Enclosure: 1 Product Detail
Sr. No. Products Quantity (MT/Month)
Existing Proposed Total
1
a. 2 Ethyl Pyridone (Carbamyal 2 pyridone) 7 93
100
b. Cyano 2 pyaridone
-- 100
c. sulpho 2 pyaridone d. Napthol As e. Napthol ASBS f. Napthol ASD g. Napthol ASE h. Napthol ASOL i. Napthol ASBO j. M.U.A
2 Magnesium Sulphate 100 200 300
3
a. M.N.A -- 20 20 OR b. Dispersing agent phenol base – liquid,
Dispersing agent phenol base – solid, Dispersing agent Napthlene base – liquid, Dispersing agent Napthlene base – solid
-- 200 200
By products : 1 Dilute spent acid H2SO4 (45%) -- 575 575
Enclosure: 2 Packing & Final Use of Product
Sr. No. Product Type of Packing Final Application of Product
1 2 Ethyl Pyridone (Carbamyal 2 pyridone) Bag Manufacturing of dyes
2 Cyano 2 pyaridone Bag Manufacturing of dyes 3 sulpho 2 pyaridone Bag Manufacturing of dyes
4 Napthol As Bag
For dyeing & printing as well as Manufacturing of pigment
5 Napthol ASBS Bag
For dyeing & printing as well as Manufacturing of pigment
6 Napthol ASD Bag
For dyeing & printing as well as Manufacturing of pigment
7 Napthol ASE Bag
For dyeing & printing as well as Manufacturing of pigment
8 Napthol ASOL Bag
For dyeing & printing as well as Manufacturing of pigment
9 Napthol ASBO Bag
For dyeing & printing as well as Manufacturing of pigment
10 M.U.A Bag
For dyeing & printing as well as Manufacturing of pigment
11 Magnesium Sulphate Bag For dyeing & printing as well as Manufacturing of
pigment
12 M.N.A Bag
For dyeing & printing as well as Manufacturing of pigment
13 Dispersing agent phenol base – liquid Drum Manufacturing of dyes 14 Dispersing agent phenol base – solid Bag Manufacturing of dyes
15 Dispersing agent Napthlene base – liquid Drum Manufacturing of dyes
16 Dispersing agent Napthlene base - solid Bag Manufacturing of dyes
Enclosure: 3 Detail of Raw Material with his Quantity
Sr. No. Name of product Capacity
MT/Month Name of Raw
Material Raw Material Consumption
MT /MT MT/ Month
1
2 Ethyl Pyridone (Carbamyal 2 pyridone)
100
Cyano 2 Pyridone 0.956 95.6 Sulphuric Acid 2.623 262.3
Cyano 2 pyaridone MCA 0.727 72.7 MEA 0.636 63.6 MAA 0.909 90.9
Sulpho 2 pyaridone
Sodium Bi Sulphite 0.385 38.5 Formaldehyde 0.111 11.1 Carbamyal 2 Pyrodine 0.725 72.5
Caustic 0.324 32.4 Salt 0.139 13.9 Spent Sulphuric Acid (45%) 0.648 64.8
Napthol As
BON Acid 0.750 75 Toluene 4.329 432.9 Caustic flakes 0.159 15.9 PCl3 0.216 21.6 Aniline 0.361 36.1 Soda Ash 0.027 2.7
Napthol ASBS
BON Acid 0.649 64.9 Toluene 3.745 374.5 Caustic flakes 0.137 13.7 PCl3 0.187 18.7 Meta nitro Aniline 0.400 40 Soda Ash 0.074 7.4
Napthol ASD
BON Acid 0.694 69.4 o-Toluene 4.004 400.4 Caustic flakes 0.141 14.1 PCl3 0.200 20 Meta nitro Aniline 0.380 38 Soda Ash 0.024 2.4
Napthol ASE
BON Acid 0.667 66.7 Toluene 3.846 384.6
Caustic flakes 0.137 13.7 PCl3 0.192 19.2 P Chloro Aniline 0.436 43.6 Soda Ash 0.024 2.4
Napthol ASOL
BON Acid 0.591 59.1 Toluene 3.546 354.6 Caustic flakes 0.118 11.8 PCl3 0.177 17.7 O-Anisidine 0.402 40.2 Soda Ash 0.022 2.2
Napthol ASBO
BON Acid 0.658 65.8 Toluene 3.871 387.1 Caustic flakes 0.142 14.2 PCl3 0.193 19.3 Meta Nitro Aniline 0.412 41.2 Soda Ash 0.023 2.3
M.U.A MPD 0.497 49.7 HCl 1.163 116.3 Sodium Cynate 0.327 32.7
2 Magnesium Sulphate 300
Mgo 0.272 81.6 Sulphuric acid (98%) 0.670 201
Spent Sulphuric Acid 2.516 754.8
3
a. M.N.A 20 MDNB 1.250 250 NaHS 2.375 475
b.
Dispersing agent phenol base – liquid
200
Sulphuric Acid (98%) 0.139 27.8
Phenol 0.178 35.6 Formaldehyde 0.217 43.4 EDTA 0.008 1.6 Caustic soda lye 0.155 31
Dispersing agent phenol base – solid
Phenol based dispersing agent(Liquid)
2.227 445.4
Dispersing agent Napthlene base – liquid
Oleum (23%) 0.144 28.8 Sulphuric Acid(98%) 0.052 10.4
Napthalene 0.196 39.2
Formaldehyde 0.118 23.6 Caustic lye 0.196 39.2
Dispersing agent napthlene base - solid
Naphthalene based dispersing agent(Liquid)
2.380 476
Overall List of Raw Material
Sr. No. Raw material Chemical Name CAS No. MT/Month
Existing Proposed Total 1 Cyano 2 Pyridone Cyano 2 Pyridone 28141-13-1 6.692 88.91 95.6 2 Sulphuric Acid Sulphuric Acid 7664-93-9 23.051 253.149 276.2 3 MCA Methyl Cyno Acetate 105-34-0 0 72.7 72.7 4 MEA Mono Ethyl Amine 75-04-7 0 63.6 63.6
5 MAA Methyl Aceto Acetate 105-45-3 0 90.9 90.9
6 Sodium Bi Sulphite Sodium Bi Sulphite 7631-90-5 0 38.5 38.5 7 Formaldehyde Formaldehyde 50-00-0 0 32.8 32.8
8 Carbamyal 2 Pyrodine
Carbamyal 2 Pyrodine 1121-60-4 0 72.5 72.5
9 Caustic flask Sodium Hydroxide 1310-73-2 0 48.3 48.3 10 Salt Sodium Chloride 7647-14-5 0 13.9 13.9 11 BON Acid B-Oxy napthaoic Acid 92-70-6 0 75 75 12 Toluene Toluene 108-88-3 0 432.9 432.9
13 PCl3 Phosphorous Tri Chloride 7719-12-2 0 21.6 21.6
14 Aniline Aniline 62-53-3 0 36.1 36.1 15 Soda Ash Sodium Carbonate 497-19-8 0 7.4 7.4 16 o- Anisidine o- Anisidine 90-04-0 0 41.23 41.23 17 o- Tolune o- Tolune 108-88-3 0 38.4 38.4 18 Meta nitro Aniline Meta nitro Aniline 100-01-6 0 41.2 41.2 19 Alfa Napthyl Amine Alfa Napthyl Amine 86-56-6 0 40.2 40.2 20 MPD m-Phenylenediamine 108-45-2 0 49.7 49.7
21 HCl Hydro Chloric Acid 7647-01-0 7732-18-5 0 116.3 116.3
22 Sodium Cynate Sodium Cynate 917-61-3 0 32.7 32.7 23 Mgo Magnesium Oxide 1309-48-4 1.904 79.67 81.6 24 MDNB 0 250 250
25 NaHS Sodium Hydro Sulphide 7775-14-6 0 475 475
26 Phenol Phenol 108-95-2 0 35.6 35.6 27 EDTA Ehylene dyamine 60-00-4 0 1.6 1.6
tetra acetic acid 28 P Chloro Aniline P Chloro Aniline 106-47-8 0 43.6 43.6
29 Oleum (23%) Fuming Sulphuric Acid
7664-93-9 7446-11-9 0 28.8 28.8
30 Napthalene Napthalene 91-20-3 0 39.2 39.2
Enclosure: 4 Chemical Name & Physical form of raw material with his storage facility
Sr. No. Raw Material Physical form Type of Packing MOC Max. at a time
storage capacity MT 1 Cyano 2 Pyridone Solid Bag HDPE bag with liner 150 2 Sulphuric Acid Liquid Storage Tank MS 51.9 3 MCA Liquid Storage Tank MS 13.3 4 MEA Liquid Drum HDPE 8.6 5 MAA Liquid Drum MS 15.8 6 Sodium Bi Sulphite Solid Bag HDPE bag with liner 60 7 Formaldehyde Liquid Storage Tank HDPE 80 8 Carbamyal 2 Pyrodine Solid Bag HDPE bag with liner 150 9 Caustic flask Solid Bags HDPE bag with liner 6.3
10 Salt Solid Bag HDPE bag with liner 50 11 BON Acid Solid Bags HDPE bag with liner 30.0 12 Toluene Liquid Storage Tank MS 6.04 13 PCl3 Liquid Drum/ Storage Tank MS 8.64 14 Aniline Liquid Drum MS 14.4 15 Soda Ash Solid Bags HDPE bag with liner 1.04 16 o- Anisidine Liquid Drum MS 16.4 17 o- Tolune Liquid Drum MS 15.20 18 Meta nitro Aniline Solid Bags HDPE bag with liner 15.9 19 Alfa Napthyl Amine Solid Bag HDPE bag with liner 7.7 20 MPD Solid Drum MS 0.99 21 HCl Liquid Tank/drum HDPE 2.3 22 Sodium Cynate Solid Bag HDPE bag with liner 0.65 23 Mgo Solid Bag HDPE bag with liner 100 24 MDNB Solid Bag HDPE bag with liner 6.0
25 NaHS Solid Bag HDPE bag with liner 11.8 26 Phenol Liquid Storage Tank MS 17.8 27 EDTA Solid Bag HDPE bag with liner 0.7 28 P Chloro Aniline Solid Bag HDPE bag with liner 17.4 29 Oleum (23%) Liquid Storage Tank MS 72 30 Napthalene Solid Bag HDPE bag with liner 98
Enclosure: 5 Property of Raw Material
Sr. No
Product
Physical & Chemical Composition B.P. F.P. LEL
TLV LD50
mg/kg Sp.Gr.
(Water=1)at
V.D. at
(air=1)
Odor Threshold Solubility in
Water Chemical Formula State MW oC oC % ppm or
mg/nm3 ppm,
mg/Nm3
1 Sulphuric Acid H2SO4 Liquid 98.08 270 NA NA 3 320 1.84 3.4 NA Soluble
2 MCA C4H5NO2 99.09 204 NA NA NA NA NS NA NA Soluble
3 Sodium Bi Sulphite NaHSO3 Solid 104.7 NA NA NA 5 2000 1.48 NA NA Soluble
4 Formaldehyde HCHO Liquid 30.02 98 50 6 0.37 5628 1.08 1.03 NA Soluble
5 Caustic flask NAOH Liquid 40 1390 NA NA 2 NA 2.12 NA NA Soluble
6 Salt NaCl Solid 58.44 1413 NA NA NA 3000 2.165 NA NA Soluble
7 Toluene C6-H5-CH3 Liquid 92.14 110.6 16 1.1 50 14100 0.8636 3.1 1.6 Soluble
8 Aniline C6H5NH2 Liquid 93.13 184.1 70 1.3 7.6 820 1.0216 3.22 2.4 Soluble
9 Soda Ash Na2CO3 Solid 106 NA NA NA NA 4090 2.532 NA NA Soluble
10 HCl HCl Liquid 36 127 NA NA 7 900 1.19 1.267 0.25-10 Completely Soluble
11 Sodium Cynate CNNaO Powder 65.01 NA NA NA 1500 1.89 NA NA NA Soluble
12 Oleum (23%) H2SO4 + 20% SO3 Liquid 178.14 254.47 NA NA NA 2140 1.92 3.4 NA Soluble
13 Napthalene C10H8 Solid 128.19 218 88 0.9 15 305.2 1.162 4.4 0.038 Soluble
Enclosure: 6 Detail of Hazardous Chemicals
The Raw materials, which are termed as hazardous Chemicals as per the “Manufacturing, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989” are as listed below Table
Sr. No.
Name of Hazardous chemicals
Reference in MSIHC Threshold
Quantity (MT) Maximum
Storage Capacity (MT) Sc-2 Sc-3
1 Aniline Sr. No. 37 (Sch-1 of MSIHC, 1989) -- -- 14.4 2 Formaldehyde Sr. No. 285 (Sch-1 of MSIHC, 1989) -- 50 80 3 HCL Sr. No. 313 (Sch-1 of MSIHC, 1989) 25 25 2.3 4 Naphthalene Sr. No. 417 (Sch-1 of MSIHC, 1989) -- -- 98 5 o-toludine Sr. No. 441 (Sch-1 of MSIHC, 1989) -- -- 15.20
6 Phosphorous Tri Chloride Sr. No. 506 (Sch-1 of MSIHC, 1989) -- -- 8.64
7 Caustic Soda (Sodium Hydroxide)
Sr. No. 571 (Sch-1 of MSIHC, 1989) -- -- 6.3
8 Sulphuric acid Sr. No. 591 (Sch-1 of MSIHC, 1989) -- -- 51.9 9 Toluene Sr. No. 628 (Sch-1 of MSIHC, 1989) -- -- 6.04
Enclosure: 7 Manufacturing Process and Chemical Reaction and Mass Balance
1. 2 Ethyl Pyridone:
Cyano 2 pyridone & sulphuric acid are taken in reactor. Then mass is drown in water & filter nutch. Filtrate is collected as spent acid which is either use for manufacturing of magnesium sulphate, sulpho 2 pyridone or sell to actual user.
2. Cyano 2 pyridone:
MEA, MCA & MAA are taken in a reactor for condensation. After that; distillation is carried out. During distillation mixture of methanol & water are generated, which will be used as fuel in boiler. Reactor mass is dried and packed as final product.
3. Sulpho 2 Pyridone:
In vessel-1 carbamoly 2 pyridone solution is prepared by taking water, carbamoly 2 pyridone & caustic solution. Meanwhile Water, Sodium bi sulphite & formaldehyde are taken in vessel-2. After that carbamoly 2 pyridone solution & salt are added to vessel-2. Further the mass is reacting with spent acid. Then mass is drown in water& filter nutch. Filtrate is sent to ETP. Wet cake is packed as final product.
4. Magnesium sulphate:
Magnesium oxide is taken into reactor. Add spent acid and sulphuric acid. The mass is then filtred in filter press. Wet cake is collected and sends to TSDF. Filtrate is crystallized in a crystallizer. Crystals are filter in a filter nutch. Filtrate is collected and recycles in the next batch. Crystals are packed as final product. Chemical Reaction:
MgO + H2SO4 + H2O MgSO4.7H2O
Chemical reaction:
OH
COOH BON Acid
ONa
COOH
Sodium Salt of Bon Acid
+ H2O + NaOH
ONa
COOH
Sodium Salt of Bon Acid
+ PCI3 + 3 H2N—
3
OH
C—NH—
Naphthol AS
3 + 3NaCI + H3PO3
O
5. Naphthol AS:
BON Acid, caustic flakes & toluene are taken into reactor for dehydration. Water is removed and taken to ETP. Then mass is further taken for Naphthol formulation. Add PCI3, aniline, water & soda ash. Toluene is distilled & recycled. During reaction HCI gas is generated which is scrubbed in alkali scrubber & effluent is taken to ETP. Wet cake is dried in dryer & packed as final product.
Chemical reaction:
O
OH
COOH BON Acid
ONa
COOH
Sodium Salt of Bon Acid
+ H2O + NaOH
ONa
COOH
Sodium Salt of Bon Acid
+ PCI3 + 3 H2N—
3
OH
C—NH—
Naphthol ASBS
3 + 3NaCI + H3PO3
NO2
NO2
m-Nitro aniline
6. Napthol ASBS:
BON Acid, Caustic flakes & toluene are taken into reactor for dehydration. Water is removed and taken to ETP. Then mass is further taken for Naphthol formulation. Add PCI3, Meta Nitro aniline, water & soda ash. Toluene is distilled & recycled. During reaction HCI gas is generated which is scrubbed in alkali scrubber & effluent is taken to ETP. Wet cake is dried in dryer & packed as final product.
Chemical reaction:
O
OH
COOH BON Acid
ONa
COOH
Sodium Salt of Bon Acid
+ H2O + NaOH
ONa
COOH
Sodium Salt of Bon Acid
+ PCI3 + 3 H2N—
3
OH
C—NH—
Naphthol ASD
3 + 3NaCI + H3PO3
o-Toluidine
H2C
H3C
7. Naphthol ASD :
BON Acid, Caustic flakes & toluene are taken into reactor for dehydration. Water is removed and taken to ETP. Then mass is further taken for Naphthol formulation. Add PCI3, O-toludine, water & soda ash. Toluene is distilled & recycled. During reaction HCI gas is generated which is scrubbed in alkali scrubber & effluent is taken to ETP. Wet cake is dried in dryer & packed as final product.
Chemical reaction:
O
OH
COOH BON Acid
ONa
COOH
Sodium Salt of Bon Acid
+ H2O + NaOH
ONa
COOH
Sodium Salt of Bon Acid
+ PCI3 + 3 H2N—
3
OH
C—NH—
Naphthol ASE
3 + 3NaCI + H3PO3
P-Chloro aniline
CI
CI
8. Naphthol ASE:
BON Acid, Caustic flakes & toluene are taken into reactor for dehydration. Water is removed and taken to ETP. Then mass is further taken for Naphthol formulation. Add PCI3, P-chloro aniline, water & soda ash. Toluene is distilled & recycled. During reaction HCI gas is generated which is scrubbed in alkali scrubber & effluent is taken to ETP. Wet cake is dried in dryer & packed as final product.
Chemical reaction:
O
OH
COOH BON Acid
ONa
COOH
Sodium Salt of Bon Acid
+ H2O + NaOH
ONa
COOH
Sodium Salt of Bon Acid
3
OH
C—NH—
Naphthol ASBO
3 + 3NaCI + H3PO3
AlfaNaphthly amine
+ PCI3 + 3
NH2
9. Naphthol ASBO:
BON Acid, Caustic flakes & toluene are taken into reactor for dehydration. Water is removed and taken to ETP. Then mass is further taken for Naphthol formulation. Add PCI3, Alpha Napthyl amine, water & soda ash. Toluene is distilled & recycled. During reaction HCI gas is generated which is scrubbed in alkali scrubber & effluent is taken to ETP. Wet cake is dried in dryer & packed as final product.
Chemical reaction:
O
OH
COOH BON Acid
ONa
COOH
Sodium Salt of Bon Acid
+ H2O + NaOH
ONa
COOH
Sodium Salt of Bon Acid
+ PCI3 + 3 H2N—
3
OH
C—NH—
Naphthol ASOL
3 + 3NaCI + H3PO3
o-Anisidine
H3CO
H3CO
10. Naphthol ASOL:
BON Acid, Caustic flakes & toluene are taken into reactor for dehydration. Water is removed and taken to ETP. Then mass is further taken for Naphthol formulation. Add PCI3, O-Anisidine, water & soda ash. Toluene is6 distilled & recycled. During reaction HCI gas is generated which is scrubbed in alkali scrubber & effluent is taken to ETP. Wet cake is dried in dryer & packed as final product.
11. Meta Nitro Aniline:
MDNB is reduced with sodium hydro sulphite, add water, then filtered the mass. Filtrate is taken to ETP. Wet cake washed with water. Wash water is taken to ETP. Wet cake dried & packed as a finished product.
12. Meta Urido Aniline: MPD, Hydro chloric acid & sodium cyanate are taken into reactor. Add water inti it. Mass is then filtered. Filtrate is taken to ETP. Wet cake is packed as final product.
13. Dispersing Agent based on phenol (liquid):
Phenol is first reacted with sulphuric acid in a sulphonator rector. This is condensed with formaldehyde & water, mass solution is filled directly in drums as a final product. In this process there is no filtration or washing hence no generation of any process effluent.
14. Dispersing Agent based on phenol (Solid) : Dispersing agent based on phenol liquid mass is spray dried in spray dryer. Finally dry powder is packed as a final product. There is no generation of any process effluent.
15. Dispersing Agent based on Naphthalene (liquid):
Naphthalene is first reacted with oleum & sulphuric acid in a sulphonator reactor. This is condensed with formaldehyde & water. After completion of reaction mass is neutralized with caustic lye & add water. Finally the liquid mass solution is filled directly in drums as a final product. In this process there is no filtration or washing hence no generation of any process effluent.
16. Dispersing Agent based on Naphthalene (Solid): Dispersing agent based on naphthalene liquid mass is spray dried in spray dryer. Finally dry powder is packed as a final product. There is no generation of any effluent.
Drawning
Filter
Draying
Reaction
Spent acid (45%): 5639 Kg
Use for production of sulpho 2 pyridone & magnesium sulphate or sell to actual users
Water: 3060 kg
Cyano 2 pyridone : 956 kg
Sulphuric acid: 2623 kg
2 Ethyl Pyridine: 1000 kg
Mass Balance of the Products
1. 2 Ethyl Pyridone:
Distillation
Drying
Cyano2-pyridone: 1000 kg
Condensation
Distillate: methanol & water mixture: 1227 kg
Used as fuel in boiler
MCA: 727 kg
MEA: 636 kg
MAA: 909 Kg
Vapors loss 45 Kg
2. Cyano 2 pyridone:
Addition
Addition
Filter
Addition
Sulpho 2 pyridone: 1000 kg
Effluent: 3795 kg
Salt: 139 Kg
Spent sulphuric acid: 648 Kg
Water :417 kg
Pyridine Solution
Water: 185 kg
Caramyal 2 pyridone : 725 kg
Caustic : 324 kg
Water: 1861 kg
Sodium bi sulphite : 385 kg
Formaldehyde : 111 Kg
3. Sulpho 2 Pyridone:
Reactor: 119360
Product (MgSO4): 1000 kg
Filtration in Filer Press
Mgo: 272 Kg Sulfuric Acid (98%): 67000 Kg
Spent H2SO4: 25160 Kg
Filtrate: 115860
Crystallization
Crystal: 110000
Centrifuge: 110000
Filter in Filter Nutch Filtrate: 58
Filtrate: 2365 kg
Wet Cake: 35
TSDF
4. Magnesium sulphate:
WET CAKE
DRYING
Effluent to ETP: 2649 kg
NAPHTHOL
FORMATION
PCI3 : 216 kg Aniline : 361 kg
Soda ash : 27 kg Water : 2597 kg
DEHYDRATION BON Acid : 750 kg
Toluene: 4329 kg
Caustic flakes: 159 kg
Water: 69 kg to ETP
HCI: 50 kg
Solvent Loss: 210 kg
Distill Toluene Recycle: 4250
Water: 100 kg + 10 kg Caustic
Alakli scruber
Effluent to ETP: 2919 kg
Drying Loss: 211 kg
3-Hydroxy-2-Napthonilide: 1000
5. Naphthol AS:
WET CAKE
DRYING
Effluent to ETP: 2512 kg
DEHYDRATION
BON Acid : 520 kg
Toluene: 3745 kg
Caustic flakes: 137 kg Water: 60 kg to ETP
HCI Gas: 11 kg
Solvent Loss: 131 kg
Distill Toluene Recycle: 3614 kg
Water: 100 kg + 10 kg Caustic
Water Scrubber
Effluent to ETP: 100 kg
Drying Loss: 111 kg
3-Hydroxy-3-Napthonilide: 1000 Kg
NAPHTHOL
FORMATION
PCI3: 187 kg Meta Nitro Aniline: 400 kg
Soda ash: 74 kg Water: 2247 kg
6. Napthol ASBS:
DEHYDRATION
BON Acid: 694 kg o-
Toludine: 4004 kg
Caustic flakes: 141 kg
PCI3: 200 kg Meta Nitro Aniline: 380 kg
Soda ash: 24 kg Water: 2403kg
NAPHTHOL
FORMATION
WET CAKE
DRYING
3-Hydroxy 2-Naptho O-Toludine: 1000 Kg
Water: 65 kg to ETP
HCI Gas: 16 kg
Effluent to ETP: 2643 kg
Solvent Loss: 140 kg
Effluent to ETP: 100 kg
Distill Toluene Recycle: 3863 kg
Drying Loss: 119 kg
Water: 100 kg + 10 kg Caustic
Water Scrubber
7. Naphthol ASD :
BON Acid: 667 kg
Toluene: 3846 kg
Caustic flakes: 137 kg
DEHYDRATION Water: 63 kg to ETP
PCI3 : 192 kg P Chloro Aniline : 436 kg
Soda ash : 24 kg Water : 2308 kg
NAPHTHOL
FORMATION
HCI Gas: 17 kg
Effluent to ETP: 2569 kg
Solvent Loss: 135 kg
WET CAKE
DRYING Drying Loss: 114 kg
4 Chloro 3-Hydroxy-2-Napthonilide: 1000 Kg
Distill Toluene Recycle: 3712 kg
Water: 100 kg + 10 kg Caustic
Water Scrubber
Effluent to ETP: 100 kg
8. Naphthol ASE:
BON Acid: 500 kg
Toluene: 3546 kg
Caustic flakes: 118 kg
DEHYDRATION Water: 55 kg to ETP
PCI3: 177 kg Alfa Napthyl Amine: 402 kg
Soda ash: 22 kg Water: 2128 kg
NAPHTHOL
FORMATION
HCI Gas: 14 kg
Effluent to ETP: 2305 kg
Solvent Loss: 124 kg
WET CAKE
DRYING Drying Loss: 105 kg
3-Hydroxy N-Napthyl 2 -Napthonilide: 1000 Kg
Distill Toluene Recycle: 3381 kg
Water: 100 kg + 10 kg Caustic
Water Scrubber
Effluent to ETP: 100 kg
9. Naphthol ASBO:
PCI3: 193 kg o-Anisidine: 412 kg
Soda ash: 23 kg Water: 2323 kg
WET CAKE
DRYING
Effluent to ETP: 2557 kg
DEHYDRATION BON Acid: 658 kg
Toluene: 3871 kg
Caustic flakes: 110 kg
Water: 62 kg to ETP
HCI Gas: 17 kg
Solvent Loss: 135 Distill Toluene Recycle: 3736
Water:100 kg + 10 kg
Water
Effluent to ETP: 100 kg
Drying Loss: 115 kg
3-Hydroxy 2 Naptho O- Anisidine : 1000 Kg
NAPHTHOL
FORMATION
10. Naphthol ASOL:
REDUCTION MDNB: 250 kg NaHS: 2375 kg
Water: 4000 kg
FILTERATION
WET CAKE WASHING
DRAYING
META NITRO ANILINE: 1000 Kg
Vapour loss: 1125 kg
Effluent: 6200 kg
Wash Water: 1700 kg
11. Meta Nitro Aniline:
12. Meta Urido Aniline:
REDUCTION
MPD: 497 kg HCI: 1163 kg
Water: 1576 kg Sodium Cyanate: 327 kg
FILTERATION
WET CAKE
META URIDO ANILINE: 1000 Kg
Effluent: 2563 kg
NEUTRALIZATION Up to 7pH
At room temperature (1 HRS)
6450
Product: 1000 kg
SULPHONATOR at180oc (10HRS)
2050
Vapor Loss: 2 kg
Vapor Loss: 5 kg
Carbon Adsorption
Scrubber
PAKING IN DRUM/TANKER
CONDENSATION at 110oc (20 HRS)
5540
Sulphuric Acid (98%): 900 kgs
Phenol :1150 kgs
Sulphuric Acid (98%): 139 kg
Phenol: 178 kg
Water: 310 kg
Formaldehyde: 217 kg
EDTA: 8 kg
Caustic Soda lye: 155 kg
13. Dispersing Agent based on phenol (liquid):
Product: 1000 Kg
Phenol based Dispersing Agent (liquid): 2227 kg
Water Evaporation: 1227 kg SPRAY DRAYING
14. Dispersing Agent based on phenol (Solid) :
NEUTRALIZATION At room temperature
(1 HRS)
PRODUCT: 1000 kg
SULPHONATOR at180oc (10HRS)
Vapor Loss: 19 kg
Vapor Loss: 10 kg
Scrubber
PAKING IN DRUM/TANKER
CONDENSATION at 110oc (15 HRS)
Sulphuric Acid (98%): 52 kg
Naphthalene: 196 kg
Water: 98 kg
Formaldehyde: 118 kg
Water: 225 kg
Caustic Soda lye: 196 kg
Oleum: 735 kg
Condenser Carbon
Absorber
15. Dispersing Agent based on Naphthalene (liquid):
Product: 1000 Kg
Naphthalene based (Liquid)
: 2380 kg
Water Evaporation: 1380 kg SPRAY DRAYING
16. Dispersing Agent based on Naphthalene (Solid):
Enclosure: 8 Detail of Water Consumption & Waste Water Generation
Total water consumption will be 37.5 KLPD. Domestic water consumption will be 4 KLPD & Industrial water consumption will be 33.5 KLPD.
Domestic effluent @ 4 KLPD will be disposed to soak pit system. Industrial effluent 24 KLPD will be treated in Effluent treatment Plant consisting primary & secondary units and 24 KLPD will be discharged to CETP, Vapi.
Water Consumption KL /Day
Effluent Generation KL /Day
Existing Proposed Total Existing Proposed Total Domestic 1 3 4 1 3 4 Industrial Process 4 19 23 2 19 21 Boiler 0.5 4.5 5 0.5 0.5 1 Cooling 1 1 2 0 0.5 0.5 Plant washing 1 0.5 1.5 1 0.5 1.5 Gardening 1 1 2 0 0 0 Total 8.5 29.5 37.5 5.5 22.5 28
Water Balance Diagram
All the Figures are in KL/Day
Water Consumption 37.5
Cooling 2
Boiler 5
Process 23
Effluent 21
Gardening 2
Domestic Effluent goes to septic tank
4
Domestic 4
Industrial 33.5
Blow Down 1
Effluent 0.5
Effluent Sand to ETP 24
CETP Vapi 24
Plant Washing 1.5
Washing Effluent
1.5
24
3
Enclosure: 9 Detail of Effluent Treatment Plant
Sr. No. Name of Unit Capacity
(m3)
Retention Time (hr)
MOC
1 Collection tank 10 4 RCC
2 Neutralization cum Flocculator tank 3 1 RCC
3 Settling tank 25 9 MS
4 Aeration tank with built in secondary clarifier 15 5.5 RCC
5 Sand Filter 1.5 0.5 MS 6 Carbon Filter 1.5 0.5 MS 7 Sludge Drying Bed 1 m2 --- Brick masonry
1 2 6 4 5 3
7
Effluent Inlet
Treated Effluent to
CETP
ETP Diagram
Enclosure: 10 Detail of Flue Gas Emission & Process Gas Emission with APCM System
Type of Flue Gas Emission:
No. Stack attached To Stack
Height (Meter)
APC Measures
Pollutants
SPM Mg/NM3
SO2 ppm
NOX ppm Existing Proposed
1. Boiler 600
kg/hour --- 11 ---
< 150
mg/NM3
< 100 ppm
< 50 ppm
2 D.G. Set 125 KVA
---
11 ---
< 150
mg/NM3
< 100 ppm
< 50 ppm
3 ---
Steam Boiler
800 kg/hr
11 Wet scrubber
< 150
mg/NM3
< 100 ppm
< 50 ppm
4 ---
HAG 400
kg/Hour
11 --- -- < 100 ppm --
Type of Process Gas Emission:
No. Stack attached To Stack Height (Meter) APC Measures Pollutants and their
limits
1. Napthol Reactor 11 Alkali Scrubber HCl< 20 mg/Nm3
2 Oleum Storage Tank and Sulphonator 11 Alkali Scrubber SO2< 40 mg/Nm3
3 HCHO Reactor 11 Carbon
Adsorption System
Formaldehyde Vapors< 10 mg/Nm3
Details of Fuels
Methanol + water mixer generates from manufacturing of cyano 2 Pyridone which will be used as fuel in our boiler. We will use methanol+ water mixer as a fuel in our proposed boiler (800 Kg/Hr). And in case of unavability of methanol + water mixer in case of zero production of cyano 2 pyridone, we will use Bio Coal/Coal as optional fuel.
We have decided to put our existing boiler (600 Kg/Hr) on standby. We will also use methanol + water mixer in stand by boiler. And in case of unavability of that fuel we will use PNG as optional fuel in standby boiler.
We will use Bio Coal/Coal as a Fuel in HAG.
Sr. No Name of Fuel Quantity
Existing Proposed Total
1 Diesel 10 Liter/Day -- 10 Liter/Day
2 Natural gas 55 SCM/Hr -- 55 SCM/Hr
3 Methanol + water Mixer -- 5 MT/Day 5 MT/Day
4 Bio Coal/Coal -- 1.60 MT/Day 1.60 MT/Day
Enclosure: 11 Detail of Hazardous Waste Management
Sr.
No.
Type of
Waste Category
Quantity Management
Existing Proposed Total
1 ETP Waste
Cat. No.: 35.3 3.6 MT/Year
196.4 MT/Year
200 MT/Year
Collection, Storage, Transportation, Disposal to TSDF site
2 Process Waste
Cat. No.: 34.3 42
MT/Year 84
MT/Year 126
MT/Year
Collection, Storage, Transportation, Disposal to TSDF
3 Used oil
Cat. No.: 5.1 0 0.012 KL/Year
0.012 KL/Year
Collection, Storage, Transportation, sell to authorize recycler.
4 Discarded
Containers/ Bags
Cat. No.: 33.1 2 MT/Year
430 MT/Year
432 MT/Year
Used for packing of ETP waste or return back to raw material supplier.
Enclosure: 12 Name & Address of Partner
Sr. No. Name of Partners
Residential Address
1 Mr. Nareshbhai N. Patel Flat No. A-1/102, Jalaram Co Operative Housing So. Ltd, Chharvada Road, GIDC Vapi, Pardi, Valsad
2 Mr. Mohanbhai N. Patel Village: Laloda, Ta: Idar, Dist: Sabarkantha
Enclosure: 13 Land Supporting Document
Enclosure: 14 Site Plan & Layout Plan
Enclosure: 15 CA Certificate
Enclosure: 16 Membership Certificates
Enclosure: 17 SSI Certificate
Enclosure: 18 Existing Consent Order Copy