ENCLOSURE: G ADDITIONAL ATTACHEMENTS INDEX FOR...

M/s. Tridev Resins (I) Pvt Ltd., Plot No. 136/E-1, Phase II, GIDC Estate, Vapi – 396195, Dist – Valsad. EC Application for: Expansion in Existing unit

ENCLOSURE: G

ADDITIONAL ATTACHEMENTS

INDEX FOR ADDITIONAL ATTACHMENTS

Sr. No. Name of Enclosure

1. Name of Product with its quantity.

2. Packing, Storage and Final use of Product.

3. Physical & Chemical properties of Products

4. Name of Raw Material with its quantity.

5. Storage facility of Raw Material

6. Manufacturing Process with Chemical Reactions

7. Mass Balance of the Product

8. Details of water consumption and waste water generation

9. Effluent Treatment Plant Details

10. Effluent Treatment Plant Flow diagram

11. Details of Flue gas emission and process gas emission with APCD system

12. Fuel Details

13. Details of hazardous waste generation with its management.

14. Name & Address of Directors.

15. Land Supporting documents

16. Site Plan & Layout Plan of Unit.

17. Existing Consent Order Copy


Enclosure: 01

Name of product with Qty.

Sr. no.

Name of Product Quantity in MT /M

Existing Proposed Total After product Mix

1 Ketonic Resin 50 250 300

2 M.F.Resin 30 20 50

3 Water Base Adhesive 150 50 200

4 PVB (Poly Vinyl Butryl Resin)

0 50 50

5 Adhesion Promoter TA ‐10 0 20 20

230 390 620


Enclosure: 02

Packing & Final Use of Products

Sr No Name of proposed Product Type of Packing

Final application of product

1 Ketonic Resin 15 Kg Paper bag

Ink, paint & coating industries

2 MF Resin 25 kg Paper bag

3 Water Based Additive 200 kg Drum

4 Poly Vinyl Butyl Resin 10 Kg Paper bag

5 Adhesion Permoter(TA‐10 200 kg HDPE Drum


Enclosure: 03 Physical & Chemical Properties of Products

Sr.

No.

Name of the Products

State Main Properties (refer MSDS)

B.P.

º C

M.P.

º C

Flash

Point

º C

LEL

UEL

%

TLV ppm or

mg/m3

LD50

mg/kg

1 Ketonic Resin Solid NA 95 >149 NA NA NA

2 MF Resin

Powder NA >200 F NA 0.75

ppm

500 mg/Kg

3 Poly Vinyl Butyl Resin

Solid

NA 105‐125

300 F ND NA 10000

mg/kg Rat

4 Water Based Additive

Liquid NA NA >100 C NA NA NA

5 Adhesion Permoter (TA‐10)

Liquid NA NA 30 NA NA NA


Enclosure: 04

Name of Raw Material with its Quantity

Sr. No.

Name of product Capacity TPM

Name of R.M. Raw Material Consumption MT /MT of product

MT per Month

1 Ketonic Resin 250 Cyclohexanone 0.7737 193.425 Formaldehyde 1.1315 282.875 Caustic Soda 0.05 12.5

2 M F Resin 50 Melamine 0.219 10.95 Formaldehyde 0.756 37.8 Butanol 0.405 20.25 Xylene 0.081 4.05

3 Water based additives

200 Butyl acrylate 0.367 73.4 Methyl acrylic acid 0.0128 2.56 Acrylic acid 0.0285 5.7 Vinyl acetate 0.19 38.0 Dibutyl maleate 0.0928 18.56 Additives 0.022 4.4

4 Poly Vinyl Butyrl Resin

50 Poly Vinyl alcohol 0.75 35.0 n‐butryaldehyde 0.4 20.0 Additives 0.08 4.0

5 Adhession Promoter (TA‐10)

20 Acetyl aceton 0.53 10.6 t‐Iso propyl titanate

0.4 8.0

Additives 0.07 1.4


Sr. no. Name of Raw Material Quantity MT /M

1 Cyclohexanone 193.425 2 Formaldehyde 320.675 3 Caustic Soda 12.5 4 Melamine 10.95 5 Butanol 20.25 6 Xylene 4.05 7 Butyl acrylate 73.4 8 Methyl acrylic acid 2.56 9 Acrylic acid 5.7 10 Vinyl acetate 38.0 11 Dibutyl maleate 18.56 12 Additives 9.8 13 Poly Vinyl alcohol 35.0 14 n‐butryaldehyde 20.0 15 Acetyl aceton 10.6 16 t‐Iso propyl titanate 8.0

Total 783.47


Enclosure: 5

Storage Facility of Raw Material

No. Name of Raw Material

Chemical Name Physical Form

Container Type

MOC of container

1. Cyclohexanone Cyclohexanone Liquid Tank SS 304

2. Formaldehyde Formaldehyde Liquid Tank HDPE

3. Caustic soda

Flakes

Sodium Hydroxide solid Bags HDPE

4. Xylene xylene Liquid Tank HDPE

5. Poly vinyl

Alcohol

Ethanolhomo polymer solid Bags HDPE

6. n- Butaldeyade n- Butaldeyade Liquid Tank HDPE

7. Acetyl acetone 2,4-Pentanedione Liquid Tank HDPE

8. t-Iso propyl

titrate

t-Iso propyl titrate

Liquid Tank HDPE

9. Melamine 1,3,5Triazine2,4,6

triamine

solid Bags HDPE

10. Butanol Butanol Liquid Drum HDPE

11. Butyl acrylate Butyl acrylate Liquid Tank HDPE

12. Methyl acrylic acid Methacrylllic Acid Liquid Drum HDPE

13. Acrylic acid Prop-2-enoic acid Liquid Drum HDPE

14. Vinyl acetate Vinyl Acetate Liquid Tank HDPE

15. DIbutyl maleate DIbutyl maleate Liquid Drum HDPE


Sr. No.

Name of Raw Material

Container Type

MOC Container

Physical form Max. Storage Capacity

in MT

At a time storage in MT

1 Cyclohexanone Tank SS 304 Liquid 25 19.5

2 Formaldehyde Tank HDPE Liquid 40 37

3 Caustic Soda Bags HDPE Solid 3 0.5

4 Xylene Tank HDPE Liquid 1 0.2

5 Poly Vinyl Alcohol Bags HDPE Solid 20 10

6 N – Butryaldehyde Tank HDPE Liquid 16 5

7 Acetyl Acetone Tank HDPE Liquid 1 0.2

8 T – Iso propyl titanate

Tank HDPE Liquid 1 0.2

9 Melamine Bags HDPE Solid 5 10

10 Butanol Drum HDPE Liquid 10 10

11 Butyl Acrylate Tank HDPE Liquid 20 20

12 Methyl Acrylic Acid Drum HDPE Liquid 1 5

13 Acrylic Acid Drum HDPE Liquid 5 5

14 Vinyl Acetate Tank HDPE Liquid 20 20

15 Di Butyl Maleate Drum HDPE Liquid 10.0 20.0


Sr. No.

Name of R.M. Place of Its storage State Operating Pressure, Temp.

Possible Type of hazards

Control measures provided

1 Cyclohexanone Storage Tank

SS 304

Norma( Liquid) at RT Flammable Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc. provided.

2 Formaldehyde Storage Tank

HDPE

Normal(Liquid) at RT Skin sensitivity,

Suspected

Carcinogen

Wear gloves,goggles,gas mask, closed system

3 Caustic Soda RM Storage

Yard/bags

Normal(Solid) at RT Skin sensitivity


4 Xylene RM Storage

Yard/Storage tank

Normal (Liquid)

at RT

Flammable Fire existingusher, double Earthing, bonding on flange joint,level indicator, flame proof fitting, water shower etc

5 Poly Vinyl Alcohol RM Storage

Yard/bags

Normal(Solid) at RT None Use Rubber gloves

6 N – Butryaldehyde RM Storage

Yard/Storage tank

Normal (Liquid)

at RT

Flammable Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc

7 Acetyl Acetone RM Storage

Yard/Storage tank

Normal (Liquid)

at RT

None Use Rubber gloves & goggles


8 T – Iso propyl titanate

RM Storage

Yard/Storage tank

Normal (Liquid)

at RT

None Use Rubber gloves & goggles

9 Melamine Bags Normal (Powder)

at RT

Toxic

Nonflammable


10 Butanol Drum Normal (Liquid)

at RT

Flammable Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc

11 Butyl Acrylate Tank Normal (Liquid)

at RT

Flammable

Monomer

Wear gloves,goggles,gas mask ,closed system

12 Methyl Acrylic Acid Drum Normal (Liquid)

at RT

Non

Flammable


13 Acrylic Acid Drum Normal (Liquid)

at RT

Non Flammable


14 Vinyl Acetate Tank Normal (Liquid)

at RT

Flammable

monomer

Fire extinguisher, double earthing , bonding on flange joint, level indicator, flame proof fitting, water shower etc

15 Di Butyl Maleate Drum Normal (Liquid)

at RT

Flammable

monomer

Fire extinguisher, double earthing , bonding on flange joint, level indicator, flame proof fitting, water shower etc


Enclosure: 06 Manufacturing Process with Chemical Reaction

1. KETONIC RESINS:

Charge cyclo hexane none and formaldehyde through measuring tank in a reactor. Then start addition of caustic soda lye and maintain the temperature 70 to 75 0C by jacketed cooling and hold for two hours. After start cooling up to 40 to 450C Temperature and allow to settling down. Discharge bottom layer in another reactor for cooking up to the requirement melting point and upper layer is drain into ETP for Treatment

n

H2 H2

O

O C

C

O

O

+7 CH2O 4 CH2OH

37% FORMALDEHYED 30

CYCLOHEXANE 98

+ 4 H2O MW APP 600-800

KETONIC RESIN STRAIGHT CHAIN


2. POLY VINYL BUTRYL RESIN:

Charge water and PVA in Reactor& prepare solution by stirring.add additives, mix for one hour then start addition of n-butryaldehyde and allow to setting down for two hours, removing upper layer drain to ETP for treatetment.Wash bottom layer with water. Wash water is drain in to ETP. Wet cake is dried & packed.


H

O

+ R’ - OH RC OR

OH

H

+ R’ - OH R C (-OR’) 2+ H2O

H

Aldehyde Alcohol Hemi acetyl Alcohol Acetyl

CH2

C

O

C3H7

O

C C

H

H

CH2 C

H

OH

CH2 C

H

O

CH3

C

O

PV Butryl PV Alcohol

PV Alcohol


3. ADHESION PERMOTER

Charge Acetyl Aceton and TIPT in Reactor, & mixed for one hour and Add additives within three hours time then packed as final product

C3H7OH + C4H10O+ (C3H7O)4 Ti

4. MF RESIN:

Charge melamine& formaldehyde through measuring tank in reactor, mix for 1 hour than start addition of Butanol within water within 3 to 4 hours& maintain the temperature 600C by Jacket cooling& hold for 2hrs after start cooling up to 40 to 45 0C& filter in filter nutch and packed as bye product. After reaction is over, water is removed by dehydration Butanol appears with the product. Very small quantity of xylene is

Recovered by distillation along with Butanol and recycled.

TI(OiC3H7O)4


Stage-1: Mono Urea Formaldehyde

Stage-2: Di urea formaldehyde

Stage-3: Melamine Urea Formaldehyde Glue

O = C NH2

NH2 O = C

NHCH2OH

NHCH2OH + O = C

NHCH2OH

NHCH2NH - C NH2

O

Di urea Formaldehyde

M.W: 162

Mono urea Formaldehyde

M.W: 120

O = C

NH2

NH2

+ HCHO

O = C

NHCH2OH

NH2

O = C

NHCH2OH

NHCH2OH

+ HCHO

Urea

M.W: 60

Formaldehyde

M.W: 30 Urea Formaldehyde

Resin

+ nNH2CONHCO NH2

Melamine M.W: 126.13

NH3

N N

N H3N

NH3

NH2CONHCONH

N N

N HN

NH3

n

+ H2O


5. WATER BASED ADDHETIVES

Charge Butyl Acrylate &Meta Acrylic acid in water for mixing in tank. Start stiring for two hours for proper mixing of monomer. Then charge in a reactor &keep the temperature up to 600 0C by Stem in jacketed then add adhesive& mix for one hours then start addition from mixing up to600c by steam in jacketed then add adhesive& mix for one hours then start addition form mixing vessel by rotameter for three hours after cool down temperature at 4000C&then packed. This is a formulation process, there is no generation of any effluent as water added remain with product.

C C +Additives

O

O O

O

C C

Monomers like

C C

Butyl Acrylate Methyl Acrylic Acid Acrylic acid Vinyl Acetate Di Butyl Maleate

Free radicals of monomers

C C

C C Polymer of monomers


Enclosure: 07

Mass Balance of the Products

1. KETONIC RESIN

REACTOR

CYCLOHEXANONE: 773.7KGS

SLUDGE:19KGS FORMALDEHYDE:1131.5 KGS

CAUSTIC SODA:50KGS

TSDF,Vapi WATER:1354 KGS

COOKING EFFLUENT:2290.2KGS

ETP

BREKING

PACKING IN BAGS

KETONIC RESIN:1000 KGS


2. POLY VINYL BUTYRL RESIN

Upper Layer: 10230 Kgs

Reactor

Poly Vinyl Alcohol: 750kgs

N- ButyrlAldehyed: 400kgs

Water: 10000 Kgs

Additives: 80 Kgs

Settling

ETP

Bottom Layer Wash Water: 16166.66 Kgs

ETP

Drying: 1500kgs

Poly VinyalButyrl Resin: 1000 Kgs

Evaporation Loss: 500kgs

Wash Water: 16166.66 Kgs


3. ADHESION PERMOTER

Acetyl Acetone: 530 Kgs

TIPT: 400 Kgs

Additives: 70 Ks

Reactor

Mixing

Packing in Drums

Adhesion Permoter: 1000 Kgs


4. M.F. RESIN

Melamine: 406 Kgs

Formaldehyde: 1400Kgs

Mixing Tank

1806 Kgs

Jacketed : Heat upto 600C

Packing

M.F. Resin: 1850 Kgs

Butanol: 1250 Kgs

500 Kgs Recyle + 750 Kgs Fresh

Xylene: 150 Kgs

Cooling

DehydrationDistilled water: 856

Liter

Distillation Recovered Xylene with Butanol: 500 Kgs


5. WATER BASED ADDITIVES

Butyl Acrylate: 1103.6 Kgs

Methyl Acrylic Acid: 38.6 Kgs

Water : 857.1 Liter

Mixing Tank

Jacketed: Heat upto 600C

Packing

Water Based Additives: 3000 Kgs

Additive: 66.4 Kgs

Acrylic Acid : 85.7

Vinyl Acetate: 570 Kgs

Dibutyl Maleate: 278.6

Mixing Tank


Enclosure: 08

Water Consumption and Wastewater generation

Calculation of water consumption & Wastewater generation (For Process)

Sr. No.

Product Batch Size in Kgs

Production in MT /M

No. of Batches per Month

Water Consumption Liter /batch

Effluent Generation Liter /Batch

Water Consumption Liter /day

Effluent Generation Liter /day

Process Washing Process Washing Process Washing Process Washing

1 Ketonic Resin 1000 300 300 1354 0 2290 0 16248 0 27480 0

2 Poly Vinyl Butyrl Resin

1000 50 50 10000 16666 10230 16166 20000 33332 20460 33332

3 Adhesion Permoter

1000 20 20 0 0 0 0 0 0 0 0

4 MF Resin 1850 50 27 0 0 856 0 0 0 925 0

5 Water based Additives

3000 200 67 857 0 0 0 2297 0 0 0

Total 38545 33332 48865 33332


Water Consumption In KL /Day

Effluent Generation in KL /Day

Existing Proposed Total After

Expansion

Existing Proposed Total After Expansion

Domestic 2.0 2.0 4.0 1.0 1.0 2.0 Industrial

Process 4.8 67.2 72.0 5.0 77.3 82.3 Washing 21.0 4.0 25.0 21.0 4.0 25.0

Boiler 1.0 3.0 4.0 0.5 0.5 1.0 Cooling 2.0 1.0 3.0 0.5 0.1 0.6

Gardening 1.0 1.0 2.0 0.0 0.0 0.0 Total 31.8 78.2 110.0 28.0 82.9 110.9

1. Domestic effluent is discharged through Septic tank/soak pit. 2. Total 116.0m3/day of water will be used for industrial activity&4.0m3/day of water

used for domestic activity. 3. Boiler condensate shall be recycled as boiler feed water. Softening rejection, boiler

blow down & Steam loss shall be compensating by fresh water. Softening rejection and boiler blow down shall be drain to ETP.

4. Cooling water is recirculated through cooling tower. Cooling tower Blow down and evaporation loss shall be compensated by fresh water. Cooling tower blow down shall be drain to ETP.

5. Floor/container washing shall be drain to ETP. 6. Thus total 118.90m3/Day of industrial effluent will be generated, which will treat in

primary, secondary & tertiary treatment plant& discharge into CETP, Vapi.


Enclosure:09

Details of Existing Effluent Treatment Plant:

Sr.

No. Name of Unit

Capacity

(m3)

Retention Time

(hr)

MOC

1 Oil & Grease trap 2.5 2.29 RCC

2 Collection tank 18 16.48 RCC

3 Neutralization Tank 18 16.48 RCC

4 Flash Mixer / Flocculator Channel 1 -- RCC

5 Lime Slurry Preparation Tank 0.5 -- HDPE

6 FeSO4 Tank 0.2 -- HDPE

7 Poly Electrolyte Tank 0.5 -- HDPE

8 Primary Clarifier 4.5 4.12 MS /EPOXY

9 Aeration tank 60.0 54.96 RCC

10 Diffused Aeration system -- -- HDPE

11 Air Blower 7.5 hp -- CI

12 Secondary Clarifier 15.5 14.20 RCC

13 Filter Pump -- -- CI

14 Sand Filter 3.5 3.20 MS

15 Activated Carbon Filter 3.5 3.20 MS

16 Sludge Drying Bed 8.0 -- Brick

For proposed expansion activity, Effluent Treatment Plant will be modified as per the treatability Study Report.


Enclosure:10

Effluent Treatment Plant Flow diagram:

Collection

Tank

Oil & Grease Tank

Neutralization tank

Sand Filter

Primary clarifier

Aeration Tank

Sludge drying Bed

Activated Carbon

Holding tank

Secondary Clarifier

FeSO4 tank

Poly Electrolyte

Lime slurry

Flash mixer

Effluent


Enclosure:11

Details of Flue Gas Emission &Process Gas Emission with APC system

Type of Flue Gas Emission:‐

No. Stack attached To Stack Height

(Meter)

APC Measures

Pollutants

SPM

Mg/NM3

SO2

ppm

NOX

ppm

1. Thermic fluid

Heater

2 lakh kcal/hr

(Proposed)

11 ‐‐‐

< 150 mg/NM3

< 100 ppm

< 50 ppm

2 Steam boiler

800 kg/hr

(Existing)

11 ‐‐‐

< 150 mg/NM3

< 100 ppm

< 50 ppm

3 D.G. Set

125 KVA

(Proposed)

11 ‐‐‐ ‐‐ < 100 ppm

‐‐

Type of Process Gas Emission:‐ There will be no process emission from our proposed manufacturing activity.


Enclosure:12

Details of Fuels

Sr.No Name of Fuel Total

Existing Proposed Total

1 LDO 200 Liter /Day 800 Liter /Day 1000 Liter /Day

2 HSD 0 20 Lit/hr 20 Lit/hr

3 Natural gas 200 scm /Day 800 scm /Day 800 scm /Day


Enclosure:13

DETAILS OF HAZARDOUS WASTES GENERATION AND ITS MANAGEMENT

No Type of waste Category Quantity

Management

1 ETP Waste, 34.3 7.2 MT /Yr

92.8 MT /Yr

100 MT /Yr

Collection, Storage, Transportation, Disposal to TSDF site

2 Process Waste 0.06 MT /Yr

68.34 MT /Yr

68.4 MT /Yr

Collection, Storage, Transportation, Disposal to CHWIF.

3 Used oil 5.1 25 Liter /Yr

10 Liter /Yr

35 Liter /Yr

Collection, Storage, Transportation, sell to authorize recycler.

4 Discarded Container 33.3 14400 Nos ./Yr

20000 Nos ./Yr

34400 Nos. /Yr

Used for packing of ETP waste or return back to raw material supplier.


Enclosure: 14

Name & Address of Director

Sr .No Name of Proprietor Address 01 Vinaykumar V Oza 102, Anukul Complex, 1st floor,

Koperli Road, Vapi. 02 Ansari Atikur Raheman Vakil

104, Al Husen Palace, Godalnagar, Vapi


Enclosure:15

Land Supporting Document


Enclosure:16

Site Plan & Layout Plan


Enclosure:17

Existing Consent Order Copy

ENCLOSURE: G ADDITIONAL ATTACHEMENTS INDEX FOR...

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