Annexure Contents No. EC copy of existing plant 4. 5. 6. 7....
Transcript of Annexure Contents No. EC copy of existing plant 4. 5. 6. 7....
List of Annexure
Annexure
No. Contents
1. a. EC copy of existing plant b. Letter seeking validity of EC extension
2. MEK Capacity
3. Land Breakup of Existing - MEK & Expansion MIBK
4. Topo Map of The Study Area
5. Layout of The MIBK Plant
6. Process Description And Flow Chart For Erection of MIBK
7. Effluent Treatment Plant Details
8. MoU Letter Made With Common TSDF in Tamilnadu For Hazardous Waste Disposal
Annexure 1a EC copy of existing plant
Annexure 1b Letter seeking validity of EC extension
Annexure 2
MEK Plant Capacity
S.No Name of the product Existing
capacity TPA
capacity after expansion TPA
(EC obtained on 16th Sep 2008)
1 Methyl Ethyl Ketone 5000 10000 2 Secondary Butyl Alcohol 6000 12000
Fine Chemicals 3 Cinnamic Alcohol 180 1080 4 Anisyl Alcohol 180 276 5 Styrallyl Alcohol 180 228 6 Styrallyl Acetate - 150 7 Oximone - 20 8 Phenyl Enthyl Alcohol - 96 9 Tertiary Butyl Cyclohexyl Acetate - 200 11540 24050
MIBK Proposed Project
S.No Name of the product Proposed (MTPA)
1 Methyl Iso Butyl Ketone 30000 By products 2 Methyl Iso Butyl Carbinol 10000 3 Di Acetone Alcohol 5000 4 Hexylene Glycol 5000
Annexure 3
Land Breakup of MEK & MIBK
Description
Area (in acres) Area in
percentage MEK plant I MEK Expansion MIBK
(Proposed) Total Area
Build up area 2.25 2.19 9.0 13.44 49.4 Solid waste
disposal 0.20 0.50 0.20 0.90 3.3
Green Belt 2.00 2.50 2.84 7.34 27.0 Roads 1.00 1.00 3.52 5.52 20.3 Total 5.45 6.19 15.56 27.20 100.00
Annexure 4 Topo Map
Annexure 5
Annexure 6
MIBK Process Description Introduction Cetex petrochemicals propose to produce MIBK commercially using acetone and hydrogen
as raw material in a three step route. The key raw material in the manufacture of Methyl
Isobutyl Ketone (MIBK) is Acetone and shall be imported as bulk via M/s Mitsui & Co. at
Ennore port and stored at port storage tanks. The same will be transported via tankers to
factory site.
The first step in process is Acetone converted to Diacetone alcohol (DAA) by Aldol
condensation, followed by dehydration of DAA to Mesityl oxide (MO) and mild
hydrogenation of Mesityl oxide to MIBK. MIBK on further hydrogenation yields MIBC.
Diacetone alcohol (DAA) section Aldol condensation of acetone takes place in the presence of strong base as catalyst
resin
Formation of DAA is an equilibrium reaction which is favored at low temperature
below 15°C
Conversion of Acetone to DAA is mainly governed by the quality of acetone feed
(Since, low converter activity is due to aldehydes, oxides and acids in recycle or fresh
makeup stream), temperature of the feed to the converters and the activity of the
catalyst.
Stabilizing agent (here Citric acid is used) is added to the product stream at a point
downstream from the converters before it is heated for distillation to prevent the
reversion of DAA to Acetone
Two stage converters with inter-stage cooling system provided, since the reaction is
slightly exothermic
For maintaining low temperature of converter feed, butane chilling system will been
employed at both before and after first stage converter
Product effluent from second stage converter after dosing stabilizing agent, fed to
Acetone recycle column to separate unreacted acetone and DAA product
Crude DAA separates at bottom of recycle column and taken out to MO section
Top distillates of recycle column condensed and recycled back to converters along
with fresh makeup
Mesityl Oxide (M.O) section
Mesityl oxide is produced by dehydration of Crude DAA in the presence of acid
catalyst (2% Sulphuric acid) along with water as dehydration product in DAA
dehydration column
Reaction take place at 125 – 130 °C in liquid phase
M.O along with light components is distilled out as top product
Bottoms sent to M.O flash kettle for flash separation of M.O from unreacted DAA
Heavier component at the bottom of M.O flash kettle is sent to recovery column for
neutralization and recovery of DAA and acetone from aqueous phase
Top distillate from dehydration column is sent to M.O distillation column for
separation of M.O from acetone and water
Acetone along with water is getting separated out from M.O in M.O distillation
column as top distillate
M.O and some quantity of water stays at bottom in M.O distillation column is pumped
to M.O Phase separator for separation of Organic at top and Aqueous at bottom in
separator
Top organic phase is taken as reflux for DAA dehydration Column and a part is stored
in intermediate storage tank for MIBK / MIBC section
Methyl Isobutyl Ketone (MIBK) section
Mesityl Oxide along with hydrogen is superheated and fed to MIBK reactors
MIBK is formed by mild hydrogenation of Mesityl Oxide in the presence of
Palladium based catalyst
MIBK reaction is taking place in vapour phase @ 175 °C and 4 barg
Crude MIBK is then sent to distillation section for purification and to obtain finished
MIBK product
During MIBK reaction, MIBC also formed as by product, separated in distillation
section and sent to MIBC section
Methyl Isobutyl Carbinol (MIBC) section
Crude MIBK shall be feed to MIBC reactors along with hydrogen after superheated to
170 °C
MIBC is formed on intense hydrogenation of MIBK in the presence of Nickel based
Catalyst
MIBC reaction is taking place in vapour phase @ 170 °C and 11 barg
Crude MIBC is then sent to distillation section for purification and to obtain finished
MIBK product
Heavy ends (High boiling components) formed during reaction are separated in
distillation section and taken as by-product
Hexylene Glycol (HG) section
A part of Fin. DAA is fed to HG reactor along with Hydrogen after DAA purified via
distillation
Raney nickel is used as catalyst since the reaction is liquid phase
Crude HG obtained from reactor is taken for purification section
High boiling and unreacted DAA are separated and fed back into system, finished HG
is taken as product
Recovery Section
Purpose of this section is to recover organics that come from the water cuts collected
from all other sections
Organic separated in phase separator is fed back in corresponding purification section
and aqueous phase is taken out and sent to effluent treatment plant
Utilities
For process heat supply, high pressure steam shall be supplied from boiler having
capacity of 25 tons per hour
For high temperature applications such as superheating required before MIBK/MIBC
reactor, thermic fluid/oil shall be supplied from thermic fluid heater having capacity
of 4 Million Kcal / day
Common stack for boiler and thermic fluid heater will be installed as per norms
Fuel for Boiler & Thermic fluid heater will be design as multi-fuel fired with Wood,
Biomass and COAL
Process Flow Diagram
Annexure 7 Description of Proposed Effluent Treatment Plant Collection Tank
Effluent like cooling tower blow down, acid and alkali effluent from process waste water will be
collected in the equalization tank for homogenizing the effluent. From the collection tank the
homogenized effluent will be pumped through the Flash mixer for further treatment.
Flash Mixer & Flocculator
Collected effluent is pumped to flash mixer and flocculator where suitable coagulant, flocculent and
polymer are used to remove the suspended solids, turbidity.
Lamella Clarifier
The effluent from the flocculator will be fed in to lamella clarifier tank where the precipitated flocs
produced in flash mixer and flocculator will settle and the supernatant liquid overflows to the clarified
water tank.
UASB Reactor
The clarified water is pumped to anaerobic digester. During this process suitable alkaline chemical
(Na2CO3) is dosed for increasing the alkalinity of the effluent to make the effluent ambient for
anaerobic process. Since the BOD & COD load is heavy in the effluent, anaerobic reactor is designed
to reduce the load. The gas produce from the UASB reactor will lead into the bio gas flare system.
Primary use of the bio gas flare system is to combust the flammable or toxic gases to less
objectionable compounds.
Aeration tank
Effluent will be pumped at a constant flow rate from UASB reactor into the aeration tank. An
activated sludge treatment process occurs as a reaction between sewage and attached micro organisms
in the aeration tank. Air diffusers supply oxygen for biochemical processes as well as mixing sewage
with return sludge from the settling tank.
An air pump (positive displacement type roots blower) delivers air to a battery of fine bubble diffusers
at a constant rate thereby ensuring the growth of micro organisms in the sewage.
These include: Pseudomonas, Flavobacterium, Comamonas, Bacillus, Archromobacter, Alacingenes,
Sphaerotilus, Zoogloea, Archromobacter, Alacingenes, Flavobacterium, Pseudomonas / heterotrophic
bacteria, which disintegrate organic substances into a floc like substance. This is otherwise known as
an aerated suspended growth treatment process.
Secondary Settling Tank
The aerated effluent is then piped to the settling tank where the sludge sinks to the bottom. The clear
water overflows via a weir and is then fed to a disinfection tank. Suspended solids are collected at
bottom of clarifier; some of the active micro organism in the form of sludge is recirculated back to
aeration tank and mixed with the primary effluent with excess sludge pumped to sludge drying bed for
drying & disposal.
Disinfection cum clarified water tank
A suitable disinfectant, e.g. Hypo chlorite is dosed in the disinfection cum clarified water tank to
ensure that any remaining pathogenic micro organisms are eliminated and the water is fit for further
polishing & recycling.
Polishing Filters
The clarified water after disinfection and DM regeneration waste is pumped through Dual Media
Filter for filtering the suspended impurities and for removing free residual chlorine, organics & bad
odor through adsorption process. The filtered water at the outlet of the ACF is suitable for gardening
applications.
UF System
UF Automation
Operation of the Ultra filtration unit will be completely automated
Service & backwash sequence will be controlled by a PLC in the control panel
PLC will perform a programmed set of operations consisting of service’ backwash
and forward flush of the membranes at a preset sequence
It will also initiate the addition of chemicals during backwash to enhance the cleaning
efficiency during backwashing
The Ultra filtration unit will be provided with all safety features and any fault or
abnormal condition will be indicated by an audiovisual alarm in the control panel
RO System
UF permeate is pumped through the Micron Cartridge filter using the RO feed pump. It is primarily
used for the removal of turbidity.
Prior to the micron filter suitable Anti Scalant, Anti oxidant & Acid dosing are dosed to prevent any
low soluble salts settling over the surface of the membranes, to neutralize any oxidizing agents &
adjusting the pH entering into membranes respectively.
The conditioned water from the micron cartridge filter is pumped to the RO system by RO high
pressure pump.
The membrane separates the feed water into two streams namely permeate with low dissolved solids
& reject with high solid concentration. RO reject is fed into multiple effect evaporator system
followed by basket centrifuge.
Effluent Treatment Plant Schematic Diagram
REJECT REJECT
PERMEATE PERMEATE
Bar Screen
Raw Sewage Inlet
Equalization Tank
Flocculator Flash Mixer
Lamella clarifier Clean Water Tank
Bag Filter Dual Media Filter
Filter Feed Tank
Secondary Settling Tank
Aeration Tank
UF Permeate Tank
UASB Reactor
Micron Cartridge Filter
RO Module 1 RO Reject Tank 1 Micron Cartridge Filter
RO Module 2
RO Reject Tank 2
RO Sludge Settling Bed
Collection Tank
RO Permeate Tank
To Evaporation Feed Tank
Solar Pond Evaporation
Lamella Filtration
Annexure 8 MoU Letter Made with Common TSDF in Tamilnadu For Hazardous Waste Disposal