LIST OF PRODUCTS (PROPOSED)

LIST OF PRODUCTS (PROPOSED)

Sr.No. Name of Product Existing Quantity

(MT/Month)

Total Quantity after expansion

(MT/Month) 1 Benzyl Acetate 20 50 2 Benzyl Benzoate 20 50 3 Benzyl Alcohol 20 50 4 Benzyl Cyanide 20 50 5 Phenyl Acetic Acid 20 50 6 Benzyl Salicylate 20 50

7 Naphthalene Acetic Acid (Tech) and Sodium Salt

5 30

8 Sodium Acetate 6 0 9 Sodium Benzoate 6 0 10 Para Methoxy Phenyl Aceto nitrile 0 50 11 Para Methoxy Phenyl Acetic Acid 0 10 12 Naphthalene Acetamide 0 10

13 Dibenzyl Ether (High boiler of Benzyl Alcohol)

0 30

14 High boiler of Benzyl Benzoate 0 10 15 High boiler of Benzyl Acetate 0 15 16 Trading (Repacking)

0 150 Benzyl Acetone

1 Acetyl Naphthalene

Benzyl Acetate The existing manufacturing capacity of the plant is 137 MT/Month. The Total Manufacturing capacity of the plant after expansion will be 205 MT/Month. The total manufacturing capacity for Benzyl Acetate / Benzyl Benzoate / Benzyl Alcohol / Benzyl cyanide / Phenyl Acetic Acid / Benzyl Salicylate will be 50 MT/Month. Trading activities will be carried out for Benzyl Acetone, 1-Acetyl Naphthalene and Benzyl Acetate. The total quantity for trading will be 150 MT/Month.

Raw Material Requirement :

Raw Materials Existing Qty (MT/Month)

Proposed Qty (MT/Month)

Benzyl Chloride 27.50 68.50

Benzyl Cyanide 21.50 53.50

Beta Napthol 0.00 10.00

Catalyst 0.50 0.85

Caustic Soda Lye 0.00 23.00

Caustic Lye 7.50 19.00

HCl 24.00 60.00

Liq. Ammonia 0.00 19.00

MCA 0.00 14.00

Napthlene Acetic Acid 6.00 36.00

N-Hexane 0.00 14.00

Para Anisyl Alcohol 0.00 54.50

Paraformaldehyde 1.65 10.00

Refined Naphthalene 6.65 40.00

Soda Ash 13.60 34.00

Sodium Acetate 1.30 3.50

Sodium Benzoate 15.50 39.00

Sodium Cyanide 9.50 24.00

Sulfuric Acid 1.75 10.50

Thionyl Chloride 0.00 10.50

Toulene 0.00 46.20

Trimethyl Amine 0.20 0.75

Zinc Chloride 0.30 1.50

Details of each Product: 1) Benzyl Acetate :

Name Existing Production Quantity

(MT/Month)

Proposed Production Quantity

(MT/Month) Product Benzyl Acetate 20 50

Raw material consumption per Month

Material Existing Requirement (MT/Month)

Proposed Requirement (MT/Month)

Benzyl Chloride 18.0 45 Sodium Acetate 1.27 3.18

Catalyst 0.22 0.55

Brief process: Benzyl chloride and Sodium Acetate is reacted in presence of catalyst for 8 hours. The temperature is maintained and then the reacted mass is cooled, washed. The crude is separated, distilled under high vaccum Chemical Reaction:

CH2.Cl

+ Na. COO CH3

CH2COOCH3

+ NaCl

C6H5CH2.Cl + Na.COOCH3 C6H5CH2.COOCH3 + NaCl

Benzyl Chloride Sodium Acetate Benzyl Acetate

Flowchart with Mass Balance:

REACTOR

BENZYLACETATE1100 KGS

VACCUMDISTILLATION

WASHING

BENZYL ACETATE

HEAT

BENZYL CHLORIDE 1000 kgs

SODUIM ACETATE 700 kgs

CATALYST 12 kgs

CRUDE BENZYL ACETATE

WATER 3000 KGS WASHING TO ETP 3000 KGS

High Boiler of Benzyl Acetate

2) Benzyl Benzoate :


(MT/Month)


(MT/Month) Product Benzyl Benzoate 20 50




Benzyl Chloride 13.4 33.5 Sodium Benzoate 15.5 38.75

Catalyst 0.34 0.85

Brief process: Benzyl chloride and sodium benzoate is reacted in presence of catalyst at elevated

temperature for 12 hours. After the reaction, the mass is washed and layer separated to get

Benzyl Benzoate crude. The separated crude is washed under high vacuum to get pure Benzyl

Benzoate.

Chemical Reaction :

CH2Cl

+ NaCOOC6H5

CH2COOC6H5

+ NaCl

C6H5CH2Cl + NaCOOC6H5 C6H5CH2.COOC6H5 + NaCl

Benzyl Chloride Sodium Benzoate Benzyl Benzoate


REACTOR

BENZYLBENZOATE1000 KGS

VACCUMDISTILLATION

WASHING

BENZYL BENZOATE

HEAT

BENZYL CHLORIDE 670 kgsSODUIM BENZOATE 775kgs

CATALYST 17 kgs

CRUDE BENZYL BENZOATE


HIGH BOILER OF BENZYL

BENZOATE

3) Benzyl Alcohol :


(MT/Month)


(MT/Month) Product Benzyl Alcohol 20 50




Benzyl Chloride 27.3 68.25 Soda Ash 13.6 34.0

Brief process: Benzyl chloride is hydrolysed with dilute soda ash for 12 hours at an elevated temperature. The mass is washed and the layer is separated to get crude Benzyl Alcohol. The crude is distilled under high vacuum at normal temperature to get pure Benzyl Alcohol. Chemical Reaction :

CH2Cl

+ Na2CO3

CH2OH

+ NaCl + CO2

C6H5CH2Cl + Na2CO3 C6H5CH2OH + NaCl + CO2

Benzyl Chloride Sodium Ash Benzyl Alcohol

Flowchart with Mass Balance

REACTOR

BENZYLALCOHOL1000KGS

VACCUMDISTILLATION

WASHING

BENZYL ALCOHOL

HEAT

BENZYL CHLORIDE 1365 kgs

CRUDE BENZYL ALCOHOL


HIGH BOILER OF BENZYL ALCOHOL

SODA ASH 680 KGS

4) Benzyl cyanide :


(MT/Month)


(MT/Month) Product Benzyl Cyanide 20 50




Benzyl Chloride 24.2 60.5 Sodium Cyanide 9.44 23.6

Brief process: Benzyl Chloride and Sodium Cyanide is reacted in presence of catalyst for 10~12 hours. After reaction layer is separated and after proper washing, Benzyl Cyanide crude is separated. The crude is distilled under high vacuum to get the final product. Chemical Reaction :

CH2Cl

+ NaCN

CH2CN

+ NaCl

C6H5CH2Cl + NaCN C6H5CH2CN + NaCl

Benzyl Chloride Sodium Cyanide Benzyl Cyanide

Flowchart with Mass Balance :

REACTOR

BENZYLCYANIDE1000 KGS

VACCUMDISTILLATION

WASHING

BENZYL CYANIDE

HEAT

BENZYL CHLORIDE 1210 kgsSODUIM CYANIDE 472 kgs

CRUDE BENZYL CYANIDE

WATER 2500 KGS WASHING TO ETP2500 KGS

RESIDUE FOR INCINERATOR

5) Phenyl Acetic Acid:


(MT/Month)


(MT/Month) Product Phenyl Acetic Acid 20 50




Benzyl Cyanide 21.3 53.25 Caustic Lye 7.5 18.75

HCl 24.0 60.0

Brief process: Benzyl Cyanide is hydrolised with strong alkali solution and acidified with dilute HCl. The slurry formed is then centrifuged. The centrifuged cake is dried to get Phenyl Acetic Acid powder or flakes. Chemical Reaction :

CH2CN

+ NaOH

CH2COOH

C6H5CH2CN + NaOH C6H5CH2COOH.

Benzyl Cyanide Sodium Hydroxide Phenyl Acetic Acid

Flow Chart with Material Balance:

REACTOR

CENTRIFUGE &DRYING, PACKING

P.A.A.

REACTOR

BENZYL CYANIDE (1065 kgs)

WATER

CAUSTIC LYE(375 kgs)

HCl (1200 kgs)

Phenyl Acetic Acid

CHARCOAL (1200 kgs)

5) Naphthalene Acetic Acid:


(MT/Month)


(MT/Month) Product Naphthalene Acetic Acid 5 30




Refined Naphthalene 6.65 40.0 Paraformaldehyde 1.65 10.0

Zinc Chloride 0.245 1.5

Sodium Cyanide 2.67 16.0

Soda Ash 0.125 0.75

Trimethyl Amine 0.125 0.75

Caustic Lye 5.75 34.5

Sulfuric acid 1.75 10.5

Brief process: Chloromethylation: Refined Naphthalene and paraformaldehyde is reacted with HCl to produce Chloromethyl Naphthalene. Nitrilation: The chloromethyl naphthalene is nitriled and hydrolysed with strong alkali. Distillation: Nitriled crude is distilled to remove any unreacted material. The mass is diluted in large volume for acidification. Acidified material is centrifuged and dried to get Naphthyl Acetic Acid.

Chemical Reactions CH2Cl

CH 2CN

CH 2COOH

Naphthalene Chlorom ethyl

Naphthalene Acetic Acid

CHLORO METHYL

REACTION

NAPHTHALENE ACETIC ACID

1000 KGS

DRYER IN FLUID BED DRYER

CENTRIFUGE

ACIDIFICATION

HYDROLYSIS

NITRILEDISTILLATION

NITRILEREACTION

NAPHTHALENE ACETIC ACID

HCl 4250 KGS WATER 1500 KGS

REFINED NAPHTHOIENE 1330 KGS

PARAFORMALDEHYDE 530 KGS

ZINC CHLORIDE 49 KGS

SODUIM CYANIDE 534 KGS

SODA ASH 25 KGS

TRIMETHYL AMINE 25 KGS

CAUSTIC LYE 1150 KGS

WATER 4000 KGS

WATER 25000 KGS

SULFURIC ACID 350 KGS

WATER 25000 KGSMOTHER LIQUOR

TO ETP

Flow Chart with Material Balance:

Sodium Salt of Naphthalene Acetic Acid:


(MT/Month)


(MT/Month) Product Sodium Salt of

Naphthalene Acetic Acid 5 30




Naphthalene Acetic Acid 6.0 36.0 Caustic Lye 2.0 12.0

Brief process: Naphthalene Acetic Acid, caustic lye and water are added in a reactor and the material is spray dried to get Sodium salt of Naphthalene Acetic Acid Flowchart with Mass Balance:

REACTOR

Na. SALT OFNAPHTHALENE

ACETIC ACID1000 KGS

SPRAY DRIER

SODUIM SALT OF NAPHTHALENE ACETIC ACID

NAPHTHANE ACETIC ACID1200 KGS

CAUSTIC LYE 400 KGS

WATER 3000 KGS

6) Para Methoxy Phenyl Aceto Nitrile: (New Product)


(MT/Month)


(MT/Month) Product Para Methoxy Phenyl

Aceto Nitrile --- 50




Para Anisyl Alcohol --- 54.55 Toulene --- 39.5

Soda Ash --- 1.0

Brief process: Para Anisyl Alcohol and toluene are chlorinated with HCl in a reactor. The reacted mass is cynated by addition of sodium cyanide in presence of soda ash and toluene. The mass is distilled under vacuum to get the product. Flowchart with Mass Balance:

CHLORINATION

4- METHOXYLPHENYL ACETO NITRILE

1650 KGS

DISTILLATION

CYANATION

PARA METHOXYL PHENYL ACETO NITRILE

PARA ANISYL ALCOHOL 1800 KGS

TOLUENE 650 KGSHCl 3500 KGS

PARA ANISYL CHLORIDE

SODIUM CYANIDE 750 KGS

4- METHOXYLPHENYL ACETO NITRILE (CRUDE)

SODA ASH 34 KGS

TOLUENE 650 KGS

RESIDUE FOR INCINERATION

6) Beta Naphthoxy Acetic Acid: (New Product)


(MT/Month)


(MT/Month) Product Beta Naphthoxy Acetic

Acid --- 10




MCA --- 13.5 Caustic Soda Lye --- 23.1

Beta Napthol --- 10.0

HCl --- 15.4

Toulene --- 46.2

Brief process: MCA, Caustic Soda Lye and water are mixed in a reactor to form salt of MCA. Then Beta Napthol is added in presence of caustic soda lye to form salt of Beta Naphthol. Then HCl is added to form salt of Beta Naphthoxy Acetic acid. The crude is dried and recrystallized in presence of toluene. The pure Beta naphthol acetic acid which is centrifuged, dried and packed. Chemical Reaction :


REACTORMCA (440 KGS)

CAUSTIC SODA LYE (400 KGS)

WATER

REACTORBETA NAPHTOL (325 KGS)

CAUSTIC SODA LYE (350 KGS)

WATER

SALT OF MCA

SALT OF BETA NAPHTHOL

REACTOR HCl (500 KGS)

SALT OF BETA NAPHTHOXY ACETIC ACID

CENTRIFUGE,DRYING OF

CRUDE

ML TO ETP

RECRYSTALLISATION OF CRUDE

TOULENE (1500 KGS) DISTILLATION

RECYCLED BACKTO PROCESS

RESIDUE FORINCINERATION

CENTRIFUGE,DRYING OF BETA

NAPHTHOXY ACETIC ACID (325 KGS)

7) Naphthalene Acetamide: (New Product)


(MT/Month)


(MT/Month) Product Naphthalene Acetamide --- 10




Naphthalene Acetic Acid --- 11.1 Thionyl Chloride --- 10.5

N- Hexane --- 14.0

Liquor Ammonia --- 19.0

Brief process:

Naphthalene acetic acid, N-Hexane and Thionyl Chloride are charged in a reactor. Then liquor ammonia is added to the reactor. After the completion of the reaction, the material is centrifuged, dried and packed.

Chemical Reaction:

CH2COOH CH2COCl

CH2COCl CH2CONH2

+ Cl2OS + HCl + SO2

+ NH3 + HCl


REACTOR

NAPHTHALENE ACETIC ACID 1110 KGS

THIONYL CHLORIDE 1050 KGS

N - HEXANE 1400 KGS

REACTORLIQ. AMMONIA 1900 KGS

CENTRIFUGE ML TO

ETP

RECRYSTALLIZATION AND CENTRIFUGE

DRYING, BLENDING & PACKING

NAPHTHALENE ACETAMIDE (1000 KGS)

SITE PLAN

&

LAYOUT PLAN

1. DETAILS OF WATER CONSUMPTION.

2. DETAILS OF WASTE WATER GENERATION.

Details of water consumption:

Source of water: GIDC Water Supply

Waste Water Generation Details : Sr. No.

Breakup Existing Waste Water Generation (M3/Day)

Proposed Waste Water Generation (M3/Day)

1. Domestic 1 8

2.

Industrial

a) Process 17 70

b) Boiler Blowdown 0.5 3

c) Cooling Tower Blow Down 0.5 2

d) R.O. Reject - 30

3. Washing 1 15

Total 20 128 Total waste water generation from the plant will be 128 KL/Day, of which 8 KL/Day will be

from domestic activities and rest 120 KL/Day from industrial activities. 120 KL/Day will be

taken to ETP plant for its treatment and further disposed to CETP of NIA.

Sr. No.

Breakup Existing Water Consumption

(M3/Day)

Proposed Water Consumption

(M3/Day)

1. Domestic 2 10

2.

Industrial

a) Process 31 105

b) Boiler Makeup 2 10

c) Cooling tower make up 2 10

3 Washing 1 15

4 Gardening 1 2

Total 39 152

EFFLUENT TREATMENT SCHEME.

Effluent Treatment Scheme: Domestic waste water and industrial waste water will be sent to the effluent treatment plant

for treatment. The treated waste water will be sent to CETP of NIA, GIDC, Nandesari for its

further disposal after meeting its inlet norms.

PROPOSED TREATMENT SCHEME :

The waste water from the plant will be collected in the waste water collection tank. The

composite COD will be about 8500 mg/L. As per the recommendation received from the

CETP of Nandesari Industries Association, we will be installing the hydrodynamic cavitation

process for the treatment of the waste water.

The setup for the hydrodynamic cavitation reactor is given in the figure below: The waste

water is equalised over organic matter and flow. The pH of the waste water is raised to 10 by

hydrated lime and filtered. The waste water is then pumped through a venturi. At the suction

side, chlorine is injected to achieve hydrodynamic cavitation. This is a batch process and the

system is kept under recirculation till the COD is reached to desired limit. This is again

filtered in the filter press and the filtered waste water will be sent to the CETP.

DETAILS OF AIR EMISSIONS

Details on Existing Air Emissions:

Sources of gaseous emissions

Existing Thermic Fluid heater

No. 1

Existing Thermic Fluid heater

No. 2 Capacity 4 lac KCL/HR 4 lac KCL/HR Fuel used Piped Natural Gas Agro waste/ briquette / woodQuantity of fuel 350 SCM/Day 5 MT/day Type of emissions NOx, PM SO2, NOx, PM Stack height 11 meters 11 meters Stack diameter at top 13 inches 13 inches APC Provided None Built in Particulate Matter

collection Mechanism

Details of the New Thermic Fluid Heater

Flowchart of Dust collector From the firing in the combustion chamber (furnace), Gas will travel to radiative heat exchanger through Dust collector and from there to preheater to ID fan and Chimney. All the dust is collected in Dust collector through bottom connective heat exchanger.

Other sources of Utility Emissions There is no change in other utility emissions.

Sources of gaseous emissions

Existing Boiler DG Set (used only in case of power failure)

Fuel used Wood / Briquettes HSD Quantity of fuel 10 MT/day 200 lts/month Type of emissions SO2, NOx, PM SO2, NOx, PM Stack height 11 meters 3 meters Stack diameter at top 13 inches 4 inches APC Provided Cyclone None

Cyclone in the existing boiler Details of Existing Process Emissions

Process emission Vent attached to Scrubber No.1 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches

Details of Proposed Air Emissions :

Process emission Vent attached to Scrubber No. 2 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches

Process emission Vent attached to Scrubber No. 3 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches

Process emission Vent attached to Scrubber Gas Scrubbed Ammonia Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Water Stack height 15 meters Stack diameter at top 6 inches

DETAILS OF HAZARDOUS WASTE GENERATION AND

DISPOSAL.

Details of hazardous waste generation and disposal:

Sr. No.

Waste Details

Waste Category

Existing Total Volume to be disposed

Proposed Total Volume to be disposed

Mode of Disposal

1 ETP Sludge

34.3 180 MT/Yr 400 MT/Yr Collection, storage, transportation and disposal to TSDF, NECL for landfilling

2. Waste / Residue

28.1 18 MT/Yr 30 MT/Yr Collection, storage, transportation and disposal to CHWI, NECL for incineration

3. Used Oil 5.1 0.5 MT/Yr 1 MT/Yr Applied on MS structures for

corrosion control or will be sent to NECL for incineration

4.

Liner Bags and discarded containers

1 MT/year 1.5 MT/Yr Used for filling of ETP Sludge and Process residue or is Sold to registered recyclers

LIST OF PRODUCTS (PROPOSED)

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