M/s. Ion Exchange (I) Ltd, Ankleshwar M/s. Jyoti Om Chemical ...

M/s. Ion Exchange (I) Ltd, Ankleshwar

M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar.

ANNEXURE- I

PROPOSED TERMS OF REFERENCE

Site description and plant layout.

Project falls under B Category.

List of finished products and production quantity.

List of raw materials and consumption quantity.

Process details with mass balance.

Details of process emissions, 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 due to excavation and 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-A

SITE PLAN



ANNEXURE-II-B

EXISTING PLANT LAYOUT



ANNEXURE-III C

PROPOSED PLANT LAYOUT



ANNEXURE- III

LIST OF PRODUCTS AND THEIR PRODUCTION CAPACITY Sr.

No.

Name of Products Existing quantity as

per Consent No.

AWH-56490 in

(M3/Month)

Proposed

quantity for

Expansion in

(M3/Month)

Total quantity

(M3/Month)

1. Resin-Anion 250 250 500

2. Resin-Cation 1400 600 2000

By-Product

1. Sulphuric Acid (60-70%) 350 250 600

LIST OF RAW MATERIALS

Name of

Product

Name of Raw Materials Existing quantity

as per Consent No.

AWH-56490

(MT/Month)

Proposed

quantity

(MT/Month)

Total quantity

(MT/Month)

Resin-Anion Styrene(Monomer) 60.00 + 35.00 95.00

DYB (Monomer) 3.600 + 2.4 6.00

Egdma(Monomer) 0.865 + 0.185 1.05

BPO 0.529 + 0.121 0.65

PVA 0.250 -0.05 0.20

DN-14 0.397 -0.187 0.21

IBA 1.200 + 1.0 2.20

AQ-B 0.110 + 0.15 0.26

CaCl2 0.500 + 0.5 1.00

Gelatin 0.100 -0.50 0.50

Common salt 7.600 + 26.4 34.00

CSA 130.00 + 70 200.00

EDC 20.200 + 1.8 22.00

Fecl3 2.400 + 2.4 4.80

MF 70.750 + 39.25 110.00

TMA 45.00 + 25 70.00

DMA 15.00 + 20 35.00

DMEA 12.00 + 8 20.00

MYL 10.00 -4 6.00

Caustic lye 36.00 + 40 76.00

HCl 20.00 + 15 35.00

Methanol 20.00 -5 15.00



Hydrated lime 108.300 -108.3 0

Urea 1.00 -1 0

Kmno4 1.200 + 0.8 2.00

H2o2 0.100 -0.8 0.20

Iodine 0.420 -0.08 0.50

P.Iodine 0.250 -0.05 0.30

Dap 0.500 -0.05 0

Phosphoric acid 0.416 + 1.284 1.70

Hexamine 0.416 + 1.084 1.50

Formaldehyde 0.416 -0.016 0.40

Tri ethyl amine 0.416 + 0.234 0.65

2-ethyl hexanol 0.416 -0.416 0

AFS 0.500 + 0.5 1.00

IPA 0.25 + 0.15 0.40

Thiourea 0.25 + 0.15 0.40

Caustic flakes -- + 20 20.00

NaHCO3 -- + 20 20.00

Global-3 -- + 0.11 0.11

Global-4 -- + 0.17 0.17

Toluene -- + 0.50 0.50

Resin-

Cation Styrene (Monomer) 275.400 + 118.029 393.429

DVB (Monomer) 44.385 -9.385 35.000

EDC 37.187 + 7.813 45.000

BPO 1.452 + 0.248 1.700

PVA 1.403 -1.203 0.200

Oleum 590.675 + 459.325 1050.000

Caustic lye 150.106 + 24.894 175.000

Hydrated lime 100.00 -100 0

DN-14 0.034 -0.034 0

AQ-B 0.047 -0.047 0

Cacl2 0.179 -0.179 0

Gelatin 0.041 -0.041 0

Common salt 24.843 + 17.157 42.000

Na2SO4 1.00 0 1.000

Methy acrylate 18.125 + 6.875 25.000

Methyl methacrylic acid 0.500 + 0.214 0.714

Methy acrylic acid 8.750 + 8.75 17.500

AZDN 0.101 + 0.029 0.130

CMC 0.365 + 0.285 0.650

P. carbonate 5.625 + 2.375 8.000

HCl 45.00 + 30 75.000

Sodium benzoate 0.001 -0.001 0

Hexamine 0.416 -0.416 0



Alum 0.416 + 0.178 0.594

Sodium sulphite 0.416 + 0.178 0.594

NaHCO3 --- + 16.000 16.000

Global-3 --- + 0.700 0.700

Global-4 --- + 1.100 1.100

Oxalic acid --- + 0.700 0.700



ANNEXURE-IV

BRIEF PROCESS DESCRIPTION

MANUFACTURING PROCESS DETAILS FOR ANION

BEADING

Beads are formed by suspension polymerization of styrene along with cross-linking agent

like EGDMA / DVB in a stainless steel reactor called beading pan. After post

polymerization the beads are dropped into a drain table where they are backwashed with

water. The beads are then dried and screened to get required size.

CHLOROMETHYLATION OF BEADS

Methanol formaldehyde mixture is received in a glass lined reactor. Chloro-sulphonic

acid is added at a controlled rate maintaining the temperature of 60 °C. The reactor mass

is stirred per one hour and allowed to settle.

The above chloro mixture along with catalyst is received in another glass lined reactor

containing pre-packed Beads in solvent Ethylene di-chloride (EDC). The temperature is

maintained < 60 °C. The reactor is terminated with addition of sufficient quantity of the

water. The reaction mass is received in dilutor where EDC is separated and recovered and

acid is neutralized. The neutralized batch is taken for amination.

AMINATION

Chloromethylated batch is Aminated using suitable amine at less then 60 °C. The batch is

then neutralized and subsequently EDC is recovered by distillation. Aminated batch is

then washed and dropped in a drain table and the resins are packed. Alternatively,

Chloromethylated beads are further added to a mixture of suitable amine and solvent at

less then 60 °C. in a stainless steel aminator. The reaction is allowed to complete solvents

are then recovered and the batch is cooled and transfer to the washer. The animated batch

is then washed and dropped in a drain table and the resins are packed.

MANUFACTURING PROCESS DETAILS FOR CATION

Styrene and Di-vinyl Benzene are co-polymerized in aqueous medium consisting of

Polyvinyl Alcohol / Gelatin acting as a stabilizer and common salt as electrolyte. Benzyl

Peroxide is used as initiator for the addition polymerization reaction; polymerization

reaction is taken in stainless steel vessel with anchor type S.S. agitator. Polymerization is

exothermic process and temperature is controlled by steam and cooling water between 80

°C. to 85

°C. The polymerized product in the beads from which is heated at 100

°C. after

reaction stage. This product is cooled and dropped in drain table.

The product is washed and the washed product is discharged, centrifuged and dried in

fluid bed drier. The dried beads are screened. The different fractions are collected and

packed.



FINISHED PRODUCT

The co-polymer styrene and Di-Vinyl Benzene is sulphonated in glass lined M.S. reactor

with turbine type glass lined agitator. Beads are first soaked in EDC for 2.5 hours, then

sulphonation is carried out with 20% Oleum at 100°C. EDC is distilled out with simple

distillation column of glass coiled condenser. No pressure reaction is required. After

sulphonation the product is cooled to 50°C. and dropped by gravity to the M.S.G.L.

dilutor. Batch is diluted stage by stage with varying concentration of sulphuric acid and

the batch is transferred to washer. Caustic lye is used to convert the resin in Na form if

required. The resin is washed in water and become ready for packing.

CHEMICAL REACTION FOR CATION PROCESS

1. POLYMERIZATION

CATALYST

(BENZYL

PEROXIDE) CH=CH2

CH=CH2 CH=CH2 H2C CH CH2 CH2

H2C CH CH2 CH

HEAT



2. SULPHONATION

CHEMICAL REACTION FOR ANION PROCESS

1. POLYMERIZATION

POLYSTYRENE BEADS

CATION RESIN

OLEUM 23%

HEAT 1000 C

H2C CH CH2 CH2

H2C CH CH2 CH

SO3

SO3

H2C CH CH2 CH2

H2C CH CH2 CH

DI-VINYL BENZENE

STYRENE

CATALYST (BENZYL

PEROXIDE) CH=CH2

CH=CH2 CH=CH2 H2C CH CH2 CH2

H2C CH CH2 CH

HEAT

CO-POLYMER

BEADS OF STYRENE & D.V.B.



2. CHLOROMETHYLAION

CH3OH + HCHO + HCl CH3 O CH2Cl + H2C

CHLOROMETHYLATED CO-POLYMER CROSS-LINKED

BEADS

POLYSTYRENE BEADS

+ CH3OH

CH2Cl

CH2Cl

CATALYST

CH3-O-CH2Cl

H2C CH CH2 CH2

H2C CH CH2 CH

H2C CH CH2 CH2

H2C CH CH2 CH

+ H2O



3. AMINATION

CH2Cl

CH2Cl

H2C CH CH2 CH2

H2C CH CH2 CH

NH(CH3)2

CH2NH(CH3)2Cl

CH2NH(CH3)2Cl

H2C CH CH2 CH2

H2C CH CH2 CH

ANION RESIN

CHLOROMETHYLATED CO-POLYMER CROSS-LINKED

BEADS



CHEMICAL REACTION FOR ANION PROCESS

1. POLYMERIZATION

STYRENE

E.G.D.M.A.

CO-POLYMER BEADS OF STYRENE & E.G.D.M.A.

CH2

CH3

CH3

O

H2C

O

O

O 2

CH=CH2

CH3 CH3 O O

CH3 C C O CH2 CH2 O C C CH3

CH=CH2 CH=CH2

CATALYST

(BENZYL PEROXIDE) HEAT



2. CHLOROMETHYLAION

CH3OH + HCHO + HCl CH3 O CH2Cl + H2C

+

CH3OH

+ H2O

POLYSTYRENE BEADS

CATALYST CH3-O-CH2Cl

CH3 CH3 O O


CH=CH2 CH=CH2

CHLOROMETHYLATED

CO-POLYMER CROSS-LINKED

BEADS CH2 Cl CH2 Cl

CH3 CH3 O O


CH=CH2 CH=CH2



3. AMINATION

ANION RESIN

CHLOROMETHYLATED CO-POLYMER CROSS-

LINKED

BEADS

NH(CH3)2

CH2 Cl CH2 Cl

CH3 CH3 O O


CH=CH2 CH=CH2

CH2NH(CH3)2Cl

CH2NH(CH3)2Cl

CH3 CH3 O O


CH=CH2 CH=CH2



MANUFACTURING PROCESS FLOW DIAGRAM FOR CATION (SA)

Finished Products – Solid Granules.

Packing

Stabilizers

HCl

Convert to dry product as per

required parameter

Caustic Lye

Monomers (Styrene / DVB)

Poly Vinyl Alcohol/Gelatin/MMA

+ Benzyl Peroxide + AZDN +

CMC + Salt

Beading (Polymerization) – 22

hours.

Conversion & Washing 10 hours.

Fluid Bed Dryer 10 hours.

Screening 10 hours.

Dry Material Sulphonation 24

hours.

Dilution 10 hours.

Oleum 23%

E. D.C. SO2 for Scrubbing

Sulphonation

Mass Slurry

Washing 10 hours.

Drain Table 1 hour.

Sulphuric Acid (70

5 %) (By-

Product)



MANUFACTURING PROCESS FLOW DIAGRAM FOR CATION (WA)

K2CO3

HCl 30%

A

Drain Table 1 hour.


Packing

Washing 2hours.

Methyl Acrylate + Metha

Acrylic Acid + Divinyl

Benzene + AZDN

Salt + CMC

Beading (Polymerization) – 20 hours.

Hydrolysis - 04 hours.

HCl Treatment 12 hours.

Caustic Lye



MANUFACTURING PROCESS FLOW DIAGRAM FOR CATION (DRY)

A

Drying

Packing

Pulverizing

Screening



MANUFACTURING PROCESS FLOW DIAGRAM FOR CATION (SP)

Styrene + Di-Vinyl Benzene +

IBA

Poly Vinyl Alcohol + Benzyl

Peroxide


Washing 8 hours.


Screening 5 hours.

Dry Material Sulfonation 24 hours.

Dilution 10 hours.

OLEUM 23%

E. D. C.

SO2 for Scrubbing

Washing 10 hours.

Drain Table 1 hour.


E. D. C. Recovery

Packing

IBA Recovery 8

hours

Spent Acid



MANUFACTURING PROCESS FLOW DIAGRAM FOR ANION

Amines

HCl

Styrene + E. G. D. M. A/DVB Poly Vinyl Alcohol + Benzyl

Peroxide


Washing 10 hours.


Screening 5 hours.

Dry Material Chloromethylation 24

hours.

Washing 8 hours.

M.F., C.S.A.

& HCl

E. D. C. HCl for Scrubbing

C. M. Beads for Amination 24 hours.

Conversion & Washing 8 hours.

Drain Table 1 hour.


E. D. C. Recovery

MYL Recovery

Packing

KMnO4, I2, KI,

H2O2



MANUFACTURING PROCESS FLOW DIAGRAM FOR ANION

Formaldehyde,

Phosphoric Acid &

Hexamine

IBA Recovery 8

hours

Stabilizers

Packing

MYL / Caustic

Amines

MYL Recovery

Styrene + Di-Vinyl Benzene +

IBA Poly Vinyl Alcohol + Benzyl Peroxide +

Salt


Washing 8 hours.


Screening 5 hours.

Dry Material Chloromethylation 24

hours.

Washing 8 hours.

M.F., C.S.A.,

MeOH & HCl

E. D. C. HCl for Scrubbing

C. M. Beads for Amination 24 hours.

Washing 8 hours.

Drain Table 1 hour.


E. D. C. Recovery



ANNEXURE-V

DETAILS OF WATER CONSUMPTION

Source of water: GIDC

NOTE: There will not be increase in fresh water requirement. The unit has proposed to

install RO system and recover additional 235 KL water. The efficiency of RO plant will

be almost 70% permeate and 30 % reject. Earlier it was only 50% efficiency.

Particulars Existing Quantity

(KL/Day)

Proposed

Quantity

(KL /Day)

Total Quantity

(Proposed

Scenario)

(KL/Day)

i) Domestic 8 0 8

ii) Industrial

Process

527 (Fresh) +

200 (Reused RO

Permeate)

-20 (Fresh)+ 235

(Reused RO

Permeate)

507 (Fresh)+ 435

(Reused RO

Permeate)

Boiler + Cooling 90 +20 110

Washing 26 0 26

Gardening 14 0 14

Total 665 (Fresh) + 200

(Reused RO Permeate

235 (Reused RO

Permeate)

665 (Fresh) +

435 (Reused RO

Permeate)



DETAILS OF WASTEWATER GENERATION

Particulars Existing Quantity

(KL/Day)

Proposed scenario

(KL /Day)

i) Domestic 8 8

ii) Process 723 938

Boiler + Cooling

Tower

45 65

Washing 24 24

Gardening 0 0

Total 800 1035

Recovered by

RO plant

200 435

Actual Discharge 600 600

Note: Total Waste water generation will be 1035 KL/Day. It will be sent to RO Plant and

Bio stream. 435 KL/ Day permeate water will be recovered and reuse in process.

Rejected from RO 300 KL/ Day and Bio stream 300 KL/Day will be sent to the NCTL

after treatment for final disposal.



WATER BALANCE DIAGRAM (EXISTING)

Gardening

(14 KL) Process:

(Fresh: 527 KL + RO Permeate:

200.0* KL)

Boiler + Cooling Tower

(Fresh: 90 KL) Domestic

(8 KL)

General Washing

(26 KL)

Low COD effluent

to recycle stream

(523 KL)

Blow down

(45 KL)

Sewage-

soak pit

(8 KL)

From

Washing

(24 KL)

Effluent Treatment Plant (800 KL/D)

(Bio Stream: 200 KL/D +

Recycle Stream: 600 KL/D)

High COD

Effluent to

Biostream

(200 KL)

Evaporation

Loss

(20 KL)

RO Plant (400KL)

RO Reject

(200 KL)

Waste Water Tank

(200 +200+ 200) = 600 KL

Final Discharge to NCTL

(600 KL/D)

GIDC Water Consumption (665.0 KL/D)

Bio Stream

(200 KL)

RO Permeate

(200.0* KL)

Reuse in

Process

Evaporation

Loss

(2 KL)

Evaporation

Loss

(4 KL)

Steam Water (25)*

(Recycle)

Recycle Stream (600 KL

From Bio

Stream

(200 KL)

From

Recycle

Stream

(200 KL)



WATER BALANCE DIAGRAM (PROPOSED)

Process:

(Fresh: 507 KL + RO Permeate:

435.0* KL)

Boiler + Cooling Tower

(Fresh: 110 KL) Domestic

(8 KL)

General Washing

(26 KL)

Gardening

(14 KL)

Low COD/TDS

effluent to recycle

stream (638 KL)

Blow down

(65 KL)

Sewage-

soak pit

(8 KL)

From

Washing

(24 KL)

Effluent Treatment Plant (1035 KL/D)

(Bio Stream: 300 KL/D +

Recycle Stream: 735 KL/D)

High COD/TDS

Effluent to

Biostream

(300 KL)

Evaporation

Loss

(20 KL)

RO Plant (735 KL)

RO Reject

(300 KL)

Waste Water Tank

(300 + 300) = 600 KL

Final Discharge to NCTL

(600 KL/D)

GIDC Water Consumption (665.0 KL/D)

Bio Stream

(300 KL)

RO Permeate

(435.0* KL)

Reuse in

Process

Evaporation

Loss

(2 KL)

Evaporation

Loss

(4 KL)

Steam Water (25)*

(Recycle)

Recycle Stream (735 KL)

From Bio

Stream

(300 KL)



ANNEXURE-VI

DETAILS OF EFFLUENT TREATMENT PLANT

MODE OF COLLECTION

Mainly two types of effluent streams are generated in this scheme. One of recycle

stream for recycle through biological, UF and RO system and another Biostream are

for treatment through anaerobic & biological system.

Recycle stream contain low COD generated within the manufacturing plant will be

conveyed to the effluent treatment plant after due neutralization and collection in the

separate equalization tank, equalization tank is designed for 1400 m3 / day.

Bio stream contain high COD generated within the manufacturing plant will be

conveyed to the effluent treatment plant after due neutralization and collection in the

separate equalization tank, equalization tank is designed for 450 m3 / day.

Cationic Recycle Stream:

A. Effluent Collection Tank (200 m3):

The Recycle stream effluent from the production units comes to the tank through by

gravity and domestic sewage comes to the tank through pump. It follows the

treatment mentioned below.

B. Neutralisation Tank: Pump the effluent from the common collection sump to neutralization tank. Effluent

is mixed up with 5% caustic lye solution to make pH 7-8. For this operation we are

having dedicated one caustic lye dosing tank.

C. Equalization Tank (1400 m3):

We are having one Equalization tank of having total capacity of 1400 m3.

Equalisation tank is equipped with perforated pipe grid to supply air to mix the

contents of equalization. Then transfer to fenton tank.

D. Fenton Tank (20 m3):

The effluent coming from the Equalization is mixed up with 2% of lime solution to

adjust pH. Here, ferric chloride is added for floc generation. For this operation we are

having dedicated one lime dosing tank and one ferric chloride dosing tank.

E. High Rated Solid Contact Clarifier (HRSCC) (100 m3):

Neutral effluent with suspended particles comes here by gravity from fenton tank.

Here, polyelectrolyte is added approximately 2-4 ppm in concentration. Hence,

suspended particles are settled down. The clean supernatant effluent is transferred to

aeration Tank and settled sludge is transferred to sludge pit for further treatment.



F. Aeration Tank (850 m3):

The neutral effluent is comes to the aeration tank for bio degradation, which is,

equipped with imported silicone membranes for diffused aeration. The capacity of

tank is 850 m3. One air blower is operating on continuously and another one for

standby.

G. Secondary Clarifier (170 m3):

The mixed liquor from aeration tank comes to this system by pump. Here,

biodegradable polyelectrolyte is added, so the active sludge is settled down and

recycled to aeration tank. The supernatant effluent is transferred to clarifier water

tank for further treatment in UF and RO plant. Here, sodium hypo chlorite is added in

supernatant for antibacterial treatment.

H. Clarifier Water Tank (40 m

3):

The supernatant from secondary clarifier comes to clarifier water tank by gravity for

further treatment. Then water transfer through multi grade filter (MGF) and activated

carbon filter to Ultra filtration (UF) plant by pump.

I. Ultra Filtration (UF) (34 m

3/Hrs):

After passing through ACF, effluent feed into UF via cartridge filter for ultra

filtration which is set in auto system. UF permeate water taken in UF permeate tank

for treatment of RO plant.

J. Reverse Osmosis Plant (807 m

3/Day) :

After treatment of UF plant, UF permeate water feeding in RO plant. RO Permeate water

taken in RO permeate tank through degasser tower. Permeate water reusing for

Process/Boiler/Cooling Tower. RO Reject water transfer to final collection sump.

K. Final Collection Sump (50 m3):

The effluent coming from the RO plant, after blending with MBR permeate water and then

discharge to the GIDC drainage system for further treatment to NCTL through final outlet

tank.

Anionic Bio Stream:

L. Effluent Collection Tank (450 m

3):

The Bio stream effluents from the production units comes to the tank through pumps and

Decantor washing effluent comes to the tank through pump. Equalisation tank is equipped

with perforated pipe grid to supply air to mix the contents of equalization. Then transfer to

fenton tank. It follows the treatment mentioned below.



M. Fenton Tank (10 m3):

The effluent coming from the Equalization is mixed up with 2% of lime solution to adjust pH.

Here, poly alluminium chloride is added for floc generation. For this operation we are having

dedicated one lime dosing tank and one poly alluminium chloride dosing tank.

N. High Rated Solid Contact Clarifier (HRSCC) (45 m3):

Neutral effluent with suspended particles comes here by gravity from fenton tank. Here,

polyelectrolyte is added approximately 8-10 ppm in concentration. Hence, suspended

particles are settled down. The clean supernatant effluent is transferred to recirculation tank

and settled sludge is transferred to sludge pit for further treatment.

O. Recirculation Tank (30 m3) :

The supernatant from HRSCC comes to recirculation tank by gravity for further treatment.

Here, nutrients are added for bacteria growth and sodium carbonate is added for maintain

alkalinity. The effluent is transferred to UASB reactor.

P. Up flow Anaerobic Sludge Blanket Reactor (UASB) (1100 m3) :

Effluent from the recirculation tank is pumped to the two numbers of division boxes placed at

the platform above the UASB reactor. Effluent is then further distributed to the ten numbers

of inlet boxes from where by gravity effluent is fed to the UASB reactor with the help of 20

Nos HDPE pipes connected on each inlet box. Treated effluent is collected through two FRP

launders and falls in to the common RCC launder. From this launder, one part of the UASB

treated effluent is recycled back to the UASB through the UASB buffer tank, while other part

is clarified in a lamella clarifier. Flow equal to the HRSCC outlet shall be sent to the lamella

clarifier the other part has to be recycled back to UASB tank. The settled sludge, in normal

operation is disposed off through centrifuge after mixing with other sludge. Biogas is flared

off through a biogas flare system installed at site and excess biomass has to be disposed

above a certain level of MLSS in the reactor.

Q. Lamella Clarifier:

The treated effluent from UASB comes to lamella clarifier by gravity for further treatment.

The clean supernatant effluent is transferred to pre aeration tank and settled sludge is

transferred to sludge pit for further treatment.

R. Pre Aeration Tank (30 m3) :

Clarified effluent from lamella clarifier is collected by gravity in to the Pre-aeration

tank from where it is pumped to the aeration tank for its further treatment.

S. Aeration Tank (315 m

3):

The neutral effluent is comes from pre aeration to the aeration tank for bio

degradation, which is, equipped with imported silicone membranes for diffused

aeration. The capacity of tank is 315 m3. One air blower is operating on continuously

and another one for standby.



T. Membrane Bio Reactor (117 m3):

The mixed liquor from aeration tank comes to this system by pump. Always keep the

flow at slightly higher than the permeate flow so that the effluent is always in a

circulation mode. MBR tank blower will always be in continuously operation. One air

blower is operating on continuously and another one for standby. MBR permeate

water taken in MBR permeate tank for further treatment. The effluent coming from

the MBR permeate water, after blending with RO plant effluent and then discharge to

the GIDC drainage system.

Anionic - Acidic Stream:

Highly Acidic effluent of the plant is neutralized with 10% of lime solution in

separate neutralizer reactor. After neutralization of effluent, drain to decanter feed

tank. Here, other tanks drain sludge is mixed with these neutral effluents.

U. Decanter:

The slurry of decanter feed tank is pumped into the decanter for dewatering. Here,

polyelectrolyte is added approximately 8-10 ppm in concentration. The clean

supernatant effluent is transferred to bio effluent collection tank for further treatment

and separated sludge is transferred to sludge storage area and finally sent to cement

industries for recycle purpose. Decanter will always be in continuously operation.

One decanter is operating on continuously and another one for standby.



DEMENTIONAL DETAILS OF ETP UNITS

Sr.

No.

Name of Units Nos. Dimensions of Bio

Stream

Dimensions of

Recycle Stream

1 Effluent Collection Tank 01 NA 200 m3

2 Equalization Tank 02 450 m3 1400 m

3

3 Fenton reaction tank 02 10 m3 20 m

3

4 HRSCC Tank 02 45 m3 100 m

3

5 Aeration Tank 02 315 m3 850 m

3

6 Secondary clarifier 01 NA 170 m3

7 Clarifier water tank: 02 30 m3 40 m

3

8 MGF 02 10 m3/hr 34 m

3/hr

9 UF 01 NA 34 m3/hr

10 UF Permeate tank 01 NA 100 m3

11 RO Plant 01 NA 807 m3/Day

12 Final Collection Sump 02 50 m3 50 m

3

13 Sludge Pit for HRSCC 01 10 m3 Common

14 Final Outlet Tank 01 Common 50 m3

15 Recirculation tank 01 30 m3 NA

16 UASB 01 1100 m3 NA

17 MBR (87 m3

+ 30 m3) 01 10 m

3/hr NA

18 Lime preparation Reactor 02 10 m3 10 m

3

19 Neutralizer Reactor 02 10 m3 10 m

3

DETAIL OF EQUIPMENTS

1. Perforated pipe grid installed in the equalization tank :

Function : To supply diffused air to the contents of the equalization tank.

Type : Perforated HDPE Pipe with 90.0 OD header and 50.0 OD

Laterals.

Quantity : One lot.

2. Air blowers

Function : To supply diffused air to the equalization tank, neutralization

and aeration tank.

Type : Twin lobe rotomy.

Accessories :Suction and discharge silencer, suction filter, pressure

relief valve, NRV, set of an Evil oration pads, etc.

Capacity : 1030.00 m3

/hr air @ 0.5 kg/cm2 pressure.



Quantity : 2 nos. (1 Standby)

3. Air blowers :

Function : To supply diffused air to the aeration tank.

Type : Twin lobe rotomy.

Accessories : Suction and discharge silencer , suction filter, pressure relief

valve, NRV, set of an Evil oration pads, etc.

Capacity : 900.00 m3 / hr air @ 1.0 kg/cm

2 pressure.

Quantity : 2 nos. (1 Standby)

4. Equalized effluent transfer pumps :

Function : To transfer equalized effluent to the neutralization tank.

Type : PS, centrifugal with suitable drive motor.

Capacity : 7.0 m3 /hr @ 3.0 meter head.

Quantity : 2 nos.(1 Standby)

5. Diffused grid in the neutralization tank :

Function : To supply air to the contents of the neutralization tanks.

Type : HDPE pipe grid with course bubble tank.

Quantity : One lot.

6. Drum Skimmer in the Floating tank :

Function : To skim the pollutants from floating layer.

Type : Rotating drum coated with oleophilic material with scrapper.

Quantity : One nos.

7. Diffused grid in the separation tank :

Function : To supply diffused air in the contents of the operation tank.

Type : HDPE / PVC air grid with fine bubble diffusers.

Quantity : One lot.

mailto:[email protected]



8. Diffuser grid in the aeration tank :

Function : To supply diffused air in the contents of the operation tank.

Type : MS / SS air grid with fine bubble diffusers.

Quantity : One lot.

9. Mechanical internals – secondary clarifier :

Function : To collect sludge in the central sludge pocket.

Type : Centrally driven rotating scrapper mechanism with fixed

Bridge spanning between walls of the tank, MS feed well,

Central shaft, 2 nos of scrapper arms, scrapper blades and

Squeeze.

Capacity : Suitable for installation in RCC tank.

Quantity : Two lots.

10. Return sludge pumps :

Function : To return activated sludge to the inlet of the aeration tank

and access sludge to the sludge drying beds.

Type : Cl, Centrifugal.

Capacity : 7.0 m3

/hr. @ 10.0 meter head.

Quantity : 2 nos. (1 Stand by)

11. Chemical Dosing system :

Hypochloride solution preparation and dosing tanks.

Capacity : 500 ltrs.

Quantity : 2 nos.

Nutrients solution preparation and dosing tanks.

Capacity : 1000 ltrs

Quantity : 1 nos.

Lime solution preparation and dosing tanks.



Capacity : 1000 ltrs

Quantity : 2 nos.

Agitators in hypochloride and dosing tanks.

Type : High Speed

Capacity : 0.5 hp.

Quantity : 2 nos.

Agitators in lime dosing tank.

Type : Slow Speed

Capacity : 0.5 hp.

Quantity : 2 nos.

Activated Carbon Filter feed pumps.

Function : To feed effluent to ACF.

Type : Cl, Centrifugal.

Capacity : 7.5 m3

/ hr. @ 15 meter head.

Quantity : 2 nos. (1 stands by)

Activated Carbon Filter.

Function : Final polishing.

Type : Down flow with local Activated carbon.

Capacity : 1200 mm & 2200 mm dia.

Quantity : 2 nos. (Each both)

Instruments.

Pressure Gauges : 6 nos.

Level indicators : 5 nos.

pH indicator : 2 nos.

Piping : Interconnecting piping in HDPE and valves.

Electrical works : Consisting of MLC, Push button stations,

Power cables and control cables.



FLOW DIAGRAM OF ETP ANIONIC – ACIDIC STREAM

ACID

NEUTRALIZATION

DECANTO

R FEED

TANK

ANIONIC

EFFLUENT

(ACIDICSTRE

AM)

DECENTOR

CENTRIFUG

E

SLUDGE

COLLECTION

TANK LIME SLURRY TANK

PRIMARY

TREATMENT

SLUDGE STORAGE

AREA

EQUALIZATION

TANK (450KL)

EFFLUENT TREATMENT

VIA ANIONIC (BIO

STREAM)

SLUDGE

POLYELECTROLYTE

Sludge FROM MBR & BOTH HRSCC’s& Secondary clarifier

Effluent LIME ADD



FLOW DIAGRAM OF ETP ANIONIC - RECYCLE STREAM

CATIONIC

EFFLUENT

(RECYCLE

STREAM)

EQUALIZ

ATION

TANK

(1400KL)

FENTON

TANK

HRSCC

MULTI

GRADE

FILTER

SECONDARY

CLARIFIER TANK AERATION TANK

(850 KL)

ULTRA

FILTRATION

PLANT

REVERSE

OSMOSIS

PLANT

FINAL

COLLECTION

SUMP

OXIDATION

SUMP

CARBON

FILTER

TREATED

EFFLUENT

OUTLET

TANK

GIDC

DRAIN

PERMEATE FOR

REUSE

ACTIVETED

CARBON FILTER

EFFLUENT

COLLECTIO

N TANK

RO REJECT

RO PERMEATE

POLYELECTROLYTE, HYPO

FeCL3, LIME Poly electrolyte



FLOW DIAGRAM OF ETP CATIONIC - BIO STREAM

TREATED

EFFLUENT

OUTLET

TANK FOR

DISCHARGE

PRE-AERATION

RECIRCULATIO

N TANK

HRSCC TANK ANIONIC EFFLUENT

(BIO STREAM)

UASB TANK

MEMBRAN

E BIO

REACTOR

FINAL

COLLEC

TION

SUMP

LAMELLA CLARIFIER

OXIDATI

ON

TANK

COLLECTION

/EQUALIZATIO

TANK (450 KL)

AERATIO

N TANK

FENTON TANK

(BIO STREAM)

GIDC DRAIN

PAC, Lime POLYELECTROL

YTE

ACF

TANK

DAP, Na2CO3

BIOMASS UREA, DAP



BRIEF DESCRIPTION OF SLUDGE GENERATION PROCESS

Acid and acidic water from chloro methylation process is separately collected into acid

tank. The acid is neutralized with 10 % of lime slurry. The neutral slurry is sent to

decantor. From decantor, lime sludge is drained into sludge drying bed. After drying

process in sludge drying bed sludge is ready to dispatch.

FLOW DIAGRAM OF SLUDGE GENERATION

ACIDIC WATER

LIME SLURRY

NEUTRALIZER

DECANTOR

Clear liquid for effluent

treatment

Lime sludge to sludge

drying bed



ANNEXURE-VII

ELECTRICITY AND FUEL CONSUMPTIONS

Sr.

No.

Name Existing as per

Consent Quantity

Proposed

Quantity

Total Quantity Source

1. Natural Gas

for Boilers

202.5 M3/Hr. 00 202.5 M

3/Hr. GGCL

2. LDO as

Alternate Fuel

to Boilers

0.025 Kl/Hr.(Only

When Natural Gas

not Available)

00 0.025

Kl/Hr.(Only

When Natural

Gas not

Available)

Local

Market

3. Diesel For DG

Sets

0.135 Kl/Hr. 00 0.135 Kl/Hr. Local

Market

4. Energy-

Electricity

900 KVA 700 KVA 1600 KVA DGVCL



ANNEXURE-VIII

DETAILS OF FLUE GAS EMISSIONS

Sr.

No.

Stack

Attach

to

Stack

Height

in Meter

Diameter

in meter

Parameter Permissible Limit

As per Consent No. AWH· 56490

1. Boiler

(I to

IV)

30 0.45 Particulate

Matter

SO2

NOx

150 Mg/Nm3

100 ppm

50 ppm 2. Boiler

(V)

30 0.45

3. D.G Set

(2

Nos.)

09

(Each)

0.1 Particulate

Metter

SO2

NOx

150 Mg/Nm3

100 ppm

50 ppm

As per proposed expansion

There will be no change in Flue gas emission due to Proposed Scenario.

DETAILS OF PROCESS EMISSION

Sr.

No.

Stack

Attached

to

Stack

Height

in

meter

Diameter

in meter

APCM Parameter Permissible

Limit

As per Consent No. AWH· 56490

1. HCl

Process

Scrubber

27 0.1 Water

Scrubber

followed

by Alkali

scrubber

HCl

Cl2

20 Mg/Nm3

09 Mg/Nm3

2. SO2

Process

Scrubber

20 0.1 Caustic

Scrubber

SO2 40 Mg/Nm3

As per proposed expansion

There will be no change in Process emission due to Proposed Scenario.



SCRUBBING SYSTEM - CATION

PROCESS VENT :

The vent from process is connected to scrubbing system. Alkaline water is constantly

sprayed & circulated in scrubbing tower where SO2 vapors from process are moving

upward in counter current direction. Scrubber is connected to blower having stack

height of 17 meters before venting of vapors, the pH of alkaline water is continuously

monitored and maintained by addition of caustic solution. Standby blowers & pump

are provided with PLC controlled automatic system to ensure trouble free

performance.

FLOW DIAGRAM OF PROCESS VENT :

VAPOURS FROM PROCESS VENT

BLOWER PUMP

CAUSTIC CIRCULATION TANK

S C

R U

B B

E

R

VENT



SCRUBBING SYSTEM - ANION

PROCESS VENT :

The vent from process is connected to scrubbing system. Alkaline water is constantly

sprayed & circulated in scrubbing tower where HCl vapors from process are moving

upward in counter current direction. Scrubber is connected to blower having stack

height of 17 meters before venting of vapors, the pH of alkaline water is contently

monitored are maintained by addition of caustic solution. Standby blowers & pump

are provided with PLC controlled automatic system to ensure trouble free

performance.

FLOW DIAGRAM OF PROCESS VENT :

VAPOURS FROM PROCESS

VENT

BLOWER PUMP

CAUSTIC CIRCULATION TANK

S C

R U

B B

E R

VENT



ANNEXURE-IX

DETAILS OF HAZARDOUS WASTE

Sr.

No.

Name of waste Cat.

No.

Quantity Method of disposal

As per

consent No.

AWH· 56490

As per

proposed

expansion

Total

1. Used Oil 5.1 100 Lit/Month 200 Lit/Month 300 Lit/Month Collection, Storage, Sold to

MoEF Approved Vendors.

2. Discarded Barrels 33.3 100 Nos./Month 500 Nos./Month 600 Nos./Month Collection, Storage, Sold to

GPCB approved vendors

after decontamination &

other items will be disposed

to TSDF-BEIL, Ankleshwar.

Liners 2000 Kg/Month 3000 Kg/Month 5000 Kg/Month

Insulation Waste 65 Kg/Month 85 Kg/Month 150 Kg/Month

Personal Protective

Equipment’s

250 Kg/Month 450 Kg/Month 700 Kg/Month

Broken Glassware 20 Kg/Month 40 Kg/Month 60 Kg/Month

3. Chemical Gypsum

& Bio-Mass from

Waste Water

Treatment

34.3 655 MT/Month 0 655 MT/Month Gypsum Will Be Sold to

Cement Industry, M/s.

Gujarat, Ambuja Cement,

Kodinar, Gujarat & M/s.

Ultratech Ltd (A Unit Of

Gujarat Cement Works),

Kovaya, Rajulacity, Amreli

& Bio-Mass Will Be

Disposed to BEIL,

Ankleshwar.

4. Spent Resin/Fines

Resin From Ion

Exchange Type

Material Used For

Water Purification

(Non-Toxic & Non-

Hazardous)

34.2 50 MT/Month 0 50 MT/Month Disposed to BEIL -

Ankleshwar.

5. Spent Carbon 35.3 10 MT/Month 0 10 MT/Month Disposed to BEIL-

Ankleshwar.

6. Wet Scrubber

Residue

36.1 10 Kg/Month 0 10 Kg/Month Send to ETP for further

treatment.

7. Spent Acid (H2SO4) D2 350 M3/Month 600 M

3/Month 950 M

3/Month Sold to actual end users.

Note: There will be no change in quantity of Chemical Gypsum & Bio-Mass from Waste

Water Treatment, Spent Resin/Fines Resin from Ion Exchange Type Material Used for

Water Purification (Non-Toxic & Non-Hazardous), Spent Carbon and Wet Scrubber

Residue.

M/s. Ion Exchange (I) Ltd, Ankleshwar M/s. Jyoti Om Chemical ...

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