industrial training report in camphor and allied product ltd. bareilly (up). For download contact us 7300898470

1. 1
A
TRAINING REPORT
ON
CAMPHOR & ALLIED PRODUCT LTD.
C.B.GANJ BAREILLY, ( U.P)
DURATION - 01JUNE2017 TO 15JULY2017
SUBMITTED TO
MECHANICAL DEPARTMENT
SUBMITTED BY
SACHIN KUMAR
B.TECH -3RD YEAR
MECHANICAL ENGINEERING
S.S.V.I.T. BAREILLY
ROLL NO. -: 1447440104

2. 2
CERTIFICATE
This is hereby declare that the Industrial training entitled “PROCESSOF CAMPHOR
MANUFACTURING ” submitted by SACHIN KUMAR to CAMPHOR AND
ALLIED PRODUCT LTD. (U.P.) for the award of the Industrial Training is a genuine
record ofthe work carried out by them during the period of 15 JUNE, 2017to 15 JULY,
2017.
It is further certified that this project has been developed by SACHIN KUMAR, in
original and has been the result of their personal efforts with little assistance wherever
required.

3. 3
ACKNOWLEDGEMENT
I express my deepest and sincere thanks to all officer and employees of “Camphor & Allied
Product Ltd.”, who provided me their valuable time and information. This report was not
possible without their able support and guidance.
Specially , I would like to thanks my respectedMr. S.Pal , Mr. Rahul johri , Mr. M.K. Bhojwani
, who have been a constant source of inspiration for me during the completion of my training .
They give me invaluable input during my endeavour to complete training.
SACHIN KUMAR

4. 4
TABLE OF CONTENTS
CHAPTER . A
1. Introduction
2. Administration Department
2.1 Introduction
2.2 Personnel department
2.3 General Administration
2.4 Time office
2.5 Account
2.6 Taxation & M.I.S
2.7 E.D.P
2.8 Purchase
2.9 Sales & sales ware house
2.10 Safety
2.11 Store
3. Engineering Department
3.1 Introduction
3.2 Utility section
3.3 Electrical section
3.4 Work shop
3.5 Instrument section
4. Production department
4.1 Introduction
4.2 Production general office
4.3 Camphor production plant 1 & 2
4.4 Tablet and packaging section
5. Laboratory
5.1 Introduction
5.2 Lab

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CHAPTER . B
1. MANUFACTURING PROCESS
2. INTRODUCTION
3. PROCESS
A. ISOMERIZATION
B. DISTILLATION OF CRUDE CAMPHENE
C. ESTERIFICATION
D. DISTILLATION OF CRUDE IBA (ISO- BORNEOL ACETATE )
E. SPONIFICATION
F. WASHING AND DEWATERING
G. DEHYDRATION
H. DISTILLATION OF CRUDE CAMPHOR
4. REFERENCE

6. 6
1. INTRODUCTION
 CAMPHOR & ALLIED PRODUCTS LTD. (CAP) was founded in 1961 by chair man
Shri Jayant Dayal and managing director Shri Harshul Dayal.
 The camphor firstly published by Gustaf Komppa in 1903 by the camphoric acid.
 Camphor is a waxy, white or transparent solid with a strong; the chemical formula of
camphor is C10H16O (4,7,7-trimethylbicyclo 2,2,1 heptan-3-one)
 The ground breaking ceremony performed by late Shri Jayant Dayal in 1963, broke new
ground in the terpene based chemicals industry in 1964 when its factory of Bareilly (U.P)
started production with very few items in its product range.
 Today CAP's factory is turning out a total of over forty terpene based quality products and
specialty chemicals at Bareilly and Baroda factories.

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2. ADMINISTRATION DEPAARTMENT
2.1. INTRODUCTION
 As the name suggests Administration department related to the Administration of industry.
 In simple word Administration Department related to management and whole
administration of the industry.
 In “Camphor & Allied products Ltd”, work of Administration Department is to control all
the administrative work of the factory.
OBJECTIVE
 the main objective of Administration Department are as follow
1. Recruitment process in factory
2. Maintain the discipline in industry
3. Shift control
4. Maintain record of contractor's labours
5. Maintain different account in industry
6. Calculation and payment of all taxes
7. Control sales and purchase in factory
8. Maintain store for normal working day and for inventory

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COMPONENT
 These are various component of Administration Department
1. Personnel department
2. General Adam
3. Time office
4. Account
5. Taxation and M.I.S
6. E.D.P
7. Purchase
8. Sale and sale warehouse
9. Safety
2.2 PERSONNELSECTION
 The main objective of personal section is to monitor and control the recruitment process in
factory and at the time of joining providing training schedule to the candidates.
2.3 GENERALADMINISTRATION
 The purpose of above section is maintained discipline in the whole organisation and to
look after the welfare of the company employees.
 The other main work of the above of section is to deal with the outside agencies like, court,
police etc. and make good relation with the industries.

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2.4 TIME OFFICE
 The main function of time office is related to time in factory the main objective of above
sectionare as follow -
1. shift control
2. recording of overtime
3. daily record of contractor’s labourers
4. salary calculation of contractors labourers
5. Maintaining the record of entry and leave work in the factory.
2.5 ACCOUNT DEPARTMENT
 The purpose of this department is to maintain different account of the organisation and
salary distribution.
2.6 TAXATION & M.I.S. SECTION
 The M.I.S section means section of management information system.
 The Taxation section is the part of account and its objective is to calculate both type of tax,
excise and sale.

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2.7 EDP SECTION
 The full form of EDP is Electronic data processing this sectiondeal with all type of
Software and Hardware and networking problem of the company.
2.8 PURCHASE SECTION
 The main function of the sectionis to provide best possible items to different department
which are to be bought from outside agencies.
2.9 SALE WAREHOUSE
 This section deal with dispatching of product to the customer.
2.10 SAFETYDEPARTMENT
 Safety department is concerned with the safety of man machine and material involved in
manufacturing and those who are supporting the manufacturing process.
2.11 STORE
 Store department keeps necessary item for the smooth function of plant it store raw
material packing material and Engineering material.

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3. ENGINEERING DEPARTMENT
3.1 INTRODUCTION
 Engineering department is the most important department of industry.
 Engineering department is used to maintain the need of raw material machinery and other
important requirement.
 Engineering department work as a strong pillar of the industry without this department not
a single industry can serve.
 In “Camphor & Allied Products Ltd”, Engineering department maintaining the supply of
raw material different type of engineering and machinery.
OBJECTIVE
 In “Camphor & allied Products Ltd”, the main objective of engineering department are as
follow –
1. Provided heat energy (by means of heating and cooling).
2. Provide electricityto the whole plant.
3. Maintained smooth work of machines.
4. Maintain efficiency of plant and also improve it.
5. Automation of whole plant.
6. Control production and working of plant.

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COMPONENT
 There are four part of above department in camphor and allied products Limited which are
as follow-
1. Utility section
2. Electrical
3. Work shop
4. Instrument lab
3.2 UTILITY SECTION
INTRODUCTIN
 Utility means usefulness so as per name utility is the sectionof engineering department
which provide useful energy to the raw material.
OBJECTIVE
 these are the various objective of utility section
1. Provide required heating to raw material
2. Provide required cooling to raw material

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COMPONENT
 These are various components of utility section-
1. Boiler (one is wood fired boiler and other is oil fired boiler)
2. Heater
3. Cooling tower
4. Nitrogen plant
5. Air compressor
 In plant there are two utilities section –
1. Utility -1 (Both boiler)
2. Utility -2 (Heater , Cooling – tower , Nitrogen- plant , air- compressor )
3.2.1. BOILER
INTRODUCTION
 In camphor and allied products limited to type of boiler are used which can be
differentiated according to the fuel used-
1. Wood fired boiler
2. Oil fired boiler.

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A: WOOD FIRED BOILER
INTRODUCTION
1. In this weather be used wood cheap as a fuel.
2. This world is a combination of fire tube boiler and water tube boiler.
3. Its capacity is 10 ton per hour.
4. The pressure of generated steam is approximate 9 to 9.5 kg.
5. This wire produce wet steam
COMPONENT
 these are there is component of above boiler
1. Air preheater
2. Feed water tank
3. Economiser
4. Heating chamber
5. Safety valve
6. Water and steam level indicator
7. Manhole
8. Mud hole
9. Dust collector
10. Water and fire tube
11. Chimney
12. Softener

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B: OIL FIRED BOILER
INTRODUCTION
 As per the name the above boiler used oil (furnace oil) as a fuel.
 This is a three Paas boiler it means in this boiler hot gases passes in threeway in boiler.
 This is a fire tube boiler.
 Its capacity is 8 Ton.
 It always act in stand by condition.
 Most of the component of this boiler is same as wood fired boiler
3.2.2. HEATER
 Heater is a heating machine which is used to heat H.T.O ( high thermo oil).
 In heater we increase the temperature of H.T.O up to 270 oc.
 The HTO is used for heating chemicals which are used as a raw material.
 HTO flow in the tube in heating Chamber of heater.
 The components of heater are similar as boiler.
3.2.3. COOLING TOWER
 The purpose of cooling tower is to cool water of high temperature.
 As we know that there are two type of cooling tower one is natural and other is artificial
cooling tower.

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 In natural cooling tower air circulator naturally while in artificial cooling tower air
circulator take place by artificial means.
 In camphor and allied products Limited artificial cooling tower is used because its
efficiency is more than natural cooling tower.
 In Camphor plant there are two cooling tower 375 m3/hr. and 240 m3/hr.
 The temperature of cooling water is 28 to 30 oc.
3.2.4. NITOGEN PLANT
 As the name suggests the purpose of this plant is to absorb nitrogen from air and store in
the tank.
 In nitrogen plant molecular is sheaves are used , these sheaves absorb oxygen for some
time.
 When these sheaves absorb oxygen nitrogen is sent to another tank with the help of
pipeline.
Hot waterin
coolingtower
CoolingwateroutAirby usingfan Coolingtower
F.1.) Block diagram of coolingtower

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 Due to pressure difference molecular sheaves reject the oxygen this oxygen is then sent to
another Storage tank.
 As per requirement be used both in plants.
3.2.5. REFRIGERATION SYSTEM
 There are two reparation in each unit is 42 TR capacity
 In this refrigeration plant ammonia is used as a refrigerant and it is used to cool
refrigeration water up to - 5 oc
3.2.6. AIR COMPRESSOR
 In this unit there are three compressors these compressors are used to compress the air and
that air is used to flush the different type of tank in plant.
Nitrogenplant
withmolecular
chips
Norm
al air
in
plant
O2 N2
O2
storage
tank
N2
storage
tank
F.2.) Block diagram ofnitrogen plant

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3.3 ELECTRICAL DEPARTMENT
INTRODUCTION
 As per the name this department is related to electricity, this department supplies
electricityto whole factory.
COMPONENT
1. These are component of above department
2. Transformer- 1 having capacity 750KVA
3. Transformer -2 having capacity 500KVA
4. Diesel- 1 having capacity 1000KVA
5. Diesel -2 having capacity 750KVA
3.4 WORK SHOP
INTRODUCTION
 The main working of workshop is repair and maintenance. Workshop is the most
important part of not only of the engineering department but also of the whole department.

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OBJECTIVE
1. Shutdown maintenance
2. Breakdown maintenance
3. Preventive maintenance
4. Fabrication of equipmen
COMPONENT
1. Lathe machine
2. Drill machine
3. Shaper
4. Power saw
5. Rectifier AC welding Transformer
6. Milling machine
3.4.1. LATHE MACHINE
 Lathe is a machine tool used principally for shipping articles of metals the workpiece is
held and rotate by the late while a tool bit is advanced into the work causing the cutting
action.
 There are too late in workshop of plant one is four jaw and other is three jaw.

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COMPONENT
 These are principal part of lathe
1.Bed the way
2.Head stroke
3.Tail stock
4.Carries and Saddle
5.Tool post and tool
6.Lead screw power feed
7.Half nut and threading dial
OPERATION
 These are various operation which perform on lathe
1. Turning
2. Facing
3. Knurling
4. Parting and grooving
5. Drilling
6. Boring
7. Reaming
8. Milling
9. Grinding
10.Taper turning
11.Screw thread cutting

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3.4.2. DRILLING MACHINE
 The drilling machine is single purpose machine for the production of whole the process is
simple and reasonable accurate and the drill is easily control i.e both it’s cutting speed
and feed rate are easily controlled
OPERATION
 There are the various operation performed on drilling machine
1. Core drilling
2. Step drilling
3. Boring
4. Reaming
5. Counter boring
6. Countersinking
7. Spot facing
8. Taping
WORKING
 During the operation of drilling machine cutting tool rotate and reciprocates while the job
remains in stationary condition
Work piece
Cuttin
g
Tool
Directionof motion
of cuttingtool

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3.4.3. SHAPER
INTRODUCTION
 Shaper have largely been superseded by milling machine or grinding machine is modern
the shaper is relatively simple machine and is used fairly often in the tool room or
machining one or more piece for prototype work.
COMPONENT
 There are various component of shaper -
1. Ram
2. Tool head
3. Clapper box
4. Table
5. Saddle
6. Column
7. Tool holder
8. Work holding
Work piece
Cutting
tool
Directionof motionof cutting
tool
F.4.) Block diagram of shapermachine

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3.5 INSTRUMENT SECTION
INTRODUCTION
 This department deal with the controllers in the plant basically this department is a
combination of electric and numeric quantity.
OBJECTIVE
 The main objective of this department is to make record of production of the plant and
control all controllers.
COMPONENT
 There are two type of controllers in plant
1. Single loop controller
2. Double loop controller
 In single loop controller there is only one Input and one output while in double loop
controller there are more than one input and output.

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4..PRODUCTION PLANT
4.1 INTRODUCTION
 As the name suggests the purpose of production plant is to maintain the production process
and produce finish product from raw material.
OBJECTIVE
 The main objective of production department is to produce finished product and maintain
material balance sheet.
COMPONENT
 These are the various component of production department
1. Production General office
2. Camphor production plant- 1 and 2
3. Tablet and packaging section
4.2.. PRODUCTION GENERALOFFICE
 The main purpose of the sectionis to maintain the material balance sheet for every month
and on quarterly basis.

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 In material balance sheet the recordof conception of raw material and production of
finished product is maintained.
 On the basis of consumption and production overall loss of efficiency of the plant is
calculate
4.3.. CAMPHOR PRODUCTION PLANT-1 & 2
 These are those plants which are used for carrying out various chemical process.
 Whole process of production take place in both plant raw material passes from both the
plant in the form of cycle.
 There are various subsection in both production plant first we talked about Camphor
production plant- 1 it is known as old Camphor plant.
 In old Camphor plant there are total 10 reactor and 9 distillation Tower there are also these
subsection-
1. Isomerisation
2. Esterification (R-12/902) ; R-14
3. T-10/901/7/9
4. R-2/14A/15/16
 In camphor production plant -2 there are total fifteenreactors and five distillation tower.
This plant is also known as New Camphor Plant.
 These are the various sub- section in the above plant –
1. Resins (R-301/302/303 & T-301)
2. Terpincols (R-204/902A) & R-212
3. R-903A/904B/905A
4. R-903/904/905
5. T-902/903/904

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4.4. TABLET AND PACKAGING SECTION
 The purpose of this sectionis to manufacture tablets and packing for further supply.
 These are the various machine used in this section.
1. Slab manufacturing machine
2. Granulator
3. Tablet manufacturing machine
4. PEL packaging machine

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5.. LABORATORY DEPARTMENT
5.1 INTRODUCTION
 The function of this department is quality control and process control. In process control
samples are checked during various processes while in quality control final product is
tested.
5.2 COMPONENT
 These are various component of above department-
1. Gas chromatography
2. Carl fisher Titration
3. Refract meter
4. Distillation range operator
5. Flesh point operator
6. Softening point operator
7. Viscometer
8. Calorimeter
9. Melting point Apparatus

28. 28
CHAPTER - B
1. MANUFACTURING PROCESS
INTRODUCTION
Camphor is a waxy, white or transparent solid with a strong aromatic odour. It is a terpenoid
with a chemical formula C10H16O. It is found in the wood of the camphor laurel, a large
evergreen tree found in the Asia (Particularly in Borneo and Taiwan). It also occurs in some
other related trees in the laurel family. It can also be recovered from turpentine oil. It is use for
its scent as an ingredient is cooking as a embalming fluid in religious ceremonies and for
medical purpose. A major source of camphor is in Asia.
RAW MATERIALS
The basic raw material for the production of camphor is alpha pinene. Alpha pinene is mostly
abundant in coniferous trees and can distilled from turpentine produced as a side product of
chemical pulping. Turpentine is commonly recovered from pine trees extremely found in
CHINA.
Turpentine oil : is mainly recovered from pine trees. It contains a greater percentage of alpha
pinene , small amount of beta pinene and some amount of longifolene. Alpha pinene is
recovered from thae distillation of turpentine under vacuum conditions.
 Pine tree : pine oil
 Alpha pinene - 70%
 Beta pinene and Longfolene - 2 to 3% and 5%

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2. PROCESS
Crude Camphene
Pure Camphene
Alpha Pinene
Distillation
Pure Isoborneol Acetate
Ti Catalyst ( isomerization )
Esterification
(Acetic Acid)
Cu - Ni catalyst ( Dehydration )
Crude Isoborneol Acetate
Saponification (NaOH)
Distil
Crude Camphor
Isoborneoleol
Distil
Pure camphor

30. 30
Isomerisation
inpresence of
TiO2 catalyst
at 1550
C
Alpha pinene
T-1 Distilledcamphor
Aceticacid(1:2:4)
mixingtankVF26/904
Crude Camphor
Esterification
inR11/R902
T-10 T-901
Crude IBA
CAMPHOR MANUFACTUREING PROCESS
R903/R903A
T = 1800
C
P=8Kg/cm2
saponification
R901/R904A/R904B
De-watering,
washing
R905/R905A
Dehydration
T-903
vacuum
T-902
Atm.
T-903
vacuum
DistilledIBA
SupplyCPP-2
Xylene
IB + sodiumAcetate
Catalyst
Xylene
P 914
Flakers
Pure Camphor
Material Flow in CPP - 1
Material Flow in CPP - 2

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PROCESS
 In manufacturing of camphor there are some unit process used in the production of
camphor.
(a) . ISOMERIZATION
PARAMETER OF ISOMERISATION :
Feed temperature : 40oC
Dewatering temperature : 115oC
Catalyst : TiO2
Filtration temperature : 155oC
Time : Depends upon the grade of parameter of catalyst
Approx 20-25 hours.
Process : First of α-pinene is taken as raw material from the storage tank.
We use firstly isomerisation process. Take feed in reactor R-
1/9/901 at the room temperature or above (approx 40 to 45oC) and
heated the feed up to 115oC for dewatering then add TiO2 for the
isomerisation reaction temperature maintains 155oC. The
temperature are controlling through vacuum when total α-pinene
converts C-6 camphene, then reaction is complete cools the
reactor 90oC and re-circulates from via filter (F -1/901/A). C-6
Camphene is filter catalyst TiO2 rest in the filter. C-6 camphene is
transferred into vessel (VF-2/2A).

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(b). DISTILLATION OF CRUDE CAMPHENE
PARAMETER OF DISTILLATION OF CRUDE CAMPHENE IN TOWER T -1
Feed Temperature : 250C
Feed Rate : 1000 J/H
Top Pressure : 130 mmHg
Differential Pressure : 170 mmHg.
Top Temperature : 920C
Crystallization point of camphene : 400C
Process : Further Crude camphene is feed in distillation namely T-1
which process. Firstly vacuum apply in tower Crude
camphene is feed top of the tower. It is heated by steam,
when the tower stabilized boilers vapour produced and
comes to the top tower. These vapours are condensed in
primary to secondary condenser. For sharply done. Low
distilled camphene collectionin vessel (V-45) product
line. Crystalline must be 400C.

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(c). ESTERIFICATION
PARAMETER OF ESTERIFICATION
Ratio of camphene and acetic acid : 2:1
Reaction temperature : 450C
Catalyst : Resin Tulsan
Reaction time : 7 hours depends upon grade of resin
Setting time : 1 1/2 Hr
Process : camphene and acetic acid mixture will be prepare for
the further process in mixture tank. The ratio of
mixing is 2:1 (2 part of camphene and 1 part acetic
acid). This mixture is prepared in VF-904 and VF-
26. Then start esterificationprocess in the presence
of catalyst Tulsan in the esterification reactor's
namely R-I I and R-902. We produce crude IBA,
which is storage in VF-903.

34. 34
(d). DISTILLATION OF CRUDE IBA IN TOWER T10 AND T901
PARAMETER FOR DISTILLATION OF CRUDE IBA IN TOWER T10 AND T901
Tower T10
Top pressure : 225mmHg
Bottom pressure : 250 mmHg
Pressure difference : 25 mmHg
Top temperature : 600C
Feed Rate : 1200/H
Tower T901
Top pressure : 52 mmHg
Bottom pressure : 60 mmHg
Pressure difference : 0.08 mmHg
Top Temperature : 700C
Middle Temperature : 1160C
Bottom Temperature : 1370C
Process : Further we use tower T10and T901 for the distillation of
crude IBA. Firstly we remove the moisture from (crude
IBA in tower T10) in presence of acetic acid. After
remove the moisture, further we fired in tower T901
from the top, when the tower stabilized, low boilers
vapours, produced and condensed in condensed Crude
IBA is separates from middle of the tower and
collectedin storage vassal. High boiler is find out from
the sump collectedin tank (E-34).

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(e). SAPONIFICATION
PARAMETER OF SAPONIFICATION
Pressure : 8 kg/cm2
Reaction Temperature : 1650C
Time : 5 – 6 Hr.
Process : From the CPP 1st pure IBA is collectedin storage tank VF-
35/36, that is further used in R-903/903A reactors for the
saponification process. There are IBA is mixed with caustic in
presence of solvent (Xylene). After reaction isoborneol and
sodium acetate are produced. Since isoborneol is insoluble in
sodium acetate and it is separates and collectedin a tank -
sodium acetate is transferred in acetate plant.

36. 36
(F). WASHING AND DEWATERING
From saponification, collected1B is feed in R-904/ 904M 904B here mainly and
dewatering process well be processed for maintaining ph 7 - 8. Water is used for washing.
PARAMETER
Pressure : Atmosphere
Washing temperature : 80 – 900C
Dewatering Temperature : 1500C
(g). DEHYDROGENATION
In this section we use feed from previous washing and watering section. In this section
mainly dehydrogenation will be done. For dehydrogenation we use reactor R - 905/
905A feed in reactor namely catalyst. The mixture of CuCO3, NiCO3, MgCO3 is called
catalyst no-l, since this reaction is endothermic reactor hated continuous of to 2500C.
Mainly product of dehydrogenation is Crude camphor.
(H). DISTILLATION OF CRUDE CAMPHOR
Parameter of Tower T2
Pressure : Atm

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Bottom : 196 – 1980C
Feed point : Feed plate (middle)
Parameter of Tower T3
Top Pressure : 250 mmHg
Pressure difference : 200 – 210 mmHg
Feed Point : Feed plate (middle)
Parameter of Tower T4
Pressure : Atm
Top Temperature : 1650C
Middle Temperature : 2040C
Process : There are mainly three towers are taken in use namely T2, T3 and
T4. First of all feed is collectedin the tower T2 from Re-905/A
(Crude Camphor). In this tower we separate mainly xylene and
collectedin storage tank. Further product from T2 to feed in T3
here, we separate mainly low boiled (fenchion and Iso fenchions
which is called Camphor Oil) and collected in storage tank. Then
product from T3 (Distillate) crude Camphor feed in tower T4.The
final product of Cr camphor will be separate out in the form of
pure camphor. The flack of pure camphor is made by flakers.

38. 38
4. REFERENCES
 WWW.capl.com
 All the officers and employees are the source of this particular information for
making training report.
 K.M.Moeed , “Manufacturing Science –II ”, Umesh publication, 2012