PRE-FEASIBILITY REPORT For EXPANSION OF DYES INTERMEDIATE UNIT [Schedule 5 (f) Category “B” as per EIA notification 2006 and its amendment thereof] At Plot No. 1708, A-2/1715, Phase-III, Notified Industrial Area, GIDC Vapi, Dist- Valsad (Gujarat). Land/Plot Area: 8219 m 2 Production Capacity: 608.34 TPM to 1673.35 TPM APPLICANT CONSULTANT SARNA CHEMICALS PVT. LIMITED (UNIT: II) ECO CHEM SALES & SERVICES Plot No. 1708, A-2/1715, Phase-III Office Floor, Ashoka Pavilion - A Notified Industrial Area, New Civil Road, Surat, 395001 GIDC Vapi, Dist- Valsad (Gujarat) NABET/EIA/1720/RA 051 E-mail: [email protected]E-mail: [email protected]Mo. No.: +91-9825886564 Tel No. +91 261 2231630
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PRE-FEASIBILITY REPORT
For
EXPANSION OF DYES INTERMEDIATE UNIT
[Schedule 5 (f) Category “B” as per EIA notification 2006 and its amendment thereof]
Detailed project description with process details - MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance & mole balance for the product.
MANUFACTURING PROCESS , CHEMICAL REACTION & MASS BALANCE
1 (A) Chlorination with Chlorine such as Meta Nitro Chloro Benzene (MNCB)
HCl
�
Nitrobenzene (NB)(123)
Chlorine(71)
o-Nitrochlorobenzene(ONCB)(157.5)
Hydrochloricacid(36.5)
P-Nitrochlorobenzene(PNCB)(157.5)
m-Nitrochlorobenzene(MNCB)(157.5)
Nitrobenzene(NB)(123)
HCl
Process: Charge raw material, dehydrate it and add catalyst Ferric chloride and purge chlorine. Test the completion ofreaction. Then wash the reaction mass with water. Wash water is drained to ETP. Then reaction mass is transfer to thecontinuous fractional distillation column for separating isomers. Excess chlorine is scrubbed in reactant mass trap (use innext batch).
Where R =Nitro group
Generalized Reaction Scheme
Reaction Scheme of particular example with high effluent load
Excess Chlorinescrubbed in Nitro Benzenetrap (next batch
chlorination)
Fractional Distillation Handling Loss
MNCB & PNCB/ONCB
1st Wash water Neutralization
Lime
Filteration
Filtrate to MEE
Solid waste TDSF2nd & 3rd wash water to ETP
HCl (g) Scrubber
Water
HCl (30 %)For product
(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: MNBC
Process: Charge raw material,(MNBA ) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.
(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: NMTCl
Process: Charge raw material,(NMMT) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.
(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: Chloroester
Process: Charge raw material,(BTL and IPA) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.
(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: SACl
Process: Charge raw material,(S-Acid) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.
(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: AEC.HCl
Process: Charge raw material,(AEE.HCL) add thionyl chloride. During addition hydrochloric acid generated isscrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye toform sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next
(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: 5ClABTF
Process: Charge raw material,(ABTF) add sulfuryl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold.
Process: The solution/suspension of raw material in proper solvent is heated to reacting temperature and chlorinating agent is added slowly. Aftercompletion of reaction tested by analytical technique, amine was added and maintained at reacting temperature. After completion of theamidation it is filtered to obtain the wet cake. and the ML is recycled in next batch and loss of solvent is compensated by adding requisitequantity of fresh solvent. After 4-5 batch the filtrate is taken for distillation and solvent is distilled out and residue is send to incineration waste.The wet cake is washed with waterand washing is end to MEE.
Generalized Reaction Scheme
3HCl33
3 H3PO3
Where R= 4-carbomethoxy-3-nitro-benzoylR’=2,5-dichlorophenyl
Reaction Scheme of particular example with high effluent load
Process: Charge Water/solvent, add raw material containing base like nucleophilic group. Simultaneously add main raw material containingleaving group and also add NaOH with maintaining pH. Maintain till completion of reaction. During reaction the salt generated is dissolved inaqueous layer which is separated from organic layer of reaction mass. Aqueous layer treated in MEE and recoverwater is recycled.
Generalized Reaction Scheme
Base like NaOH
NaZ H2O
Where R = HO-CH2-CH2-S-CH2-CH2-; HO-CH2-CH2-; NH2-CO-NH-; NH2-R‘ = 3-nitrobenzoyl; ClNH3-CH2-CH2-O-CH2-CH2-; iPr-OOC-(CH2)2-CH2-; 2-Nitrophenyl-; -CO-X = NH; SH; Z = Chloride, OH; MeO-
Reaction Scheme with Perticular Example with High Effluent Load
(2) Mass Balance for Condensation such as SAMBA-III
Reactor
Sup-1Sup-2Caustic lyeMethanol
Filtration Salt
Distillation Methanol recoverMethanol loss
SAMBA-III
(2) Condensation such as Triazolone
Process: Charge solvent (formic acid), add raw material containing base like nucleophilic group (semicarbazide). Simultaneously add main rawmaterial containing leaving group (formic acid) and maintain till completion of reaction. After completion of reaction formic acid is distilled andrecycled. Traces of formic acid is then removed by co-distilltion with water. Product is filtered and ML partly used in next batch and part of itsend to ETP
Formic acid recoverFormic acid lossWater loss.Water ML 1828used in next batchsend to ETP.
Triazolone
(2) Condensation such as 1,3-DAU
Process: Charge raw material containing base like nucleophilic group (Hydrazine hydrate). Simultaneously add main raw material containingleaving group (dimethyl carbonate) and Maintain till completion of reaction. After completion of reaction, excess hydrazien is distilled andmethanoladded and product formed is filtered. ML is recycled.
Process: Charge Water and EDC, add raw material containing base like nucleophilic group (Phenol). Simultaneously add main raw materialcontaining leaving group (ITC) and also add NaOH with maintaining pH. Maintain till completion of reaction. During reaction the salt generatedis dissolved in aqueous layer which is separated from organic layer of reaction mass. Aqueous layer treated in MEE and recover water isrecycled.
Process: Charge Water, add raw material containing base like nucleophilic group (Monoethaanol amine MEA). Simultaneously add main rawmaterial containing leaving group (NOXSC) and also add NaOH with maintaining pH. Maintain till completion of reaction. During reaction thesalt generated is dissolved in aqueous layer which is separated from organic cake of reaction mass. Aqueous layer treated in MEE
Process: Charge amino compound (HH) and urea. Heat the reaction mass at reacting temperature till completion of reaction. During the reactionammonia liberated is srubbed in the water to make 30% aq. Ammonia. This aq. Ammonia is used as raw material in other products or will be soldin the market. After completion of reaction, HH is distilled and methanol is added. it is cooled and HCl is added . The product formed is filtered toseparate. The Filtrate MLis recycle in next batch.
Filtrate ML MCB Methanol lossResidueRecycle Qty-4X/5 after 4-5
recycle it is for distillation
Scrubber
Water
30% solution of liquor ammonia used in Amidation process
DistillationHH recoveredHH loss
Methanol(R)Methanol (F)
HCl (g)
(3) Deamination process such as MBI
Process: Charge Solvent (MCB) and add amino compound (MOPDA) and urea. Heat the reaction mass at reacting temperature till completion ofreaction. During the reaction ammonia liberated is srubbed in the water to make 30% aq. Ammonia. This aq. Ammonia is used as raw material inother products or will be sold in the market. After completion of reaction, it is cooled and filtered to separate the product. The Filtrate ML isrecycle in next batch.
Recycle Qty-4X/5 after 4-5 recycle it is for distillation
Scrubber
Water
30% solution of liquor ammonia used in Amidation process
(3) Deamination process such as BI
Process: Charge Solvent/water and add amino compound and urea. Heat the reaction mass at reacting temperature till completion ofreaction. During the reaction ammonia liberated is srubbed in the water to make 30% aq. Ammonia. This aq. Ammonia is used as raw materialin other products or will be sold in the market. After completion of reaction, it is cooled and filtered to separate the product. The Filtrate ML isrecycle in next batch.
Generalized Reaction Scheme
or NH3
Where R = NH2-; -NH-Ph-NH-; -NH-Ph(Me)-NH-
Reaction Scheme with Perticular Example with High Effluent Load
Process: Add main raw material (lactum) in solvent (ODCB) and then DES is added simultaneously with caustic lye maintaining pH 8-9. Aftercompletion of reaction, layers are separated. Organic layer is send to distillation where pure product is obtained. Aqueous layer is send to MEE.
Process: Add main raw material in solvent (acetone) and then DMS is added simultaneously with potassium carbonate maintaining pH 8-9. Aftercompletion of reaction, solid salt is filtered . Organic layer is send to distillation where pure product is obtained.
(5) Unit Process Nitration with dilute nitric acid such as NDMB
Process: Charge 25% dilute nitric acid. Add raw material (DMB) at reacting temperature. Maintain till completion of reaction. Cool the reactionmass and filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water andwashing is send to ETP.
ML recycleAfter adding required quantity of 98% nitric
acid
Washing ML send to ETP
(5) Unit Process Nitration with dilute nitric acid such as NBI
Process: Charge 25% dilute nitric acid. Add raw material (BI) at reacting temperature. Maintain till completion of reaction. Cool the reactionmass and filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water andwashing is send to ETP.
ML recycleAfter adding required quantity of 98% nitric
acid
Washing ML send to ETP
(5) Unit Process Nitration with dilute nitric acid such as NMBI
Process: Charge 25% dilute nitric acid. Add raw material (MBI) at reacting temperature. Maintain till completion of reaction. Cool the reactionmass and filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water andwashing is send to ETP.
ML recycleAfter adding required quantity of 98% nitric
acid
Washing ML send to ETP
(5) Unit Process Nitration with dilute nitric acid such as Ac-DCPNA
Process: Charge Sulfuric acid and Add raw material and add nitric acid at reacting temperature. Maintain till completion of reaction. Drawn thereaction mass in ice water and filter it. Filtrate obtained is neutralize in ETP to get salt (TSDF) and ETP waste water. Wet cake is washed withwater and washing is send to ETP.
(5) Unit Process Nitration with dilute nitric acid such as NIPA
Process: Charge Sulfuric acid and Add raw material (IPA) and add nitric acid at reacting temperature. Maintain till completion of reaction. Drawnthe reaction mass in ice water and filter it. Filtrate obtained is neutralize in ETP to get salt (TSDF) and ETP waste water. Wet cake is washed withwater and washing is send to ETP.
(5) Unit Process Nitration with dilute nitric acid such as NABT
Process: Charge 25% dilute nitric acid. Add raw material at reacting temperature. Maintain till completion of reaction. Cool the reaction massand filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water and washing issend to ETP.
Generalized Reaction Scheme
H2OHNO3
Where R = methoxy; -NH-CO-NH; Methyl
Reaction Scheme with Perticular Example with High Effluent Load
Process:Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material (NN-DEA). Maintain it till completion of reaction. Add water andneutralize Layers are separated. Aqueous layer is send to MEE for salt and water recovery. Organic layer is washed with water and washing send to MEE..
(6) Mass Balance for Unit Process Formylation such as DEAB
Reactor
POCl3DMFNN-DEA
Water
Wet cakeFilter
Water
Washing ML send to MEE Filtrate ML to MEE
Washing of Wet cakeProduct
Water loss
(6) Unit Process Formylation such as DMAB
Process:Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material (NN-DMA). Maintain it till completion of reaction. Add water andneutralize Layers are separated. Aqueous layer is send to MEE for salt and water recovery. Organic layer is washed with water and washing send to MEE..
(6) Mass Balance for Unit Process Formylation such as DMAB
Reactor
POCl3DMFNN-DMA
Water
Wet cakeFilter
Water
Washing ML send to MEE Filtrate ML to MEE
Washing of Wet cakeProduct
Water loss
(6) Unit Process Formylation such as DMBA
Process:Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material (DMB). Maintain it till completion of reaction. Add water, cooled andfiltered. Filtrate ML is neutralize and send to MEE. Wet cake is washed with water and washing is send to ETP.
(6) Mass Balance for Unit Process Formylation such as DMBA
(6) Unit Process Formylation such as DHB
Process:When product is liquid (DMAB; DEAB):Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material. Maintain it till completion of reaction. Add water and neutralize withcaustic lye. Layers are separated. Aqueous layer is send to TEE for salt and water recovery. Organic layer is washed with water and washing send to ETP.When product is solid (DHB, DMB):Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material. Maintain it till completion of reaction. Add water, cooled and filtered.Filtrate ML is neutralize and send to MEE. Wet cake is washed with water and washing is send to ETP.
Generalized Reaction Scheme
�
POCl3 5NaOH 3H2O
Na2HPO4 Me2NH 5H2O 3NaCl
Where R = NEt2; NMe2; Methoxy; hydroxy
Reaction Scheme with Perticular Example with High Effluent Load
(6) Mass Balance for Unit Process Formylation such as DHB
(7) Unit Process Amidation such as NMT-amide
Process: Charge Water Add liquor ammonia (23%), cool to 0-5�C. Add acyl chloride. Check for completion of reaction. After completion ofreaction filter it in ANF, wash with water ( and this wash is directly use in the next batch as ammonia gas scubbing then another ammonia+water will make up) Cake dry and filtrate take in another vessel, heat to 75�C and add caustic flakes at 75�C to recover excess ammonia which ispurge washing of last batch. After recoverof ammonia remaining to MEE to recover the salt.
(7) Mass Balance for Unit Process Amidation such NMT-amide
Water loss
(7) Unit Process Amidation such as p- Nitro Benzamide (PNBA)
Process: Charge Water Add liquor ammonia (23%), cool to 0-5�C. Add acyl chloride. Check for completion of reaction. After completion ofreaction filter it in ANF, wash with water ( and this wash is directly use in the next batch as ammonia gas scubbing then another ammonia+water will make up) Cake dry and filtrate take in another vessel, heat to 75�C and add caustic flakes at 75�C to recover excess ammonia which ispurge washing of last batch. After recoverof ammonia remaining to MEE to recover the salt.
Generalized Reaction Scheme
2 NH4Clor or
Where R = 4-carbomethoxy-3-nitro-phenyl; 4-nitrophenyl; 2-amino-3-sulfonyl-4chloro phenyl
Reaction Scheme with Perticular Example with High Effluent Load
(7) Mass Balance for Unit Process Amidation such as p- Nitro Benzamide (PNBA)
(7) Unit Process Amidation such as DSA
Process: Charge MIBK ;cool to 0-5�C. Add sulfonyl chloride (DSC). Add ammonia gas. Check for completion of reaction. After completion ofreaction. Distill out the MIBK. Filter it in ANF, wash with water ( and this wash is heat to 75�C and add caustic flakes at 75�C to recover excessammonia which is purge in next batch). After recoverof ammonia remaining to MEE to recover the salt.
(7) Mass Balance for Unit Process Amidation such DSA
Steam distillationWaterMIBK recoveredMIBK loss
Water lossProduct
(7) Unit Process Amidation such as ONCBPSA
Process: Charge Water Add liquor ammonia (23%), cool to 0-5�C. Add acyl chloride. Check for completion of reaction. After completion ofreaction filter it in ANF, wash with water ( and this wash is directly use in the next batch as ammonia gas scubbing then another ammonia+water will make up) Cake dry and filtrate take in another vessel, heat to 75�C and add caustic flakes at 75�C to recover excess ammonia which ispurge washing of last batch. After recoverof ammonia remaining to MEE to recover the salt.
(7) Mass Balance for Unit Process Amidation such ONCBPSA
Water loss
(8) Unit Process Acylation such as 2HMB
Process: In EDC, Add main raw materials, charge aluminium chloride heat and maintain till completion of reaction. Drawn the reaction mass to thewater, separate layer and aqueous layer (containing AlCl3) is sell to actual user. Organic layer is washed with water and washing is send to ETP.During reaction HCl gas evolved is scrubbed in water. Organic layer is for distillation to get finished product. Recoverd EDC is recycle in next batch.
(8) Unit Process Acylation such as (2,4 Di Chloro Phenacylchloride DCPC)
Process: In EDC, Add main raw materials, charge aluminium chloride heat and maintain till completion of reaction. Drawn the reaction mass to thewater, separate layer and aqueous layer (containing AlCl3) is sell to actual user. Organic layer is washed with water and washing is send to ETP.During reaction HCl gas evolved is scrubbed in water. Organic layer is for distillation to get finished product. Recoverd EDC is recycle in next batch.
Generalized Reaction Scheme
AlCl3�HCl
Where R = chloro, methoxyR’ = chloroacyl
Reaction Scheme with Perticular Example with High Effluent Load
(8) Mass Balance for Acylation such as (2,4 Di Chloro Phenacylchloride DCPC)
HCl Gas Scrubber
Water
HCl for productDrowningWater
Layer Separation Organic Layer
AlCl3 solution (30%) to be sold Wash Water to ETP
Distillation
EDC recovered Residue ProductEDC Loss Water Loss
(9 (A) Unit Process Reduction with Sodium hydrogen sulfide (NaSH) such as m- Chloro Aniline (MCA)
Process: In a vessel charge water and raw material. Heat and add reducing agent (NaSH). Test completion of reaction. After completion ofreaction, layer is separated and layer containing co-product sodium thiosulfate. Organic layer is washed with water. Organic layer transferred tovacuum distillation where pure product is obtained.
Generalized reaction scheme:
6 NaSH 4H2O3Na2S2O3�4
Where R= Cl-phenyl; 3-nitro-5-sulfonyl-6-hydroxy-phenyl; 3-methylsulfone-6- methylamine-phenyl
(9) (A) Mass Balance Reduction with Sodium hydrogen sulfide (NaSH) such as m- Chloro Aniline (MCA)
Layer Separation Sodium Thio Sulphate for product
Organic Layer Wash Water to ETP
Residuewater loss
(9 (A) Unit Process Reduction with Sodium hydrogen sulfide (NaSH) such as 4NAPSA
Process: In a vessel charge water and raw material (CDNBSA). Heat and add reducing agent (NaSH). Test completion of reaction. After completionof reaction, filter it and layer containing co-product sodium thiosulfate and sellable wet cake.
(9) (A) Mass Balance Reduction with Sodium hydrogen sulfide (NaSH) such as 4NAPSA
Sodium Thio Sulphate for productwater loss
(9 (A) Unit Process Reduction with Sodium hydrogen sulfide (NaSH) such as MSMAA
Process: In a vessel charge water and raw material (MSMNA). Heat and add reducing agent (NaSH). Test completion of reaction. After completionof reaction, filter it and layer containing co-product sodium thiosulfate. Wet cake is washed with water to get pure product
(9) (A) Mass Balance Reduction with Sodium hydrogen sulfide (NaSH) such as MSMAA
Sodium Thio Sulphate for productwater loss
Wet cake washingWater for washing Washing water to ETP
(9 B) Unit Process Reduction with Iron and acid in water such as m- Anisidine (MA)
Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material and maintain till reaction iscompleted. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtained byvacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.
acid49Fe 4H2O
3Fe3O44
Generalized reaction scheme:
Where R= methoxy-phenyl; N-{2-[(2-hydroxyethyl)sulfonyl]ethyl}benzamide
(9 B) Unit Process Reduction with Iron and acid in water such as VJD
Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material (OJD) and maintain till reaction iscompleted. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtained byvacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.
Reaction Scheme
NO2
CONHCH2CH2SCH2CH2OH
O
O
9Fe 4H2O
NH2
CONHCH2CH2SCH2CH2OH
O
O
Acetic acid
3Fe3O4
OJD(302)
Iron powder(56)x 9
Water(18) x 4
VJD(272)
Iron oxide(232)x 3
4 4
(9 B) Mass balance for Reduction with Iron and acid in water such as VJD
(9 B) Unit Process Reduction with Iron and acid in water such as AOX
Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material (NOXSA) and maintain till reaction iscompleted. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtained byvacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.
Reaction Scheme
9Fe 4H2OAcetic acid
3Fe3O4
NOXSA(274) x 4
Iron powder(56) x 9
Water(18) x 4
AOX(244) x 4
Iron oxide(232) x 4
NO2
S
NH
O
O
HO
NH2
S
NH
O
O
HO
(9 B) Mass balance for Reduction with Iron and acid in water such as AOX
(9 B) Unit Process Reduction with Iron and acid in water such as OPSAMIDE
Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material (ONCBPSAH) and maintain till reactionis completed. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtainedby vacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.
Reaction Scheme
9Fe 4H2OAcetic acid
3Fe3O4
ONCBPSAH(234.2)
Iron powder(56) x 9
Water(18) x 4
OPSAMIDE(204.2) x 4
Iron oxide(232) x 4
OH
NO2
SO2NH2
OH
NH2
SO2NH2
4 4
(9 B) Mass balance for Reduction with Iron and acid in water such as OPSAMIDE
(9C) Unit Process Reduction Hydrogenation such as AMBI
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NMBI), solvent (DMF:Water) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.
Reaction Scheme
NH
HN
O2N
O 3H2
NH
HN
H2N
O 2H2O
NMBI(193)
Hydrogen(2) x 3
AMBI(163)
Water(18) x 2
NMBI Hydrogen CatalystDMF (Recycled)DMF (Fresh)
Reactor
Catalyst RecycleFilter
DMF lossWater LossProduct AMBI
Residue
Filtrate ML
(9C) Unit Process Reduction by Hydrogenation such as AMBI
(9C) Unit Process Reduction Hydrogenation such as AM3
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NABT), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.
(9C) Unit Process Reduction Hydrogenation such as MOPDA
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (MNPT, solvent (MCB) and catalyst is charge in hydrogenatorreactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogen pressure wasreleased in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pure product. FiltrateML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches the filtrate is takenfor distillation and solvent is distilled out and residue is sent to incineration waste.
Reaction Scheme
NH2
NO2
3H2
NH2
NH2
2H2O
MNPT(152)
Hydrogen(2) x 3
MOPDA(122)
Water(18) x 2
MNPTHydrogen Catalyst MCB (Recycled) MCB (Fresh)
MCB lossWater LossWater recoverProduct
(9C) Unit Process Reduction by Hydrogenation such as MOPDA
(9C) Unit Process Reduction Hydrogenation such as ABI
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material, solvent and catalyst is charge in hydrogenator reactor.Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogen pressure was released inwater. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pure product. Filtrate ML isrecycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches the filtrate is taken fordistillation and solvent is distilled out and residue is sent to incineration waste.
Generalized reaction scheme:
3H2 2H2OCatalyst
Water(18)
3H2Catalyst
5-Nitro-BenzimidazoloneNBI (179)
Hydrogen(2)
5-AminoBenzimidazoloneABI (149)
2H2O
Where R = CF3; NHCOCH3; CH3; -NHCONH-; -NH2Catalyst = Pd or Ni
Reaction Scheme of Particular Example having maximum effluent load
(9C) Unit Process Reduction by Hydrogenation such as ABI
Filtrate
Crystallizer
Filter
After 5-6 recycle taken for distillation
(9C) Unit Process Reduction Hydrogenation such as AMBA
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NMBA), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.
(9C) Unit Process Reduction Hydrogenation such as MPBA
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (MPB), and catalyst is charge in hydrogenator reactor.Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogen pressure was released inwater. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pure product. Filtrate ML isrecycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches the filtrate is taken fordistillation and solvent is distilled out and residue is sent to incineration waste.
(9C) Unit Process Reduction by Hydrogenation such as MPBA
Filtrate
Distillation
Residue
(9C) Unit Process Reduction Hydrogenation such as AIPA
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NIPA), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.
(9C) Unit Process Reduction by Hydrogenation such as AIPA
NIPA Hydrogen CatalystMethanol (Recycled)Methanol (Fresh)
Methanol loss Water LossProduct
Reactor
Catalyst RecycleFilter
Residue
Filtrate ML
Filtrate
Crystallizer
Filter
After 5-6 recycle taken for distillation
(9C) Unit Process Reduction Hydrogenation such as DABA
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (DNBA), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.
(9C) Unit Process Reduction Hydrogenation such as o-phenoxy aniline
Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (2PNB), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.
(10 A) Unit Process Chloroxidation/Oxidation such as S Acid
Process: Charge water or washing of last batch containing HCl. Then Charge main raw material. Shift pH to 0.5 by adding extra HCl. Cool and passchlorine gas till completion of reaction . Settle down the product and remove mother liquor, give water wash to the product. Washing is recycle innext batch reaction. Mother liquor is distilled to recover 30% HCl. Or Charge water; HCl and main raw material. Cool and pass chlorine gas tillcompletion of reaction. Excess of HCl and water is distilled to get desired quantity of HCL left in product. Distilled acidic water is recycled in nextbatch.
Generalized reaction scheme:
Cl2� H2O HCl
Iso-propyl alcohol(60)
2Cl2 2H2O
3HCl
GBL-condensed(164)
Chlorine(71)
Water(18)
Schwander Acid(S. Acid; 214.5)
Hydrochloric acid(36.5)
Reaction Scheme of particular example with high effluent load
Where R = HOOC-CH2-CH2-CH2-; NH2-CH2-CH2-O-CH2-CH2-; O-Nitrophenyl- etcR‘ = HO-CH2-CH2-; O-Nitrophenyl etcR'‘ = Cl-CH2-CH2-; Cl-
(10 A) Mass balance for Unit Process Chloroxidation/Oxidation such as S Acid
Scrubber
NaOH and water
NaOCl Soln. (7%) for product
Wet cake
Washing of Wet cake
Wash Water recycled in next
batch
DistillationLoss
Product: S Acid
IPA recovered & reused in Chloroester
product
HCl (30%) Recovered for product
Product
Loss
(10 A) Unit Process Chloroxidation/Oxidation such as Ether amine
Process: Charge water or washing of last batch containing HCl. Then Charge main raw material (AHD). Shift pH to 0.5 by adding extra HCl. Cooland pass chlorine gas till completion of reaction . Excess of HCl and water is distilled to get desired quantity of HCL left in product. Distilled acidicwater is recycled in next batch.
(10 A) Mass balance for Unit Process Chloroxidation/Oxidation such as Ether amine
Scrubber
NaOH and water
NaOCl Soln. for product
Distillation
Water loss HCl Recovered for product
Product
(10 A) Unit Process Chloroxidation/Oxidation such as ONBSC/PNBSC
Process: Charge water or washing of last batch containing HCl. Then Charge main raw material (DDD). Shift pH to 0.5 by adding extra HCl. Cooland pass chlorine gas till completion of reaction . Settle down the product and remove mother liquor, give water wash to the product. Washing isrecycle in next batch reaction. Mother liquor is distilled to recover 30% HCl. Or Charge water; HCl and main raw material. Cool and pass chlorinegas till completion of reaction. Excess of HCl and water is distilled to get desired quantity of HCL left in product. Distilled acidic water is recycled innext batch..
(10 A) Mass balance for Unit Process Chloroxidation/Oxidation such as ONBSC/PNBSC
Recycled Water HClChlorineDDD
Reactor Excess Chlorine
Filter
Filtrate ML
Water
Scrubber
NaOH and water
NaOCl Soln. for product Wet cake
Washing of Wet cake
Wash Water
recycled in next batch
Distillation Loss
Product: ONBSC
Water loss HCl Recovered for product
Product
(10 B) Unit Process Chloroxidation/Oxidation such as Sodium Hypo Chlorite
Process: Charge sodium hypo chlorite (7%) solution from S acid and caustic lye and purged the chlorine gas in it. The resultantproduct is 10% Sodium Hypo Chlorite Solution.
2NaOHCl2 NaOCl NaCl
ChlorineM. Wt. 71
Sodium hydroxideM. Wt. 40
Sodium hypochloriteM. Wt. 74.5
H2O
SaltM. Wt. 58.5
WaterM. Wt. 18
Reaction Scheme
Caustic LyeNaOCl soln from S acidChlorine
Reactor
Sodium hypochlorite soln
(10 B) Mass Balance Unit Process Chloroxidation/Oxidation such as Sodium Hypo Chlorite
(11 A) Unit Process Dehydration using POCl3 such as Nitrile
Process: Charge Xylene and main raw material. Add phosphorus oxy chloride and heat the reaction. HCl gas evolved is scrubbed in waterto make 30% HCl solution. The reaction mass is then drowned in the water and layers are separated. Aqueous layer is send to MEE afterneutralization. Organic layer is for azeotropically distillation with water to recover the xylene. After complete recovery of xylene reactionmass is cooled and filtered to obtained the product and filtrate is then send to ETP.
POCl3� HPO2Cl2
Generalized reaction scheme:
2H2OHCl H3PO4
Hydrochloric acid(36.5)
2HCl
NMT-amide(224)
PhosphorusOxychloride(153.3)
Nitrile(206)
Phosphoric acid (98)
Hydrochloric acid(36.5)
POCl3 HPO2Cl2
Where R = Nitro, Methyl carboxylate group etc
Reaction Scheme of particular example with high effluent load
(11 B) Mass balance for Unit Process Dehydration by Evaporation such as Sodium Thio Sulfate
Condensate used in processWater loss
(12) Unit Process for Chloro sulphonation such as NOXSC
Process: Charge CSA and main raw material and heat the reaction to reacting temperature. Drawn the reaction mass to ice wate r and filter the cake obtained. Filtrate is sell as spent acid.
Generalized reaction scheme:
�
ClSO3H H2O
ClSO3H
NOXM. Wt. 151
CSAM. Wt. 116.5
NOXSCM. Wt. 249.5
WaterM. Wt. 18
H2O
Where R = NH2; Cl; CH3
Reaction Scheme with Particular Example with High Effluent Load
(12) Mass Balance for Unit Process Chloro sulphonation such as NOXSC
Lime
SaltSend to TSDF
Calcium chloride solution (19-23%)used as a brine in
chilling plant
Water loss
(12) Unit Process for Chloro sulphonation such as DSC
Process: Charge CSA and main raw material (MCA) and heat the reaction to reacting temperature. Drawn the reaction mass to ice water and filter the cake obtained. Filtrate is neutralize with lime to get salt and brine
(12) Mass Balance for Unit Process Chloro sulphonation such as DSC
CSAMCA
Reactor
Drawning in water
Water
Filtration
ML (H2SO4 + HCl)
Wet cake
Water wash
Washing ML Recycled
Product
Lime
Salt Send to TSDF Calcium chloride solution (20-25%)used as a brine in
chilling plant
Water loss
(12) Unit Process for Chloro sulphonation such as ONCBPSC
Process: Charge CSA and main raw material (ONCB) and heat the reaction to reacting temperature. Drawn the reaction mass to ice water and filter the cake obtained. Filtrate is neutralize with lime to get salt and brine
Process: Charge main raw material and water. Add sodium hydroxide and heat to reaction temperature. After completion of reaction shift the pH to 1-2 by 30% HCl and then cool and filter. Filtrate is treated in MEE to get salt.
NaOH NaCl
HCl
ONCBPSAM. Wt. 252.63�
Sodium HydroxideM. Wt. 40
Hydrochloric acidM. Wt. 36.5
ONCBPSAHM. Wt. 234.19
Sodium ChlorideM. Wt. 58.5
2NaOH 2NaCl
Where R = Nitro, SONH2
Reaction Scheme of particular example with high effluent load
HCl (30%)ONCBPSAWater
Caustic Lye
Reactor
Filter
Water
Filtrate ML to MEE Water wash to MEE
Wet cake for washing Wet cake for drying
Product
(13) Mass Balance for Unit Process Hydrolysis ONCBPSAH
Process: Charge main raw material (Ac-DCPNA) and water. Add sodium hydroxide and heat to reaction temperature. After completion of reaction and then cool and filter. Filtrate is treated in MEE to get salt.
Reaction Scheme
NHAc
Cl
Cl
NO2
NaOH
NH2
Cl
Cl
NO2
CH3COONa
AC-DCPNA(249)
Sodium hydroxide(40)
DCPNA(207)
Sodium acetatesalt(82)
Ac-DCPNAWaterCaustic Lye
Reactor
Filter
Water
Filtrate ML to MEE Water wash to MEE
Wet cake for washing Product
(13) Mass Balance for Unit Process Hydrolysis DCPNA
Process: Charge solvent, main raw material and sulfuric acid and heat the reaction to reacting temperature. Recover the solvent by steam distillation and filter the product. ML is send to ETP.
H2O
3,4-DCAM. Wt. 162
Sulfuric acidM. Wt. 98
DCASAM. Wt.242
WaterM. Wt. 18
H2O
Where R = NH2; Cl
Reaction Scheme with Particular Example with High Effluent Load
ODCB (Recovered)ODCB (fresh)3,4-DCA
Sulfuric acid
SS reactor
Steam DistillationWater
Filtration
ML to ETP
Wet cake
Recover ODCBLoss ODCBWater loss
Product
(14) Mass Balance for Unit Process Hydrolysis such as DCASA
Process: Charge solvent (ODCB), main raw material (VJD) and sulfuric acid and heat the reaction to reacting temperature. Recover the solvent by steam distillation and filter the product. ML is send to ETP.
Reaction Scheme
NH2
CONHCH2CH2SCH2CH2OH
O
O
H2SO4
NH2
CONHCH2CH2SCH2CH2OSO3H
O
O
H2O
VJD(272)
Sulfuric acid(98)
FJD(352)
Water(18)
ODCB (Recovered)ODCB (fresh)VJDSulfuric acid
SS reactor
Steam DistillationWater
Filtration
ML to ETP
Recover ODCB Loss ODCBWater loss
Product
(14) Mass Balance for Unit Process Hydrolysis such as FJD
(15) Unit Process for Neutralization such as Sodium Sulphite
Chemical reaction :
Process: Sulfur dioxide treated with caustic lye and water is distilled. The material is then cystalize and filtered. The solid sodium sulfite isobtained. The filtrate MLis then recycled in next batch distillation. The condensate from the reaction is used in process or in utility.
2NaOH Na2SO3 H2O
Sulfur dioxideM. Wt. 64
Sodium hydroxideM. Wt. 40
Sodium sulfiteM. Wt. 126
WaterM. Wt. 18
Sodium sulphite Soln (73%)ML recycle
Crystalizer
Filter
Filtrate MLRecycle in next batch
Sodium sulphite crystal
(15) Mass Balance for Unit Process Crystallization such as Sodium Sulphite
(16) Unit Process for Purification such as Hydro Chloric acid (30%)
Process: 30% HCl from scrubbing system is passed through resin (Agrion A 600 MP) and the colorless 30% HCl obtained.
Resin treatment tank filled with Resin
30% HCl
Washing of resin after4-5 treatment with water
White HCl
Resin recycled
Water Water washing
(16) Mass Balance for Unit Process for Purification such as Hydro Chloric acid (30%)
Process: Charge methanol to the reactor and add sodium metal to it portion wise. Maintain till completion of sodium methoxide formation. Addsolvent and Remove methanol by simple distillation. Add main raw material slowly and maintain till completion of reaction. After completion ofreaction filter to remove the salt and extract the material in cyclo hexane. Distill the cyclo hexane layer to get product; main raw material andcyclo hexane.
�
CH3ONa NaCl
2,6-DichlorotolueneDCTM. Wt. 161
Sodium methoxideM. Wt. 54
3-Chloro-2-methylanisoleCMAM. Wt. 156.5
Salt58.5
CH3ONa NaCl
Where R = CH3; Cl
Reaction Scheme with Particular Example with High Effluent Load
Quantity of Waste Water (liquid waste) generation and its management :
Sr. No. Particulars Existing Total after expansion
Normal Concentrated (high TDS)
Normal Concentrated (high TDS)
1 Domestic 5.0 0 8.0 0
2 Processing , Product washing & scrubber
14.2 15.91 23.07 24.3
3 Boiler 4.0 0 6.0 0
4 Cooling 3.0 0 10.0 0
5 Floor, equipment & container Washing
5.0 0 20.0 0
6 Total 31.2 15.91 67.07 24.3
7 Total Industrial 26.2 15.91 59.07 24.3
8 High TDS to MEE 0 15.91 0 24.3
9 High TDS to MEE from Unit:I
0 9.7 0 9.7
10 Total high TDS to MEE 0 25.61 0 34.0
11 Net Discharge to ETP 26.2 0 59.07 0
Note:
After proposed expansion, total fresh water consumption will be 206.86 m3/day.
After proposed expansion, Total industrial effluent generation will be 83.37 m3/day.
Out of which 83.37 m3/day of industrial effluent; 24.3 m3/day of high TDS effluent will be segregated and will be treated in MEE and high TDS effluent from Unit:I is 9.7 will be treated in MEE of Unit:II. Average 27.05 m3/day of MEE condensate will be recycled and 6.37 MT/day of salt will be disposed off into TSDF.
Average 59.07 m3/day of normal effluent will be treated in primary, secondary and tertiary effluent treatment plant and discharge into CETP Vapi for further treatment and disposal into tidal zone of River Damanganga to Arabian Sea.
Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install: Details of effluent treatment plant for normal industrial effluent stream:
Sr. No.
Name of Equipment Capacity in (KL) MOC
Existing Proposed
01 Oil & Grease Chamber 5.0 5.0 RCC
02 Collection Tank 23.0 23.0 RCC/TL
03 Equalization tank 50.0 50.0 RCC/TL
04 Neutralization Tank 2 Nos. 6.0 12.0 MSRL
05 Lime Dozing Tank 1.0 1.0 MS
06 FeSO4 Dozing Tank 0.2 0.2 HDPE
07 P. E. Dozing Tank 0.05 0.05 HDPE
08 Floculator 2.5 5.0 MS/FRP
09 Primary Lamella separator 7.0 14.0 MS/FRP
10 First stage Aeration tank with diffuser
100.0 100.0 RCC
11 Floculator 2.0 2.0 MS/FRP
12 Secondary Lamella separator 2.0 4.0 MS/FRP
13 second stage Aeration tank with diffuser
100.0 100.0 RCC
14 Secondary Clarifier 45.0 45.0 RCC
15 Holding Tank 40.0 40.0 RCC
16 Carbon Sand Filter Bed 1.6 3.2 MS
17 Sand Filter Bed 1.6 3.2 MS
18 Final discharge tank 2.0 2.0 HDPE
19 Air Blower with Condenser for Diffuser
400 m3/h 400 m3/h -
20 Transfer Pump 6 Nos. 6 Nos. CI
21 Filter Press 48 48 PP
22 Final Discharge Tank 5.0 5.0 HDPE
23 Energy Meter 1 No. 1 No. -
24 Discharge Flow Meter 1 No. 1 No. -
25 Online pH meter 1 No. 1 No. -
Details of effluent treatment plant for concentrated effluent stream:
ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED
EXPANSION
The details of air pollution & its control measures at existing & after proposed expansion are as under;
Flue gas emission: At present, the unit is having one number of coal fired 7 TPH capacity of steam boiler and two
numbers of HSD fired D G Set of 250 KVA capacity each. Adequate height of chimney and MDC followed by bag filter provided to the boiler and adequate height of chimney is provided to D G set.
After proposed expansion, there will be no addition of boiler, as existing boiler having spare capacity to take care of additional steam requirement.
Process gas emission:
At present, there is a generation of process gas like SO2, NOx, HCl, Cl2 and NH3 from sulphonation, Nitration, Chlorination, Amination and Oleum storage tank. To scrub all the said gases we have provided total five numbers of two stage scrubbing system and 11 meters height of vent.
After proposed expansion, there will be a generation of process gas emission like SO2, NOx, HCl, Cl2 and NH3 from sulphonation, Nitration, Chlorination, Amination and Oleum storage tank. To scrub all the said gases we will utilize existing five numbers of two stage scrubbing system and 11 meters height of vent. Thus after proposed expansion, there will be no addition of new scrubbing system.(Detail of Air pollution control measures is attached as Annexure-10)
1. Specifications of Falling Film Graphite HCl Scrubber: Type : Parallel flow falling film type Tube side : HCl gas, Cl2 gas, water, HCl solution Shell side : cooling water HCl/Cl2 gas /hour : 100 kg/h Scrubbing media : water Heat of solution kcal/h : 10000 kcal/h Cooling water required at 40 approach : 2.5 m3/h No of tubes required : 65 tubes, 20 dia x 2.5 m length HTA required : 10 m2 Diameter of scrubber : 350 mm Overall length : 3000 mm MOC tubes : Glass MOC shell : HDPE/Graphite Specifications of tails tower Inlet HCl : 50 kg/h Inlet Cl2 gas : 2 kg/h Scrubbing media : Water, 58 kg /h, to be fed to main scrubber Tower dia : 350 mm Packed length : 1500 mm Overall length : 2000 mm MOC : FRP Packing dia : 40 mm PP Outlet HCl : 0.0025 KG/h Chlorine gas : 6 kg/h Specifications of Alkali Ventury Inlet HCl : 0.0025 kg/h Inlet Cl2 gas : 2 kg/h Scrubbing media : 10 % dilute alkali Size of Ventury : 150 dia x 1250 mm ht. MOC : FRP Alkali circulation tank : 2000 liter HDPE Circulation pump : 2.5 m3/h S/S Vent diameter : 150 mm Height of vent : 11 meters
6 Water Circulation tank 5m3, MS jacketed with chilled water cooling
7 Water circulation pump 3 HP
8 Liquor ammonia cooler 10 m2
9 Capacity of Blower 3 HP
10 Height of vent 11 meter
11 Dia of vent 150 mm
4. Specification of NOx scrubbing system: Scrubber dia : 400 mm Packed length : 3000 mm Overall scrubber height : 4500 mm MOC of scrubber : PP/FRP Scrubbing media : 10 % NaOH Dilute alkali circulation tank : 2000 liter HDPE Alkali circulation pump : 3 m3/h, SS, 10 m head Vent size : 200 mm, 11 m height.
Sub: Expansion of Dyes intermediates manufacturing unit at plot no 1708 & A2-1715, 3rd
phase, GIDC Vapi, dist. Valsad, Gujarat by M/s Sarna chemicals Pvt. Ltd. - Environmental Clearance regd.
Sir,
This has reference to your letter no. nil dated 22.04.2008 along with form 1 and pre- feasibility report on the above mentioned subject seeking environmental clearance under the Environment Impact Assessment Notification, 2006. 2. The Ministry of Environment and Forests has examined your proposal. It is noted that M/s Sarna chemicals Pvt. Ltd. have proposed for expansion of Dyes intermediates manufacturing unit. The unit is located at GIDC Vapi which is identified as on of the critically polluted areas by the CPCB. River Damanganga flows at a distance of 3 Kms. Company is in position of 5500 m2 of land area and additional land of 2702 m2 will be utilized for the proposed expansion. Total plant area after the proposed expansion will be 8250 m2. Green belt will be developed in the 180 m2 of land area. No eco-sensitive areas are located within 10 km radius of the plant. The details of the products to be manufactured are annexed. Cost of the project is Rs. 619.00 lakhs of which Rs. 55.00 lakhs is utilized for environmental protection measures. 3. Total water requirement after the proposed expansion will be 94.6 m3/day which will be sourced from GIDC, Vapi. Waste water generation will be 42.45 m3/day, out of which 2.05 m3/day high TDS effluent will be evaporated in proposed evaporation system & 40.4 m3/day of dilute effluent stream will be treated in primary, secondary & tertiary effluent treatment plant & treated effluent will be sent to CETP, Vapi. Three stage scrubbing system will be provided for control of HCl, Cl2 and SO2 emissions. Water scrubber followed by acid tank will be provided to control the NH3 emission. NOx emission will be controlled by 2-stage scrubbing system. Oleum storage tanks
will be provided by acid pot followed by packed alkali tower. To control the particulate emissions from the coal fired boiler, multi cyclone separator and bag filter will be
-2- provided. The gaseous emissions will be dispersed through a stack 30m height. IPA, Toluene, Methanol, MCB, EDC will be used as solvents. Solvents will be recovered & reused. All reactors will be connected to condensers with chilled water circulation. Power requirement of 350 KVA is sourced from DGVCL. No additional power is required for the proposed expansion. Stand by power supply will be met from two numbers of D G set having capacity 250 KVA each. Fuel for DG set will be HSD (40 lts/h) and boiler will be coal (750 kg/h.).
3. After proposed expansion, iron oxide waste generated from the process (24 MTPM ) will be disposed to TSDF Vapi. Organic Distillation residue (3.73 MTPM) will be sent to common incinerator of VWEMCL Vapi. ETP waste (4.0 MTPM) will be sent to VWEMCL Vapi. Salt from evaporator (19.6 TPM) will be sent to actual users/ VWEMCL Vapi. Salt from the process (256 TPM) and sludge from wet scrubber (0.010 TPM ) will be sent to common TSDF, Vapi for final disposal. Discarded containers (150 Nos/Month) will be reused for packing of finish products or sold to authorized recyclers. Waste oil/used oil ( 0.01 TPM ) will be sold to registered re-refiner.
4. The Dye intermediates manufacturing unit are listed at serial no. 5(f) of schedule of EIA Notification, 2006 and categorized under “A” or “B” category depending upon the location of the plant outside or inside the notified industrial area. In instant case the plant is located within the notified industrial area GIDC Vapi and covered under category “B”. But the Vapi is an identified critically polluted area hence as per general condition of EIA Notification, 2006 the proposal has been appraised at centre. The proposal was considered by the Expert Appraisal Committee in its 84rd meeting held on 19-21st August, 2008.The public consultation of the project is not required as per para 7 (i)-III (b) Stage (3) – public consultation of EIA Notification, 2006. 5. Based on the information submitted by the Project Authorities, the Ministry of Environment and Forests hereby accords the environmental clearance to the above project under the provisions of EIA Notification dated 14th September, 2006 subject to compliance of the following specific and general conditions: A SPECIFIC CONDITIONS: i) The Effluent generation shall not exceed 42.45 m3/d. The effluent shall be segregated into
high TDS (2.05 m3/d) and Low TDS streams (40.40 m3/d) and 1.60 m3/d condensate from the triple effect evaporator. The dilute effluent stream after primary, secondary and tertiary treatment shall meet the industry specific discharge standards notified under Environment (Protection) Act, 1986. The high TDS effluent stream shall be treated in triple Effect Evaporator followed by treatment in ETP.
ii) GPCB shall not permit any new discharges from new industries or expansion of existing industries in the area that lead to CETP Vapi till the said CETP’s and FETP meet the required standards and have adequate hydraulic capacities.
iii) The company shall obtain Authorization under the Hazardous Waste (Management and
Handling) Rules, 2003 for management of Hazardous wastes and prior permission from GPCB shall be obtained for disposal of solid / hazardous waste in the TSDF.
iv) The process emissions in the form of HCl, Cl2, SO2, NH3 and NOx , shall be controlled by scrubber. Graphite scrubber followed by water and alkali scrubber for control of HCl and Cl2, alkali scrubber for SO2 and NOx, Water scrubber for NH3 and acid followed by alkali scrubber for Oleum storage tank and SOx shall be install to scrub the emissions. Monitoring arrangements shall be provided in the vents/stacks and emissions shall conform to the
prescribe standards. Monitoring of sources and fugitive emissions in the work zone environment, product, raw materials storage area etc. shall be regularly carried out. The emissions shall conform to the limits imposed by GPCB. The monitoring reports shall be submitted to the SPCB/CPCB/ROMoEF.
v) For control of fugitive emission following steps shall be followed :
A. Closed handling system shall be provided for chemicals. B. Reflux condenser shall provided over reactor. C. System of leak detection and repair of pump/pipeline based on preventive maintenance. D. The acids shall be taken from storage tanks to reactors through closed pipeline. Storage
tanks shall be vented through trap receiver and condenser operated on chilled water. vi) Solvent management shall be as follows :
A. Reactor shall be connected to chilled brine condenser system B. Reactor and solvent handling pump shall have mechanical seals to prevent leakages. C. The condensers shall be provided with sufficient HTA and residence time so as to
achieve more than 95% recovery D. Solvents shall be stored in a separate space specified with all safety measures. E. Proper earthing shall be provided in all the electrical equipment wherever solvent
handling is done. F. Entire plant shall be flame proof. The solvent storage tanks shall be provided with
breather valve to prevent losses. vii) During transfer of materials spillages shall be avoided and garland drains be constructed to
avoid mixing of accidental spillages with domestic waste and storm drains. viii) The project authorities shall develop greenbelt in 33% of plant area as per the guidelines of
CPCB to mitigate the effect of fugitive emission. ix) Adequate financial provision shall be made in the budget of the project for implementation of
the above suggested environmental safeguards. Fund so earmarked shall not be diverted for any other purposes.
x) Occupational health surveillance of the workers shall be done on a regular basis and records
maintained as per the Factories Act. xi) The company shall make the arrangement for protection of possible fire hazards during
manufacturing process in material handling. xii) The project authorities shall undertake measures for rainwater harvesting and ground water
recharge.
GENERAL CONDITIONS i. The project authorities shall strictly adhere to the stipulations of the SPCB/state government
or any statutory body. ii. No further expansion or modifications in the plant shall be carried out without prior approval
of the Ministry of Environment and Forests. In case of deviations or alterations in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any.
iii. The project authorities shall strictly comply with the rules and regulations under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 as amended. Authorization from the SPCB shall be obtained for collection, treatment, storage, and disposal of hazardous wastes.
iv. Ambient air quality monitoring stations shall be set up in the downwind direction as well as
where maximum ground level concentration are anticipated in consultation with the State Pollution Control Board.
v. For control of process emissions, stacks of appropriate height as per the Central Pollution
Control Board guidelines shall be provided. The scrubbed water shall be sent to ETP for further treatment.
vi. The company shall undertake following Waste Minimization measures :-
Metering of quantities of active ingredients to minimize waste. Reuse of by-products from the process as raw materials or as raw material
substitutes in other processes. Maximizing recoveries Use of automated material transfer system to minimize spillage. Use of Closed Feed system into batch reactors.
vii) The project authorities must strictly comply with the rules and regulations with regard to
handling and disposal of hazardous wastes in accordance with the Hazardous Wastes (Management and Handling) Rules, 2003. Authorization from the SPCB shall be obtained for collections/treatment/ storage/disposal of hazardous wastes.
viii. The overall noise levels in and around the plant area shall be kept well within the standards
(85 dBA) by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. The ambient noise levels shall conform to the standards prescribed under Environment (Protection) Act, 1986 Rules, 1989 viz. 75 dBA (day time) and 70 dBA (night time).
ix. A separate Environmental Management Cell equipped with full fledged laboratory facilities
shall be set up to carry out the environmental management and monitoring functions.
x. The implementation of the project vis-à-vis environmental action plans shall be monitored by Ministrys Regional Office /SPCB / CPCB. A six monthly compliance status report shall be submitted to monitoring agencies.
-5- xi. The project proponent shall inform the public that the project has been accorded
environmental clearance by the Ministry and copies of the clearance letter are available with the SPCB and may also be seen at Website of the Ministry at http://envfor.nic.in. This shall be advertised within seven days from the date of issue of the clearance letter, at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the Ministry`s Regional Office.
xii. The project authorities shall inform the Regional Office as well as the Ministry, the date of
financial closure and final approval of the project by the concerned authorities and the date of start of the project.
6. The Ministry may revoke or suspend the clearance, if implementation of any of the above conditions is not satisfactory.
7. The Ministry reserves the right to stipulate additional conditions, if found necessary. The company in a time bound manner shall implement these conditions.
8. Any appeal against this environmental clearance shall lie with the National Environment Appellate Authority, if preferred within a period of 30 days as prescribed under Section 11 of the National Environment Appellate Authority Act, 1997.
9. The above conditions will be enforced, inter-alia under the provisions of the Water (Prevention & Control of Pollution) Act, 1974, Air (Prevention & Control of Pollution) Act, 1981, the Environment (Protection) Act, 1986, Hazardous Wastes (Management and Handling) Rules, 2003 and the Public Liability Insurance Act, 1991 along with their amendments and rules.
(Dr. P L Ahujarai) Director
Copy to : - 1. The Secretary, Department of Environment and Forests, Govt. of Gujarat, Secretariat
Gandhinagar-382010 2. The Chairman, Central Pollution Control Board, Parivesh Bhavan, CBD-cum-Office Complex,
East Arjun Nagar, New Delhi ? 110032. 3. The Chairman, Gujarat State Pollution Control Board, Paryavaran Bhavan, Sector-10A,
Gandhinagar-382010. 4. The Chief Conservator of Forests (Central), Ministry of Environment & Forests, Regional Office
(WZ), Ravishankar Nagar, Link Road-3 , Bhopal- 462016, M.P. 5. Adviser IA(II), Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New
Delhi-110003 6. Monitoring Cell, Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New