INTRODUCTION - environmentclearance.nic.in · The proponent has planned to increase the production quantity of MEK & SBA chemicals and ... • It is an intermediate in methyl-ethyl

PRE FEASIBILITY REPORT

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1 INTRODUCTION 1.1 Identification of Project

The project proponent M/s Cetex Petrochemicals Limited was established in the year 1988-1989

by RPG group of companies as a green field petrochemical plant at the petrochemical zone at

Manali, Chennai. The plant manufactures Methyl Ethyl Ketone (MEK) and its intermediate,

Secondary Butyl alcohol (SBA) was setup with technology from Edeleanu, GMBH, a German

company belonging to the then Deutsche Texaco group. Their existing production line includes

1) Cinnamic Alcohol, 2) Anisyl Alcohol, 3) Styrallyl Alcohol, 4) Styrallyl Acetate, 5) Oximone,

6) Phenyl Ethyl Alcohol, 7) Tertiary Butyl Cyclo hexyl Acetate.

The proponent has proposed to increase the production capacity and also proposing to add a new

manufacturing facility to produce Methyl Iso Butyl Carbinol (MIBC), Phenyl Propyl alcohol

(PPA) and Mixed Alcohol at their factory located in Manali Industrial Area, Chennai.

1.2 Identification of Project Proponent

Cetex Petrochemicals Limited located at S.No. 268, 269, 270, 271, 272 & 273, Sathangadu

village, Ambattur Taluk, Thiruvallur District and S.No. 67/7, 67/8, 67/9, 67/10, 74/1, 75/4, 75/5,

76/1, 76/2, 77/1, 77/2, 77/3, 77/4, 77/5, 77/6, 77/7, 77/8, 78/1, 78/2, 78/3, 79/1, 79/2, 79/3, 79/4,

79/5, 79/6, 79/7, 79/8, & 79/9, Chinnasekkadu Village, Ambattur Taluk, Thiruvallur District,

Tamil Nadu - Manali Industrial Area was established in 1988-1989 by RPG group of companies

as a green field petrochemical plant at the petrochemical zone at Manali, Chennai. The plant to

manufacture Methyl Ethyl Ketone (MEK) and its intermediate, Secondary Butyl Alcohol (SBA)

was set up with Technology from Edeleanu, GMBH, a German company belonging to the then

Deutsche Texaco group.

After initial difficulties, the plant stabilized operations from 1991 and has been a leading player

in the MEK market in India. Since then M/s Cetex petrochemicals limited has applied for

Environmental Clearance (EC) to MoEF for Methyl Ethyl Ketone (MEK) plant expansion &

Fine Chemical manufacturing unit and obtained EC vide reference J-11011/1113/2007-IA-II (I)

dated 16.09.2008 (Annexure I). The present production capacity of the plant is 12000 TPA of

SBA, 10000 TPA of MEK and 2050 TPA of Fine Chemicals.


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1.3 Brief Description of Nature of the Project

The unit currently manufactures nine products namely,

1. Methyl Ethyl Ketone (MEK) – 10000 TPA. 2. Secondary Butyl Alcohol (SBA) – 12000 TPA.

Fine Chemicals 1. Cinnamic Alcohol – 1080 TPA. 2. Anisyl Alcohol – 276 TPA. 3. Styrallyl Alcohol – 228 TPA. 4. Styrallyl Acetate – 150 TPA. 5. Oximone – 20 TPA. 6. Phenyl Ethyl Alcohol – 96 TPA. 7. Tertiary Butyl Cyclohexyl Acetate – 200 TPA.

The proponent has planned to increase the production quantity of MEK & SBA chemicals and

also proposing a new manufacturing facility to produce Methyl Iso Butyl Carbinol (MIBC),

Phenyl Propyl alcohol (PPA) and Mixed Alcohol at their existing plant to the following

quantities.

1. Methyl Ethyl Ketone (MEK) – 5000 TPA. 2. Secondary Butyl Alcohol (SBA) – 10000 TPA. 3. Methyl Iso Butyl Carbinol (MIBC) – 5000 TPA. 4. Phenyl Propyl Alcohol (PPA) – 1000 TPA. 5. Mixed Alcohol – 1000 TPA. (Fine Chemical)

The proposed expansion project will fall under Schedule 5 (f) & Category ‘B’ as per

Environmental Impact Assessment (EIA) Notification 2006 and its amendments. The expansion

activity requires prior Environmental Clearance from SEIAA-TN. But, due to absence of the

SEAC committee in Tamil Nadu the proposal is submitted to MoEFCC.

1.4 Need for the Project

Presently there is no manufacture of MIBC in India and all the country’s requirement is currently

being met by imports, mainly from Taiwan, Europe, USA and Korea. The current Indian market

demand for MIBC is around 20000 TPA and is being fully imported in to the country. Cetex is

proposing to produce Methyl Iso Butyl Carbinol (MIBC) to further increase its Indian market

presence and also secure more markets in the International market in the South East Asian


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region. Cetex will be in an advantageous position to supply the entire requirement of this region

due to low costs of shipping. With FTA (Free Trade Agreement) between ASEAN countries,

those countries will also prefer supplies from India to take advantage of duty benefits.

MIBC's major application is in the manufacture of lube oil additives, followed by its use as the

principal flotation frother in treating copper and other ores. Surface coatings make up a minor

portion of MIBC consumption. World MIBC statistics are difficult to estimate, but overall,

MIBC will experience positive growth in lube oil applications and as a flotation frothier

(especially in actively mined regions). Consumption of MIBC Worldwide is forecast to grow at

an average annual rate of 2.5% during 2011–2016. Indian demand is expected to grow at an

average 7% to 8% per year (Source: IHS Chemical).

Consumers

There are a number of industries in India using MIBC as a Frother in the manufacture of Metals

from Ores. Hindustan Copper Limited, Cominco Binani, Vedanta Group are some of the users of

MIBC.

Apart from use as Frother in the Ore Beneficiation process of Copper and other metals, MIBC is

a key raw material for the manufacture of specialty additives for the Lube Oil segment. Chevron

Oronite, Singapore, USA and France gets these products contract manufactured at United

Phosphorous Limited, Gujarat using MIBC

Indian Additives Limited, Chennai, a Group company of Chevron Oronite Pte, Singapore, also is

manufacturing the Specialty chemicals using MIBC.

All lube oil manufacturing majors are potential customers for MIBC such as Lubrizol, USA,

Infineum International, UK. Total, France and Afton UK also use MIBC for the manufacture of

specialty chemicals.

There are other potential MIBC users in the Printing, Automotive and Specialty chemicals

segments who face constraints on availability of MIBC.


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2 SITE ANALYSIS 2.1 Location

The proposed project is an expansion project S.No. 268, 269, 270, 271, 272 & 273, Sathangadu

village, Ambattur Taluk, Thiruvallur District and S.No. 67/7, 67/8, 67/9, 67/10, 74/1, 75/4, 75/5,

76/1, 76/2, 77/1, 77/2, 77/3, 77/4, 77/5, 77/6, 77/7, 77/8, 78/1, 78/2, 78/3, 79/1, 79/2, 79/3, 79/4,

79/5, 79/6, 79/7, 79/8, & 79/9, Chinnasekkadu Village, Ambattur Taluk, Thiruvallur District,

Tamil Nadu. No alternative site is considered, as it is an expansion of an existing plant

production and the proposed manufacturing unit for production of MIBC, PPA and Mixed

Alcohol will be installed within the existing premises. Land document is enclosed as Annexure

II. Satellite Image of project site and location of the plant is shown in Figure 2.1 & 2.2.


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Figure 2-1 Satellite Map Images


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Figure 2-2 Location of the Project Site

2.2 Connectivity

The site has excellent connectivity through road & railways. Tiruvottiyur railway station is the

nearest Railway Station, which is 3 km [ENE] away from project site. Metropolitan Transport

Corporation (MTC) runs passenger buses to Manali from other major parts of the Chennai city.

Figure 2.3 Connectivity map of project site


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2.3 Land Use & Maps

Existing land use of the project site is “Industrial Use Zone”. The total plot area of the existing

facility is 207360.92 Sq.m (51.23 Acres). The topo & land use maps of the project site and its

surrounding area covering 10 km radius are given in Figures 2.4 & 2.5. Environmental settings

are presented in Table 2.1.


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Figure 2-3 Topo map (10km surrounding project site)


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Figure 2-4 Land use map (10km surrounding project site)


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Table 2-1 Environmental Settings of Project Site

Sl. No. Particulars Details 1 Site Latitude 13° 9'2.69"N

2 Site Longitude 80°15'56.32"E

3 Site Elevation above MSL 5 m

4 Nearest highway

SH 56 – 628 m (E) SH 1A – 500 m (W) SH 111 – 3.7 km (W) NH 5 – 4.9 km (W)

5 Nearest railway station Tiruvottiyur Railway Station – 3.0 km (ENE)

6 Nearest airport Chennai International Airport – 20 km (SSW)

7 Nearest town/ city Tiruvottiyur – 3 km (E)

8 Topography Plain

9 Archaeologically important places Fort St. George – 8.3 km (SSE)

10 National parks/ Wildlife Sanctuaries Nil in 15km radius

11 Reservoir

Puzhal lake – 8.1 km (W) Korattur lake – 8.3 km (SW) Cholavaram lake – 14.7 km (NW) Retteri Lake 5 Km (W)

12 Reserved/ Protected Forests Nil in 10km radius

13 Seismicity Zone III

14 Defense Installations Nil in 15km radius

15 Nearest Port Chennai Port – 8.1 km (SSE)

2.4 Site Suitability / Alternate Sites Considered

The proposed expansion in production will take place within the existing facility owned &

operated by M/s Cetex petrochemicals Ltd. This site has the following advantages:

• As the factory is currently in operation all infrastructural facilities are already in place.

• It is the expansion of existing operation and space for new unit is also available within the

premises as a vacant land.

• There is no adverse sitting factor such as reclassification of land use and pattern, R & R

as the facility is located within Manali Industrial Area.

Hence, no alternative sites were considered.


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2.5 Brief Profile of Thiruvallur District

A. Climate

The district enjoys tropical climate.

B. Temperature

The annual mean minimum and maximum temperature are 24.3 ° and 32.9°C respectively.

The day time heat is oppressive and the temperature is as high as 41.2°C. The lowest

temperature recorded is of the order of 18.1°C.

C. Rainfall

The district receives the rain under the influence of both southwest and northeast monsoons.

Most of the precipitation occurs in the form of cyclonic storms caused due to the depressions

in Bay of Bengal chiefly during Northeast monsoon period. The southwest monsoon rainfall

is highly erratic and summer rains are negligible. The average normal rainfall of the District

is 1104 mm. Out of which 52% has been received during North East Monsoon period and

41% has been received during South West Monsoon period. Rainfall data analysis shows that

the normal annual Rainfall varies from 950mm to 1150mm.

D. Relative Humidity

The period from April to June is generally hot and dry. The weather is pleasant during the

period from November to January. Usually mornings are more humid than afternoons. The

relative humidity varies between 50 and 85% in the morning while in the afternoon it varies

between 40 and 70%.

E. Geology

The prominent geomorphic units identified in the district through interpretation of Satellite

imagery are 1) Alluvial Plain, 2) Old River Courses 3) Coastal plains 4) Shallow & deep

buried Pediments, 5) Pediments and 6) Structural Hills. The elevation of the area ranges from

183 m amsl in the west to sea level in the east. Four cycles of erosion gave rise to a complex

assemblage of fluvial, estuarine and marine deposits. The major part of the area is

characterised by an undulating topography with innumerable depressions which are used as

irrigation tanks. The coastal tract is marked by three beach terraces with broad inter-terrace

depressions. The coastal plains display a fairly lower level or gently rolling surface and only

slightly elevated above the local water surfaces or rivers. The straight trend of the coastal


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tract is resultant of development of vast alluvial plains. There are a number of dunes in the

coastal tract.

F. Soil

Soils in the area have been classified into i) Red soil ii) Black soil iii) Alluvial soil iv)

colluvial soil. The major part is covered by Red soil of red sandy/clay loam type. Ferruginous

red soils are also seen at places. Black soils are deep to very deep and generally occur in the

depressions adjacent to hilly areas, in the western part. Alluvial soils occur along the river

courses and eastern part of the coastal areas. Sandy coastal alluvium (Arenaceous Soil) are

seen all along the sea coast as a narrow belt.

G. Infrastructure

Manali Industrial Area, Chennai

Chennai Petroleum Corporation Limited (CPCL) (formerly MRL) is the largest company in

Manali. Started in 1969, CPCL's Manali Refinery now has a capacity of 9.5 MMTPA and is

one of the most complex refineries in India with Fuel, Lube, Wax and Petrochemical feed

stocks production facilities. The main products of the company are LPG, Motor Spirit,

Superior Kerosene, Aviation Turbine Fuel, High Speed Diesel, Naphtha, Bitumen, Lube Base

Stocks, Paraffin Wax, Fuel Oil, Hexane and Petrochemical feed stocks

Other Industries located in Manali are given below:

• Madras Fertilizers Limited (MFL)

• Manali Petro Chemical Ltd(MPL)

• Balmer Lawrie & Co Ltd

• Tamil Nadu Petro products Limited (TPL)

• Sriram Fibres Ltd(SRF)

• Madras Rubber Factory(MRF)

• Kothari chemicals and pesticides

• Infra tanks and polymers

• Supreme Petro Chemical Industries

• Nicholas Piramal

• NATCO Pharmaceutical

• TOSHIBA


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3 PROJECT DESCRIPTION 3.1 Magnitude of Operation

M/s. Cetex Petrochemicals Limited is currently manufacturing following chemicals at the

production rates are detailed below,

1. Methyl Ethyl Ketone – 10000 TPA. 2. Secondary Butyl Alcohol – 12000 TPA.

Fine Chemicals 1. Cinnamic Alcohol – 1080 TPA. 2. Anisyl Alcohol –276 TPA. 3. Styrallyl Alcohol – 228 TPA. 4. Styrallyl Acetate – 150 TPA. 5. Oximone – 20 TPA. 6. Phenyl Ethyl Alcohol – 96 TPA. 7. Tertiary Butyl Cyclohexyl Acetate – 200 TPA.

The unit has obtained Environmental Clearance from MoEF Vide letter: J-11011/1113/2007-

IA-II (I) dated 16.09.2008 for manufacturing the above mentioned products. The proponent

has planned to increase the production of MEK & SBA products with additional one new

manufacturing facility to produce Methyl Isobutyl Carbinol (MIBC), Phenyl Propyl alcohol

(PPA) and Mixed Alcohol to the quantities detailed below,

1. Methyl Ethyl Ketone – 5000 TPA. 2. Secondary Butyl Alcohol – 10000 TPA. 3. Methyl Iso Butyl Carbinol – 5000 TPA. 4. Phenyl Propyl alcohol (PPA) – 1000 TPA. 5. Mixed Alcohol – 1000 TPA. (Fine Chemical)

Individual production capacities of the products for the existing and proposed expansion have

been detailed in Table 3.1.

Table 3-1 List of products & manufacturing capacities

S.No. Name of the product Existing Capacity

(TPA)

Proposed expansion

(TPA)

Capacity after expansion (TPA)

1 Methyl Ethyl Ketone 10000 5000 15000 2 Secondary Butyl Alcohol 12000 10000 22000 3 Methyl Iso Butyl Carbinol – 5000 5000 4 Phenyl Propyl Alcohol – 1000 1000


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Fine Chemicals 4 Mixed Alcohol - 1000 1000 5 Cinnamic Alcohol 1080 – 1080 6 Anisyl Alcohol 276 – 276 7 Styrallyl Alcohol 228 – 228 8 Styrallyl Acetate 150 – 150 9 Oximone 20 – 20 10 Phenyl Ethyl Alcohol 96 – 96 11 Tertiary Butyl Cyclohexyl Acetate 200 – 200

Total 24050 22000 46050

3.2 Uses of Production Products

Methyl ethyl ketone (MEK)

MEK is used as a solvent in the surface coating industry, in the dewaxing of lubricating oils,

and in the manufacture of colorless synthetic resins, artificial leather, rubbers, lacquers,

varnishes, and glues. MEK is seldom used alone in industrial applications; it is usually found

in mixtures with acetone, ethyl acetate, n-hexane, toluene, or alcohols.

Use of Methyl Ethyl Ketone

• The primary use of methyl ethyl ketone is as a solvent in processes involving gums,

resins, cellulose acetate, and cellulose nitrate.

• Methyl ethyl ketone is also used in the synthetic rubber industry, in the production of

paraffin wax, and in household products such as lacquer and varnishes, paint remover,

and glues.

Secondary Butyl Alcohol (SBA)

Secondary Butyl Alcohol (SBA) is a water white color highly volatile liquid with

characteristic odour. Secondary Butyl alcohol is primarily used in the manufacture of methyl

ethyl ketone and other organic compounds. It is used as a solvent, cleaning agent, paint

remover, and is found in perfumes, flavors, dyestuffs, and wetting agents. Gasoline exhaust

may also contain sec-butyl alcohol.

Uses of Secondary Butyl alcohol

• As a solvent for paints, coatings, varnishes, resins, gums, camphor, vegetable oils,

dyes, fats, waxes, shellac, rubbers, alkaloids, alkyd resins, lacquers, enamels, paint

removers, and adhesives


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• In manufacture of industrial cleaners, perfumes, dyes, wetting agents +as a component

of flotation agents, hydraulic and brake fluids

• In extraction of fish meal to produce fish protein concentrate and for the production of

fruit essences

• It is an intermediate in methyl-ethyl ketone production

• It is a starting product for sec-butyl acetate synthesis

Methyl Iso Butyl Carbinol (MIBC)

MIBC is primarily used in solvent applications in the Ore Beneficiation for rare metals and

also as a co-solvent along with SBA in the manufacture of the Lube Oil Additive, Zinc Di

Alkyl Di Thio Phosphate, which is internationally dominated by the Lube Additive

Manufacturing Majors Chevron Oronite, Lubrizol, Total, Afton and Infineum International.

The global Methyl Iso butyl Carbinol (MIBC) market is expected to register a CAGR

of 2.85% during the forecast period. MIBC is used in frothers, surface coatings, adhesives,

cosmetics, toiletries, and cleaners, finds application in the pharmaceutical industry for the

extraction of vitamins and minerals, as wetting agents in lithographic printing, and as

chemical intermediates, it is used in the production of lube oil additives, hydraulic fluids, and

plasticizers

Need of Methyl Iso Butyl Carbinol

• It is used as flotation- frother for treatment of copper ores, coal, tar and sand mining.

• It is used as a latent solvent for coatings to reduce viscosity and improve flow and

leveling.

• It is used as coupling solvent for waterborne coatings.

• It is used in talc processing.

• Solvent for dyes and stains.

• Solvent for oils, esters, gums, natural resins, phenolic, waxes.

• Solvent for nitrocellulose lacquers and ethyl cellulose lacquers.

• Production of plasticizers.

• Hydraulic Fluid Diluent.

• Process solvent for soaps.

• It is primarily used to manufacture lube oil additives.

• Chemical intermediate for higher alcohols, surfactants.


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Phenyl Propyl Alcohol (PPA)

Phenyl Propyl Alcohol is a colorless liquid. It can be synthesized from organic chemicals. It

has a characteristic Balsamic odour and used in perfumery formulations. Leading Global

Perfumery and Flavour manufacturers such as Givaudan, Symrise, IFF, Takasago,

Firmenisch, source various Aroma chemicals and blend them to produce Perfumes and

Flavours for various segments such as soaps and Toiletteries, Detergents, Shampoos,

Deodorants, Shaving products, Personal Hygiene products, Hair care products, Room

fresheners etc. apart from various Food additives and flavours. The Flavours and Fragrance

market segment is growing at a healthy pace of over 10% buoyed up by the consumer

demand and increasing purchasing power of middle class society. Global demand for this

product is driven by trends in the Perfumery industry and is likely to be over 5000 Tons per

year.

Need of Phenyl Propyl Alcohol

• In pharma industries, it is used for the manufacture of phenyl propylamine, fluxoetine,

3-phenyl propyl carbamate

• In cosmetic industries, it is used as a preservative as it has antimicrobial properties

• Used in combination with heliotropin or piperonal as a preservative for cosmetic

products

• In fragrance industries, used as a fragrance component in fresh flower composition

like lilac and lily of the valley because of the balsamic odour. Also used as flavouring

agent in alcoholic beverages

Mixed Alcohol

Mixed Alcohol is a mixture of Secondary Butyl Alcohol (SBA) and Methyl Iso Butyl

Carbinol (MIBC) blended in a proprietary proportion based on customer’s needs. It is

primarily used along with SBA in the manufacture of the Lube Oil Additive, Zinc Di Alkyl

Di Thio Phosphate (ZDP), which is internationally dominated by the Lube Additive

Manufacturing Majors Chevron Oronite, Lubrizol, Total, Afton and Infineum International.

The total demand for mixed alcohol is driven by growth of ZDP, which is again driven by

growth of Lube Oil demand related to Automobile sector. The total usage of Mixed Alcohol

by the ZDP manufacturers for the Lube Oil Additive Majors is over 10000 Tons per year.

Cetex is already a supplier of SBA to Chevron Oronite, India, USA and Singapore and

therefore is likely to be favored supplier of Mixed alcohol too.


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3.3 Raw Materials Required for Production

Major raw materials required for producing MIBC and PPA are power, Cinnamaldehyde &

Hydrogen. MIBK and Cinnamaldehyde are imported and Hydrogen is sourced from Indian

manufacturer & In-house generation.

Table 3-2 List of Raw Materials

S.No Raw Materials Required (in tons) Source

SBA & MEK 1 C4 Mix (2-Butene) 18000 CPCL, Manali 2 98% Sulphuric Acid 15500 Indian manufacturer/Trader 3 Caustic Flakes 170 Indian manufacturer/Trader 4 Hydrochloric acid 60 Indian manufacturer/Trader

MIBC 1 Methyl Isobutyl Ketone (MIBK) 6000 Import 2 Hydrogen 200 Indian manufacturer/Trader

PPA 1 Cinnamaldehyde 1250 Import 2 Hydrogen 50 Indian manufacturer/Trader

MIXED ALCOHOL 1 Secondary Butanol (SBA) 600 Indian manufacturer/Trader 2 Methyl Isobutyl Carbinol (MIBC) 400 Indian manufacturer/Trader

3.3.1 STORAGE OF RAW MATERIALS

Existing and proposed tank details for storage of raw materials are given in Table 3.3 and

Table 3.4 respectively.

Table 3-3 Storage Tank Details

S. No. Tank No. Service Dimension Diameter X

height in M Capacity

in KL 1 T-904 B SBA Storage Tank 6.85 X 6.85 252 2 T-905 OFFSPEC SBA Storage Tank 2.95 X 2.95 20 3 T-904 C SBA Storage Tank 6.85 X 6.85 252 4 T-1904 B SBA Storage Tank 6.25 X 8.6 264 5 T-1905 B MIBK Storage Tank 5.2 X 7.45 158

Bullet Storage Tanks 1 T-901 A BUTENE Storage Bullet 4.25 X 17.9 274 2 T-901 B BUTENE Storage Bullet 4.25 X 17.9 274


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3 T-1903 C4 HYDROCARBON

BUTENE Storage Bullet

5 X 30 589

Table 3-4 Proposed Raw Material Storage Tanks

S. No. Tank No. Service Dimension Diameter

X height in M Capacity

in KL

1 T 6901 MIBK Storage Tank 6.85 X 6.85 252

2 T 6903 CRUDE SBA Storage Tank 6.85 X 6.85 252

3 T 6904 SBA Storage Tank 6.85 X 6.85 252

4 T 6902 MIBC Storage Tank 6.85 X 6.85 252

3.4 Manufacturing Process

3.4.1 SBA - Process Description Feedstock (Raw Material)

Received from the Feed Preparation Unit of Chennai Petroleum Corporation Limited. (CPCL)

with the butene content of minimum 70% and free of Buta-Diene and Iso-Butene.

Feed Acid

The acid (Sulphuric Acid) feed to the SBA reactor (esterification) is of 75% concentration,

which is prepared by mixing the fresh 98% Sulphuric Acid to the spent Sulphuric Acid (60%

concentration) recovered from the process in Hydrolysis Section.

Esterification

75% Conc. Sulphuric Acid (Feed Acid) at the temperature of 45 Deg.C. is made to react with

n-Butene (Feed Stock) in two stage reactor at a pressure of around 5 bar (g) and temperature of

45 Deg C.. The feed acid and n-Butene to reactor is fed through a ratio controller.

Hydrolysis

Crude Secondary Butyl Alcohol (SBA) with Secondary Butyl Ether (SBE) is recovered by

hydrolysing the ester with water. The dilute Sulphuric Acid is concentrated to 60% and

recycled in feed acid preparation (75% Conc.). Hydrolysis of ester is carried out at a

temperature of 40 Deg.C and pressure of 1.3 bar (g).

Neutralization

The raw SBA with SBE is neutralized by 2-4% caustic solution to make it free of traces of

acidity. After neutralization, spent caustic goes as waste to solar pond. The crude SBA with


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SBE is passed to distillation section. Neutralization of crude SBA with SBE is carried out at a

temperature of 110 Deg.C and a pressure of 1.2 bar (g).

Purification of SBA

SBE is separated by distillation of the raw SBA/SBE liquid. SBA after this separation is

concentrated and recovered as pure SBA. By this purification, some unwanted heavies

formed in the reaction are also separated from the bottom of the purification column. The

purification process is carried out at a temperature of around 110 Deg.C. Pressure in the

purification section is maintained at 1.5 bar. The by-products separated at this stage are used

as fuel.

3.4.2 MEK - Process Description Process operation involves conversion of Secondary Butyl Alcohol (SBA) into Methyl Ethyl

Ketone (MEK). Brief description of various stages in operation is as follows:

MEK Synthesis

Pure SBA is vaporized at 140 Deg.C temperature and at 3.5 bar (g) pressure is given as feed

to the MEK reactors. In presence of copper catalyst, the reaction takes place at 260 Deg.C

and 2.0 bar (g) pressure and crude MEK comes out.

MEK Purification

In purification section, water in MEK is stripped off by Hexane addition as an entrained and

re-boiling. Purification takes place at a temperature of 95 Deg.C and at pressure of 0.1 bar

(g). Pure MEK in liquid form is stored in storage tanks.

• Secondary Butyl Ether used in paint and printing industries.

• Ethyl Amyl Ketone used in Special paint manufacturing and Aroma chemicals.

• Dimer fraction is used in manufacture thinner and paint industries

• 52 % sulfuric acid is used in Fertilizer, Alum and Magnesium sulfate manufacturing.

• LPG is used as Industrial Domestic fuel.


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Figure 3-1Flow Diagram of SBA & MEK Manufacturing Process

WASTE TO SOLAR POND

SECONDARY BUTYL ETHER BUTANE

RECOVERY SYSTEM

BUTANE (LPG) RECOVERY

SYSTEM

BUTANE (LPG) STORAGE

DIMER FRACTION

HEAVY FRACTION

SUPPLY C4 FROM CPCL

RETURN C4 TO CPCL

FEED PREPARATION

UNIT

SULPHURIC ACID (98%)

FEED ACID (75%)

SPENT ACID (52%)

SPENT ACID DISPOSAL

BUTENE

ESTERIFICATION

HYDROLYSIS

NEUTRALIZATION

SBA PURIFICATION

PURE SBA STORAGE

PURE MEK SORATGE

MEK PURIFICATION

RAW MEK SEPARATION

MEK SYNTHESIS HYDROGEN


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Figure 3-2 Material Balance - SBA & MEK Product (EOU)

3.4.3 MIBC Process Description

Raw Materials

Methyl isobutyl ketone (MIBK) & Hydrogen are the raw materials for the synthesis of

Methyl isobutyl carbinol (MIBC) using nickel based catalyst

Hydrogenation

In the presence of nickel (catalyst), MIBK reacts with hydrogen to form MIBC under

pressure @ 6 bar. Since, hydrogenation is an exothermic process, temperature of reactor

being maintained @ 120 °C using cooling water

Catalyst separation

Once the MIBC reaction is complete, reaction product sent to a filtration process to separate

nickel catalyst, filtrate (Crude MIBC) is diverted to purification section

Purification of MIBC

Crude MIBC contains unreacted MIBK & undesired reaction products, shall be removed and

Pure MIBC product distilled out & transfer to storage tank

+H2

O OH

(MIBK) (MIBC)

SBA (10000)

MEK (5000)

LPG (3400)

SBE (300)

Heavies (80)

Dimer (800)

Spent acid (34000)

SBA & MEK

Process (MTPA)

Butene – 2 (18000)

98% H2SO4 acid (15500)

Hydrochloric acid (60)

Caustic flakes (170)

DM Water (19000)


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Figure 3-3 Process Flow Diagram - MIBC

Figure 3-4 Material Balance - MIBC Product (EOU)

3.4.4 Phenyl Propyl Alcohol (PPA) – Process Description

Raw Materials

Cinnamaldehyde & Hydrogen are the raw materials for the synthesis of Phenyl Propyl

Alcohol (PPA) using nickel based catalyst

Hydrogenation

In the presence of nickel (catalyst), Cinnamaldehyde reacts with hydrogen to form Phenyl

Propyl Alcohol under pressure @ 10 bar. Since, hydrogenation is an exothermic process,

temperature of reactor being maintained @ 100 °C using cooling water

MIBC

Process (MTPA)

MIBK (6000)

HYDROGEN (200)

MIBC (5000)

LIGHT ENDS (560)

HEAVIES (580)

HYDROGEN

MIBC SYNTHESIS

MIBK RECYCLE

MIBK STORAGE

BY PRODUCTS & WATER

MIBC DISTLLATION

PRODUCT MIBC

LOSSES (60)


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Catalyst separation

Once the reaction is complete, the product is sent to a filtration process to separate nickel

catalyst, filtrate (Crude PPA) is diverted to purification section

Purification of MIBC

Crude PPA may contain unreacted Cinnamaldehyde & undesired reaction products, shall be

removed and Pure PPA product distilled out & transfer to storage tank

Figure 3-5 Process Flow Diagram - Phenyl Propyl Alcohol

Figure 3-6 Material Balance – Phenyl Propyl Alcohol Product (EOU)

3.4.5 MIXED ALCOHOL – Process Description

Raw Materials

Secondary Butyl Alcohol (SBA) & Methyl Iso-Butyl Carbinol (MIBC) are the raw materials

for the preparing Mixed Alcohol.

CINNAMALDEHYDE

HYDROGEN

HYDROGENATOR

CINNANALDEHYDE RECOVERY

CRUDE PPA

CATALYST

DISTILLATION

PPA LIGHT ENDS (BYPRODUCT)

PPA PRODUCT

PPA HEAVIES (BYPRODUCT)

PHENYL PROPYL

ALCOHOL (MTPA)

CINNAMALDEHYDE (1250)

HYDROGEN (50)

PHENYL PROPYL ALCOHOL (1000)

PPA LIGHT ENDS (140)

PPA HEAVIES (145)

LOSSES (15)


24

Blending:

Based on the customer specifications, SBA & MIBC are blended together and then loaded in

tanker/drums

Figure 3-7 Process Flow Diagram - Mixed Alcohol

Figure 3-8 Material Balance – Mixed Alcohol

3.5 Infrastructure Requirements

3.5.1 Land Use Breakup

The existing and proposed land use breakup of the site is given in below table 3.5. The layout

showing the plant area is given in Figure 3.9.

Table 3-5 Land use breakup

Description Existing

plant Proposed Expansion

After Expansion Percentage

Area (Acres)

Plant and R&D area 4.99 3.61 8.61 16.80

Hazardous waste Storage area 0.49 -- 0.49 0.95 Green Belt 2.50 14.41 16.91 33.01 Roads 2.36 2.4 4.75 9.27 Open Area 20.47 39.95 Total 20.42 51.23 100

BLENDING

VESSEL

SBA PRODUCT

MIXED ALCOHOL

MIBC PRODUCT

MIBC (400)

MIXED ALCOHOL (1000)

MIXED ALCOHOL

PROCESS (MTPA)

SBA (600)


25

Figure 3-9 Layout of the facility


26

3.5.2 Equipments

The utility requirements for the above manufacturing process and the proposed utility

requirement for proposed production are given as follows,

Table 3-6 List of Equipments (Existing & Proposed)

S. No Equipments Existing No’s Proposed No’s Total after Expansion

1 Reactors 13 8 21 2 Distillation Columns 20 11 31 3 Condensers 19 15 34 4 Reboilers 20 11 31 5 Heat exchangers 10 10 20

6 Process Vessels and intermediate tanks 15 20 35

7 Bulk Storage tanks 11 8 19 Total 108 83 191

A. Hot Oil System

A Natural Gas based Hot Oil heater with a capacity of 2 Million Kcal/hour is being

considered. Cetex will be supplied piped Natural Gas by Indian Oil Corporation (IOC)

limited, with whom Cetex has signed a contract for supply from 2019.

B. Boiler

A Natural Gas based Boiler with a capacity of 8 TPH is being considered as a standby Boiler

for the project. However, the Steam supply under normal situations from the existing Wood

Fired 22 TPH cogeneration plant boiler.

C. Chillers

Vent Condenser Chiller

Freon chiller system of capacity 40 TR @ (-) 1.1°C has been considered for the chilling

demand from the process vent condensers. The compressor shall be water cooled, direct

driven rotary screw type with variable volume ratio and capacity control. Freon will be used

as the refrigerant.

D. Cooling Water System

Cooling water is required to cool the process streams and is circulated through the heat

exchangers. Hot water leaving the exchangers is cooled in the circulating evaporative


27

Cooling Tower. The Cooling water Pumps take suction from the sump of the Cooling tower

and discharge into the header for distribution to the coolers. The cooling water return header

collects warm water from the exchangers and sends to the top of the Cooling tower. Soft

water is used as make up to the tower. Chemicals are dosed into the Cooling Tower sump to

prevent corrosion and scaling in the system.

E. Flare

The flare system will handle the relieved gases from the pressure safety valves and venting of

process gases. All the vent gases are connected to the existing flare header (MEK plant).

Presence of hydrogen should demand special attention while connecting with the existing

flare. All hydrocarbon vented to atmosphere through dry flare shall have (4 Kg/Cm2.g) steam

diffuser arrangement.

F. Process & Instrument Air

Instrument Air Compressor

Ambient air is drawn through air filters into the instrument air suction vessel. Air passes on to

the air compressors where it is compressed to the required pressure. Air is cooled in the air

compressor coolers using cooling water and condensate is separated in a knockout drum. The

cooled compressed air is passed on to the air surge vessel, which provides the surge capacity

necessary to eliminate flow pulsations.

A portion of compressed air is sent to the plant for use as the plant air. The remainder of

compressed air is passed over to the Instrument Air Dryer, which removes moisture from the

air and produces air of the required dew point for instrument air. Dried air passes through the

Instrument Air Receiver which serves to provide sufficient hold up capacity for the needs of

the plant.

H. Caustic Storage System

25% & 10% Caustic (NaOH) solution required for the process is prepared from caustic flakes

and transferred to the respective dosing tanks. DM water is used for preparing caustic

Solution.

H. Waste Water System

Waste water collected from the various sections is sent to treatment section for reducing the

organic load and disposed.


28

I. Power Requirement

As regard to the supply of power, it has around their factory area, the 110 KV line, 33 KV

line and the supplies are made from state and national grids. It can have an uninterrupted

power supply for the MIBC project. As a standby to run the critical equipment, Cetex has

also planned for a huge capacity generating set to meet the power crisis.

J. Water Requirement

Though the ground water is salty due to sea close to the Manali industrial belt, the metro

water of Chennai has laid pipelines to cater to the industrial hub of Manali. There are also lots

of local private suppliers of water in tanker loads and Cetex can buy water from these sources

for the process. Cetex has to plan for an uninterrupted supply of water for process and other

utilities.

3.5.3 Manpower

The existing manpower is 80 numbers and for proposed expansion, estimated manpower

requirement is 10 numbers of employees. And most of the employees are hired locally based

on the qualifications.

3.5.4 Power

The power consumption for existing MEK plant I & II and Fine Chemicals unit is 0.95 MW

and for proposed expansion, additional power requirement will be 0.7 MW. The power will

be sourced from TANGEDCO. For the expansion, 1 number of 2000 KVA DG set is

proposed.

Table 3-7 Details of DG sets

SL.NO. Equipment Capacity (kVA)

1 DG Set – 1 No. (Existing) 1500

2 DG Set – 1 No. (Proposed) 2000

3.5.5 Water

The source of water for the project is from CMWSSB. The existing consumption is 845 KLD

& additionally 270 KLD is required for proposed operations. Water balance table for the

operation of the existing & proposed plant are as follows.


29

Table 3-8 Water balance table

S.No Requirement Existing (KLD) Proposed (KLD) Final (KLD)

A Domestic 20 2 22

B DM Plant

i. Process Plant 96 52 148

ii. Boiler Make up 105 40 145

iii. Regeneration waste 20 14 34

Total 221 106 327

C Cooling Tower 604 162 766

Fresh water (A+B+C) 845 270 1115

D Recyclable water

i. RO Permeate 52 26.6 78.6

ii. Condensate (ME) 11 6.8 17.8

Recycled water (D) 63 33.4 96.4

Total Water Requirement (Fresh water – recycled water) 782 236.6 1018.6


30

Figure 3-10 Water balance chart (existing)

95 KLD

REGENERATION WASTE

16 KLD

Total Water Input

845 KLD

96 KLD

TO PROCESS

Make up 105 KLD

221

KLD

20

KLD

Yield 201 KLD

Raw Water Make up

782 KLD

DM PLANT

COOLING TOWERS

DOMESTIC USAGE

BOILER

IN PRODUCT

IN SPENT ACID

IN EFFLUENT

CONDENSATE LOSS

BLOWDOWN EVAPORATION

LOSS

DRIFT LOSS

BLOW DOWN

STP

SLUDGE DRYING BED

GARDENING

604 KLD

20 KLD

580 KLD

4 KLD

20 KLD

20 KLD

19 KLD

1 KLD

60 KLD

20 KLD

10 KLD

70 KLD

PERMEATE

REJECT

MECHANICAL EVAPORATOR

SOLAR EVAPORATION

POND

18 KLD

7 KLD

11 K

LD

52 K

LD

REC

YC

LED

WA

TER

63 K

LD

63 KLD


31

Figure 3-11 Water balance chart (after expansion)

133 KLD

REGENERATION WASTE

28 KLD

Total Water Input

1115 KLD

148 KLD

TO PROCESS

Make up 145 KLD

327

KLD

22

KLD

Yield 293 KLD

Raw Water Make

up 1019 KLD

DM PLANT

COOLING TOWERS

DOMESTIC USAGE

BOILER

IN PRODUCT

IN SPENT ACID

IN EFFLUENT

CONDENSATE LOSS

BLOWDOWN EVAPORATION

LOSS

DRIFT LOSS

BLOW DOWN

STP

SLUDGE DRYING BED

GARDENING

766 KLD

34 KLD

727 KLD

7 KLD

32 KLD

22 KLD

20.9 KLD

1.1 KLD

90 KLD

30 KLD

12 KLD

108 KLD

PERMEATE

REJECT

MECHANICAL EVAPORATOR

SOLAR EVAPORATION

POND

29.4 KLD

11.6 KLD

17.8

KLD

78.6

KLD

REC

YC

LED

WA

TER

96.4

KLD

96.4 KLD


32

3.5.6 Pollution Control Measures

3.5.6.1 Air (Emissions) For existing plant the following measures are taken up for control of gaseous emissions:

• The existing emission sources i.e., Boiler, DG set & Reactor are designed with adequate

stack heights and air pollution control measures to meet the standards set by the TNPCB /

CPCB.

Table 3-9 Details of air pollution control measures

S.No. Sources of Emission APC Measures Provided

Stack Details

Dimension ( Dia. in mm)

Height from GL (in Meter)

1. Multi fuel Boiler/Hot oil heaters

Running only as standby 750 30

2. Relief headers , Balance headers

Flare recovery system 600 36

3. Exhaust of 1500 KVA DG Stack 200 30

4. Wood fired boiler- 4 T capacity Wet chamber 750 30

5. Bio Mass fuel Boiler – 8T

capacity and Thermic heater 20,00,000 K.Cals.

Dust collector 1100 30

6. Bio Mass Boiler – 22 T

capacity and Thermic heater 20,00,000 K.Cals.

Electro Static Precipitator 2500 35

II Fugitive/Noise Emission Type of emission Control measures

1 DG set 1500 KVA Noise In built acoustic barrier -


33

3.5.6.2 Liquid (Effluent) The main sources of effluent are DM plant regeneration, Boiler and cooling tower.

Table 3-10 Trade Effluent Generation Details

Sl. No. Source Existing Quantity

(KLD) After Expansion Quantity

(KLD)

1 Cooling Tower Blowdown 20 32

2 Boiler Blowdown 10 12

3 Process effluent 20 30

4 DM plant regeneration 20 34

Total 70 108

Table 3-11 Trade Effluent Disposal Details

Sl. No. Description of Outlet Quantity (KLD)

Disposal Existing Expansion

1

From cooling tower blowdown, DM plant, boiler blowdown &

Process

70 108 Zero Liquid Discharge (UASBR & Aeration,

UF, RO & ME)

3.5.6.2.1 Effluent Treatment Plant The wastewater generated during the production process of proposed products is from the

following sources; flow chart of the various units involved in ETP is shown in Figure 2.6.

Process waste streams from column bottoms.

Cooling tower blow down.

Boiler blow down.

Water treatment plant effluent.

Water from condensate.

Regeneration waste.


34

Treatment Units

Flash mixer & Flocculator

Collected effluent is pumped to flash mixer and flocculator where suitable coagulant, Flocculent

and polymer are used to remove the suspended solids, Turbidity.

Lamella Clarifier

The effluent from the flocculator will be fed in to lamella clarifier tank where the precipitated

floes produced in Flash mixer and flocculator will settle and the supernatant liquid overflows to

the clarified water tank.

UASB Reactor

The clarified water IS pumped to anaerobic digester. During this process suitable alkaline

chemical (Na2C03) is dosed for increasing the alkalinity of the efflu.ent to make the effluent

ambient for anaerobic process. Since the BOD & COD load is heavy in the effluent, anaerobic

reactor is designed to reduce the load. The gas produce from the UASB reactor will lead into the

bio gas flare system. Primary use of the bio gas flare system is to combust the flammable or toxic

gases to less objectionable compounds.

Aeration Tank

Effluent will be pumped at a constant flow rate from UASB reactor into the Aeration tank. An

activated sludge treatment process occurs as a reaction between Sewage and attached

microorganisms in the Aeration tank.

Air diffusers supply oxygen for biochemical processes as well as mixing, sewage with

return sludge from the settling tank.

An Air Pump {Positive Displacement Type Roots Blower} delivers air to a battery of Fine

Bubble Diffusers at a constant rate thereby ensuring the growth of microorganisms in the

sewage.

These include: Pseudomonas, Flavobacterium, Comamonas, Bacillus, Archromobacter,

Alacingenes, Sphaerotilus, Zoogloea, Archromobacter, Alacingenes, Flavobacterium,

Pseudomonas or heterotrophic bacteria, which disintegrate organic substances into a floc like

substance. This is otherwise known as an aerated suspended growth treatment process.


35

Secondary Settling Tank

The aerated effluent is then piped to the settling tank where the sludge sinks to the bottom. The

clear water overflows via a weir and is then fed to a disinfection tank. Suspended solids are

collected at bottom of clarifier; some of the active microorganism in the form of sludge is

recirculated back to Aeration tank and mixed with the primary effluent with excess sludge

pumped to sludge drying bed for drying & disposal.

Disinfection cum Clarified water tank

A suitable disinfectant, e.g. Hypo Chlorite 1s dosed in the disinfection cum clarified water tank

to ensure that any remaining pathogenic microorganisms are eliminated and the water is fit for

further polishing & recycling.

Polishing Filters

The clarified water after disinfection and DM regeneration waste is pumped through Dual Media

Filter for filtering the suspended impurities and for removing free residual chlorine, organics &

bad odor through adsorption process.

The filtered water at the outlet of the ACF is suitable for gardening applications

UF Automation

• Operation of the Ultra-filtration unit will be completely automated.

• Service & backwash sequence will be controlled by a PLC in the control panel.

• PLC will perform a programmed set of operations consisting of service; backwash and

forward flush of the membranes at a preset sequence.

• It will also initiate the addition of chemicals during backwash to enhance the

cleaning efficiency during backwashing.

• The Ultra-filtration unit will be provided with all safety features and any fault or

abnormal condition will be indicated by an audio-visual alarm in the control panel.

RO System

UF permeate IS pumped through the Micron Cartridge filter using the RO feed pump. It is

primarily used for the removal of turbidity.


36

Prior to the micron filter suitable Anti Sealant , Anti-Oxidant & Acid dosing are dosed to prevent

any low soluble salts settling over the surface of the membranes, to neutralize any oxidizing

agents & adjusting the pH entering into membranes respectively.

The conditioned water from the micron cartridge filter is pumped to the RO system by RO high

pressure pump.

The membrane separates the feed water into two streams namely Permeate with low dissolved

solids & reject with high solid concentration. RO reject is fed in to multiple effect evaporator

system followed by basket centrifuge.

Table 3-12 Details of ETP Units (Existing)

S.No. Treatment Unit No. of Unit Dimensions/ Capacity

1 Dosing Tank 1 500 Lt. 2 RO System 2 7.5m3/hr & 2.8m3/hr.

3 Micron Cartridge Filter 1 7.5m3/hr.

4 Acid dosing Tank 1 50 Lt. 5 Evaporator 1 650 Lts/hr.

6 Evaporator Calendrias 2 --

7 Pre Heater 2 -- 8 Surface Condenser 1 --

9 Solar Pond 4 6m X 6m X 1m


37


38

Figure 3-12 Effluent Treatment Plant (Existing)


39

Proposed Effluent Treatment Plant Scheme

For proposed expansion to cater the quantity of effluent generated from the plant, ETP will be

revamped with proposed units and equipments given in Table 3-13. The layout showing

proposed units in the existing ETP is given in Figure 3.13.

Table 3-13 Details of ETP Units (Proposed)

S.No Description Dimensions (in meters) MOC Nos

1 Bar Screen chamber 0.5m x 1.25m x 0.5m RCC 1

2 Equalization tank 3m x 3m x 3.5m (3 + 0.5m FB) RCC 1

3 Raw effluent transfer pump 2.0 m3/hr 12 mWC CI 2

4 Flash mixer 0.5 m x 0.5 m x 1.2 m MSFRP 1

5 Lime preparation tank 500 LTRS MSEP 1

6 Lime dosing system 0.5 m3/Hr 200 Ltrs CI/HDPE 1

7 Flocculant dosing system 0 - 4 lph / 50 Ltrs PP / LDPE 1

8 Flocculator 0.8 m X 0.8 m X 1.5 m MSFRP 1

9 Polymer dosing system 0 - 4 lph / 50 Ltrs PP / LDPE 1

10 Lamella clarifier 1.5 m X 2.1 m FRP 1

11 Sludge transfer pump 1.0 m3/hr 10 mWC CI 1

12 Clarified water tank 3 KL HDPE 1

13 UASB Feed pump 2.0 m3/hr 12 mWC CI 2

14 UASB Reactor 2.85 m x 2.85 m x 4.5 m RCC 1

15 Aeration tank 6.0 x 4 x 4 (0.5m FB) RCC 1

16 Air blower 150 m3/hr 0.4 mWC CI 2

17 Secondary settling tank 1.5m x 1.5m x 2.5m (+0.4 FB) RCC 1

18 Sludge return pump 1.0 m3/hr 10 mWC CI 1

19 Filter feed tank 10 KL HDPE 1

20 Hypo dosing tank 50 Ltrs LDPE 1

21 Filter feed pump 0 - 4 LPH LDPE 1


40

22 Dual media filter φ500 x 1300mm Hos FRP 1

23 Bag filter 3.0 m3/hr 50 micron PP 1

24 UF system 3.0 m3/hr PVDF 2

25 UF permeate tank 5 KL HDPE 1

26 Organic dosing pumps 24 LPH @ 25 mWC PP 1

27 Organic dosing tank 100 Ltrs LDPE 1

28 Hypo dosing tank 100 Ltrs LDPE 1

29 Hypo dosing pump 20 LPH @ 25 mWC PP 1

30 UF backwash pump 7.5 m3/hr 15 mWC CI 1

31 RO feed pump 5 m3/hr @ 25 mWC CI 2

32 Antiscalent dosing tank 50 Ltrs LDPE 1

33 Antiscalent dosing pump 4 LPH PP 1

34 Antioxidant dosing tank 50 Ltrs LDPE 1

35 Antioxidant dosing pump 4 LPH PP 1

36 Acid dosing tank 50 Ltrs LDPE 1

37 Acid dosing pump 4 LPH PP 1

38 Micron cartridge filter I 5 m3/hr, 5 micron PP 1

39 High pressure pump I 5 m3/hr, 45.7 bar SS316 2

40 RO module - I 8" x 4 Ele long FRP 2

41 RO reject tank 5 KL HDPE 1

42 RO permeate tank 5 KL HDPE 1

43 Sludge drying bed 1.5m x 1.5m x 1.2m B/W 4

44 CIP tank 300 Ltrs FRP 1

45 CIP pump 5 m3/hr @ 2.5 bar SS304 1

46 CIP cartridge filter 5 m3/hr @ 5 micron PP 1

47 Evaporator calendria 650 ltr/hr SS316L 2

48 Solar pan 20m x 18m x 1m RCC 1


41

Figure 3-13 Layout showing proposed units in the existing ETP area


42

3.5.6.3 Liquid (Sewage) Sewage generated through the domestic usage is treated in STP, it is estimated that about 22

KLD of domestic sewage will be generated in the facility after proposed expansion. The existing

capacity of STP is 20 KLD with 20 hours of operation and to cater the quantity generated after

expansion the operating hours will be increased to 24 hours. As a result, existing STP will

achieve adequacy to treat the sewage generated after expansion.

Table 3-14 Sewage Disposal Details

Sl. No.

Description of Outlet

Existing Quantity (KLD)

After Exp. Quantity (KLD)

Disposal

1 STP Outlet 20.0 22.0 On land for gardening

Figure 3-14 Flow Chart of STP

3.5.6.3.1 Sewage Treatment Plant Process details of STP

Capacity : 20 KLD. Flow Rate : 1.0 cum/hr. Operating Hours : 20 hours.

The following raw sewage characteristics were considered for designing of STP

Bar screen

Collection Tank

Aeration Tank

Settling Tank

Sludge drying bed

Clear Water Tank

Pressure Sand Filter

Domestic waste water

Activated Carbon Filter

Treated water storage tank


43

Raw sewage Characteristic

Parameters Value pH 7.5 – 8.5

TSS 200 mg/l BOD 450 mg/l

Treated Sewage Characteristics

Parameters Value pH 6.5 – 8.5

TSS < 30 mg/l BOD < 20 mg/l

Sewage Treatment Plant Details

Sewage and canteen wash water will be received at the inlet of the bar screen to trap any floating

particles and debris. The debris free sewage overflow to the existing collection tank. Sewage

from the collection tank will pumped to the aeration system by the sewage transfer pumps the

biological reaction takes place in the aeration tank where incoming BOD and COD reduced to

greater than 90%. Air Blowers are provided to maintain an adequate air flow in aeration tank.

The overflow from the aeration tank flow to a settling tank by gravity where the bio mass will be

separated and the same will be re circulated back to aeration tank to maintain the MLSS and the

digested sludge will be sent to sludge drying beds. The supernatant liquid overflows to the

Clarified Water tank where Chlorine will be dosed for disinfection.

The clarified water will be pumped through Pressure Sand filter and Activated Carbon filter for

removal of suspended solids and any traces of organics. Electro-magnetic Flow meters provided

in Inlet and Outlet of Sewage treatment plant as per Pollution control board regulatory norms.

Table 3-15 Details of STP units

Description Size Quantity Make MOC

Collection Tank 3.15 m dia. X 1.20 m 1 -- --

Bar Screen 0.5 m x 0.5 m 1 AEC MSEP

Raw Sewage transfer pump 1.0 m3/hr @ 12 mwc 2 (1W+1S) Kirloskar/Eqv CI

Air Blower 40 m3/hr @ 0.5 Kg/cm2 2 (1W+1S) KAY/Eqv CI


44

Coarse/Fine Diffusers 90 mm dia./1000 mm long 1 LOT AEC PVC/EPDM

Media for Aeration tank 185 mm x 45 mm ht 4 m3 AEC PP

Settling tank Feed well 315 mm dia x 1200 mm Ht 1 AEC MSEP/FRP

Sludge transfer Pump 0.5 m3/hr @ 12mwc 1 Kirloskar/Eqv CI

Chlorine dosing pump 0- 4 lph 1 Anala/Eqv PP

Chlorine dosing Tank 50 lit 1 Sintex/Eqv LDPE

Filter Feed pump 1.0 m3/hr @ 32 mwc 2 (1W+1S) Kirloskar/Eqv CI

Pressure Sand filter 0.3 m dia x 1.3 m HOS 1 Advanced

Composite/Eqv FRP

Activated Carbon Filter 0.3 m dia x 1.3 m HOS 1 Advanced

Composite/Eqv FRP

MSEP TANKS • Aeration Tank • Settling Tank • Clarified Water tank

2.4x2.4x3.5m 0.8x1.3x2.8m 0.8x1.1x2.6m

1 AEC

MSEP

(Internal FRP)

Electro Magnetic Flow Meter 1 m3/hr 2 Forbes Marshall PP


45

The following figure shows the layout of Sewage Treatment Plant located in site

Figure 3-15 STP Layout


46

3.5.6.4 Solid (Non-hazardous) The main sources of solid wastes will be from kitchen, process and STP sludge.

Table 3-16 Non-Hazardous waste generation

Sl. No. Nature of Solid Waste Quantity Unit Mode of Disposal

1 STP sludge 4 Kg/day Used as Manure

2 Bio degradable Waste (Food and Garbage) 40 Kg/day

Municipal Disposal/Food waste handed over to pig

farming as feed.

3 Non-Bio degradable Waste (Stationary, Scrap and Packaging Waste)

30 Kg/day Authorized Venders / scrap material collected and sold

to authorized recyclers

3.5.6.5 Solid (hazardous) Table 3-17 Hazardous waste generation

Sl. No. Name of the Process Name of the

process waste (Category No.)

Accum. Quantity

T/Y

Annual Generation

T/Y

Waste Disposal

1 Spent catalyst and molecular sieves

(Schedule I)

1.7 Spent Catalyst 0.75 1.0 (Once

in 5 years)

Common Landfill TSDF

2

Purification and treatment of exhaust air, water and

waste water from the processes in this schedule and CETPs (Schedule I)

34.3 Chemical sludge from waste water treatment

3.0 2.0 Common Landfill TSDF

3.5 RAINWATER HARVESTING & STORMWATER MANAGEMENT

Recently we have constructed 7 Nos of rain water connecting system and existing storm water

management will be continued effectively.

• Storm water drains will be provided along the factory to ensure that this is totally separated

from process effluent. This will minimize runoff of the contaminated water to the land

surrounding the site.

• Runoff from roof top area will be collected by means of down take pipes and recharged into

the ground after filtration.


47

• Surface runoff will be diverted to the channel provided along the site boundary and

discharged in the external storm water drain.

4 GREENBELT DEVELOPMENT In proposed expansion project, the existing green belt area will be increased to 33.01% which is

16.91 acres from total extent. Following table shows the floral species already been planted at

the site and proposed species for expansion of greenbelt.

Table 4.1 List of greenbelt species

S. No. Floral species Status 1 Anona squamosa Existing 2 Azadirachta indica Existing 3 Bauhinia purpurea Existing 4 Caesalpinia pulcherrima Existing 5 Eucalyptus citriodora Existing 6 Hibiscus rosa-sinensis Existing 7 Psidium guayava Existing 8 Albizia odoratissima Proposed 9 Bahinia varigata Proposed 10 Derris indica Proposed 11 Polyalthia longifolia Proposed 12 Psidium longifolia Proposed 13 Saraca asoka Proposed 14 Mangifera indica Proposed


48

Figure 4-1 Greenbelt area marking in satellite image


49

5 ENVIRONMENTAL MANAGEMENT PLAN So far amount of 290 Lakhs for Capital and 17.2 Lakhs amount were incurred for Environmental

Management activities. The details are as follows

Table 5.1 EMP budget

S. No. Infrastructure Capital cost Recurring cost

1. Air Pollution Control 80 Lakhs 2 Lakhs/Month

2. Effluent Treatment Plant (ETP) & Rain water harvesting measures 120 Lakhs 10.Lakhs/Month

3. Environment Monitoring and Management 40 Lakhs 2 Lakhs/Month

4. Solid and Hazardous Waste Management (Membership & Facility development)

0 Lakhs 0.2Lakhs/Month

5. Energy Management 20 Lakhs -

6. Occupational Health & Safety 20 Lakhs 2 Lakhs/Month

7. Green belt Development 10 Lakhs 1 Lakhs/Month

8. Environment Management Cell - -

Total 290 Lakhs 17.2 Lakhs

6 PROJECT COST Cost for the proposed expansion is estimated at 42 Crores approximately.

INTRODUCTION - environmentclearance.nic.in · The proponent has planned to increase the production quantity of MEK & SBA chemicals and ... • It is an intermediate in methyl-ethyl

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