ANNEXURE – 1 DETAILS OF EXISTING PRODUCTS AND PROPOSED PRODUCTSenvironmentclearance.nic.in/writereaddata/Online/TOR/0… ·  · 2015-03-14LIST OF EXISTING PRODUCTS AND PROPOSED

ANNEXURE – 1

DETAILS OF EXISTING PRODUCTS AND PROPOSED PRODUCTS

LIST OF EXISTING PRODUCTS AND PROPOSED PRODUCTS:

Sr.

No.

Product As Per Consent Quantity

(MT/Month)

Total Proposed Quantity

(MT / Month) 1. Monochloro Acetic Acid (MCAA) 500 2000

2. Sulfur Mono Chloride 40 80

3. Trichloro Acetic Acid (TCAA) 25 250

By-Products

1 Mixed Chloro Acetic Acid or ML

of MCAA

175.5 702

2 HCl 1010 3764

3 Sodium Hypochlorite 40 200

LIST OF RAW MATERIAL REQUIRED:

Sr.

No.

List of raw materials

required

Existing (MT / Month)

Proposed (MT /

Month)

1. Acetic Acid 403 1612

2. Liquid Chlorine 600 2242

3. Sulfur Monochloride 15.25 65.5

4. Mixed Chloro Acetic Acid 17.5 175

5. Sulfur 20 38.4

ANNEXURE – 2

MANUFACTURING PROCESS

CHEMICAL EQUATION

MATERIAL BALANCE DIAGRAM

DETAILS OF EACH PRODUCT :

NAME OF PRODUCT : MONOCHLORO ACETIC ACID (MCAA) QUANTITY TO BE PRODUCED : 2000 MT / Month

Raw material consumption per month: Manufacturing Process: The Chlorinators (Reaction Vessels) are MS Glass Lined, steam jacketed vessels. These vessels are charged with 99% pure Acetic Acid. Then, sulfur Mono chloride, as a catalyst, is charged equivalent to 1% of the Acetic Acid quantity. The vessel is then heated up to 90 oC and Chlorine is fed through pipeline from Chlorine tonner. While the chlorination is carried out, SMC (Catalyst) is again fed periodically (3-4%) of total quantity of Acetic Acid. The reaction temperature is maintained between 90 oC to 95 oC by cooling water in the jacket. During the above chlorination process, one Hydrogen (H) element of Acetic Acid is replaced by Chlorine (Cl) and generates Hydrochloric Acid in gaseous form. The Hydrochloric Acid Gas generated from the reaction is drawn through a 4 inch HDPE/Lead pipe and two Glass (Shell & Tube) Reflux Condensers of Cooling water and Chilled water respectively to the Aqueous Scrubbing system. The end point of reaction is determined by measuring the specific gravity. When the specific gravity of reaction mass reaches to 1375 gm/lt. at 62 oC, the reaction is complete. The above completed reaction mass known as Chlorinated Acetic Acid Mass (CAAM) contains following composition. Mono Chloro Acetic Acid: 90 to 92 % Di Chloro Acetic Acid : 7 to 8 % Unreacted Acetic Acid : 1 to 2 % The Chlorinated Acetic Acid mass (CAAM) produced is also sold as a separate product. CAAM of about 730MT/month is produced as per the market demand by using the same conventional method as that for mono chloro acetic acid preparation. The CAAM is then taken in to the Glass lined crystallizing vessel (Crystallizer) provided with the stirrer and the temperature is brought down to 35 oC. Then the mass is sent to the centrifuge from the bottom outlet and the mixture of Dichloro Acetic Acid and Acetic Acid with dissolved

Raw materials Requirement (MT/Month)

Acetic Acid 1612MT

Liquid Chlorine 2020MT

Sulfur Monochloride 58MT

Monochloro Acetic Acid is taken out as Mother Liquor OR Mixed Chloro Acetic Acid. The crystals of Monochloro Acetic Acid from centrifuge are packed in the bags as a final product. Thus, from the above reaction, Monochloro Acetic Acid, Mother Liquor or Mixed Chloro Acetic Acid (MCAA), and Hydrochloric Acid of 30% Concentration are produced. Chemical Reaction: CH3COOH + Cl2 --------------> ClCH2COOH + HCl Material Balance Basis: 10,000 Kgs of MCAA in each reactor Input Output

Material

Quantity Kgs/ batch

Material

Quantity Kgs / batch

Acetic Acid 8065 Monochloro Acetic Acid – crude 11431

Chlorine 10114 Dichloro Acetic Acid 1387

Sulfur Monochloride 291 Unreacted Acetic Acid 162

Hydrochloric Acid 5200

Sulfur Chloride 290

TOTAL 18470 18470

MCAA in Crude Mass 11431

Kgs

MCAA dissolved in DCA and Unreacted Acetic Acid 1431 Kgs

Net quantity of MCAA per Batch as output 10,000 Kgs. OR Quantity of chlorinated acetic acid mass (CAAM) 12862 Kgs.

Hydrochloric Acid is scrubbed in Scrubbing tower as 30% solution in water.

FLOW CHART:

NAME OF PRODUCT : TRI CHLORO ACETIC ACID (TCAA)

QUANTITY TO BE PRODUCED : 250 MT / Month

Raw material consumption per month:

Raw materials Requirement

(MT/Month)

Mixed Chloro Acetic Acid 175 MT

Liquid Chlorine 180 MT

Sulfur Monochloride 7.5 MT

Manufacturing Process:

The mixed Chloro acetic acid, generated from the Monochloro Acetic Acid reaction is a mixture of

unreacted Acetic Acid, Monochloro Acetic Acid and Di Chloro Acetic Acid. This mixture is further

chlorinated to Trichloro Acetic Acid. In case of Monochloro Acetic Acid, the Chlorination process

carried out is a partial chlorination.

The quantity of Liquor Generation is very less, and this liquor of Trichloro acetic acid is recycled.

Hence, there is only Hydrochloric Acid produced. The Trichloro Acetic Acid process is carried out

in the same reaction vessel in which Monochloro Acetic Acid is being produced. Thus, from the

above Reaction, Trichloro Acetic Acid is produced, Mother Liquor is recycled and Hydrochloric

Acid of 30% Concentration is produced.

Chemical Reaction:

CH3COOH + 3Cl2 --------------> Cl3CCOOH + 3HCl

Material Balance – TCAA

Basis: 10,000 Kgs of TCAA in each reactor

Input Output

Material

Quantity Kgs / Batch

Material

Quantity Kgs / Batch

Mixed Chloro Acetic Acid 6938 Trichloro Acetic Acid (crude mass) 10632

Chlorine 6941 Hydrochloric Acid 3547

SMC 300

Total 14179 Total 14179

TCAA in Crude Mass 10632Kgs

Unreacted mix chloroacetic acid + dissolved TCA + catalyst 632 Kgs

Net quantity of TCAA per Batch as output 10,000 Kgs

Hydrochloric Acid is scrubbed in Scrubbing tower as 30% solution in water.

FLOW CHART:

NAME OF PRODUCT : SULFUR MONO CHLORIDE

QUANTITY TO BE PRODUCED : 80 MT / Month

Raw material consumption per month:

Manufacturing Process:

Chlorinators are charged with 99.9% pure Sulfur Granules, with some quantity of Sulfur Mono

Chloride inside reactor as a reaction media. Chlorine is then sparged through the sparger from a

chlorine cylinder. The sulfur charged, will react with this Sulfur Mono Chloride and make Crude

form of Sulfur Mono Chloride. Crude mass is first converted into Mono Chloride and if any excess

chlorine is available, this mono chloride will be converted into Di Chloride and Tri Chloride

respectively. Hence, there is practically no chance of liberation of unreacted chlorine gas, since the

reaction is suspended at a Mono stage.

The vent of the second reactor is connected to the Caustic Scrubber. The unreacted Chlorine, if any,

is scrubbed here to make Sodium Hypochlorite which is then sold.

Chemical reaction:

2S + Cl2 --------------> S2Cl2

Material Balance: Basis : 8000 Kgs./batch

Input Output

Material Qty in Kgs. /

batch

Material Qty in Kgs. / batch

SMC 2000 SMC 8000

Sulfur 3840 SMC (Recycle) 2000

Chlorine gas 4160

Total 10,000 Total 10,000

FLOW CHART:

Raw materials Requirement (MT/Month)

Sulfur 38.4 MT Liquid Chlorine 41.6 MT

ANNEXURE – 3

WATER CONSUMPTION

WASTE WATER GENERATION

DETAILS OF EFFLUENT TREATMENT PLANT

MEMBERSHIP COPY OF THE CETP

Details of Water Consumption:

Source of Water : Existing Borewell in the Plant premises

Breakup Existing Consumption

m3/day

Proposed consumption

m3/day Domestic 0.5 2.0

Process 21.425 85.7 Utilities 3.3 13.2 Washings 1.0 1.0 Total 26.225 104.9

The source of water supply is from the borewell located inside the factory premises. Most of the

water consumption is utilized for scrubbing activities and manufacturing byproducts.

Details of waste water generation :

Breakup Existing Proposed New

Products

Domestic 0.5 1.8

Process Nil Nil

Utilities Nil Nil

Washings 1.0 1.0

Total 1.5 2.8

The domestic waste water will be disposed off in soak pit.

Process water through the scrubbing activity is used for the production of 30% HCl and sodium

hypochlorite, which will be sold. Water from the boiler condensate is recycled.

The only waste water generated from the unit is from plant washings, which will be neutralized in

the effluent treatment plant using caustic soda. The neutralized waste water will then be collected in

10 KL storage tanks (2 in Nos.) and sent to the CETP of Enviro Infrastructure Co. Ltd. (EICL) for

further treatment.(Membership of the CETP is already available)

DETAILS OF EFFLUENT TREATMENT PLANT :

ANNEXURE 4

DETAILS OF AIR EMISSION SOURCES

AND

AIR POLLUTION CONTROL DEVICES (SCRUBBERS)

Details of Air Emission:

Existing scenario:

Stack attached to Non-IBR steam boiler

Fuel used Wood waste / LDO Quantity of fuel Wood - 2000 Kgs/ day or

LDO – 1200 Lit/ day Type of emissions SO2, NOX & PM Stack height 40 feet. Stack diameter at the top 8 inches

For the existing plant, only Non-IBR steam boiler is used for heating purposes. For recovery of HCl

one FRP graphite scrubber is installed. The tail gases containing chlorine is then scrubbed in the

caustic scrubber (2 in No.) to produce sodium hypochlorite. HCl and Sodium hypochlorite are sold

as by-products.

Stack attached to Water Scrubber for HCl

Type of emission HCl

Stack height 20 mts.

Capacity of Scrubber 50 kg/hr

Scrubber medium Water

Stack attached to Caustic Scrubber

Type of emission Cl2

Stack height 20 mts.

Capacity of scrubber 10 kgs/hr

Scrubbing medium Caustic Soda

Proposed Expansion Activity:

For the Proposed Expansion (2 Nos.) IBR 3Mt/hr steam boiler and a Thermic fluid boiler will be

installed for heating activities.

Utility Stacks :

Stack attached to IBR steam boiler No. 1

Capacity 3 MT/hr

Fuel used White coal/ Agrowaste/ Wood waste

Quantity of fuel 3.8 MT / day

Type of emissions SO2, NOX & PM

Stack height 40 feet

Stack diameter at the top 8 inches

Stack attached to IBR steam boiler No. 2

Capacity 3 MT/hr

Fuel used White coal/ Agrowaste/ Wood waste

Quantity of fuel 3.8 MT / day

Type of emissions SO2, NOX & PM

Stack height 40 feet

Stack diameter at the top 8 inches

Stack attached to Thermic fluid boiler

Fuel used LDO

Quantity of fuel 200 ltrs/ day

Type of emissions SO2, NOX & PM

Stack height 40 feet

Stack diameter at the top 8 inches

To reduce the emissions of particulate matter from the burning of wood, a cyclone followed by bag

filter will be installed. A schematic of the cyclone is given below :

Process Stacks :

HCl which will be scrubbed off from the tail gases will be recovered in 2 stage water scrubbers

and sold as a product. The unreacted chlorine will be passed through two stage caustic scrubber

and converted to sodium hypochlorite which will be also sold off

Stack attached to Water Scrubber

Gas scrubbed HCl

Stack height 20 mts

Type of scrubber - primary FRP/Graphite (shell & tube)

Capacity of the primary scrubber 500 kgs/hr

No. of Scrubbers 2 Nos.

Type of scrubber - secondary SCC

Capacity of the secondary scrubber 50 Kgs/hr.

No. of Scrubbers 2

Scrubbing medium Water

By product recovered HCl

Sources of Gaseous Emission Caustic Scrubber

Gas scrubbed Cl2

Stack height 20 mts.

Stages of Scrubbing primary

Type of Scrubber - primary FRP/HDPE

Capacity of the primary scrubber 100 kgs/hr

No. of Scrubbers 2

Type of scrubber - secondary PP/HDPE

Capacity of the secondary scrubber 100 kgs/hr

Scrubbing medium Caustic

By-product recovered Sodium Hypochlorite

ANNEXURE – 5

DETAILS OF HAZARDOUS WASTE GENERATION AND DISPOSAL

Details of solid waste generated after the expansion:

For the proposed expansion activitites, the effluent is generated from the plant washings. The

effluent will be slightly acidic in nature which will be neutralized with caustic soda and does not

generate any sludge.

Raw materials like, acetic acid is received in tanker load, Cl2 in returnable tonners and sulphur in

loose. Hence no empty bags / liner / empty barrel generation.

The only hazardous waste generated from the plant is the used oil,which will be sold to the

authorized recyclers.

Sr

no

Waste

detail

Waste

category

Chemical

form

Physical

form

Existing

Quantity to

be

disposed

Proposed

Quantity to

be disposed

Mode of

disposal

1 Used

oil

5.1 Gear box,

transformer,

lubrication oil,

thermic fluid

heater oil

Viscous

liquid

0.2 KL/Yr 1.0 KL/Yr Applied on

MS

Structures

to prevent

corrosion or

sold to

authorized

oil

recyclers.