ANNEXURE- I PROPOSED TERMS OF REFERENCEenvironmentclearance.nic.in/writereaddata/FormB/TOR/Additional... · ANNEXURE- I PROPOSED TERMS OF REFERENCE ... generation and disposal. ...

ANNEXURE- I PROPOSED TERMS OF REFERENCE

Site description and plant lay out.

List of finished products and production quantity.

List of raw materials and consumption quantity.

Process details with mass balance.

Details of process emissions, flue gas emission, waste water discharge & solid waste

generation and disposal.

Complete water balance.

Details of air pollution control systems.

Base line data for soil, water, air and noise for one season.

Environment impact assessment study due construction activities, manufacturing

process and its operations etc.

Details of environmental management plan (EMP) and mitigation measures.

Occupational health and safety program for the project.

ANNEXURE- II LIST OF PROPOSED PRODUCTS AND THEIR PRODUCTION CAPACITY: Sr.No. Name of Products

Capacity (MT/Month)

1 Acetic Anhydride 3600 2 Easter of Acetic acid like Ethyl Acetate etc 1800 3 Mono Chloro Acetic Acid(MCAA) 3000 4 Chloro Acetyl Chloride (CAC) 650 5 2 Ethylexyl Nitrates (2EHN) 3000 6

Nitro derivaties of hydrocarbon such as Nitro Xylene, Nitro Cumene .etc.

3000

7 Phenyl ethyl alcohol (PEA) 500 8 Sodium Monochloro Acetate (SMAC) 300 9 Methyl Chloro Acetate

500

10 Ethyl Chloro Acetate 11 Dichloro Acetic Acid 12 Trichlo Acetic Acid 13 Calcium chloride 2500 14 Coal Based Power plant 4 MW

By Product 1 Spent Acid 2373.453 2 Hydrochloric acid 6958 3 Sodium hypo chloride 808 4 Sodium Bi Sulphite (SBS) 7722 5 Mother liquor of MCAA 1400

ANNEXURE-III LIST OF PROPOSEDRAW MATERIALS PRODUCT WISE Sr.No. Name of Product Name of Raw Materials Quantity in T/Month 1 Acetic Anhydride Acetic acid 2650.29

Catalyst 7.76 Ammonia 1.80 Ethyl acetate 13.64 Total 2673.49

2 Ethyl acetate Acetic acid 1227.11 Ethyl alcohol 1040.59 Para Toluene Sulphonic acid (PTSA)

52.59

Total 2320.29 3 Mono Chloro Acetic

Acid Acetic acid 2700 Chlorine 3408 Caustic 247.5 SMC 72 Acetic anhydride 60 Total 6487.5

4 2 Ethylexyl Nitrates (2EHN)

2-Ethyl Hexanol (2EH) 2250 Nitric acid 99 % 114 Sulfuric acid 98 % 1530 Sodium sulfate 300 Caustic Soda 150 Total 4344

5 Nitro Xylene Xylene 1666.52 Nitric acid 1443.18 Sulfuric acid 1332.17 Spent acid 1959.077 Soda 130.60 Total 6531.547

6 Nitro cumene Cumene 2203.256 Nitric acid 1180.465 Sulfuric acid 969.76 Spent acid 3488.37 Total 7841.851

7 Phenyl ethyl alcohol (PEA)

Styrene 174.65 SBC 55.01 DMF 4.80 TBSA 0.087 Soda ash 1.22 NaOH 0.611 H2O2 220.07Total 456.448

8 Sodium Monochloro Acetate (SMAC)

MCA 246 Soda Ash 138 Total 384

9 Methyl Chloro Acetate

MCA 435 Methyl alcohol 148 Sulphuric acid 454.5 Total 1037.5

10 Ethyl Chloro Acetate MCA 385.5 Ethyl alcohol 188 Sulphuric acid 402.5 Total 976

11 Dichloro Acetic Acid Chlorine 555 Acetic acid 235 Total 790

12 Trichlo Acetic Acid Chlorine 800 Acetic acid 250 Total 1050

13 Calcium chloride Limestone 2250 HCl 1675 Lime solution 25 Total 3950

ANNEXURE-IV LIST OF HAZARDOUS RAW MATERIAL Sr.No. Name of Products Name of Hazardous Raw

Materials 1 Acetic anhydride Ammonia 2 Ethyle acetate PTSA 3 Mono Chloro Acetic

Acid Chlorine

4 2 EHN Sodium sulfate5 Nitroxylene Sulfuric acid 6 Nitrocumene Sulfuric acid

ANNLAY

NEXURE-V YOUT PLANN

ANNSITE

NEXURE-VIE PLAN

I

ANNEXURE-VII

MANUFACTURING PROCESS,CHEMICAL REACTION & MATERIAL BALANCE

(1) ACETIC ANHYDRIDE

Acetic anhydride is produced from glacial acetic acid via ketene. Acetic acid is vaporized and

fed together with a catalyst to a cracking furnaces operating under vacuum where ketene is

produced together with water at high temperature. The reaction mixture is rapidly cooled to

avoid the reversing of the reaction. The condensed dilute acid is separated and gases then

pass through two absorption towers in which they are scrubbed by acetic acid/acetic

anhydride of various concentrations.

Glacial acetic acid is added to the second absorption tower.ketane is reacting with acetic acid

to form acetic anhydride in following washing towers the gases are further scrubbed before

released to the atmosphere. In a distillation column the crude acetic anhydride is distilled and

recovered as bottom product. The top product is acetic acid which is recycled to the process.

Acetic anhydride is raw material for cellulose acetate (fibers, films plastic, cellulose lacquers)

aspirin, agricultural chemicals, fragrances, pharmaceuticals and explosives.

CH3CO2H = CH2=C=O + H2O Acetic acid ketene Water 60 42 18 CH3CO2H + CH2=C=O = (CH3CO) 2 O Acetic acid ketene Acetic anhydride 60 42 102

MATERIAL BALANCE FOR ACETIC ANHYDRIDE-

INPUT KG

PROCESS WATER 186.67

CATALYST 17.52

AMMONIA 4.08

ACETIC ACID 4040.33

TOTAL 4248.6

KG OUTPUT

2411.6 KETANE GAS

1837 DILUTE ACID

4248.6 TOTAL

KETANE GAS 2411.6

ACETIC ACID 2567.84

ACETIC ACID Recover 628

TOTAL 5607.44

5200 ACETIC ANHYDRIDE

61 RESIDUE

346.44 DILUTE ACID

5607.44 TOTAL

DILUTE ACID 2183.44

PROCESS WATER 1336.87

ETHYL ACETATE 30.8

TOTAL 3551.11

2923.11 Water to ETP

628 ACETIC ACID RECO.

3551.11 TOTAL

KETANE GENERATION 

SCRUBBING AND 

DISTILLATION 

ACETIC ACID RECOVERY 

(2) ETHYL ACETATE

Ethyl acetate is produced by etherification of acetic acid with ethanol using sulphuric acid as catalyst. Ethanol and acetic acid are continuously fed to the steam heated reactor. The ethyl acetate formed is removed from the top of the reactor column together with some ethanol and water. The oily phase is separated and washed and then sent to the ester column where the product is removed from the bottom. Water phases from decanters are sent to the recovery column where ethanol is recovered and sent back to the reactor. The bottom water phase is sent out as effluent.

Ethyl Acetate is a colourless liquid and has a characteristic sweet smell. It is used as solvent for paints, extraction agent, raw material for pharmaceuticals, cosmetics and polishes.

CH3COOH + C2H5OH = CH3COOC2H5 + H2O

Acetic acid Ethyl alcohol Ethyl acetate Water

60 46 88 18

MATERIAL BALANCE FOR ETHYL ACETATE

INPUT KG ETHYL ALCOHOL

1484

ACETIC ACID 1750 PTSA 75 TOTAL 3309

KG OUTPUT

3309 REACTION MASS

3309 TOTAL

REACTION MASS

3309

WATER 2768 TOTAL 6077

2567 ETHYL ACETATE

3510 WATER+ETHYL

ALCOHOL

6077 TOTAL

1907 WATER TO ETP

1463 ETHYL ALCOHOL

RECOVER

140 LOSS

3510 TOTAL

WATER+ETHYL ALCOHOL

3510

TOTAL 3510

PURIFICATION

ETHYL ALCOHOL RECOVERY

ESTERIFICATION

(3)ETHYLEXYL NITRATE (2EHN)

Manufacturing Process 2-Ethylhexyl Nitrate is produced by the o-nitration of 2-ethylhexanol using nitric acid along with Sulphuric Acid (Mixed Acid). The manufacturing process of 2-EHN would consist of the following process steps as presented in process block diagram in Annexure-I: 1. Preparation of Nitrating acid. 2. Nitration of 2-Ethylhexanol (2-EH) with Nitrating acid. 3. Separation of spent acid stream from 2-EHN stream. 4. Recycle / De-nitration / Recovery of Nitric Acid / Concentration of Sulphuric Acid 5. Washing & Neutralization of 2-EHN stream. 6. Drying of 2-EHN to meet moisture specifications.

OH + HNO3 T≤ 200C ONO2+H2O H2SO4 ISO-Octanol Nitric acid 2 Ethylexyl nitrates Water 130.23 63 175.23 18 1. Nitrating Acid Preparation The nitrating acid would be prepared in a continuous mode. The process requires conc. nitric; dilute sulphuric and concentrated sulphuric acid to be mixed to prepare required composition of nitrating acid (mixed acid). This acid will be cooled in heat exchangers and fed to 2-EHN nitration sections. 2. Nitration of 2EH The nitration would be carried out in a continuous tubular nitrator. The nitrating acid stream is cooled to 0 0C and fed to Nitrator along with 2-EH steam. The nitration reaction takes place in adiabatic condition in short residence time and the product and spent acid stream are further cooled in product cooler and heat exchanger followed by separation of spent acid from steam 2-EHN. For accurate flow rate measurement, mass flow meters are installed in controlling the variation of feed ratio and to have better control of system.

3. Separation of 2-EHN for Spent Acid Stream The combined stream of 2-EHN and Spent Acid is separated in phase separator in which the 2-EHN stream is separated from the spent acid stream. The spent acid stream is send to the spent acid tank for de-nitration/recycle. The phase separator has the following unique features: l. High separation efficiency compared to conventional gravity separators. Our separator breaks the micro-emulsions resulting in lower residence times and lower volumes to achieve desired separation. 2. Avoid the use of expensive centrifugal separators and dynamic separators for separating 2-EHN from acid stream. 3. The phase separator is PLC controlled and is able to control interface level and flow of individual steams resulting is steady and constant process conditions. 4. Efficient separation of 2-EHN and spent acid means safe operations as spent acids would be more stable and also ease the washing and neutralization load of downstream operations. 4. Washing and Neutralization of 2-EHN Stream The acidic stream of 2-EHN is washed in a continuous manner in a combination of series of three washers and separators. In the washer and separator the flow of 2-EHN is moved by water ejectors for safety reasons. The washed neutral 2-EHN stream contains less than 500ppm moisture and is fed for final drying. 5. Drying of 2-Ethylhexyl Nitrate The 2-EHN stream is continuously dried to get the required moisture limit of < 0.05% and is directly pumped to 2-EHN storage tanks. 6. De-nitration and Concentration Units The spent acid from 2-EHN plant is unstable and is to be de-nitrated to separate sulfuric acid from nitric acid. The nitric acid stream can further concentrated and recycled back. The sulfuric acid stream can be concentrated and recycled back.

MATERIAL BALANCE FOR 2-ETHYLEXL NITRATES.

INPUT KG

2-EH 750

NITRIC ACID 164

SULPHURIC ACID 510

REC.NITRIC ACID 126

REC.SULFURIC ACID 210

TOTAL 1760

KG OUTPUT

1760 REACTION

MASS

1760 TOTAL

1424 REACTION

MASS

336 Spent acid

1760 TOTAL

RECTION MASS 1760

TOTAL 1760

126 NITRIC RECY.

210 SULPHURIC

RECY.

336 TOTAL

Spent Acid 336

TOTAL 336

SODA 50

SODIUM SULPHATE 100

WASHING WATER 56.25

REACTION MASS 1424

TOTAL 1630

1250 REACTION

MASS

380 EFFLUENT

1630 TOTAL

REACTION MASS 1250

TOTAL 1250

1000 2EHN

250 WATER

VAPOUR

1250 TOTAL

SEPERATOR

DRYING

REACTION

WASHING

De-nitration & Concentration

(4) NITRATION OF HYDROCARBON SUCH AS NITROXYLENE,

NITROCUMENE ETC.

A) NITROCUMENE

C6H5CH (CH3)2 + HNO3 = C6H4NO2CH(CH3)2 + H2O

120.2 63 165.2 18

INPUT KG

CUMENE (FRESH) 1579

NITRIC ACID 846

SULPHURIC ACID 695

SPENT ACID 2500

TOTAL 5620

KG OUTPUT

5620 REACTION

MASS

5620 TOTAL

2171 REACTION

MASS

2500 Spent Acid

949 Spent acid sent

5620 TOTAL

RECTION MASS 5620

TOTAL 5620

REACTION MASS 2171

WASHING WATER 400

TOTAL 2571 2571 REACTION

MASS 2571 TOTAL

RECTION MASS 2571

TOTAL 2571

2191 REACTION

MASS

380 EFFLUENT

2571 TOTAL

REACTION MASS 2191

TOTAL 2191 20 WATER LOSS 2171 REACTION

MASS 2191 TOTAL

REACTION MASS 2171

TOTAL 2171

2150 NITROCUMENE

21 RESIDUE

2171 TOTAL

SEPERATOR

DRYING

REACTION

WASHING

SEPERATOR

DISTILLATION

A) NITROXYLENE

C6H4 (CH3)2 + HNO3 = C6H3NO2 (CH3)2 + H2O

106.17 63 151.16 18

INPUT KG

XYLENE 1613

REC.XYLENE 337

NITRIC ACID 1105

SULPHURIC ACID 1020

SPENT ACID 1500

TOTAL 5575

KG OUTPUT

5575 REACTION

MASS

5575 TOTAL

2740 REACTION

MASS

1500 Spent Acid

1335 Spent acid sent

5575 TOTAL

RECTION MASS 5575

TOTAL 5575

REACTION MASS 2740

WASHING WATER 800

SODA 100

TOTAL 3640

3640 REACTION

MASS

3640 TOTAL

RECTION MASS 3640

TOTAL 3640

2720 REACTION

MASS

920 EFFLUENT

3640 TOTAL

REACTION MASS 2720

TOTAL 2720

2297 NITROXYLENE

337 REC.XYLENE

86 RESIDUE

2720 TOTAL

SEPERATOR

WASHING

SEPERATOR

DISTILLATION

REACTION

(5) PHENYL ETHYL ALCOHOL (PEA)

Manufacturing process

Charge water, SBC, TABA, CATALYST, DMF & Styrene in SS reactor cool & maintain temperature, add slowly hydrogen peroxide into reaction mass & maintain temp. crude styrene oxide will form, transfer this crude mass for washing & hydrogenation. Add water, NaOH, soda ash& catalyst, then purge air with nitrogen & add hydrogen in hydrogenrator & add styrene oxide slowly in hydrogenrator, maintain temperature. Cool then mass for water washing & for vaccum distillation. About 93 to 95 % of Phenyl Ethyl alcohol will form.

Chemical Reaction

CH=CH2

H2O2

OXIDATION CH CH2

O

C8H8 C8H8O 104 120

STYRENE MONOMER104 STYRENE OXIDE

OH

H2

CH CH2

O

C8H8O C8H10O 120 122

STYRENE OXIDE PEA

Material balance for PEA.

INPUT KG STYRENE 2000 WATER 4500 SBC 630 TBSA 1 DMF 55 CATALYST-1 1.5 CATALYST-2 0.7 H2O2 2520 TOTAL 9708.2

KG OUTPUT 9708.2 REA.MASS 9708.2 TOTAL

INPUT KG REAC.MASS 9708.2 TOTAL 9708.2

KG OUTPUT 7708.2 REA.MASS 2000 EFFLUENT 9708.2 TOTAL

INPUT KG REA.MASS 7708.2 WATER 2000 SODA ASH 14 NaOH 7 CATALYST-pd 5 TOTAL 9734.2

KG OUTPUT 5734.2 REA.MASS 4000 EFFLUENT 9734.2 TOTAL

KG OUTPUT 5725.416 REA.MASS 8.784 EFFLUENT 5734.2 TOTAL

INPUT KG REAC.MASS 5734.2 TOTAL 5734.2

REACTOR

WASHER

HYDRGENATION

DISTILLATION

(6) MONOCHLOROACETIC ACID & ITS DERIVATIVES LIKE:

(A) Mono- Chloro Acetic Acid (MCAA) Manufacturing Process: Charge Acetic Acid in the reactor. Heat the reactor to 100 °C and start chlorination. Acetic acid is converted into Mono-chloro Acetic Acid in presence of Acetic anhydride and Sulfur mono chloride as catalysts. During the process HCl gas is also generated, which is scrubbed by scrubber and dissolved in water to get 30% HCl liquor. After completion of reaction, mass is transferred in bowls for crystallization where natural followed by induced cooling takes place. After about 70 hr pure MCAA crystals are recovered. After centrifuging MCAA product is ready for packing. CH3COOH + Cl2 = ClCH2COOH + HCL 60 Kg/kmol 71 Kg/kmol 94.5 Kg/kmol 36.5 Kg/kmol

INPUT KG CHLORINE 6816 ACETIC ACID 5400 SMC 144 ACETIC ANHYDRIDE

120

TOTAL 12480

KG OUTPUT

8730 REACTION MASS

3300 HCL

450 CHLORINE

12480 TOTAL

REACTION MASS

8730

TOTAL 8730

6000 MCAA

2730 MOTHER LIQUIR

8730 TOTAL

CHLORINE 450 ACETIC ACID 3300 WATER 6960 TOTAL 10710

450 CHLORINE

10260 HCL FOR SALE

10710 TOTAL

CHLORINE 450 CAUSTIC 495 WATER 315 TOTAL 1260

1260 NaOCl

1260 TOTAL

CENTRIFUGE

CAUSTIC SCRUBBER

GLASS LINED REACTOR

 HCL SRUBBER

(B) CHLORO ACETYL CHLORIDE(CAC):

1. The MCA is directly taken to CAC reactors and the mass at the desired temperature gradual addition of sulphur monochloride is carried out and chlorination is carried out. On the completion of the reaction crude product is formed. The vent gases evolved during the process sent to scrubbing system.

2. The crude CAC thus formed is distilled, condensed, collected and packed. Chemical reaction.

4ClCH2COOH + S2Cl2 +3Cl2 = 4ClCH2COCl + 2SO2 + 4HCL MCAA SMC CHLORINE CAC Sulphur dioxide Hydrochloric acid

INPUT KG MCAA/ML 8550 CHLORINE 490 SMC 2970 TOTAL 12010

KG OUTPUT

5143 REACTION

MASS

3186 HCL

945 CHLORINE

2736 SO2

12010 TOTAL

4000 MCAA

90 RESIDUE

1053 DISTILL GAS

5143 TOTAL

REACTION MASS 5143 TOTAL 5143

945 CHLORINE

11250 HCL FOR

SALE

2736 SO2

1053 DISTILL GAS

15984 TOTAL

CHLORINE 945 HCL 3186 WATER 8064 DISTILL GAS 1053 TOTAL 13248

Na2CO3 2340 CHLORINE 945 CAUSTIC 243 WATER 41301 SO2 2736 DISTILL GAS 1053 TOTAL 46278

36018 SODIUM BISULPHITE-

SBS

10260 SODIUM

HYPOCHLORIDE

46278 TOTAL

DISTILLATION

CAUSTIC SCRUBBER

GLASS LINED REACTOR

HCL SRUBBER

(C) SODIUM MONOCHLOROACETATE (SMAC)

1. Charge MCA and Soda Ash in the reactor for blending .Then the mass is called sodium Mono Chloro Acetate .Then this mass dried and pack in packing bags. Chemical Reaction: 2ClCH2COOH + Na2CO3 2ClCH2COONa + H2O + CO2 Mono chloro Soda ash Sodium Mono Acetic acid Chloro acetate

Mass balance & Process flow diagram:

INPUT KG MCA 820 SODA ASH 460 TOTAL 1280

KG OUTPUT

1089 REACTION MASS

191 CO2

1280 TOTAL

REACTION MASS

1089

TOTAL 1089

1000 SMCA

89 WATER

1089 TOTAL

DRYING

RIBON BLENDER

(D) METHYL CHLORO ACETATE

Manufacturing Process

Charge measured quantity of Methyl alcohol, Mono chloro acetic acid and sulphuric acid in to reactor. After charging of raw materials heating is given, after heating spent sulphuric acid layer is separated .The crude ester is filter or distilled. Thus output is Methyl chloro acetate and spent Sulphuric acid. The spent is resale for manufacturing copper sulphate and ferrous sulphate.Which results “Zero Discharge Process.

Reaction

CH3OH + Cl-CH2-COOH + H2SO4 CH3-COO-CH2-Cl + H2SO4.H2O

Methyl Monochloro Sulphuric Methyl Chloro Spent Acid Alcohol Acetic acid Acid Acetate 32 94.5 98.6 108.5 116.6

Mass balance & Process flow diagram

INPUT KG MCA 870 METHYL ALCOHOL

296

SULPHURIC ACID 909 TOTAL 2075

KG OUTPUT

1000 REACTION MASS

1075 Spent Sulphuric acid

2075 TOTAL

REACTION MASS

1000

TOTAL 1000

1000 Methyl chloroacetate

1000 TOTAL

DISTILLATION

REACTOR

(E) ETHYL CHLORO ACETATE

Manufacturing Process

Charge measured quantity of Ethyl alcohol, Mono chloro acetic acid and sulphuric acid in to reactor. After charging of raw materials heating is given, after heating spent sulphuric acid layer is separated .The crude ester is filter or distilled. Thus output is Methyl chloro acetate and spent Sulphuric acid. The spent is resale for manufacturing copper sulphate and ferrous sulphate.Which results “Zero Discharge Process.

Reaction

C2H5OH + Cl-CH2-COOH + H2SO4 C2H5-COO-CH2-Cl + H2SO4.H2O

Ethyl Monochloro Sulphuric Methyl Chloro Spent Acid Alcohol Acetic acid Acid Acetate 46 94.5 98.6 122.5 116.6

Mass balance & Process flow diagram

INPUT KG MCA 771 METHYL ALCOHOL

376

SULPHURIC ACID 805 TOTAL 1952

KG OUTPUT

1000 REACTION MASS

952 Spent Sulphuric acid

1952 TOTAL

REACTION MASS

1000

TOTAL 1000

1000 ethyl chloroacetate

1000 TOTAL

DISTILLATION

REACTOR

(F) Di Chloro Acetic Acid :

1. The required quantity of acetic acid/mother liquor of MCA is taken into reactor. Then steam is passed through jacketed vessel to raise the temp. From the room temperature. As soon as temp. is achieved chlorine gas is sparge through the mass. The chlorination is carried out to obtain mono chloro acetic acid.

2. After reaching to the end point the reacted mass is transferred to DCAA reactor. The vent gases from MCA reactors sent to scrubbing system.

3. The reacted mass taken into reactor is again heated to required temp.After achieving the desired temp.the chlorine gas passed through this mass.

4. This mass is an intermediate product known as Di chloro acetic acid (DCAA).It is either taken for packing and dispatch for transferred to DCAC reactor. The vent gases evolved are spurge through MCA reactor and from here they are sent to the scrubbing system. Chemical Reaction CH3COOH +2Cl2 CHCl2COOH + 2HCl Acetic Acid Liquid chlorine Di chloro Acetic Acid Hydrochloric acid

INPUT KG CHLORINE 1110 ACETIC ACID 470 Mother liquor(recycle) 100 TOTAL 1680

KG OUTPUT

1100 Di-Chloroacetic acid-

crude

580 HCL

1680 TOTAL

Di-Chloroacetic acid-crude

1100

TOTAL 1100

1100 DCAA-crystallise

1100 TOTAL

TCAA 1100 TOTAL 1100

100 Mother liq.of-(recycle)

1000 DCAA

1100 TOTAL

CRYSTALLIZATION

CENTRIFUGE

GLASS LINED REACTOR

OR

INPUT KG CHLORINE 900 Mother liquor of MCA 400 Mother liquor(recycle) 100 ACETIC ANHYDRIDE

140

TOTAL 1540

KG OUTPUT

1100 Di-Chloroacetic acid-

crude

440 HCL

1540 TOTAL

Di-Chloroacetic acid-crude

1100

TOTAL 1100

1100 DCAA

1100 TOTAL

TCAA 1100 TOTAL 1100

100 Mother liq.of-(recycle)

1000 DCAA

1100 TOTAL

CRYSTALLIZATION 

CENTRIFUGE 

GLASS LINED REACTOR

(G) Tri Chloro Acetic Acid :

1. The required quantity of acetic acid/mother liquor of MCA is taken into reactor. Then steam is passed through jacketed vessel to raise the temp. from the room temperature. As soon as temp.is achieved chlorine gas is sparged through the mass. The chlorination is carried out to obtain mono chloro acetic acid.

2. After reaching to the end point the reacted mass is transferred to TCAA reactor. The vent gases from MCA reactors sent to scrubbing system.

3. The reacted mass taken into TCAA reactor is again heated to required temp.After achieving the desired temp.the chlorine gas passed through this mass.

4. This mass is an intermediate product known as Tri chloro acetic acid (TCAA).It is either taken for packing and dispatch for transferred to TCAC reactor. The vent gases evolved are sparged through MCA reactor and from here they are sent to the scrubbing system. Chemical Reaction CH3COOH +3Cl2 CCl3COOH + 3HCl Acetic Acid Liquid chlorine Tri chloro Acetic Acid Hydrochloric acid

OR

INPUT KG CHLORINE 1600 ACETIC ACID 500 Mother liquor(recycle) 100 TOTAL 2200

KG OUTPUT

1100 TCAA(CRUDE)

1100 HCL

2200 TOTAL

TCAA (CRUDE) 1100 TOTAL 1100

1100 TCAA-CRYSTALLISE

MASS

1100 TOTAL

TCAA-CRYSTALLISE

1100

TOTAL 1100

100 Mother Liq. of TCAA

(RECYCLE)

1000 TCAA

1100 TOTAL

INPUT KG CHLORINE 1200 Mother liquor of MCA 500 Mother liquor(recycle) 100 ACETIC ANHYDRIDE

180

TOTAL 1980

KG OUTPUT

1100 TCAA(CRUDE)

880 HCL

1980 TOTAL

TCAA(CRUDE) 1100 TOTAL 1100

1100 TCAA-CRYSTALLISE

MASS

1100 TOTAL

TCAA 1100 TOTAL 1100

100 Mother Liq. of TCAA

(RECYCLE)

1000 TCAA

1100 TOTAL

CRYSTALLIZATION 

CENTRIFUGE 

GLASS LINED REACTOR 

CRYSTALLIZATION 

CENTRIFUGE 

GLASS LINED REACTOR 

(7) CALCIUM CHLORIDE

Manufacturing Process

Limestone will be fed at the top of the reactor and hydrochloric acid will flow counter current from the bottom .In the reactor HCl will react with Limestone to produce Calcium Chloride Solution and Carbon dioxide gas.

35% solution of calcium chloride produced in the reactor will overflow to a Neutralization tank where the pH of the solution will be corrected by addition of lime solution .The reacted solution will be taken to a settler where magnesium and iron components will be precipitated out.

Clarified Calcium Chloride Solution will be filtered and the clear solution will be taken to the evaporation unit for drying.

CaCO3 + 2HCl CaCl2 + CO2 + H2O

Limstone Hydrochloric acid Calcium chloride

100 73 111 18 44

INPUT KG LIMESTONE 900HCL 670 TOTAL 1570

KG OUTPUT

1170 Cal.chloride

SOLUTION

400 CO2

1570 TOTAL

Cal.chloride SOLUTION

1170

LIME SOLUTION 10 TOTAL 1180

10 SLUDGE

1170 Neutralise mass

1180 TOTAL

CaCl2 solution 1170 TOTAL 1170

170 WATER

1000 CONC.CAL.CHLOR.

1170 TOTAL

CONC.CAL.CHLOR 1000 CAL.CHLORIDE 1000

NEUTRALIZATION 

GRANULATION

REACTOR 

EVAPORATOR 

ANNEXURE-XII: DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL Sr. No.

Type of Hazardous Waste

Quantity in MT/month

Hazardous Waste Category

Storage, Collection & Disposal

1 ETP Sludge 300 34.2 Collection, Storage , Transportation & Disposal to TSDF or Sold to Actual Users (i.e. cement mfg. industries)

3 Distillation Residue

170 20.3 Collection, Storage , Transportation & Disposal to Incineration or Sold to Actual Users (i.e. cement mfg. industries)

5 Used Oil/Spent Oil

200lit/month 5.1 Collection, Storage, Transportation & Sell to GPCB Authorized Reprocessor

6 Empty Drums/Container

What so ever

33.1 Collection, Storage, Transportation & Sell to GPCB Authorized Reprocessor

7 Empty Bags What so ever

33.1 Collection, Storage, Transportation & Sell to CPCB/GPCB Authorized Vendor

8 Salt from MEE 0.450 T/Month

34.2 Collection, Storage , Transportation & Sold to End Users

Solid waste 9 Fly Ash 504

T/month --- Collection, Storage,

Transportation and disposal by selling to Brick manufacturing unit.

ANNEXURE-XI: DETAILS OF FUEL CONSUMPTION Sr. No.

Name Requirement Source

1 Diesel 300 Lit/Hr Local Market 2 Energy - Electricity 1730 KVA DGVCL 3 Coal* 387 MTD Local supplier Note: *Coal will be used for in house Power plant of 4 MW

DETAILS OF FLUE GAS EMISSION Sr.No. Stack

attached to Fuel Stack

Height in meter

Expected pollutants

Permissible limit

APC System

1. Steam boiler (78 Ton/Hr)

Coal -336 TPD

30 SPM SO2 NOX

150 100 50

Electrostatic Precipitator

2. DG Set 750KVA

Diesel- 150Lit/hr

11 Adequate stack height

3. DG Set 750KVA

Diesel-150Lit/hr

11 Adequate stack height

DETAILS OF PROCESS EMISSION Sr.No. Stack attached to Stack

Height in meter

Expected pollutants

Permissible limit

APC System

1. Chlorination process vessel

11 HCl Cl

20 mg/Nm3 9 mg/Nm3

Water Scrubber followed by Caustic Scrubber

2. Nitration Vessel 11 NOx 25 mg/Nm3 Caustic Scrubber

ANNEXURE- X ETP FLOW DIGRAM:

Collection Tank Equalization cum Neutralization tank

Flash mixer

Clariflocculator

Aeration tank

Biomass send to Sludge Drying bed

Settling tank Sand filter Carbon filter

Holding tank

R.O.

Holding sump

MEE

E) MULTIPLE EFFECT EVAPORATOR

Reject water of RO plant is feed to MEE. MEE is an apparatus for efficiently using

heat from steam to evaporate water to concentrate dissolved salts in water in multiple

effect evaporators, water is boiled in sequence of vessels, each held at lower pressure

than the last. As boiling of water the distillate from evaporate will be recycled in

Industrial process /cooling tower and residue will be sent to approve TSDF site for

final disposal.

Details of ETP equipments are given in Table and characteristic of waste water before

treatment & after treatment are given in Table.

EQUIPMENT LIST OF ETP

Sr. No.

Name of the unit Capacity in m3

MOC No.

1 Oil/grease trap 15 KL MS/FRP 1 2 Collection ANK 70 KL MS/FRP 1 3 Equalisation Tank 140 KL RCC 1 3 Flocculator 90 KL MS/FRP 1 4 Flash mixture 75 KL MS/FRP 1 5 Aeration Tank 825 KL RCC 1 6 Settling Tank 110 KL MS/FRP 1 7 Holding sump 25 KL HDPE 1 8 Sand filter 7 KL MS 1 9 Carbon filter 7 KL MS 1 11 Final pond 18 KL MS 1 12 RO-1 300 KL 1 13 RO-2 200 KL 1 14 MEE 200 KL 1 EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT Sr.No. Parameters Unit ETP inlet ETP outlet

1 pH pH scale 5-7 7-8 2 COD mg/l 1000-5000 100-250 3 TDS mg/l 1000-5000 1500-2000 4 TSS mg/l 100-200 100-200 5 Ammonical Nitrogen mg/l 15-30 10-15

5. Settling Tank

The biomass generated in aeration tank consists of zoological bacteria, protozoa;

rotifers’ etc. The biomass is generally flocculent and quick settling. For the separation

of biomass clarifier is provided. Settled biomass is collected in the centrally located

sludge pit with the help of clarifier mechanism. The biomass is partly recycled in the

aeration tank and remaining taken to sludge drying beds.

6. Clarified Effluent Holding Sump.

Overflow from the clarifier is received by clarified effluent holding sump under

gravity, from which is taken for tertiary treatment.

7. Sludge Filtration

Sludge filters are provided for the dewatering of sludge generated from the chemical

coagulation and biological oxidation process. The dewatered sludge filter, the dried

sludge cakes are properly stored in the solid storage yard. The filtrate is further taken

for the treatment by pumping the same to the equalization tanks.

C) TERTIARY TREATEMENT

Waste water treated by secondary treatment received to the final setting tank by

gravity,

The overflow of final settling tank is discharged to holding tanks. This treated water is

pumped to sand filter and activated carbon filter and collected to guard pond. This

treated effluent will be subjected to R.O. followed by MEE to achieve Zero Liquid

Discharge.

D) REVERSE OSMOSIS SYSTEM

After treatment the effluent is sent to the Reverse Osmosis plant .R.O. system

provided 300 m3 capacities. In Reverse Osmosis, when high pressure is applied liquid

moves from high concentration to lower concentration. Reverse Osmosis (RO) is

method that removes many types of particles from solutions by applying pressure to

the solution when it is on one side of selective. The result is it retained on the

pressurized side of the membrane and the pure is allowed to pass to the other side.

The R.O. permeate will be reused in industrial process or cooling tower and rejected

water will be sent into Multiple Effect Evaporator.

ANNEXURE-IX DETAILS OF TREATMENT SCHEME AND DISPOSAL METHODS

Effluent from all the manufacturing process and floor washing collected into

collection tank. After primary, secondary and tertiary treatment the effluent sent to

RO & recycles to cooling tower. The detail of treatment is covered as under.

A) PRIMARY TRETEMENT 1. Equalization cum neutralization Tank

Effluent will be first sent to equalization cum neutralization tank where the flow

will be equalized and pH will be neutralized. For proper mixing of content,

compressed air is used through well designed Aeration grid. The waste water is

pumped to the flash mixer.

2. Flash Mixer

Flash mixer is provided for rapid mixing of flocculating agent i.e. Alum with the

influent from Equalization tank. From the flash mixer, effluent flows to the

Clariflocculator under gravity.

3. Clariflocculator

Clariflocculator is provided for the flocculation of colloidal particles and further

during the process. Flocculation of the neutralized colloidal particles is achieved in

centrally located flocculate zone by slow moving paddles. Paddles enhance agitation

of minute flocks and thus this process helps in coagulation and agglomeration of

suspended and colloidal particles of the effluent. The settled flock is scraped with the

help of clarifier mechanism to centrally located sludge pit. The collected sludge is

taken to sludge drying bed. The clarifier overflow from the lauder of the clarifier is

taken to the bioreactor.

B) SECONDARY TREATEMENT

4. Aeration Tank ( Bio-reactor)

Effluent is aerated in the aeration tank with the help of the mechanical surface aerator

in presence of well-acclimatized microorganism. The synthesis reaction is followed

by subsequent separation of the resulting biological mass and the oxidation reaction is

the main mechanism in the removal of BOD in the activated sludge process. Effluent

from reaction tank will be taken to clarifier under gravity.

WATER BALANCE DIAGRAM:

Note: All units are in KL/Day.

Fresh water 2155KLD

Process water 563

DM water plant 872

Softener 680

Washing 10

Domestic 10

Garden 20

Boiler 786

Flash steam

225

Effluent from process-256

Blow down-40

673

Cooling Tower 1131

Blow down-60

Regeneration Water -86

Regeneration water-7

RO-193 MEE-158

Reject- 45 Op-1 Incin.23

Op-2 crystallizer-23

17

Reject-96

Filtration -23

ETP-271

148

Soak pit-5

458

Condensate -135

Salt(sent to land filling or incineration )-15

Treated effluent sent to RO-271

175

ANNEXURE-VIII DETAILS OF WATER CONSUMPTION, WASTEWATER GENERATION AND TREATMANT TABLE 1: DETAILS OF WATER CONSUMPTION Sr.No. Particulate Proposed Total water consumption in KL/day 1 Domestic 10 Gardening 20 2 Industrial Process 563 Washing 10 DM plant 872 Softener 680 Cooling 673(softener permeate) + 458 (recycled) Boiler 786 (DM permeate) Total(Industrial) 2125 Total 2155 TABLE 2: DETAILS OF WASTE WATER GENERATION Sr.No. Particulate Proposed wastewater generation in KL/day

1 Domestic 5 2 Industrial

Process 256 washing 10 DM plant 86 Softener 7 Cooling 60 Boiler 40 Total(Industrial) 459 Total 464*

Out of this 464 KLD, 271 KLD (256+10+5) will be sent to ETP followed by Process R.O., 193 KLD (from utility) will be sent to R.O.) and 135 KLD(from condensate of MEE) to reused in Cooling Tower. Unit will achieve Zero Liquid Discharge till it gets permission to discharge in common effluent conveyance project of M/s. Narmada Clean Tech.