible dusts. Many pyrotechnic
materials are also very sensitive to electrostatic ignition.
Many common industrial hydrocarbon gases and solvents are flammable in air over the range 1 -
12% by volume. This is referred to as the flammable or explosive range existing between the
lower explosive limit (LEL) and the upper explosive limit (UEL). The electrostatic discharge
energy required for ignition varies significantly over this range but the minimum ignition energy
value is likely to be of the order 1of 0.2 - 2.0 mill joules (m .l). This energy level is very low and
indicates that ignition may result easily.

Hazardous area classification is a method often used when undertaking risk management. The
classification is based on identifying areas or
zones within a plant according to the likelihood of sensitive flammable gas or vapour
concentrations being present. For solvents or gases there are generally 3 classifications as
follows.
 Zone 0 - in which an explosive gas/air mixture is continuously present or present for
long periods.
 Zone I - where an explosive gas/air mixture is likely to occur in normal operation.
 Zone 2 - in which an explosive gas/air. mixture is not likely to occur in normal operation
and if it does occur will exist only for a short time.

The generation of electrostatic charge is intrinsic to many industrial operations. The rate of
charge generator is notoriously difficult to predict.
However operations involving rapid and energetic movement and the contact and separation of
surfaces will produce increased charging. Milling of powder , for example. Will generate more
charge than pouring. In industry charge generation mechanisms are as follows:
 The contact and separation of solid surfaces such as moving webs over rollers.
 The movement of personnel.
 The flow/movement of liquids.
 The production of mist or aerosols.
 The flow or movement of powders.
 Charging by induction in an electric field.
 CONCLUSION

10 days of in-plant training was completed and the studies of each reactor in the pilot plant were
done. We could conclude that a Pilot plant helps to make process corrections & improvements

BIBLIOGRAPHY

 Unit Operation of Chemical Engineers-McCabe Smith Book

 The Pilot Plant Real Book – A Unique Book for Chemical Processing Industry

 Jubilant Generics Web Page

 www.google.com

 www.wikipedia.org