Till July'15 Variable Cost

Description Norms Rate Value

(MT/MT) (Rs/MT) (Rs/MT)
3-NAP 1.43 460491 660733
Acetic acid 100% 0.07 10200 699
Iron powder 1.62 22000 35603
Hydrose 0.01 10000 70
Sodium carbonate 100% 0.08 23531 1848
RM Cost 698952
Water 13.73 270 3707
Power 1000 7.50 7500
Coal 1.00 6500 6500
Utility Cost 17707

Total Variable Cost 716660

 3-AAP PRODUCTION
Norms(Kg/Kg) Rawmaterials Btch-1(Kg) Btch-2(Kg) Btch-3(Kg) Batch-4(Kg) Btch-5(Kg)
11.73 water 31500 29389 11989 30189 8989
2.23 Iron sludge ML 0 0 0 0 3500
9.59 3-AAP ML 0 0 18870 3200 20094
1.43 3-NAP 1800 1800 1800 1800 1800
0.07 Acetic acid 100% 154.5 83.43 83.43 83.43 83.43
1.62 Iron powder 2350 2100 2100 2000 2000
0.001 100% H2SO4 0.00 1.37 1.37 1.37 1.37
0.01 Hydrose 0 10 10 10 13
0.08 Sodium carbonate 100% 135 60 0 100 100
0.000 Sodium Bicarbonate 100% 0 0 200 0 0
Products
3-AAP including moisture 1271 1336 1650 1318 1346
% Moisture 10.0 14.40 15.21 12.70 11.60
1.00 3-AAP 1144 1144 1399 1151 1190
20.20 3-AAP ML 29070 28560 28560 29580 29580
2.23 Iron Sludge 3245 2900 2900 2762 2762
Conversion % 63.55 63.53 77.72 63.92 66.10
Yield % 77.65 77.63 94.97 78.11 80.77
3-AAP % in ML 0.83 0.87 0.78 0.77
3-AAP % in iron sludge 0.17 0.14 0.17 0.14

Total 3-AAP Produced 30.247 MT 3-NAP in stock

Average Conversion 69.69 % 3-AAP Dispatched(100%)
Average Yield 85.16 % 3-AAP to be dispatched
RODUCTION REPORT JULY & August 2015
Btch-6(Kg) Btch-7(Kg) Btch-8(Kg) Btch-9(Kg) Btch-10(Kg) Btch-11(Kg) Btch-12(Kg) Btch-13(Kg) Btch-14(Kg)
27669 17489 9189 9489 28800 16389 7889 25889 7089
3672 2040 3000 2000 3500 1000 5610 3500 3000
0 16320 18870 18870 0 12240 16830 0 16830
1800 2000 1800 1800 1800 1800 1800 1800 1800
83.43 83.43 83.43 83.43 83.43 83.43 83.43 83.43 83.43
2050 2300 2000 2000 2000 2000 2000 2000 2050
1.37 1.37 1.37 1.83 1.83 1.83 1.83 1.83 1.83
10 11 10 10 13 10 10 10 10
120 130 100 100 120 120 100 105 100
0 0 0 0 0 0 0 0 0

1322 1529 1562 1453 1281 1387 1301 1383 1336

11.8 13.30 14.00 11.60 9.50 13.30 10.80 12.65 11.20
1166 1326 1343 1284 1143 1203 1160 1208 1186
25500 29580 29070 25500 25500 25500 23460 23460 23460
2831 3176 2762 2762 2762 2762 2762 2762 2831
64.78 66.28 74.63 71.36 63.50 66.81 64.47 67.11 65.91
79.15 80.99 91.19 87.19 77.59 81.63 78.78 82.01 80.53
0.78 0.8 0.84 0.81 .. 0.78 0.84 0.79 0.84
0.16 0.14 0.14 0.26 .. 0.12 0.14 0.19 0.13

AP in stock 42.6 MT Total AAP ML Generated 599 KL

spatched(100%) 20.90 MT AAP ML Recycled 284.27 KL
o be dispatched 9.35 MT AAP ML Sent to ETP(Including stock in U-3) 314.73 KL
Btch-15(Kg) Btch-16(Kg) Btch-17(Kg) Btch-18(Kg) Btch-19(Kg) Btch-20(Kg) Btch-21(Kg)Btch-22(Kg)Btch-23(Kg)
7089 7089 7089 7089 24089 12089 7089 7089 7089
3500 4000 4000 4000 3500 3500 3500 3500 3500
17340 16830 16830 16830 0 12000 17000 17000 17000
1800 1800 1800 1800 1800 1800 1800 1800 1800
83.43 83.43 83.43 83.43 83.43 83.43 83.43 83.43 83.43
2000 2000 2000 2000 2000 2000 2000 2000 2000
1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83
10 10 10 10 5 5 5 5 7
100 100 110 80 95 100 100 100 100
0 0 0 0 0 0 0 0 0

1640 1645 1662 1655 1230 1517 1558 1476 1312

12.10 13.50 15.00 14.30 11.70 11.90 12.80 12.90 12.50
1442 1423 1413 1418 1086 1336 1359 1286 1148
23460 23460 23460 23460 23460 23460 23460 23460 23460
2762 2762 2762 2762 2762 2762 2762 2762 2762
80.09 79.05 78.48 78.80 60.34 74.25 75.48 71.42 63.78
97.86 96.59 95.90 96.28 73.73 90.72 92.22 87.27 77.93
0.75 0.78 0.76 0.81 0.78 0.86 0.86 0.93 0.89
0.18 0.16 0.15 0.17 0.16 0.12 0.14 0.32 0.14
Btch-24(Kg)
7089
3500
17000
1800
83.43
2000
1.83
7
100
0 0 0 0 0 0 0 0 0 0

1476
12.60
1290 0 0 0 0 0 0 0 0 0
23460
2762 0 0 0 0 0 0 0 0 0
71.67
87.57
0.89
0.12
0 0 0

0 0 0

0 0 0
 Reduction BCT
3
Charging Extractio Iron
Batch NO. DATE water and Maintaini Neutraliz ns and sludge
Starting 3-NAP Ending
heating to ng at ation to Transfer transfer
time addition Time
70°C,PH 90°C PH 7.5 to process to
Setting Crystalliz ANF
er
6 6-Jul-15 15:30 0:30 10:15 1:45 0:40 11:35 2:25 18:40

7 7-Jul-15 19:00 1:30 11:30 2:40 0:40 25:00:00 2:10 14:30

8 10-Jul-15 15:30 2:00 11:30 2:40 1:00 16:20 2:00 3:00

9 12-Jul-15 5:45 1:45 9:45 1:30 0:35 16:00 2:40 14:00

10 13-Jul-15 14:10 1:10 10:40 2:00 1:00 Delayed due to filtration issues
11 16-Jul-15 17:10 1:50 11:00 2:00 0:40 15:15 1:35 1:50
12 18-Jul-15 2:30 1:40 9:20 2:00 1:00 16:00 1:35
13 20-Jul-15 8:30 2:00 10:30 2:00 1:00 18:00 2:20 20:20
14 21-Jul-15 21:00 1:30 9:45 2:00 1:00 15:00 2:15 5:15
15 25-Jul-15 8:00 1:15 12:45 2:00 1:00 10:00 2:10 9:10

16 26-Jul-15 9:15 2:00 11:00 2:00 1:00 9:30 1:45 13:00

17 27-Jul-15 18:30 1:50 10:40 2:00 1:00 10:00 1:30 21:30
18 28-Jul-15 21:30 1:20 9:20 1:50 1:00 9:15 1:45 22:00
19 31-Jul-15 9:30 1:30 10:30 2:00 1:00 7:00 2:30 10:00
20 1-Aug-15 18:30 1:40 9:20 2:00 1:30 11:30 1:30 22:00
21 2-Aug-15 22:00 2:00 8:30 2:00 0:45 9:35 1:40 23:00
22 3-Aug-15 23:10 2:00 9:50 1:30 1:00 10:20 2:00 1:30
23 5-Aug-15 20:00 1:00 11:00 2:00 0:45 11:00 1:30 23:30
24 6-Aug-15 23:30 1:30 10:00 1:30 0:45 11:45 2:00 3:30
 Crystallization BCT

Cooling Chilling
DATE Natural
TOTAL Starting Receiving water water Transfer 3-AAP Ending
cooling to
TIME time 3 Extracts circulatio circulatio to ANF washing Time
62°C
n to 42°C n to 25°C

27:10:00 7-Jul-15 7:00 9:15 2:45 4:45 6:55 3:00 1:00 10:10

43:30:00 8-Jul-15 18:00 21:40 0:00 4:20 9:00 5:00 0:30 10:30

35:30:00 11-Jul-15 12:35 12:25 0:00 6:30 6:30 3:00 0:30 17:30

32:15:00 12-Jul-15 22:30 12:50 0:00 2:40 3:45 2:50 0:10 20:45
Delayed due to filtration issues
32:20:00 17-Jul-15 11:20 12:55 3:15 2:30 2:00 4:00 0:30 12:30
31:35:00 19-Jul-15 13:30 13:15 3:00 2:00 2:00 2:50 0:10
35:50:00 21-Jul-15 4:30 13:30 1:15 2:45 3:30 2:00 0:10 3:30
31:30:00 22-Jul-15 13:15 13:30 3:00 3:00 3:00 2:30 0:10 14:30
29:10:00 25-Jul-15 22:20 8:40 1:00 3:00 3:00 2:10 0:10 17:10

27:15:00 26-Jul-15 3:20 7:40 2:30 4:00 3:30 2:30 0:10 23:30
27:00:00 28-Jul-15 12:30 8:00 0:00 3:30 4:00 3:00 0:10 7:10
24:30:00 29-Jul-15 12:45 7:00 0:00 4:00 4:00 3:30 0:10 5:30
24:30:00 1-Aug-15 2:00 5:30 3:00 4:00 9:30 6:30 0:10 6:40
27:30:00 2-Aug-15 11:00 10:30 3:00 4:00 4:00 4:00 0:10 12:40
24:30:00 3-Aug-15 14:30 7:00 2:40 4:00 3:30 3:15 0:10 10:55
26:40:00 4-Aug-15 15:15 7:50 4:55 3:15 4:30 3:15 0:10 15:30
27:15:00 6-Aug-15 14:00 8:00 0:00 4:00 4:30 3:30 0:10 11:40
27:30:00 7-Aug-15 15:40 9:50 0:00 4:00 3:30 3:45 0:10 13:30
TOTAL Remarks
TIME

Found 3-AAP Lumps in crystallizer,Cleared, now crystallizer

27:40:00
is clean for
Process next batch
Delayed due to increase in batch size from 1800Kgs
40:30:00 NAP to 2000 Kgs ,Steam problem and 5 Extractions had been
taken
1st extraction transfer delayed due to filter cloth problem,
28:55:00 replaced with new cloth
New cooling tower had been installed,cooling and chilling time
22:15:00 reduced drastically

25:10:00 Dechocking at the time

Reduction ending bottom
notof crystallizer
included delayed2nd
bcz AAP-10 process
cropby
is 1 hr
23:15:00 recycled
23:10:00
25:10:00
18:00:00 For Extractions Carbon treated ML used. Filter press used for
Extractions.
20:20:00 For Extractions ML used. Filter press used for Extractions.
18:40:00 For Extractions ML used. Filter press used for Extractions.
18:40:00 For Extractions ML used. Filter press used for Extractions.
28:40:00 Chilling time increased bcz Chilled to 20°C
25:40:00
20:35:00
23:55:00
20:10:00 Aap ML treated with Activated Carbon & Used for this batch
21:15:00 Aap ML treated with Activated Carbon & Used for this batch
Water 24089 ML 0
ML

AAP-19

ML 23000 ML 11000
ML 34000

ML 12000
Water 12089

AAP-20 ML

ML 23000
 18500 Water 5589

AAP-21

ML 23000 ML 20000 ML 43000

For carbon treatment

18500 Water 5589

AAP-22

ML 23000