Final Form 1 with ToR 180315 -...

EPSILON CARBON PRIVATE LIMITED

EXPANSION OF COAL TAR PROCESSING UNIT AND ADDITION OF CARBON BLACK

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KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2018 23

3 ANNEXURES

Annexure 1: Production Details

Table 3-1: Production Details for Coal Tar Distillation Section

S. No.

Products Production Capacity in MTPA

Existing Additional Total

Coal tar Distillation Section

Distillation capacity 300,000 TPA 200,000 TPA 500,000 TPA

1 Coal Tar Pitch (Binder Grade) 153000 102000 255000

2 Zero QI/Impregnated Pitch 6000 10000 16000

3 Carbon Black Oil (CBO) 70000 183600 253600

4 Anthracene Oil/Heavy Creosote Oil 42000 57000 99000

5 Wash Oil 25500 16000 41500

6 Naphthalene 18000 17000 35000

7 NSF 33000 0 33000

8 Phenol Oil 6000 8900 14900

9 Light Oil 6000 4000 10000

10 De-hydrated coal tar 291000 192000 483000

11 Phenolics (Phenol, Cresols (ortho, meta, para or mixture thereof), Xylenols)

0 14900 14900

12 Special Graphite/Advanced Graphite 0 10000 10000

By- Product of Coal Tar Distillation Section

1 Neutral Sodium Phenolate (14%) 15300 10200 25500

2 Ammonical water 90 60 150

3 Calcium Carbonate 17340 17340

Sub-Total 665890 36540 1308890

Carbon Black Unit Section

1 Carbon Black 300000 300000

2 Lean Gas/ Tail Gas 270000 Nm3/hr. 270000 Nm3/hr.

Captive Power Plant

1 CPP* 54 MWH 54 MWH

* - Carbon Black - Based on commercial viability, lean gas generated during carbon black process will be either sold to nearby industries or may be converted to power using a captive power plant



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Annexure 2: Environmental Clearance of Epsilon Carbon Pvt. Ltd.



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Annexure 3: Copy of Existing CTO



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Annexure 4: Site Location Map



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Site Location Map on Google

Table 3-2: Co-ordinates of the Project Site (additional plot)

Point Latitude - Longitude

600 15° 10” 02.9’ N 76° 42” 43.8’ E

601 15° 10” 15.0’ N 76° 42” 50.9’ E

602 15° 10” 06.9’ N 76° 42” 36.7’ E

603 15° 10” 11.3’ N 76° 42” 36.2’ E

604 15° 10” 15.9’ N 76° 42” 32.5’ E

605 15° 10” 32.4’ N 76° 42” 42.5’ E

EPSILON CARBON PRIVATE LIMITED EXPANSION OF COAL TAR PROCESSING UNIT AND ADDITION OF CARBON BLACK PLANT FORM I


Annexure 5: Site Layout Map



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Area Break up at Site

S. No.

Title Area, m2 % of total

Area Existing Additional Total

1 Processing Area 36561 72417 108979 27.0

2 Storage Area

a Hazardous Chemicals 2789 8160 10950 2.7

b Other Non-hazardous chemicals 12417 13917 26335 6.5

c Hazardous Waste 0 2500 2500 0.6

d Water Storage 765 4765 5530 1.4

e Fuel Storage 0 1500 1500 0.4

3 Effluent Treatment Plant 4200 8200 12400 3.1

4 Boiler 1800 13800 15600 3.9

5 Cooling tower 1050 9050 10100 2.5

6 DG Sets 0 3000 3000 0.7

7 Roads+ walkways 22000 23000 45000 11.2

8 Administrative Building/ Laboratory

1200 2000 3200 0.8

9 Open Space 7400 12000 19400 4.8

10 Greenbelt Area 49118 73000 135000 33.5

11 Other utility areas 898 2800 3698 0.9

Total 140200 250110 403191 100.0

The proposed land will be leased/ transferred through outright sale agreement from JSW to Epsilon Carbon Private Limited.



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Annexure 6: Manufacturing Processes

1. Coal Tar Distillation Process

The various components present in the coal tar are separated by distillation process. Coal tar will be received at plant by road tankers or by means of direct pipeline which will be unloaded in unloading tanks. Coal tar from unloading tanks will be pumped to storage tanks using pumps. The preheated coal tar will then be fed to distillation system in which various fractions will be separated depending on product mix. Process and operating steps of the plant starting from receipt of raw materials to dispatch of products are briefly described below. Process flow is shown diagrammatically in Fig below.

Figure 1: Flow diagram of Coal Tar Distillation

2. Coal Tar Pitch Production

For production of Coal Tar Pitch (Binder Grade), first soft pitch is generated by removal of moisture, Light Oil, Phenol oil, Anthracene oil & three mixed oils in Dehydration & Pitch column respectively. The produced soft pitch will be converted into modified pitch in modified pitch section which also can be sell as product. Coal tar will be heated by means of Mixed Gas as a heating source. Additional High QI pitch will be blended with modified pitch for as to produce Binder pitch.

A pitch melting system will be used for melting of High QI pitch. In pitch melting system High QI pitch is crushed to reduce size in roller crusher. Crushed high QI pitch will be charged to pitch melter using conveyor assembly. The pitch melter will take approximately 12 hours to melt the pitch. The molten High QI pitch will be blended with modified pitch to produce binder pitch.

3. Zero QI/ Impregnated Production

The process comprises of blending of coal tar and creosote oil in specific ratio and raising the temperature of the mixture in preheating-distillation kettle for removal of moisture as well as improved blending of Coal Tar and Creosote Oil. The Preheating Process for each batch requires around 14 to 18 hours of time. The dehydrated mixture is transferred to Settling tank provided with draw-off valves atdifferent levels. The settling time depends on the QI value of coal tar; however the required residence time in Settler varies from 72 to 84 hours. The QI value of material in settling tank has increasing profile from top to bottom of



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the tank. The upper layer material of the settling tank at the height of about 1.5 meter to 2.5 meter has the QI value at around 0.10% which is drawn and transferred to Process distillation kettle. The residual material having higher QI is used in Coal Tar Pitch (Binder Grade) process circuit. The temperature in Process Distillation kettle is raised and maintained for about30 to 32 hours. The Creosote oil collected from the top of Process Distill is transferred to Oil receivers and Zero QI / Impregnated Pitch drawn from the bottom of Process Distill is transferred through Cooler for reducing temperature of material to around 260°C. The material thus produced is either loaded in the tanker at 260°C in liquid form for dispatch to desired destination or transferred to granulating unit for cutting into required sizes.

4. Carbon Black Oil (CBO) Production

For the production of Carbon Black Oil, soft pitch will be blended with Anthracene Oil produced in distillation process in specific proportion to meet product specification.

5. Refined Naphthalene Production

Vapors containing crude naphthalene oil generated in distillation process will be continuously cooled in condensers and collected by gravity into the receivers. The collected and cooled mixture will be transferred refined naphthalene section. In refined naphthalene section crude naphthalene will be enriched and purified using crystallizer. The refined naphthalene will be solidified using flakers. Residual naphthalene will be collected and pumped to NSF unit.

6. Naphthalene Sulfonate Formaldehyde (NSF) Production

The naphthalene oil produced from Industrial Naphthalene Section or the residual naphthalene oil generated in refined naphthalene section which is treated with sulphuric acid (Sulfonation Reaction), followed by formaldehyde (Condensation) and further neutralized by sodium hydroxide to produce Naphthalene Sulfonate Formaldehyde.

7. Oils - Light oil, Phenol oil & Anthracene oil

Tar is pumped through preheter and fed to dehydration column in which azeotropic distillation takes to remove light oil and moisture content in the tar from the top of column. Light oil and moisture is further separated in separator to obtain pure light oil. Dehydrated tar from the bottom dehydration column is pumped to pitch column. The overhead vapor from pitch column flow to the distillation column in which they are separated the top fraction contains phenol oil, the middle fraction contains Naphthalene oil along with phenols and washes oil & the bottom product contains Anthracene oil.

8. Phenol purification

Phenol oil from C3/C4 top and sodium hydroxide is charged in agitated vessel in calculated proportions

Sodium phenolate formed from phenol oil along with sodium phenolate from washing section can be processed using steam blowing. The steam blowing is carried out in order to increase the concentration of sodium phenolate from 18% to 22% and reduce neutral oil content in sodium phenolate from 2 -3 % to 0.5%.

The concentrated 22% sodium phenolate is reacted with CO2 gas in packed column to form crude phenol.

The purity of crude phenol is 83%. The remaining component is water which cannot be separated by decantation. Water can be removed by evaporation. The further separation of components is carried out by distillation

Table 3-3: Material Balance of Coal Tar Distillation Pitch Mode

S. No.

Input/MT of Product

Raw Materials Quantity (MT/MT)

1 Coal Tar 1.0



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S. No.

Input/MT of Product


2 High QI Pitch 0.13

Total 1.13

S. No.

Output MT/MT of Product

Remark Product

Liquid Effluent

Air Emission

Recovery/ Product

Solid Waste

1 Pitch 0.59

2 Light Oil 0.02

3 Phenol Oil 0.04

4 Naphthalene 0.08

5 Anthracene Oil 0.29

6 Wash Oil 0.08

7 Moisture + Loss 0.03 Treated in the ETP

Total 0.03 1.10

1.13

Table 3-4: Material Balance of Coal Tar Distillation CBO Mode

S. No.

Input/MT of Product


1 Coal Tar 1

2 Coal Tar (direct blending) 0.093

Total 1.093

S. No.


Remark Product Liquid Effluent

Air Emission

Recovery/ Product

Solid Waste

1 CBO 0.918

2 Light Oil 0.020

3 Phenol Oil 0.040

4 Naphthalene 0.085

5 Moisture + Loss 0.03 Treated in the ETP

Total 0.03 1.063

1.093

9. Carbon Black Process

Heavy aromatic oils of petroleum oil refinery or coal tar distillation units are used as main feedstock. The furnace is basically a specially designed refractory lined horizontal steel vessel having different segments like combustion zone, venture zone, reaction zone, quench zone & evaporation cum conveying sections.

Combustion zone or hot flue gas generating section:

Secondary feed stock e.g., natural gas or fuel oil or sometimes the main feed stock in proper ratio with preheated air is introduced in this section to produce hot gas. Adiabatic flame Temperature is maintained nearly 1900°C-2000°C.

Venture section:

Preheated main feed stock (aromatic oil) is introduced in atomized form under controlled conditions on the hot gas where liquid oil vaporizes. Velocity of gas stream maintained ~ 2000 FPM.



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Reaction section:

Pyrolysis of oil takes place in the vapour phase to form microscopic carbon particles. The basic reaction is dehydrogenation.

Quench zone:

The reaction rate is controlled by using water sprays.

Evaporation cum conveying sections:

Water vaporizes in this zone. After all, carbon particles along with combustion gas convey to the next downstream equipment.

Furnace black process consists of several downstream sections after reactor e.g., Heat recovery sections, filtration sections, conveying section, beading & drying sections and finished product transportation &storage, ware housing, pulling &dispatch section. The process which is selected for this project is illustrated bellow.

Heat recovery sections:

Hot reactor combustion gas along with carbon black particles are cooled down by air. Preheated air is used in combustion section of reactor. Relatively cooled combustion gas along with carbon black again passes through oil preheat to preheat main feed stock. After passing through oil preheater, the combustion gas has sufficient sensible heat. In most of the energy efficient carbon black plants have in line sensible heat recovery (waste heat recovery) boilers. Saturated Steam is generated from waste heat recovery boilers which are used for steam tracing, & other equipment heating purposes.

High filtration efficiency pulsejet bag filter modules (main filter) will be used for filtering carbon black from carbon black laden gas (process gas). A specially designed agglomerator unit will be installed before bag house to agglomerate carbon black particles. This agglomerator unit will not only enhance filtration efficiency, it will also enhance life of the filter cloth. Agglomerated carbon black particles will be deposited on the outer surface of the cloth and compressed air pulse will release carbon black particles from bags. A sequential timer will be used in pulsing system. Gas will pass through bags and finally it will be passed through a common header which is connected to other downstream unit e.g., dryer combustor etc. Carbon black dislodge from the bags will be collected in hopper. Accumulated carbon black powder will be transported to the conveying system via rotary air locks.

Conveying system:

It consists of drop box of rotary air locks, suction conveying ducts, conveying fans, conveying fan discharge ducts, conveying bag filter, conveying bag filter vent scrubber & a surge tank at the bottom of conveying bag house. All the rotary air locks placed at the bottom of main bag filter modules will be discharging carbon black particles to a common duct which is connected with a pneumatic conveying fan. In this process, air will be used for conveying carbon black. All carbon black particles from the rotary air locks discharge will be picked up by air and conveyed to another bag filter called conveying bag filter by conveying fans. Air from the bag filter can be vented to atmosphere after passing through venture scrubber. Carbon black collected from bag filter will be stored in surge tank to remove adsorbed air from carbon black.

Beading & drying system:

The beading & drying system consists of pelletizer, polisher, rotary dryer with insulated jacket and combustor as hot gas generator and purge gas filter. Fluffy carbon black, water and molasses solution (used as binder) mixed in pelletizer to form beads. Polishers are also used for making uniform diameter beads or pellets. This polisher also helps to reduce fines in carbon black. After polishing the pellets, the wet pellets pass through indirect heating rotary dryer to remove water from pellets. Hot gas required for drying



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is generated in refractory lined combustor. Process combustion gas from main bag filter is used as fuel in combustor. Vapour generated inside dryer along with fines is sucked by purge gas fan and filter through purge gas filter. Carbon black from purge gas filter is connected in main conveying line and vapour is vented to atmosphere after passing through venture scrubber.

Product transportation & storage:

This section consists of elevator, screw conveyors magnetic separator, rotary screen, storage silos, off spec silo & de dusting bag house. Dried carbon black is transported to final storage silos by above mentioned material handling equipment.

Warehouse, Packaging & Dispatch section:

Depending on customer requirement, the granular carbon black is packed in 25 kg paper bag or in 1 MT PP jumbo bulk bags.



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Figure 2: Flow diagram of the Carbon Black Manufacturing Process



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Table 3-5: Material Balance of Carbon Black

S. No.

Input/MT of Product


1 CBFS/Coal Tar/Coal Tar Based feedstock and/or Blend 1.0000

2 Fuel Oil/Heavy Oil/CBFS for firing 0.0755

3 Molasses 0.0028

4 Potassium Nitrate 0.0001

5 Water 1.2796

Total 2.3580

S. No.


Remark Product Liquid Effluent Air Emission

Recovery/ Product

Solid Waste

1 Carbon Black 0.6122

2 Lean gas 1.7457

Total 2.3580

2.3580



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10. Co-generation Power plant

A co-generation power plant may be installed vase on lean tail gas generated by power plant

Figure 3: Flow diagram of Captive Power Plant

EPSILON CARBON PRIVATE LIMITED EXPANSION OF COAL TAR PROCESSING UNIT AND ADDITION OF

CARBON BLACK PLANT FORM I


Annexure 7: Raw Material & Product Storage Details

Table 3-6: Existing Storage Details of Raw Material and Products

S. No.

Chemical State Means of Storage

Capacity of Storage Means

No. of Storage means

Total Capacity

Safety Measures Pressure Temp (°C)

Dyke Dimension (mxm)

Existing : Raw Material

1 Coal Tar Liquid Tanks 2500 3 7500 Fire Hydrant point, Dyke wall Atm. 90 103x80

2 High QI Pitch Solid Jumbo Bags/ Warehouse

1 2000 2000 Sprinkler system Atm. Amb.

3 Sodium Hydroxide Liquid Tanks 50 2 100 Fire Hydrant point, Dyke wall Atm. 50 103x80

4 Sulfuric Acid (98%) Liquid Tanks 230 1 230 Fire Hydrant point, Dyke wall Atm. Amb. 25 x 51

5 Formaldehyde (37%) Liquid Tanks 230 1 230 Fire Hydrant point, Dyke wall Atm. Amb. 25 x 51

6 Crude Benzene Liquid Tanks 50 1 50 Sprinkler system, Fire Hydrant point, Dyke wall

Atm. Amb. 23x 25

7 Sodium Chloride Solid 50 Kg bags / Warehouse

0.05 80 4 NA Atm. Amb.

Existing : Products

1 Coal Tar Pitch (Binder Grade)

Solid Jumbo Bags / Warehouse


2 Zero QI/Impregnated Pitch



3 Carbon Black Oil (CBO) Liquid Tanks 1400 2 2800 Fire Hydrant point, Dyke wall Atm. 90 103x80

4 Anthracene Oil/Heavy Creosote Oil

Liquid Tanks 1400 1 1400 Fire Hydrant point, Dyke wall Atm. 90 103x80

5 Wash Oil Liquid Tanks 1400 1 1400 Fire Hydrant point, Dyke wall Atm. 90 103x80

6 Naphthalene Solid 50 Kg bags / Warehouse

0.05 10000 500 Foam sprinkler system, Fire proof wall

Atm. Amb.

7 Napthalene Liquid Tanks 50 1 50 Fire Hydrant point, Dyke wall Atm. 90 52 x 15

8 NSF Liquid Tanks 120 3 360 Fire Hydrant point, Dyke wall Atm. 90 25 x 51

9 Phenol Oil Liquid Tanks 140 1 140 Fire Hydrant point, Dyke wall Atm. Amb. 103x80




S. No.




Total Capacity

Safety Measures Pressure Temp (°C)


10 Light Oil Liquid Tanks 100 2 200 Sprinkler system, Fire Hydrant point, Dyke wall

Atm. Amb. 18x10

11 De-hydrated coal tar Liquid Tanks 1400 2 2800 Fire Hydrant point, Dyke wall Atm. Amb. 103x80

Table 3-7: ProposedStorage Details of Raw Material and Products

S. No.




Total Capacity

Safety Measures Pressure Temp°C


Additional : Raw Material from Coaltar distillation

1 Coal Tar Liquid Tanks 2500 3 7500 Fire Hydrant point, Dyke wall Atm. 90 103x80

2 High QI Pitch Solid Jumbo Bags/ Warehouse


3 Sodium Hydroxide Liquid Tanks 50 2 100 Fire Hydrant point, Dyke wall Atm. Amb. 103x80

4 Crude Benzene Liquid Tanks 50 1 50 Sprinkler system, Fire Hydrant point, Dyke wall

Atm. Amb. 23x 25

5 Sodium Chloride Solid 50 Kg bags / Warehouse

0.05 80 4 NA Atm. Amb.

6 Lime Solid 50 Kg bags / Warehouse

0.05 5000 250 NA Atm. Amb.

7 Carbon Dioxide Gas / compressed liquid

Tank/ Gas pipeline

Fire Hydrant point, Dyke wall

Cryogenic < -10

Raw Material : Carbon Black Plant

1 CBFS/Coal Tar/Coal Tar Based feedstock and/or Blend


2 Fuel Oil/Heavy Oil/CBFS for firing


3 Molasses Liquid Tanks 100 1 100 Fire Hydrant point, Dyke wall Atm. 50 59x118

4 Potassium Nitrate Solid 50 Kg bags / 0.05 100 5 Atm. Amb.




S. No.




Total Capacity



Warehouse

5 Sodium Hydroxide - DM Plant

Liquid Tanks 17 1 17 Fire Hydrant point, Dyke wall Atm. Amb. 59x118

6 Hydrochloric Acid Liquid Tanks 40 1 40 Fire Hydrant point, Dyke wall Atm. Amb. 59x118

7 Trisodim Phosphate Solid 50 Kg bags / Warehouse

0.05 20 1 Atm. Amb.

8 Alum Solid 50 Kg bags / Warehouse

0.05 25 1.25 Atm. Amb.

Additional : Products from 300000 TPA to 500000TPA

1 Coal Tar Pitch (Binder Grade)



2 Zero QI/Impregnated Pitch



3 Carbon Black Oil (CBO) Liquid Tanks 1400 2 2800 Fire Hydrant point, Dyke wall Atm. 90 103x80

4 Anthracene Oil/Heavy Creosote Oil


5 Wash Oil Liquid Tanks 1400 1 1400 Fire Hydrant point, Dyke wall Atm. 90 103x80

6 Naphthalene Solid / Liquid

50 Kg bags / Warehouse

0.05 10000 500 Foam sprinkler system, Fire proof wall

Atm. Amb.

7 Napthalene Liquid Tanks 50 1 50 Fire Hydrant point, Dyke wall Atm. 90 52 x 15

8 Phenol Oil Liquid Tanks 140 1 140 Fire Hydrant point, Dyke wall Atm. Amb. 103x80

9 Light Oil Liquid Tanks 100 2 200 Sprinkler system, Fire Hydrant point, Dyke wall

Atm. Amb. 18x10

10 De-hydrated coal tar Liquid Tanks 1400 2 2800 Fire Hydrant point, Dyke wall Atm. 90 103x80

11

Phenolics ( Phenol, Cresols (ortho, meta, para or mixture thereof), Xylenols)

Liquid Tanks 50 5 250 Fire Hydrant point, Dyke wall Atm. >90 50x15




S. No.




Total Capacity



12 Special Graphite/Advanced Graphite



Products: Carbon Black Plant

1 Carbon Black Solid

Silo 150 26 3900 Atm. Amb.

Jumbo Bags Warehouse

3500 1 3500

Atm. Amb.



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Annexure 8: Water Details

Water is sourced from JSW Steel water network and after expansion it will be obtained from the same. Existing water consumption is 1440 KLD (1416 KLD Industrial + 24 KLD Domestic). After proposed expansion water consumption will be 10200 KLD (9880 KLD Industrial + 140 KLD Domestic). Detail of water consumption is given as below;

Table 3-8: Details of Water Consumption

S. No. Area of Consumption Water Consumption in KLD

Existing Proposed Total

1 Processing 0 3900 3900

2 Make up water WTP (DM/Regeneration / Softener, RO) 0 400 400

3 Washing (DMF, Reactor and Floor) - Misc. 24 66 90

4 Boiler 216 494 710

5 Cooling Tower 1152 3388 4540

6 Gardening 24 216 240

7 Domestic 24 116 140

Total 1440 8580 10020

Existing wastewater generation is 96 KLD (84 KLD Industrial + 12 KLD Domestic). After proposed expansion wastewater generation will be 895 KLD (815 KLD Industrial + 70 KLD Domestic). Industrial wastewater will be treated in 1000 KLD ETP and domestic wastewater will be treated in 75 KLD STP after proposed expansion.

Table 3-9: Details of Wastewater Generation

S. No. Area of Consumption Wastewater Generation in KLD

Remark Existing Proposed Total

1 Processing 36 24 60 Existing ETP/ZLD : 180 KLD

Proposed ETP/ZLD: 820 KLD ETP followed by MEE and ATFD

Recycled water would be used for Drying/ Quenching process in Carbon Black Section

2 Make up water WTP (DM/Regeneration / Softener, RO)

0 400 400

3 Washing (DMF, Reactor and Floor) - Misc.

12 58 70

4 Boiler 36 24 60

5 Cooling Tower 0 235 235

6 Gardening 0 0 0

7 Domestic 12 58 70

Existing STP: 25 KLD Proposed STP: 50 KLD

Treated sewage will be

used for gardening

Total 96 799 895



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Annexure 9: Details of Wastewater Treatment Plant

Effluent zero discharge concept will be adopted for the proposed plant. Thewastewater arising from the plant will be treated in effluent treatment plant/ZLD Plant and willbe re-utilized for the plant purposes. No effluent discharge is envisaged due torecycling into the plant operation. Hence, there will be no impact on the waterregime due to the effluents from the proposed expansion.

Existing Wastewater Treatment Plant (Existing Coal tar Distillation)

Process Description

Wastewater treatment consists of Biochemical treatment followed by Biological treatment. Details are given below:

Biochemical treatment

Pre-treatment - Wastewater of each section to be treated will be sent to the gravity-degreasing tank, and then the wastewater from which the heavy oil has removed flows automatically into the air flotation machine for air flotation treatment, where most of oil and SS will be removed. Later on, wastewater will enter the wastewater intermediate tank, and delivered into the extraction system via wastewater intermediate pump. The heavy oil and the light oil that have been removed will be transferred to the tar crude tar tank periodically by the residual oil pump.

Solvent extraction - The extraction system is comprised of the high efficiency two stage extracting tower in series. Phenol containing waste water enters the middle section of extracting tower. Extracting agent will be delivered by the extracting agent pump to the lower section of extracting tower, where a counter-current extraction is made by combing the phenol containing wastewater of the tower, and then phases are separated in both the top and the bottom of tower. The extract phase containing extracting agent and phenol at the top enter the extract phase intermediate tank, while the remaining extract phases at the bottom enter into the intermediate tank of remaining extract phases.Extract phases are delivered by the extract phase delivery pump to the reverse extraction system comprising of the high efficiency two-stage centrifugal type extractor in series. Sodium phenoate comes from the reaction of phenol and sodium hydrate. After centrifugal separation, extracting agents enter the regeneration solvent intermediate tank to be used as raw materials of extraction. Sodium phenolate will be delivered to the large tank of sodium phenolate at oil depot

Distillation process:Remaining extract phases are transferred by the remaining extract phase delivery pump to the heat exchanger of ammonia distillation wastewater /remaining extract phases. After heat exchange with the ammonia distillation wastewater, they enter ammonia distillation at the top of ammonia distillation tower. ammonia distillation wastewater discharged from the bottom of tower with ammonia content less than100mg/L are transferred by the pump at the bottom of ammonia distillation tower to the heat exchanger of ammonia distillation wastewater /remaining extract phases, and after heat exchange with remaining extract phases and cooled again in the cooler, they are delivered to the biological treatment system.For ammonia gas at the top of tower, after parts of them are condensate by the ammonia gas dephlegmator, the liquid phase flow into the stronger ammonia water tank.



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Biological Section

The section includes following sequence of operation:

Pre-aeration treatment

Anaerobic treatment

Aerobic treatment

Sedimentation treatment

Coagulation treatment

Flocculation treatment

Ceramic filtration treatment

Ozone reaction treatment

The tar wastewater after pre-chemical treatment is delivered to the regulation pond via the wastewater delivery line. Accident wastewater enters the emergency pond. In accordance with actual facts, wastewater in the emergency pond shall be pumped up to the regulating pond by the accident wastewater regulating pump. The wastewater that fulfilled their homogenization in the regulating pond is sent to the pre-aeration tank by the charging pump of pre-aeration tank.

Anaerobic Process: The wastewater after aeration treatment of the pre-aeration tank flows into the anaerobic A/B pond. The anaerobic A/B pond, a hydrolysis reaction and a de-nitrification reaction happen. The anaerobic A/B pond is equipped with hydraulic power agitators which are used to ensure sufficient mixing of mud water. The dissolved oxygen in the anaerobic A/B pond is limited at about 0.5mg/L.

Aerobic Process: The wastewater after A/B reaction in the anaerobic pond overflows into the aerobic 1 A/B pond Nitrifying reaction and some of carbonizing reaction are performed under the effect of nitrifying bacteria and carbonizing bacteria. Besides, the outlet water supernatant in the aerobic 2A/B pond turns back to the anaerobic A/B pond for de-nitrification reaction by the nitrifying liquid reflux pump. Because alkalinity will be consumed in nitrifying reaction of the aerobic pond and the aerobic pond, the alkali liquor dosing equipment’s used to provide alkalinity by extracting alkali liquor from the alkali liquor tank. Both



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aerobic 1A/B pond and aerobic 2A/B pond are equipped with aeration pipe, and the air is supplied to the aeration pipe by the fan.

Sedimentation Process: Outlet water of aerobic 2A/B pond flows automatically into the sedimentation pond, where the biomass separation is finished. The sludge is delivered to the anaerobic pond and the aerobic pond by sludge reflux pump and then flows back to each anaerobic pond and the aerobic pond. Moreover, remaining sludge shall be pumped periodically to the sludge condensate pond. The sludge from condensate pond feed to pressure filter for dewatering. The supernatant flows automatically into coagulation reaction and meanwhile the flocculent enters the coagulation reaction unit via PAC dosing equipment and PAM dosing equipment, where the coagulation reaction happens by the effect of agitator.The outlet water of coagulation reaction unit flows automatically into the flocculation sedimentation pond, where the biomass separation is finished. The sludge is pumped periodically to the sludge condensate pond by the flocculation sludge pump. The supernatant flows automatically into ceramic filter suction pond.

Ceramic Filter and Ozone reaction Process: The wastewater in the ceramic filter suction pond is pumped up to the ceramic filter where suspended solids are absorbed and removed by the ceramic filter, and the ceramic filter reaction unit is washed reversely by ceramic filter backwash pump periodically. The outlet water of ceramic filter reaction unit flows automatically into the ozone reaction pond. Under the effect of ozone reaction, residual organic substance and chromaticity are removed. The sludge at the sludge concentration pond is pumped periodically up to the sludge dewatering unit by the mud delivery pump so as to finish the treatment of sludge. Purified water in the waste water plant will be recycling back in the process to attain Zero discharge



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ProposedWastewater Treatment Plant(Coal tar Distillation Expansion)

A similar set up comprising of biochemical and biological treatment would be installed to process effluent generated by expansion of coal tar distillation complex from 300,000 TPA to 500,000 TPA

ProposedWastewater Treatment Plant(Carbon Black Section)

This plant is designed with the most advanced techniques to optimize the water consumption. Zero liquid discharge facility is proposed to meet the desired norms.

Water treatment facility:

Raw water is received in raw water storage tank. Raw water from storage will be filtered in dual media filtration unit. Filtered water is treated in RO unit to produce desired quality water. Multiple RO stages in series are used to minimize overall water consumption of the plant. Treated water from RO is mainly utilized for process uses. Part of treated water from RO is demineralized in DM Water Plant for steam generation system make-up.

Effluent treatment facility:

Effluents generated in carbon black plant are treated as below:

1. Effluents generatedDuring floor wash: Floor wash water containing carbon black particles and free oil is treated in existing facility consist of oil skimmer, settling tanks, pressure sand filter to remove free oil content and suspended solid. Treated water is recycled back for floor washing.

2. Effluents generated From RO and DM Plant:

Collection Tank - The effluent from all sections might arrive with varying frequency carrying an unsteady load at all times. In order to stabilize the flow and to maintain a constant pollutant load, the treatment scheme consists of collection tank. Effluent from RO and DM plant with high TDS content is treated in multi-effect evaporator (MEE). The effluent is send to balance tank. Feed pump will transfer the effluent from the balance tank to multi effect evaporation system where the concentration of effluent increases to >+ 35% TDS by evaporation. The concentrated effluent from this system will be taken in to Agitated Thin Film Dryer (ATFD) to recover salt.In ATFD, the effluent will get concentrated to more than 90% TDS by evaporation. Outlet mix salt coming from ATFD will be sent to CHWTDSF. Treated water from MEE is sent back for process use while sludge generated (Containing salts) is sent for disposal. Water uses are optimized by using air cooling wherever possible to reduce water consumption (Make-up) for cooling, hence reduced effluent discharge.

Sewage Treatment Plant

Process Description

Domestic Effluent from various sources in the plant are collected in tanker and Unloading in equalization tank (Collection Tank). In Equalization tank retention time provided for homogeneous feed for MBBR (Moving Bed Bio reactor). Equalization tank material feed to MBBR for aerobic reaction for reduction of COD and BOD.The overflow of MBBR is collected in secondary settling tank where the bio mass solid are settled by sedimentation.

The sludge from bottom of MBBR and Secondary settling tank is collected in sludge collection tank and feed to filter press for removal of solid sludge. Solid sludge used for gardening and Filterpress water recycle by equalization tank.)



PLANT FORM I


The overflow of secondary settling tank collected in pre- filtration tank and feed to the Pressure sand filter followed by activated carbon filter. After ACF all water collated in Collection tank and reuse for gardening purpose.

Flow diagram

Proposed STP

A similar STP set up would be installed to domestic effluent generated by expansion of coal tar distillation complex from 300,000 TPA to 500,000 TPA and 300,000 TPA Carbon black unit.



PLANT FORM I


Annexure 10: Fuel Consumption

S. No. Stack attached to Capacity(Unit) Fuel Type Consumption in Gcal /hr.

EC & CTO Received for

1 Coal Tar Tube furnace-1 38.5LKcal Mixed Gas 3.85

3 Naphthalene Tube Furnace-1 15LKcal Mixed Gas 1.5

5 Modified Pitch Furnace 10 LKcal Mixed Gas 1

6 Boiler 15TPH Mixed Gas 9.95

8 Thermic Fluid Heater-1 20 LKcal Mixed Gas 2

9 Thermic Fluid Heater-1 5 LKcal Mixed Gas 0.5

EC Received for

10 Coal Tar Tube furnace-2 38.5LKcal 2.5 Mixed Gas 2.5


12 Boiler-Stand By 15TPH Coal/Mixed Gas 5.38

13 Thermic Fluid Heater-3 20 LKcal Mixed Gas 0.5

Proposed

1 Coal Tar Tube furnace-1 38.5LKcal Mixed Gas 3.85


3 Modified Pitch Furnace 10 LKcal Mixed Gas 1

4 Boiler 15TPH Mixed Gas 9.95




8 Boilers - 3Nos 70 TPH/90 TPH

Tail Gas from CB Unit 180

9 DG Set stand by

Mixed Gas/Fuel oil -

10 Dryer stack - 3 Nos for 6 dryers

180 TPD/250 TPD

Tail Gas from CB Unit 40

11 Flare Stack Used only in case of CPP breakdown

Tail Gas from CB Unit -



PLANT FORM I


Annexure 11: Hazardous Waste Generation

S.

No. Type of Waste

Hazardous Waste Category

Tonner per annum Source Treatment / Disposal

Existing Proposed Total

1 Residual Oil 5.2 1.2 0.8 2 Process/ETP Sell to Reprocessor

2 Spent Oil 5.1 0.12 3 3.12 Process Sell to Reprocessor

3 Oil Sludge 5.1 0.12 0.08 0.2 Process Sell to Reprocessor / CHWTDSF

4 Sludge/salt from ETP/ZLD 33.2 297 698 995 ETP / ZLD CHWTDSF

6 Oily Cotton Waste 33.2 0 2 2 Cleaning Sell to Reprocessor / CHWTDSF

7 Discarded Container & Barrel 33.1 0 25 25 Various Packing material Sell to Reprocessor

8 Plastic Waste 0 0.5 0.5 Various Packing material Sent to Approved recycler

9 Oily Cotton Waste/Leather HandGloves / CottonHand Gloves

33.2 0 0.5 0.5 Process CHWTDSF

10 Waste InsulationMaterial

0 2 2 From Plant Maint. CHWTDSF



PLANT FORM I


Annexure 12: Stack Details

Flue Gas Stacks

S. No.

Stack attached to

Capacity (Unit)

Fuel Type

Consumption in Gcal/Hr

Height (m)

Diameter (mm)

APCM attached

Pollutants to be emitted


1 Coal Tar Tube furnace-1

38.5 Lakh Kcal

Mixed Gas

3.85 35 1500

Adequate Stack height / Regular interval monitoring by approved agency

PM, SOx, Nox

3 Naphthalene Tube Furnace-1

15 Lakh Kcal

Mixed Gas

1.5 35 1100 PM, SOx, Nox

5 Modified Pitch Furnace

10 Lakh Kcal

Mixed Gas

1 30 900 PM, SOx, Nox

6 Boiler 15Tonnes per Hr

Mixed Gas

9.95 48 650 PM, SOx, Nox

8 Thermic Fluid Heater-1

20 Lakh Kcal

Mixed Gas

2

35 550

PM, SOx, Nox


5 Lakh Kcal

Mixed Gas

0.5 PM, SOx, Nox


25 Lakh Kcal

Mixed Gas

2.5 35 1500 PM, SOx, Nox


15 Lakh Kcal

Mixed Gas

1.5 35 1100 PM, SOx, Nox

12 Boiler-Stand By 8 Tonnes per Hr

Coal/ Mixed Gas

5.38 48 650 PM, SOx, Nox


5 Lakh Kcal

Mixed Gas

0.5 35 550

Proposed


38.5 Lakh Kcal

Mixed Gas

3.85 35 1500

Adequate Stack height / Regular interval monitoring by approved agency

PM, SOx, Nox


15 Lakh Kcal

Mixed Gas

1.5 35 1100 PM, SOx, Nox

3 Modified Pitch Furnace

10 Lakh Kcal

Mixed Gas

1 30 900 PM, SOx, Nox

4 Boiler 15Tonnes per Hr

Mixed Gas

9.95 48 650 PM, SOx, Nox


20 Lakh Kcal

Mixed Gas

2 35 550 PM, SOx, Nox


20 Lakh Kcal

Mixed Gas

2 35 550 PM, SOx, Nox

7 Boiler Stack - 3Nos

70, 90, 90 TPH

Mixed Gas/ Tail Gas from CB Unit

62000 for 70 TPH and 80,000 for 90 TPH

100 - PM, SOx, Nox



PLANT FORM I


S. No.

Stack attached to

Capacity (Unit)

Fuel Type

Consumption in Gcal/Hr

Height (m)

Diameter (mm)

APCM attached

Pollutants to be emitted

8 DG Set stand by -


As per requirement

35 - Adequate Stack height / Regular interval monitoring by approved agency

PM, SOx, Nox

9 Dryer Stack - 3 Nos

180/250 TPD


16000 each 60 - PM, SOx, Nox

10 Flare stack

Only to be used in case of CPP breakdown for a brief period of time

Tail Gas from CB Unit

-

Process Vents

S. No

Stack attached to No of Vents

Height (m)

Pollutants as per CTO

Air Pollution Control Measures Attached


1 Scrubber Vent -1 1 23 VOC Scrubber system(Using Wash Oil)

2 Scrubber Vent - 2 1 23 VOC Scrubber system(Using Wash Oil)


4 Dedusting - Naphalene package area

1 20.5 PM Impulse dust Collector

EC Received for



Proposed




4 Dedusting - Naphalene package area

1 20.5 PM Impulse dust Collector

5 PBC Stacks 6 35 Normally closed Stack (Normally closed)

6 DBC Stacks 6 35 Air and PM Bag Filter/Adequate stack Height

7 VBC Stacks 6 35 Air/steam/PM/SOx/NOx

Bag Filter /Adequate stack Height



PLANT FORM I


Details of APCM

Bag filter details

The smoke from reactor through WHRB at 340 Deg C enter in the quenching tower where gases are quenched with the help of process water which is atomized with the help of medium pressure steam by nozzles.

At quench tower outlet temperature of smoke drop down to 260-220Deg C, the smoke then pass through agglomerator. Inagglomerator the size of dust particles increases through agglomeration principle. After Agglomerator smoke enters in a series of Process Bag Collectors (PBC) where the particles of carbon black are collected in the hopper & conveyed through the lean phase conveying system to Dense Bag Collector (DBC). In the PBC bag house 12ft long bags made from fibre glass fabric treated with PTFE and provided with PTFE membrane coating are used. These bags have very high separation efficiency of upto 99.96% which insures that the particulate matter emissions are far below the specified norms are maintained. The bag filter design would be of jet pulse offline cleaning type which give better cleaning at low capex and energy cost.

Whereas the gases from the dryer enter in Vapor Bag Collector (VBC), the particles of carbon black is collected in the hopper & conveyed to DBC through the common lean phase conveying system.

The reject material of carbon black is manually fed through the fan to the rerun bag filter where the particles of carbon black are collected in the hopper & conveyed to DBC through the common lean phase conveying system.

The collected material in DBC is discharged to the surge tank through the RAV, where collected carbon black particles are kept in fluidized condition by agitator.

The Clean gases from VBC, RBC & DBC are vented to the atmosphere.

The lean phase pneumatic conveying system is provided with push and pull fan to convey the dust from PBC, RBC, VBC hopper to DBC through micro pulveriser.

Scrubber details

Each section of coal tar distillation plant has separate scrubbing system. Scrubber is made of big tower with random packing packed for absorption of traces which are being carried out during storage tank loading and unloading.

All storage tanks has temperature less than 100 deg c though the temperature is lower than boiling point temperature of material stored in the tank it is being connected to Scrubber to avoid traces of VOCs to release into air.

Washing oil is known solvent being used in all steel industry for the absorption of VOCs and being manufactured by AVH, wash oil after achieving saturation level of absorption it is recycled in process and replaced by fresh wash oil.



PLANT FORM I


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