ANNEXURE- I PROPOSED TERMS OF...
Transcript of ANNEXURE- I PROPOSED TERMS OF...
ANNEXURE- I PROPOSED TERMS OF REFERENCE
Site description and plant lay out.
List of finished products and production quantity.
List of raw materials and consumption quantity.
Process details with mass balance.
Details of process emissions, flue gas emission, waste water discharge & solid waste
generation and disposal.
Complete water balance.
Details of air pollution control systems.
Base line data for soil, water, air and noise for one season.
Environment impact assessment study due construction activities, manufacturing
process and its operations etc.
Details of environmental management plan (EMP) and mitigation measures.
Occupational health and safety program for the project.
ANNEXURE- II LIST OF PROPOSED PRODUCTS AND THEIR PRODUCTION CAPACITY: Sr.No. Name of Products
Capacity (MT/Month)
1 Acetic Anhydride 3600 2 Easter of Acetic acid like Ethyl Acetate etc 1800 3 Mono Chloro Acetic Acid(MCAA) 3000 4 Chloro Acetyl Chloride (CAC) 650 5 2 Ethylexyl Nitrates (2EHN) 3000 6
Nitro derivaties of hydrocarbon such as Nitro Xylene, Nitro Cumene .etc.
3000
7 Phenyl ethyl alcohol (PEA) 500 8 Sodium Monochloro Acetate (SMAC) 300 9 Methyl Chloro Acetate
500
10 Ethyl Chloro Acetate 11 Dichloro Acetic Acid 12 Trichlo Acetic Acid 13 Calcium chloride 2500 14 Coal Based Power plant 4 MW
By Product 1 Spent Acid 2373.453 2 Hydrochloric acid 6958 3 Sodium hypo chloride 808 4 Sodium Bi Sulphite (SBS) 7722 5 Mother liquor of MCAA 1400
ANNEXURE-III LIST OF PROPOSEDRAW MATERIALS PRODUCT WISE Sr.No. Name of Product Name of Raw Materials Quantity in T/Month 1 Acetic Anhydride Acetic acid 2650.29
Catalyst 7.76 Ammonia 1.80 Ethyl acetate 13.64 Total 2673.49
2 Ethyl acetate Acetic acid 1227.11 Ethyl alcohol 1040.59 Para Toluene Sulphonic acid (PTSA)
52.59
Total 2320.29 3 Mono Chloro Acetic
Acid Acetic acid 2700 Chlorine 3408 Caustic 247.5 SMC 72 Acetic anhydride 60 Total 6487.5
4 2 Ethylexyl Nitrates (2EHN)
2-Ethyl Hexanol (2EH) 2250 Nitric acid 99 % 114 Sulfuric acid 98 % 1530 Sodium sulfate 300 Caustic Soda 150 Total 4344
5 Nitro Xylene Xylene 1666.52 Nitric acid 1443.18 Sulfuric acid 1332.17 Spent acid 1959.077 Soda 130.60 Total 6531.547
6 Nitro cumene Cumene 2203.256 Nitric acid 1180.465 Sulfuric acid 969.76 Spent acid 3488.37 Total 7841.851
7 Phenyl ethyl alcohol (PEA)
Styrene 174.65 SBC 55.01 DMF 4.80 TBSA 0.087 Soda ash 1.22 NaOH 0.611 H2O2 220.07Total 456.448
8 Sodium Monochloro Acetate (SMAC)
MCA 246 Soda Ash 138 Total 384
9 Methyl Chloro Acetate
MCA 435 Methyl alcohol 148 Sulphuric acid 454.5 Total 1037.5
10 Ethyl Chloro Acetate MCA 385.5 Ethyl alcohol 188 Sulphuric acid 402.5 Total 976
11 Dichloro Acetic Acid Chlorine 555 Acetic acid 235 Total 790
12 Trichlo Acetic Acid Chlorine 800 Acetic acid 250 Total 1050
13 Calcium chloride Limestone 2250 HCl 1675 Lime solution 25 Total 3950
ANNEXURE-IV LIST OF HAZARDOUS RAW MATERIAL Sr.No. Name of Products Name of Hazardous Raw
Materials 1 Acetic anhydride Ammonia 2 Ethyle acetate PTSA 3 Mono Chloro Acetic
Acid Chlorine
4 2 EHN Sodium sulfate5 Nitroxylene Sulfuric acid 6 Nitrocumene Sulfuric acid
ANNLAY
NEXURE-V YOUT PLANN
ANNSITE
NEXURE-VIE PLAN
I
ANNEXURE-VII
MANUFACTURING PROCESS,CHEMICAL REACTION & MATERIAL BALANCE
(1) ACETIC ANHYDRIDE
Acetic anhydride is produced from glacial acetic acid via ketene. Acetic acid is vaporized and
fed together with a catalyst to a cracking furnaces operating under vacuum where ketene is
produced together with water at high temperature. The reaction mixture is rapidly cooled to
avoid the reversing of the reaction. The condensed dilute acid is separated and gases then
pass through two absorption towers in which they are scrubbed by acetic acid/acetic
anhydride of various concentrations.
Glacial acetic acid is added to the second absorption tower.ketane is reacting with acetic acid
to form acetic anhydride in following washing towers the gases are further scrubbed before
released to the atmosphere. In a distillation column the crude acetic anhydride is distilled and
recovered as bottom product. The top product is acetic acid which is recycled to the process.
Acetic anhydride is raw material for cellulose acetate (fibers, films plastic, cellulose lacquers)
aspirin, agricultural chemicals, fragrances, pharmaceuticals and explosives.
CH3CO2H = CH2=C=O + H2O Acetic acid ketene Water 60 42 18 CH3CO2H + CH2=C=O = (CH3CO) 2 O Acetic acid ketene Acetic anhydride 60 42 102
MATERIAL BALANCE FOR ACETIC ANHYDRIDE-
INPUT KG
PROCESS WATER 186.67
CATALYST 17.52
AMMONIA 4.08
ACETIC ACID 4040.33
TOTAL 4248.6
KG OUTPUT
2411.6 KETANE GAS
1837 DILUTE ACID
4248.6 TOTAL
KETANE GAS 2411.6
ACETIC ACID 2567.84
ACETIC ACID Recover 628
TOTAL 5607.44
5200 ACETIC ANHYDRIDE
61 RESIDUE
346.44 DILUTE ACID
5607.44 TOTAL
DILUTE ACID 2183.44
PROCESS WATER 1336.87
ETHYL ACETATE 30.8
TOTAL 3551.11
2923.11 Water to ETP
628 ACETIC ACID RECO.
3551.11 TOTAL
KETANE GENERATION
SCRUBBING AND
DISTILLATION
ACETIC ACID RECOVERY
(2) ETHYL ACETATE
Ethyl acetate is produced by etherification of acetic acid with ethanol using sulphuric acid as catalyst. Ethanol and acetic acid are continuously fed to the steam heated reactor. The ethyl acetate formed is removed from the top of the reactor column together with some ethanol and water. The oily phase is separated and washed and then sent to the ester column where the product is removed from the bottom. Water phases from decanters are sent to the recovery column where ethanol is recovered and sent back to the reactor. The bottom water phase is sent out as effluent.
Ethyl Acetate is a colourless liquid and has a characteristic sweet smell. It is used as solvent for paints, extraction agent, raw material for pharmaceuticals, cosmetics and polishes.
CH3COOH + C2H5OH = CH3COOC2H5 + H2O
Acetic acid Ethyl alcohol Ethyl acetate Water
60 46 88 18
MATERIAL BALANCE FOR ETHYL ACETATE
INPUT KG ETHYL ALCOHOL
1484
ACETIC ACID 1750 PTSA 75 TOTAL 3309
KG OUTPUT
3309 REACTION MASS
3309 TOTAL
REACTION MASS
3309
WATER 2768 TOTAL 6077
2567 ETHYL ACETATE
3510 WATER+ETHYL
ALCOHOL
6077 TOTAL
1907 WATER TO ETP
1463 ETHYL ALCOHOL
RECOVER
140 LOSS
3510 TOTAL
WATER+ETHYL ALCOHOL
3510
TOTAL 3510
PURIFICATION
ETHYL ALCOHOL RECOVERY
ESTERIFICATION
(3)ETHYLEXYL NITRATE (2EHN)
Manufacturing Process 2-Ethylhexyl Nitrate is produced by the o-nitration of 2-ethylhexanol using nitric acid along with Sulphuric Acid (Mixed Acid). The manufacturing process of 2-EHN would consist of the following process steps as presented in process block diagram in Annexure-I: 1. Preparation of Nitrating acid. 2. Nitration of 2-Ethylhexanol (2-EH) with Nitrating acid. 3. Separation of spent acid stream from 2-EHN stream. 4. Recycle / De-nitration / Recovery of Nitric Acid / Concentration of Sulphuric Acid 5. Washing & Neutralization of 2-EHN stream. 6. Drying of 2-EHN to meet moisture specifications.
OH + HNO3 T≤ 200C ONO2+H2O H2SO4 ISO-Octanol Nitric acid 2 Ethylexyl nitrates Water 130.23 63 175.23 18 1. Nitrating Acid Preparation The nitrating acid would be prepared in a continuous mode. The process requires conc. nitric; dilute sulphuric and concentrated sulphuric acid to be mixed to prepare required composition of nitrating acid (mixed acid). This acid will be cooled in heat exchangers and fed to 2-EHN nitration sections. 2. Nitration of 2EH The nitration would be carried out in a continuous tubular nitrator. The nitrating acid stream is cooled to 0 0C and fed to Nitrator along with 2-EH steam. The nitration reaction takes place in adiabatic condition in short residence time and the product and spent acid stream are further cooled in product cooler and heat exchanger followed by separation of spent acid from steam 2-EHN. For accurate flow rate measurement, mass flow meters are installed in controlling the variation of feed ratio and to have better control of system.
3. Separation of 2-EHN for Spent Acid Stream The combined stream of 2-EHN and Spent Acid is separated in phase separator in which the 2-EHN stream is separated from the spent acid stream. The spent acid stream is send to the spent acid tank for de-nitration/recycle. The phase separator has the following unique features: l. High separation efficiency compared to conventional gravity separators. Our separator breaks the micro-emulsions resulting in lower residence times and lower volumes to achieve desired separation. 2. Avoid the use of expensive centrifugal separators and dynamic separators for separating 2-EHN from acid stream. 3. The phase separator is PLC controlled and is able to control interface level and flow of individual steams resulting is steady and constant process conditions. 4. Efficient separation of 2-EHN and spent acid means safe operations as spent acids would be more stable and also ease the washing and neutralization load of downstream operations. 4. Washing and Neutralization of 2-EHN Stream The acidic stream of 2-EHN is washed in a continuous manner in a combination of series of three washers and separators. In the washer and separator the flow of 2-EHN is moved by water ejectors for safety reasons. The washed neutral 2-EHN stream contains less than 500ppm moisture and is fed for final drying. 5. Drying of 2-Ethylhexyl Nitrate The 2-EHN stream is continuously dried to get the required moisture limit of < 0.05% and is directly pumped to 2-EHN storage tanks. 6. De-nitration and Concentration Units The spent acid from 2-EHN plant is unstable and is to be de-nitrated to separate sulfuric acid from nitric acid. The nitric acid stream can further concentrated and recycled back. The sulfuric acid stream can be concentrated and recycled back.
MATERIAL BALANCE FOR 2-ETHYLEXL NITRATES.
INPUT KG
2-EH 750
NITRIC ACID 164
SULPHURIC ACID 510
REC.NITRIC ACID 126
REC.SULFURIC ACID 210
TOTAL 1760
KG OUTPUT
1760 REACTION
MASS
1760 TOTAL
1424 REACTION
MASS
336 Spent acid
1760 TOTAL
RECTION MASS 1760
TOTAL 1760
126 NITRIC RECY.
210 SULPHURIC
RECY.
336 TOTAL
Spent Acid 336
TOTAL 336
SODA 50
SODIUM SULPHATE 100
WASHING WATER 56.25
REACTION MASS 1424
TOTAL 1630
1250 REACTION
MASS
380 EFFLUENT
1630 TOTAL
REACTION MASS 1250
TOTAL 1250
1000 2EHN
250 WATER
VAPOUR
1250 TOTAL
SEPERATOR
DRYING
REACTION
WASHING
De-nitration & Concentration
(4) NITRATION OF HYDROCARBON SUCH AS NITROXYLENE,
NITROCUMENE ETC.
A) NITROCUMENE
C6H5CH (CH3)2 + HNO3 = C6H4NO2CH(CH3)2 + H2O
120.2 63 165.2 18
INPUT KG
CUMENE (FRESH) 1579
NITRIC ACID 846
SULPHURIC ACID 695
SPENT ACID 2500
TOTAL 5620
KG OUTPUT
5620 REACTION
MASS
5620 TOTAL
2171 REACTION
MASS
2500 Spent Acid
949 Spent acid sent
5620 TOTAL
RECTION MASS 5620
TOTAL 5620
REACTION MASS 2171
WASHING WATER 400
TOTAL 2571 2571 REACTION
MASS 2571 TOTAL
RECTION MASS 2571
TOTAL 2571
2191 REACTION
MASS
380 EFFLUENT
2571 TOTAL
REACTION MASS 2191
TOTAL 2191 20 WATER LOSS 2171 REACTION
MASS 2191 TOTAL
REACTION MASS 2171
TOTAL 2171
2150 NITROCUMENE
21 RESIDUE
2171 TOTAL
SEPERATOR
DRYING
REACTION
WASHING
SEPERATOR
DISTILLATION
A) NITROXYLENE
C6H4 (CH3)2 + HNO3 = C6H3NO2 (CH3)2 + H2O
106.17 63 151.16 18
INPUT KG
XYLENE 1613
REC.XYLENE 337
NITRIC ACID 1105
SULPHURIC ACID 1020
SPENT ACID 1500
TOTAL 5575
KG OUTPUT
5575 REACTION
MASS
5575 TOTAL
2740 REACTION
MASS
1500 Spent Acid
1335 Spent acid sent
5575 TOTAL
RECTION MASS 5575
TOTAL 5575
REACTION MASS 2740
WASHING WATER 800
SODA 100
TOTAL 3640
3640 REACTION
MASS
3640 TOTAL
RECTION MASS 3640
TOTAL 3640
2720 REACTION
MASS
920 EFFLUENT
3640 TOTAL
REACTION MASS 2720
TOTAL 2720
2297 NITROXYLENE
337 REC.XYLENE
86 RESIDUE
2720 TOTAL
SEPERATOR
WASHING
SEPERATOR
DISTILLATION
REACTION
(5) PHENYL ETHYL ALCOHOL (PEA)
Manufacturing process
Charge water, SBC, TABA, CATALYST, DMF & Styrene in SS reactor cool & maintain temperature, add slowly hydrogen peroxide into reaction mass & maintain temp. crude styrene oxide will form, transfer this crude mass for washing & hydrogenation. Add water, NaOH, soda ash& catalyst, then purge air with nitrogen & add hydrogen in hydrogenrator & add styrene oxide slowly in hydrogenrator, maintain temperature. Cool then mass for water washing & for vaccum distillation. About 93 to 95 % of Phenyl Ethyl alcohol will form.
Chemical Reaction
CH=CH2
H2O2
OXIDATION CH CH2
O
C8H8 C8H8O 104 120
STYRENE MONOMER104 STYRENE OXIDE
OH
H2
CH CH2
O
C8H8O C8H10O 120 122
STYRENE OXIDE PEA
Material balance for PEA.
INPUT KG STYRENE 2000 WATER 4500 SBC 630 TBSA 1 DMF 55 CATALYST-1 1.5 CATALYST-2 0.7 H2O2 2520 TOTAL 9708.2
KG OUTPUT 9708.2 REA.MASS 9708.2 TOTAL
INPUT KG REAC.MASS 9708.2 TOTAL 9708.2
KG OUTPUT 7708.2 REA.MASS 2000 EFFLUENT 9708.2 TOTAL
INPUT KG REA.MASS 7708.2 WATER 2000 SODA ASH 14 NaOH 7 CATALYST-pd 5 TOTAL 9734.2
KG OUTPUT 5734.2 REA.MASS 4000 EFFLUENT 9734.2 TOTAL
KG OUTPUT 5725.416 REA.MASS 8.784 EFFLUENT 5734.2 TOTAL
INPUT KG REAC.MASS 5734.2 TOTAL 5734.2
REACTOR
WASHER
HYDRGENATION
DISTILLATION
(6) MONOCHLOROACETIC ACID & ITS DERIVATIVES LIKE:
(A) Mono- Chloro Acetic Acid (MCAA) Manufacturing Process: Charge Acetic Acid in the reactor. Heat the reactor to 100 °C and start chlorination. Acetic acid is converted into Mono-chloro Acetic Acid in presence of Acetic anhydride and Sulfur mono chloride as catalysts. During the process HCl gas is also generated, which is scrubbed by scrubber and dissolved in water to get 30% HCl liquor. After completion of reaction, mass is transferred in bowls for crystallization where natural followed by induced cooling takes place. After about 70 hr pure MCAA crystals are recovered. After centrifuging MCAA product is ready for packing. CH3COOH + Cl2 = ClCH2COOH + HCL 60 Kg/kmol 71 Kg/kmol 94.5 Kg/kmol 36.5 Kg/kmol
INPUT KG CHLORINE 6816 ACETIC ACID 5400 SMC 144 ACETIC ANHYDRIDE
120
TOTAL 12480
KG OUTPUT
8730 REACTION MASS
3300 HCL
450 CHLORINE
12480 TOTAL
REACTION MASS
8730
TOTAL 8730
6000 MCAA
2730 MOTHER LIQUIR
8730 TOTAL
CHLORINE 450 ACETIC ACID 3300 WATER 6960 TOTAL 10710
450 CHLORINE
10260 HCL FOR SALE
10710 TOTAL
CHLORINE 450 CAUSTIC 495 WATER 315 TOTAL 1260
1260 NaOCl
1260 TOTAL
CENTRIFUGE
CAUSTIC SCRUBBER
GLASS LINED REACTOR
HCL SRUBBER
(B) CHLORO ACETYL CHLORIDE(CAC):
1. The MCA is directly taken to CAC reactors and the mass at the desired temperature gradual addition of sulphur monochloride is carried out and chlorination is carried out. On the completion of the reaction crude product is formed. The vent gases evolved during the process sent to scrubbing system.
2. The crude CAC thus formed is distilled, condensed, collected and packed. Chemical reaction.
4ClCH2COOH + S2Cl2 +3Cl2 = 4ClCH2COCl + 2SO2 + 4HCL MCAA SMC CHLORINE CAC Sulphur dioxide Hydrochloric acid
INPUT KG MCAA/ML 8550 CHLORINE 490 SMC 2970 TOTAL 12010
KG OUTPUT
5143 REACTION
MASS
3186 HCL
945 CHLORINE
2736 SO2
12010 TOTAL
4000 MCAA
90 RESIDUE
1053 DISTILL GAS
5143 TOTAL
REACTION MASS 5143 TOTAL 5143
945 CHLORINE
11250 HCL FOR
SALE
2736 SO2
1053 DISTILL GAS
15984 TOTAL
CHLORINE 945 HCL 3186 WATER 8064 DISTILL GAS 1053 TOTAL 13248
Na2CO3 2340 CHLORINE 945 CAUSTIC 243 WATER 41301 SO2 2736 DISTILL GAS 1053 TOTAL 46278
36018 SODIUM BISULPHITE-
SBS
10260 SODIUM
HYPOCHLORIDE
46278 TOTAL
DISTILLATION
CAUSTIC SCRUBBER
GLASS LINED REACTOR
HCL SRUBBER
(C) SODIUM MONOCHLOROACETATE (SMAC)
1. Charge MCA and Soda Ash in the reactor for blending .Then the mass is called sodium Mono Chloro Acetate .Then this mass dried and pack in packing bags. Chemical Reaction: 2ClCH2COOH + Na2CO3 2ClCH2COONa + H2O + CO2 Mono chloro Soda ash Sodium Mono Acetic acid Chloro acetate
Mass balance & Process flow diagram:
INPUT KG MCA 820 SODA ASH 460 TOTAL 1280
KG OUTPUT
1089 REACTION MASS
191 CO2
1280 TOTAL
REACTION MASS
1089
TOTAL 1089
1000 SMCA
89 WATER
1089 TOTAL
DRYING
RIBON BLENDER
(D) METHYL CHLORO ACETATE
Manufacturing Process
Charge measured quantity of Methyl alcohol, Mono chloro acetic acid and sulphuric acid in to reactor. After charging of raw materials heating is given, after heating spent sulphuric acid layer is separated .The crude ester is filter or distilled. Thus output is Methyl chloro acetate and spent Sulphuric acid. The spent is resale for manufacturing copper sulphate and ferrous sulphate.Which results “Zero Discharge Process.
Reaction
CH3OH + Cl-CH2-COOH + H2SO4 CH3-COO-CH2-Cl + H2SO4.H2O
Methyl Monochloro Sulphuric Methyl Chloro Spent Acid Alcohol Acetic acid Acid Acetate 32 94.5 98.6 108.5 116.6
Mass balance & Process flow diagram
INPUT KG MCA 870 METHYL ALCOHOL
296
SULPHURIC ACID 909 TOTAL 2075
KG OUTPUT
1000 REACTION MASS
1075 Spent Sulphuric acid
2075 TOTAL
REACTION MASS
1000
TOTAL 1000
1000 Methyl chloroacetate
1000 TOTAL
DISTILLATION
REACTOR
(E) ETHYL CHLORO ACETATE
Manufacturing Process
Charge measured quantity of Ethyl alcohol, Mono chloro acetic acid and sulphuric acid in to reactor. After charging of raw materials heating is given, after heating spent sulphuric acid layer is separated .The crude ester is filter or distilled. Thus output is Methyl chloro acetate and spent Sulphuric acid. The spent is resale for manufacturing copper sulphate and ferrous sulphate.Which results “Zero Discharge Process.
Reaction
C2H5OH + Cl-CH2-COOH + H2SO4 C2H5-COO-CH2-Cl + H2SO4.H2O
Ethyl Monochloro Sulphuric Methyl Chloro Spent Acid Alcohol Acetic acid Acid Acetate 46 94.5 98.6 122.5 116.6
Mass balance & Process flow diagram
INPUT KG MCA 771 METHYL ALCOHOL
376
SULPHURIC ACID 805 TOTAL 1952
KG OUTPUT
1000 REACTION MASS
952 Spent Sulphuric acid
1952 TOTAL
REACTION MASS
1000
TOTAL 1000
1000 ethyl chloroacetate
1000 TOTAL
DISTILLATION
REACTOR
(F) Di Chloro Acetic Acid :
1. The required quantity of acetic acid/mother liquor of MCA is taken into reactor. Then steam is passed through jacketed vessel to raise the temp. From the room temperature. As soon as temp. is achieved chlorine gas is sparge through the mass. The chlorination is carried out to obtain mono chloro acetic acid.
2. After reaching to the end point the reacted mass is transferred to DCAA reactor. The vent gases from MCA reactors sent to scrubbing system.
3. The reacted mass taken into reactor is again heated to required temp.After achieving the desired temp.the chlorine gas passed through this mass.
4. This mass is an intermediate product known as Di chloro acetic acid (DCAA).It is either taken for packing and dispatch for transferred to DCAC reactor. The vent gases evolved are spurge through MCA reactor and from here they are sent to the scrubbing system. Chemical Reaction CH3COOH +2Cl2 CHCl2COOH + 2HCl Acetic Acid Liquid chlorine Di chloro Acetic Acid Hydrochloric acid
INPUT KG CHLORINE 1110 ACETIC ACID 470 Mother liquor(recycle) 100 TOTAL 1680
KG OUTPUT
1100 Di-Chloroacetic acid-
crude
580 HCL
1680 TOTAL
Di-Chloroacetic acid-crude
1100
TOTAL 1100
1100 DCAA-crystallise
1100 TOTAL
TCAA 1100 TOTAL 1100
100 Mother liq.of-(recycle)
1000 DCAA
1100 TOTAL
CRYSTALLIZATION
CENTRIFUGE
GLASS LINED REACTOR
OR
INPUT KG CHLORINE 900 Mother liquor of MCA 400 Mother liquor(recycle) 100 ACETIC ANHYDRIDE
140
TOTAL 1540
KG OUTPUT
1100 Di-Chloroacetic acid-
crude
440 HCL
1540 TOTAL
Di-Chloroacetic acid-crude
1100
TOTAL 1100
1100 DCAA
1100 TOTAL
TCAA 1100 TOTAL 1100
100 Mother liq.of-(recycle)
1000 DCAA
1100 TOTAL
CRYSTALLIZATION
CENTRIFUGE
GLASS LINED REACTOR
(G) Tri Chloro Acetic Acid :
1. The required quantity of acetic acid/mother liquor of MCA is taken into reactor. Then steam is passed through jacketed vessel to raise the temp. from the room temperature. As soon as temp.is achieved chlorine gas is sparged through the mass. The chlorination is carried out to obtain mono chloro acetic acid.
2. After reaching to the end point the reacted mass is transferred to TCAA reactor. The vent gases from MCA reactors sent to scrubbing system.
3. The reacted mass taken into TCAA reactor is again heated to required temp.After achieving the desired temp.the chlorine gas passed through this mass.
4. This mass is an intermediate product known as Tri chloro acetic acid (TCAA).It is either taken for packing and dispatch for transferred to TCAC reactor. The vent gases evolved are sparged through MCA reactor and from here they are sent to the scrubbing system. Chemical Reaction CH3COOH +3Cl2 CCl3COOH + 3HCl Acetic Acid Liquid chlorine Tri chloro Acetic Acid Hydrochloric acid
OR
INPUT KG CHLORINE 1600 ACETIC ACID 500 Mother liquor(recycle) 100 TOTAL 2200
KG OUTPUT
1100 TCAA(CRUDE)
1100 HCL
2200 TOTAL
TCAA (CRUDE) 1100 TOTAL 1100
1100 TCAA-CRYSTALLISE
MASS
1100 TOTAL
TCAA-CRYSTALLISE
1100
TOTAL 1100
100 Mother Liq. of TCAA
(RECYCLE)
1000 TCAA
1100 TOTAL
INPUT KG CHLORINE 1200 Mother liquor of MCA 500 Mother liquor(recycle) 100 ACETIC ANHYDRIDE
180
TOTAL 1980
KG OUTPUT
1100 TCAA(CRUDE)
880 HCL
1980 TOTAL
TCAA(CRUDE) 1100 TOTAL 1100
1100 TCAA-CRYSTALLISE
MASS
1100 TOTAL
TCAA 1100 TOTAL 1100
100 Mother Liq. of TCAA
(RECYCLE)
1000 TCAA
1100 TOTAL
CRYSTALLIZATION
CENTRIFUGE
GLASS LINED REACTOR
CRYSTALLIZATION
CENTRIFUGE
GLASS LINED REACTOR
(7) CALCIUM CHLORIDE
Manufacturing Process
Limestone will be fed at the top of the reactor and hydrochloric acid will flow counter current from the bottom .In the reactor HCl will react with Limestone to produce Calcium Chloride Solution and Carbon dioxide gas.
35% solution of calcium chloride produced in the reactor will overflow to a Neutralization tank where the pH of the solution will be corrected by addition of lime solution .The reacted solution will be taken to a settler where magnesium and iron components will be precipitated out.
Clarified Calcium Chloride Solution will be filtered and the clear solution will be taken to the evaporation unit for drying.
CaCO3 + 2HCl CaCl2 + CO2 + H2O
Limstone Hydrochloric acid Calcium chloride
100 73 111 18 44
INPUT KG LIMESTONE 900HCL 670 TOTAL 1570
KG OUTPUT
1170 Cal.chloride
SOLUTION
400 CO2
1570 TOTAL
Cal.chloride SOLUTION
1170
LIME SOLUTION 10 TOTAL 1180
10 SLUDGE
1170 Neutralise mass
1180 TOTAL
CaCl2 solution 1170 TOTAL 1170
170 WATER
1000 CONC.CAL.CHLOR.
1170 TOTAL
CONC.CAL.CHLOR 1000 CAL.CHLORIDE 1000
NEUTRALIZATION
GRANULATION
REACTOR
EVAPORATOR
ANNEXURE-XII: DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL Sr. No.
Type of Hazardous Waste
Quantity in MT/month
Hazardous Waste Category
Storage, Collection & Disposal
1 ETP Sludge 300 34.2 Collection, Storage , Transportation & Disposal to TSDF or Sold to Actual Users (i.e. cement mfg. industries)
3 Distillation Residue
170 20.3 Collection, Storage , Transportation & Disposal to Incineration or Sold to Actual Users (i.e. cement mfg. industries)
5 Used Oil/Spent Oil
200lit/month 5.1 Collection, Storage, Transportation & Sell to GPCB Authorized Reprocessor
6 Empty Drums/Container
What so ever
33.1 Collection, Storage, Transportation & Sell to GPCB Authorized Reprocessor
7 Empty Bags What so ever
33.1 Collection, Storage, Transportation & Sell to CPCB/GPCB Authorized Vendor
8 Salt from MEE 0.450 T/Month
34.2 Collection, Storage , Transportation & Sold to End Users
Solid waste 9 Fly Ash 504
T/month --- Collection, Storage,
Transportation and disposal by selling to Brick manufacturing unit.
ANNEXURE-XI: DETAILS OF FUEL CONSUMPTION Sr. No.
Name Requirement Source
1 Diesel 300 Lit/Hr Local Market 2 Energy - Electricity 1730 KVA DGVCL 3 Coal* 387 MTD Local supplier Note: *Coal will be used for in house Power plant of 4 MW
DETAILS OF FLUE GAS EMISSION Sr.No. Stack
attached to Fuel Stack
Height in meter
Expected pollutants
Permissible limit
APC System
1. Steam boiler (78 Ton/Hr)
Coal -336 TPD
30 SPM SO2 NOX
150 100 50
Electrostatic Precipitator
2. DG Set 750KVA
Diesel- 150Lit/hr
11 Adequate stack height
3. DG Set 750KVA
Diesel-150Lit/hr
11 Adequate stack height
DETAILS OF PROCESS EMISSION Sr.No. Stack attached to Stack
Height in meter
Expected pollutants
Permissible limit
APC System
1. Chlorination process vessel
11 HCl Cl
20 mg/Nm3 9 mg/Nm3
Water Scrubber followed by Caustic Scrubber
2. Nitration Vessel 11 NOx 25 mg/Nm3 Caustic Scrubber
ANNEXURE- X ETP FLOW DIGRAM:
Collection Tank Equalization cum Neutralization tank
Flash mixer
Clariflocculator
Aeration tank
Biomass send to Sludge Drying bed
Settling tank Sand filter Carbon filter
Holding tank
R.O.
Holding sump
MEE
E) MULTIPLE EFFECT EVAPORATOR
Reject water of RO plant is feed to MEE. MEE is an apparatus for efficiently using
heat from steam to evaporate water to concentrate dissolved salts in water in multiple
effect evaporators, water is boiled in sequence of vessels, each held at lower pressure
than the last. As boiling of water the distillate from evaporate will be recycled in
Industrial process /cooling tower and residue will be sent to approve TSDF site for
final disposal.
Details of ETP equipments are given in Table and characteristic of waste water before
treatment & after treatment are given in Table.
EQUIPMENT LIST OF ETP
Sr. No.
Name of the unit Capacity in m3
MOC No.
1 Oil/grease trap 15 KL MS/FRP 1 2 Collection ANK 70 KL MS/FRP 1 3 Equalisation Tank 140 KL RCC 1 3 Flocculator 90 KL MS/FRP 1 4 Flash mixture 75 KL MS/FRP 1 5 Aeration Tank 825 KL RCC 1 6 Settling Tank 110 KL MS/FRP 1 7 Holding sump 25 KL HDPE 1 8 Sand filter 7 KL MS 1 9 Carbon filter 7 KL MS 1 11 Final pond 18 KL MS 1 12 RO-1 300 KL 1 13 RO-2 200 KL 1 14 MEE 200 KL 1 EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT Sr.No. Parameters Unit ETP inlet ETP outlet
1 pH pH scale 5-7 7-8 2 COD mg/l 1000-5000 100-250 3 TDS mg/l 1000-5000 1500-2000 4 TSS mg/l 100-200 100-200 5 Ammonical Nitrogen mg/l 15-30 10-15
5. Settling Tank
The biomass generated in aeration tank consists of zoological bacteria, protozoa;
rotifers’ etc. The biomass is generally flocculent and quick settling. For the separation
of biomass clarifier is provided. Settled biomass is collected in the centrally located
sludge pit with the help of clarifier mechanism. The biomass is partly recycled in the
aeration tank and remaining taken to sludge drying beds.
6. Clarified Effluent Holding Sump.
Overflow from the clarifier is received by clarified effluent holding sump under
gravity, from which is taken for tertiary treatment.
7. Sludge Filtration
Sludge filters are provided for the dewatering of sludge generated from the chemical
coagulation and biological oxidation process. The dewatered sludge filter, the dried
sludge cakes are properly stored in the solid storage yard. The filtrate is further taken
for the treatment by pumping the same to the equalization tanks.
C) TERTIARY TREATEMENT
Waste water treated by secondary treatment received to the final setting tank by
gravity,
The overflow of final settling tank is discharged to holding tanks. This treated water is
pumped to sand filter and activated carbon filter and collected to guard pond. This
treated effluent will be subjected to R.O. followed by MEE to achieve Zero Liquid
Discharge.
D) REVERSE OSMOSIS SYSTEM
After treatment the effluent is sent to the Reverse Osmosis plant .R.O. system
provided 300 m3 capacities. In Reverse Osmosis, when high pressure is applied liquid
moves from high concentration to lower concentration. Reverse Osmosis (RO) is
method that removes many types of particles from solutions by applying pressure to
the solution when it is on one side of selective. The result is it retained on the
pressurized side of the membrane and the pure is allowed to pass to the other side.
The R.O. permeate will be reused in industrial process or cooling tower and rejected
water will be sent into Multiple Effect Evaporator.
ANNEXURE-IX DETAILS OF TREATMENT SCHEME AND DISPOSAL METHODS
Effluent from all the manufacturing process and floor washing collected into
collection tank. After primary, secondary and tertiary treatment the effluent sent to
RO & recycles to cooling tower. The detail of treatment is covered as under.
A) PRIMARY TRETEMENT 1. Equalization cum neutralization Tank
Effluent will be first sent to equalization cum neutralization tank where the flow
will be equalized and pH will be neutralized. For proper mixing of content,
compressed air is used through well designed Aeration grid. The waste water is
pumped to the flash mixer.
2. Flash Mixer
Flash mixer is provided for rapid mixing of flocculating agent i.e. Alum with the
influent from Equalization tank. From the flash mixer, effluent flows to the
Clariflocculator under gravity.
3. Clariflocculator
Clariflocculator is provided for the flocculation of colloidal particles and further
during the process. Flocculation of the neutralized colloidal particles is achieved in
centrally located flocculate zone by slow moving paddles. Paddles enhance agitation
of minute flocks and thus this process helps in coagulation and agglomeration of
suspended and colloidal particles of the effluent. The settled flock is scraped with the
help of clarifier mechanism to centrally located sludge pit. The collected sludge is
taken to sludge drying bed. The clarifier overflow from the lauder of the clarifier is
taken to the bioreactor.
B) SECONDARY TREATEMENT
4. Aeration Tank ( Bio-reactor)
Effluent is aerated in the aeration tank with the help of the mechanical surface aerator
in presence of well-acclimatized microorganism. The synthesis reaction is followed
by subsequent separation of the resulting biological mass and the oxidation reaction is
the main mechanism in the removal of BOD in the activated sludge process. Effluent
from reaction tank will be taken to clarifier under gravity.
WATER BALANCE DIAGRAM:
Note: All units are in KL/Day.
Fresh water 2155KLD
Process water 563
DM water plant 872
Softener 680
Washing 10
Domestic 10
Garden 20
Boiler 786
Flash steam
225
Effluent from process-256
Blow down-40
673
Cooling Tower 1131
Blow down-60
Regeneration Water -86
Regeneration water-7
RO-193 MEE-158
Reject- 45 Op-1 Incin.23
Op-2 crystallizer-23
17
Reject-96
Filtration -23
ETP-271
148
Soak pit-5
458
Condensate -135
Salt(sent to land filling or incineration )-15
Treated effluent sent to RO-271
175
ANNEXURE-VIII DETAILS OF WATER CONSUMPTION, WASTEWATER GENERATION AND TREATMANT TABLE 1: DETAILS OF WATER CONSUMPTION Sr.No. Particulate Proposed Total water consumption in KL/day 1 Domestic 10 Gardening 20 2 Industrial Process 563 Washing 10 DM plant 872 Softener 680 Cooling 673(softener permeate) + 458 (recycled) Boiler 786 (DM permeate) Total(Industrial) 2125 Total 2155 TABLE 2: DETAILS OF WASTE WATER GENERATION Sr.No. Particulate Proposed wastewater generation in KL/day
1 Domestic 5 2 Industrial
Process 256 washing 10 DM plant 86 Softener 7 Cooling 60 Boiler 40 Total(Industrial) 459 Total 464*
Out of this 464 KLD, 271 KLD (256+10+5) will be sent to ETP followed by Process R.O., 193 KLD (from utility) will be sent to R.O.) and 135 KLD(from condensate of MEE) to reused in Cooling Tower. Unit will achieve Zero Liquid Discharge till it gets permission to discharge in common effluent conveyance project of M/s. Narmada Clean Tech.