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1
FORM-1
for
Amedment in Environment Clearance of
Synthetic Organic Chemicals manufacturing Unit
of
M/s. Kutch Chemical Industries Ltd.
Plot No. Plot No. 166/1-3, 167, 168, 171/1 & 172, Vill: Padana, Tal:
Gandhidham,
Dist: Kutch, Gujarat.
EIA CONSULTANT
2
APPENDIX I
FORM 1 (I) Basic Information
Sr.
No.
Item Details
1. Name of the Project/s Kutch Chemical Industries Limited
2. S. No. in the Schedule 5(f)
3. Proposed capacity/area/length/tonnage to
be handled/command area/lease
area/number of wells to be drilled
Applying for Amendment in Environment
Clearance – Correction for missed out list of
By products in final EC Letter.
Please refer Annexure-I for proposed
quantity.
4. New/Expansion/Modernization Got Environment Clearance for Expansion
5. Existing capacity/area etc. Please refer Annexure-1 for existing capacity.
6. Category of project i.e. ‘A’ or ‘B’ 'A'
7. Does it attract the general condition? If yes,
please specify.
-
8. Does it attract the specific condition? If yes,
please specify.
-
9. Location
Plot/Survey/Khasra No. Plot No. 166/1-3, 167, 168, 171/1 & 172,
Village Padana
Tehsil Gandhidham
District Kutch,
State Gujarat
10. Nearest railway station/airport along with
distance in kms.
12 km away Gandhidham railway station
Nearest Airport: Kandla : 25 km
11. Nearest Town, city, District Headquarters
along with distance in kms.
Nearest Village: Padana: 1.5 kms,
12. Village Panchayats, zilla parishad, Municipal
corporation, Local body (Complete postal
addresses with telephone nos. to be given)
Padana Village Panchyat
13. Name of the applicant Mr. Hasting Rjyaguru
14. Registered address M/s. Kutch Chemical Industries Limited
Plot no. 166/1-3, 167, 168, 171/1, 172, Village:
Padana, Gandhidham, Dist : Kutch, Gujarat
15. Address for correspondence: As above
Name Mr. Hasting Rajyaguru
Designation (Owner/Partner/CEO) Sr. Manager -Environment
3
Address “Sara Niwas”, 20-21, Harinagar Co.Op.
Society, Gotri Road, Vadodara
Pin Code 390007
E-Mail hast.69@gmail.com
Telephone No. 0265 – 2397013/2396498/2396751
Mobile +918000367677
Fax No. 0265 - 2397245
16. Details of Alternative Sites examined, if any
location of these sites should be shown on
a topo sheet.
No
17. Interlinked Projects No
18. Whether separate application of interlinked
project has been submitted?
No
19. If Yes, date of submission Not applicable
20. If no., reason Not applicable
21. Whether the proposal involves
approval/clearance under: If yes, details of
the same and their status to be given.
(a) The Forest (Conservation) Act, 1980?
(b) The Wildlife (Protection) Act, 1972?
(c) The C.R.Z Notification, 1991?
Not applicable, as the project is located in
notified industrial estate.
22. Whether there is any Government
order/policy relevant/relating to the site?
No
23. Forest land involved (hectares) N.A.
24. Whether there is any litigation pending
against the project and/or land in which the
project is propose to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if any
and its relevance with the proposed
project.
No
• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,
mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.,)
4
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which
will cause physical changes in the locality (topography, land use, changes in water
bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes
/No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
1.1 Permanent or temporary change in land
use, land cover or topography including
increase in intensity of land use (with
respect to local land use plan)
No
1.2 Clearance of existing land, vegetation and
buildings?
No
1.3 Creation of new land uses? No
1.4 Pre-construction investigations e.g. bore
houses, soil testing?
No
1.5 Construction works? Yes Please refer Annexure-II for Lay Out
1.6 Demolition works? No
1.7
Temporary sites used for construction
workers or housing of construction workers? No
1.8 Above ground buildings, structures or
Earthworks including linear structures, cut
and fill or excavations
No
1.9
Underground works including mining or
tunneling?
No
1.10 Reclamation works? No
1.11 Dredging? No
1.12 Offshore structures? No
1.13 Production and manufacturing Yes List of Products is attached as
Annexure- I
5
1.14 Facilities for storage of goods or materials? Yes Please Refer Annexure-VII
1.15
Facilities for treatment or disposal of solid
waste or liquid effluents?
Yes Please Refer Annexure-V
1.16
Facilities for long term housing of
operational workers?
No
1.17 New road, rail or sea traffic during
construction or operation?
No
1.18 New road, rail, air waterborne or other
airports etc?
No
1.19 Closure or diversion of existing transport
routes or infrastructure leading to changes
in traffic movements?
No
1.20 New or diverted transmission lines or
pipelines?
No
1.21
Impoundment, damming, converting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No
1.22 Stream crossings? No
1.23
Abstraction or transfers or the water form
ground or surface waters?
Yes Please refer Annexure-IV
1.24
Changes in water bodies or the land surface
affecting drainage or run-off?
No
1.25
Transport of personnel or materials for
construction, operation or
decommissioning?
No
1.26 Long-term dismantling or decommissioning
or restoration works?
No
1.27 Ongoing activity during decommissioning
which could have an impact on the
environment?
No
1.28
Influx of people to an area in either
temporarily or permanently?
No
1.29 Introduction of alien species? No
1.30 Loss of native species of genetic diversity? No
1.31 Any other actions? No
2. Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or in
short supply):
Sr. No Information/checklist confirmation Yes/
No?
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
6
2.1 Land especially undeveloped or agriculture
land (ha)
No Unit is operational.
2.2 Water (expected source & competing
users) unit: KLD
Yes Please refer Annexure-IV
2.3 Minerals (MT) No
2.4
Construction material -stone, aggregates,
sand / soil (expected source MT)
No
2.5 Forests and timber (source - MT) No
2.6
Energy including electricity and fuels
source, competing users) Unit: fuel (MT),
energy (MW)
Yes
2.7 Any other natural resources (use
appropriates standard units)
No
3. Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about actual
or perceived risks to human health.
Sr.
No.
Information / Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates wherever possible)
with source of information data
3.1 Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
health or the environment (flora, fauna,
and water supplies)
Yes
Please Refer Annexure-VII
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
No
3.4
Vulnerable groups of people who could be
affected by the project e.g. hospital
patients, children, the elderly etc.,
No
3.5 Any other causes No
4. Production of solid wastes during construction or operation or decommissioning
MT/month)
7
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
4.1 Spoil, overburden or mine wastes No
4.2
Municipal waste (domestic and or
commercial wastes) No
4.3
Hazardous wastes (as per Hazardous Waste
Management Rules)
Yes Please refer Annexure-V
4.4 Other industrial process wastes No
4.5 Surplus product No
4.6
Sewage sludge or other sludge from
effluent treatment
No
4.7 Construction or demolition wastes No
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes No
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities/rates, wherever possible)
with source of information data
5.1 Emissions from combustion of fossil fuels
From stationary or mobile sources
Yes Please refer Annexure-VI
5.2 Emissions from production processes Yes Please refer Annexure-VI
5.3 Emissions from materials handling
including storage or transport
Yes Please refer Annexure-VI
5.4 Emissions from construction activities
including plant and equipment
No
5.5
Dust or odours from handling of materials
including construction materials, sewage
and waste
No
5.6 Emissions from incineration of waste No
5.7 Emissions from burning of waste in open
air (e.g. slash materials, construction
debris)
No
5.8 Emissions from any other sources No
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details there of (with approximate
Quantities /rates, wherever possible)
With source of information data
8
6.1
From operation of equipment e.g. engines,
ventilation plant, crushers
Yes The Noise level will be within the
prescribed limit. At noisy area, adequate
preventive & control measures will be
taken. No significant noise, vibration or
emission of light & heat from the unit.
6.2 From industrial or similar processes Yes -do-
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational traffic No
6.6 From lighting or cooling systems NO
6.7 From any other sources No
7. Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
7.1
From handling, storage, use or spillage of
hazardous materials
No
7.2
From discharge of sewage or other
effluents to water or the land (expected
mode and place of discharge)
No
7.3
By deposition of pollutants emitted to air
into the land or into water
No
7.4 From any other sources No
7.5 Is there a risk of long term build up of
pollution in the environment from these
sources?
No
8. Risks of accident during construction or operation of the Project, which could affect
human health or the environment:
Sr.
No
Information/Checklist confirmation
Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
8.1 From explosions, spillages, fires etc from
storage, handling, use or production of
hazardous substances
No Please Refer Annexure-VII
8.2 From any other causes No
8.3 Could the project be affected by natural
disasters causing environmental damage
(e.g. floods, earthquakes, landslides,
No
9
cloudburst etc)?
9. Factors which should be considered (such as consequential development) which could
lead to environmental effects or the potential for cumulative impacts with other
existing or planned activities in the locality
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
9.1 Lead to development of supporting.
laities, ancillary development or
development stimulated by the project
which could have impact on the
environment e.g.:
* Supporting infrastructure (roads, power
supply, waste or waste water treatment,
etc.)
• housing development
• extractive industries
• supply industries
• other
No For detail please refer Annexure – VIII
9.2
Lead to after-use of the site, which could
have an impact on the environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to proximity
to Other existing or planned projects with
similar effects
No
10
(III) Environmental Sensitivity
Sr.
No
Information/Checklist confirmation Name
/ Identity
Aerial distance (within 25 km).
Proposed Project Location
Boundary.
1 Areas protected under international
conventions national or local legislation
for their ecological, landscape, cultural
or other related value
-- --
2 Areas which are important or sensitive
for Ecological reasons - Wetlands,
watercourses or other water bodies,
coastal zone, biospheres, mountains,
forests
-- --
3 Areas used by protected, important or
sensitive species of flora or fauna for
breeding, nesting, foraging, resting,
over wintering, migration
-- --
4 Inland, coastal, marine or underground
waters
-- --
5 State, National boundaries -- --
6 Routes or facilities used by the public
for to recreation or other tourist,
pilgrim areas.
-- --
7 Defense installations -- --
8 Densely populated or built-up area -- --
9 Areas occupied by sensitive man-made
land community facilities)
-- --
10 Areas containing important, high
quality or scarce resources (ground
water resources, surface resources,
forestry, agriculture, fisheries, tourism,
tourism, minerals)
-- --
11 Areas already subjected to pollution or
environmental damage. (those where
existing legal environmental standards
are exceeded)
-- --
12 Areas susceptible to natural hazard
which could cause the project to
present environmental problems
(earthquakes, subsidence, landslides,
erosion, flooding or extreme or adverse
-- --
11
climatic conditions)
I hereby give undertaking that, the data and information given in the application and
enclosures are true to the best of my knowledge and belief and I am aware that if any
part of the data and information submitted is found to be false or misleading at any
stage the project will be rejected and clearance given, if any, to the project will be
revoked at our risk and cost.
Date: 13.04.2016
Place: Kutch
NOTE:
1. The projects involving clearance under Coastal Regulation Zone Notification, 1991 shall
submit with the application a C.R.Z. map duly demarcated by one of the authorized agencies,
showing the project activities, w.r.t. C.R.Z. (at the stage of TOR) and the recommendations of
the State Coastal Zone Management Authority (at the stage of EC). Simultaneous action shall
also be taken to obtain the requisite clearance under the provisions of the C.R.Z. Notification,
1991 for the activities to be located in the CRZ.
2. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere
Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly
authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location
and the recommendations or comments of the Chief Wildlife Warden thereon (at the stage of
EC).
3. All correspondence with the Ministry of Environment & Forests including submission of
application for TOR/Environmental Clearance, subsequent clarifications, as may be required
from time to time, participation in the EAC Meeting on behalf of the project proponent shall be
made by the authorized signatory only. The authorized signatory should also submit a
document in support of his claim of being an authorized signatory for the specific project.
12
ANNEXURES
Annexure-I
List of Products: Applied For getting Environment Clearance.
Sr.
No. Name of the Product
Existing
Capacity,
MT/Month
Additional
Capacity,
MT/Month
Total
Capacity,
MT/Month
1 Nitro Derivatives of hydrocarbon such as Nitro Chloro benzene,
Nitro toluene, nitro Cumene, nitro Xylene, nitro benzene 2400 -- 2400
2 Amino Hydrocarbon such as Chloro aniline, Toluidine, Cumidene,
Xylidine, aniline 2000 -- 2000
3 Ammonolysis of nitro chloro compound & hydrolysis such as
Ortho nitro aniline, Para nitro aniline 100 -- 100
4 Mono Chloro Benzene
1000 -- 1000
5 Di Chloro Benzene 500 -- 500
6 Chlorinated paraffin wax 550 -- 550
7 Acetanilide 1000 3000 4000
8 Vinyl Sulphone & its derivatives 500 4000 4500
9 Dimethyl Sulfate (DMS) 100 3000 3100
10 Power Plant (Coal) 2.5 MW
(FO)
10 MW
(Coal)
12.5 MW
(FO & Coal)
11 Equivalent Sulphuric Acid (Either OR Liquid SO3, Oleum 23%, Oleum 65% &
Sulphuric Acid 98%) 7500 -- 7500
12 Sulphuric Acid 15000 -- 15000
13 Oleum (23% & 65%) 3000 -- 3000
14 Liquid SO3 (70-90%) 7500 -- 7500
15 Chloro Sulphonic Acid 16200 -- 16200
16 Thionyl Chloride 5000 -- 5000
17 Sodium Bisulphite (SBS) 3000 -- 3000
18 Calcium Chloride 4000 -- 4000
19 Sulphur Monochloride 200 -- 200
20 Sulphuryl Chloride 200 -- 200
21 Aluminum Sulphate (ALUM) 1000 -- 1000
22 Sulphonation of PNT, ONT, VS, Tobias, etc. 0 1500 1500
23 Benzene Sulphonyl Chloride 0 1500 1500
24 DASDA 0 1000 1000
25 V.S. Condense 0 1000 1000
26 Dimethyl Aniline (DMA) 0 1500 1500
13
27 Diethyl Sulfate (DES) 0 1500 1500
28 Sulfamic Acid 0 1000 1000
Total 70750 19000 89750
LIST OF BY-PRODUCTS
Sr.
No. Name of the By Product
Existing
Capacity,
MT/Month
Additional
Capacity,
MT/Month
Total
Capacity,
MT/Month
1 Dil. Hydrochloric Acid (30% - 32%) 23825 5500 29325*
2 Dil. Sulphuric Acid 2000 29000 31000**
3 Dil. Acetic Acid 260 1200 1460
4 Sodium Sulphate Salt (Glauber Salt) 1040 5960 7000
NOTE:
1. The byproduct Hydrochloric Acid (Gas or 30% - 32% (Liquid)) is utilized to manufacture Chloro
Sulphonic Acid and Calcium Chloride or if excess, sold to end user. Company stores HCl (30% -
32%) in MSRL or HDPE tank. 10 tanks each of 150 MT/Day capacities.
2. Dil. Sulphuric Acid is utilized to manufacture Sulfamic Acid or if excess, sold to end user
(IFFCO, Gandhidham).
3. Dilute Acetic Acid is totally recycled in Acetanilide manufacturing Process.
4. Sodium Sulphate Salt is sold to Paper Industry, Dyes Industry and Textile Industry.
* - Captive Consumption to manufacture Chloro Sulphonic Acid & Calcium Chloride + Sale to
Actual Users
** - Captive Consumption to manufacture Sulfamic Acid, Vinyl Sulphone & Alum + Sale to Actual
Users
14
ANNEXURE-II
LAYOUT MAP OF THE PLANT
Green
Belt Area
15
ANNEXURE-III
MANUFACTURING PROCESS DESCRIPTION
Manufacturing activities in the existing & proposed plant include various processes. The
activities shall also include operation of various utilities. The manufacturing process is described
in detail in the following sections. The list of products and their manufacturing capacity (Existing
and proposed) are given in Table 1.1.
1 Nitro Derivatives of Hydrocarbon such as Nitro Chloro Benzene, Nitro Toluene, Nitro
Cumene, Nitro Xylene, Nitro Benzene
Manufacturing Process:
a. Benzene / Chlorobenzene / Cumene / Toluene / 2-Ethyl hexanol containing recycled stream.
Nitric acid and sulphuric acid are introduces into the first nitrator. The rates of flow of each
component are manually adjusted. Flow indicators with an alarm set point in the control room
are part of the plant interlock system, so that, if either flow deviates outside a certain range,
high or low, the interlock system will give an alarm or stop the process.
The nitration vessels are stainless steel reactors equipped with cooling coils and a +powerful
stirring system. The nitrator is cooled by water circulation through the coils. The reaction
temperature is maintained constant by a thermostatic control system which adjusts the water
flow to maintain the operating temperature. The nitration vessels are also provided with
heating jackets that are kept under a very light vacuum by a suction system. Inert gas is
admitted to the top of the first nitrator while the process is on-line. The amount of nitrogen
admitted is measured by online flow meters.
The reaction mixture flows from the overflow of the first nitrator of the second reactor and
from this to the last. The emulsion reflowing from the last nitrator enters a separator. The
speed separation is increased by admitting the inlet stream tangentially or the interface.
MCB /NCB/EHN/ NT / NIX and the sulphuric acid (70-72%) are continuously separated into
phases. The interface, i.e. the narrow emulsion layer, where separation has not yet taken place
is maintained at constant by means of an automatic 2 controller operating on the sulphuric acid
16
outlet valve of the separator. The heavier Sulphuric acid layer on off via this valve flows by
gravity to the stirred vessel. In the stirred vessel having cooling coils, the sulphuric acid (70-
72%) is mixed with fresh hydrocarbon which not only extracts the nitrobodies contained in it,
but also uses up the excess nitric acid. The cooled mixture flows to a continuous decanter,
where the stripped acid is separated and sent to its storage tank.
The organic layer, consisting of Benzene/CB/Cumene/2-Ethyl hexanol/Xylene and a small
amount of MCB/NCB/NT/NC/EHN/NIX flows to a small surge tank from which it is pumped to
the first nitrator.
The acidic and crude MCB/NC/NCB/NT/EHN/NIX are purified in a series of washing and
separation stages.
The moist MCB/NCB/NT/NC/EHN/NIX containing some unreacted staring product is preheated
by passage through two successive heat exchangers. The first one is fed counter-currently by
MCB/NC/NCB/NT/EHN/NIX leaving the distillation column, the second one is heated by means
of steam. The distillation is carried out in a packed column operated under vacuum.
The bottom product is MCB/NCB/NT/NC/EHN/NIX containing less than 10% moisture and
aromatic. The condensate is a mixture of water and aromatic that is separated. Water is
discarded, while part of the aromatic returns to the column (reflux) and the balance is recycled
to the nitration section.
b. Separation of Isomers
The crude NCB isomer mixture from the nitration plant is collected in an intermediate tank in
which it is blended with fractions coming either from the crystallization section or from the
distillation section. This blend rich in PNCB is sent to a batch crystallizer provided with a cooling
/ heating system.
The first crystallization fraction is rich in ONCB that is sent to the distillation column K-101.
The second crystallization fraction is a mixture of NCB having the same composition of crude
NCB, which is recycled back in to the above mentioned intermediate tank. The third
17
crystallization fraction is the pure NCB in melted form. The packed distillation column K-101
ensures a high efficiency of separation combined with a very low pressure drop.
The bottom product consists of pure ONCB containing some DNCB. This fraction is sent to the
distillation column K-301 for the removal of the DNCB and the isolation of pure ONCB and the
top product is fed to the distillation column K-201 consisting of a mixture of rich in PNCB
containing ONCB and MNCB.
The bottom product from distillation column K-201 is rich in PNCB with the remaining ONCB,
sent back to the crystallization section. The head product is PNCB containing MNCB.
The purpose of the packed distillation unit K-301 is the separation of pure ONCB from the tails
consisting of some Di-NCB.
Chemical Reaction:
Nitro chloro Benzene (NCB)
+ HNO3 + + +
c. Separation of Isomers
The crude N isomer mixture is firstly separated in the vacuum distillation column K-101 Head
product is pure ONCB, PNCB,DNCB & MNC
Cl
NO2
Cl Cl
NO2
NO2
Cl
NO2
Cl
NO2
Chloro
Benzene
(112.5)
Nitric Acid
(63)
o-Nitro Chloro
Benzene
(157.5)
p-Nitro Chloro
Benzene
(157.5)
m-Nitro Chloro
Benzene
(157.5)
Dinitro Chloro
Benzene
(202.5)
18
Mass Balance:
706
H2SO4
(72%)
1 KL/MT of Product
Water
509 H2SO4
636 HNO3
1106 Chloro Benzene
Dil H2SO4 (70%)
1 KL Wastewater to ETP
1000 PNCB, MNCB 424
Pure Isomer ONCB
121
Continuous Process DNCB
Nitrator Separator Washing Distillation
Crystallizer
Distillation
K-101
Distillation
K-201
Distillation
K-301
19
2 Amino Hydrocarbon such as Chloro Aniline, Toludine, Cumidine, Xylidine, Aniline
Manufacturing Process:
The reaction involves one-step hydrogenation process on the respective raw materials. Raw
Material is fed to the raw material preparation tank as per the batch size. Where Nitro
Derivatives of Hydrocarbon form homogenous slurry with metal catalyst, pumped to High
Pressure Autoclave. In Autoclave material is heated by means of Oil Heating to 90-95 °C.
Then H2 Supply through PRS is started. H2 pressure in autoclave maintained at 15-21.5
Kg/cm2 through PRS any unresolved, dispersed gas is unreacted in autoclave passed
through condenser and recirculated. As the reaction is exothermic in nature, Temperature
of reaction mass starts rising which is controlled and maintained at 120- 130°C by applying
cooling water jerk. After completion of Hydrogenation the product mass is cooled to 30-35
°C and transferred autoclave reaction mass to candle filter to positive pressure in Autoclave.
From Filtration the product is fed to conical separation vessel, where aqueous phase is
separated from product by providing sufficient settling time. Product from separator is
pumped to crude storage tank. Catalyst is recycled back to autoclave via. Candle filters.
The crude product contains traces of water and high boiler along with the product, which is
distilled out in High Vacuum Batch Distillation Column.
In Batch Distillation column, pure water cut which is separated in separate tank and reused
in the plant, another two cuts i.e Interphase cut and Pure Aromatic Amino product comes,
which is kept separately in respective storage tank/passed to flakers for flaking.
Chemical Reaction:
R – NO2 + 3H2(g) R- NH2 + 2H2O
Catalyst
C6H4CH3.NO2 + 3H2(g) C6H4CH3-NH2 + 2H2O
Catalyst
137 + 6 107 + 36
20
Mass Balance:
13 Catalyst
56 Hydrogen 1280 Nitro Compound
1349
Filter 13 1336
Process Waste Distillation Water 326
10 1000 Reuse
Pure Amino Product
Reactor
MASS BALANCE OF HYDROGENATION PRODUCT
21
3 Ammonolysis of Nitro Chloro compound & Hydrolysis such as Ortho Nitro Aniline, Para
Nitro Aniline
Manufacturing Process:
p-Nitro Chloro Benzene is reacted with NH3 in autoclave at 178°C. The mass is then filtered
in Nutch filter to get p- Nitro Aniline. The pressurized gas from auto clave is then taken in to
depressurize, here NH3 liberated is taken in to make –up tank. The NH4Cl is taken in to
other vessel, where is liberated ammonia taken to the makeup tank. The NH4CL is reacted
with Ca(OH)2. The mass in then filtered in Nutch filter.
Chemical Reaction: 36 Kg/Cm2
C6H4.Cl.NO2 + 2 NH3 � C6H4.NH2.NO2 + NH4Cl
178°C
157.5 34 138 53.5
p-Nitro Chloro Ammonia p- Nitro Aniline Ammonium Chloride
Benzene
36 Kg/Cm
2
C6H4.Cl.NO2 + 2 NH3 � C6H4.NH2.NO2 + NH4Cl
178°C
157.5 34 138 53.5
o-Nitro Chloro Ammonia o-Nitro Aniline Ammonium Chloride
Benzene
2NH4Cl + Ca(OH)2 � 2 NH3 + CaCL2 + 2H2O
107 74 34 111 36
22
Mass Balance:
Process Flow Chart of P Nitro Aniline
691
53
Reuse in
Plant
Water 798 Kg
ONCB/PNCB 1170KG
NH3 1117 Kg
Autoclave
178°C 36
Kg/Cm2
Nutch Filter –
2394 Kg
Depressurize
Water – 1968Kg
NH3 (28%-32%)-
2659 Kg
Agitator 1394 Kg Scrubber
Water 1330 Kg
Dil.NH3
1383 Kg
P nitro Aniline
– 1000 Kg Reactor
1341 Kg Dilute NH3 Sol. 106
Kg
Ca(OH)2 133 Kg
Nutch Filter
1368 Kg
Solid Waste
160 Kg
Calcium Chloride
Solution 1208 Kg
23
4 Mono Chloro Benzene
Manufacturing Process:
Mono Chlorobenzene plant is continuous plant. Benzene and Chlorine continuously feed in
reactor from bottom. From overflow we are getting product Mono Chlorobenzene. The
reaction is exothermic so cooling water circulation controls temperature of the reactor.
During the reaction we are getting Hydrochloric Acid vapor. This vapor is passed through the
water to produce 30% Hydrochloric Acid. Material getting from reactor is feed into acid
stripper to remove the acidity. Material from the stripper is sent to remove any unreacted
benzene. The benzene free material is feed into the MCB stripper; from MCB stripper we are
getting pure mono chloro benzene from the top and dichlorobenzene from the bottom.
Chemical Reaction:
C6H6 + Cl2 � C6H5Cl + HCl
78 71 112.5 36.5
Mass Balance:
Water 1087 Kg 1413 Kg (HCl liquid- 30% to 32%) HCl Absorber
Benzene 697 Kg Reactor – 1326 Kg
Acid Stripper
Benzene Stripper
MCB Stripper
Recycle
MCB
1000 Kg
Chlorine 629 Kg
HCl Gas
24
5 Di Chloro Benzene
Manufacturing Process:
The raw material Benzene is fed into continuous chlorinator (Packed Column) via Benzene
dryer to remove the moisture from Benzene. Chlorine is fed through vaporizer and react
with Benzene in manner to produce DCB isomer and lower high boiler by controlling the
process parameter, where HCl gas coming out from top of reactor is scrubbed with water in
absorber to produce 30% HCl as byproduct.
The reactor mass is washed with water to remove the impurity and then it is delivered to
the crystallizer to crystallize para isomer of DCB. After crystallizing the PDCB, it is
centrifuged and mother liquor is taken into distillation section. In distillation section, from
the bottom of the first column ODCB is obtained and top contains high concentrate PDCB
which is recycled in crystallization section. And from the top of the second column in
distillation section, pure ODCB will be separated as a product.
Chemical Reaction:
C6H6 + 2 Cl2 � C6H4Cl2 + 2HCl
78 142 147 73
Mass Balance: Water 926 Kg 1203 Kg(HCl liquid- 30% to 32%)
HCl Absorber
Benzene 593 Kg Reactor – 1409 Kg
Crystallizer
Centrifuge
Distillation
Recycle
ODCB 500 Kg
Chlorine 816 Kg
PDCB 500 Kg
HCl Gas
Crude TCB 132 Kg
25
6 Chlorinated Paraffin Wax
Manufacturing Process:
Raw Heavy Normal Paraffin is heated electrically to the required temperature in a Heavy
Normal Paraffin storage tank and measured quantity of Heavy Normal Paraffin is charged in
to reactor (chlorinator). Then chlorine gas is bubbled through the H.N.P in a reactor.
Reaction between HNP and chlorine takes place. The reaction is exothermic. During reaction
Hydrochloric Gas is liberated which is scrubbed in to water scrubber, where the
Hydrochloric gas is converted in to Hydrochloric Acid. The dilute hydrochloric acid is
recirculated in the system until the desired concentration of Hydrochloric Acid is attained.
The balance Hydrochloric gas is then fed in to the bubbling tank whereby rest of
hydrochloric gas is converted in to Hydrochloric Acid. In the final stage the left over gases
mostly unreacted chlorine are taken to the alkali tower, where by alkali solution is being
pumped counter. In the reactor it is necessary to maintain constant temperature so cooling
water is being circulated.
Also Hydrochloric Acid formed in water scrubber is being cooled in condenser before
recirculated it in water scrubber. After completion of reaction the product, chlorinated
paraffin wax obtained is aerated for removal of any free gases. The chlorinated paraffin wax
is then filled in drums for dispatch. Hydrochloric Acid obtained as a byproduct.
Mass Balance:
Ventury Water Scrubber
HCl Gas
Alkali Scrubber
HCl Gas
Neutral Gas to atmosphere
Chlorination
Product – CPW (1000 Kg)
HCl Absorber Dil. HCl
1830 Kg
Raw Water 1280
Kg
Heavy Normal Paraffin –
530 Kg
Chlorine Gas – 1000 Kg
26
7 Acetanilide
Manufacturing Process:
A mixture of Aniline and Acetic Acid is heated through Thermic Fluid Heater with stirring.
The reflux is circulated for 2-3 hours and collected product will be recycled for next batch.
Required quantity of acetic anhydride is added to complete the reaction. After completion
of the reaction vacuum is applied to remove the unreacted acetic acid, which is also
recycled back for next batch.
Chemical Reaction:
Mass Balance:
+ CH3COOH + H2O
93 60 135 18
Aniline Acetic Acid Acetanilide Water
NH 2
NHCOCH3
205 Kg
Reactor
Condenser
Acetic Acid Recovery
System
Aniline 732.5 Kg
Acetic Acid 472.5 Kg
Flaker
Acetanilide Packing Unit
1000 Kg
27
8 Vinyl Sulphone & Vinyl Sulphone Condense
Manufacturing Process
Chloro Sulphonation:
Thionyl chloride and Chloro Sulphonic Acid is charged into the Sulphonation reactor.
Acetanilide is then slowly added maintained the temperature below 30° C. The temperature
is then maintained between 50-60 °C. HCl gas is liberated which is converted to 30% to 32%
HCl liquid in graphite absorber.
Dumping:
In a closed RLBL reactor ice is filled and the above chlorosulpho mass is added maintaining a
temp. Below 12°C to precipitate acetyl Sulphonyl chloride. The above mass is filtered in filter
Nutsche & chilled water wash are given in nutsch to achieving less acidity in the ASC cake.
The filtrate is byproduct sulphuric acid of around 25% to 35%. The filtrate i.e. 25% to 35%
sulphuric acid is further used in the process and or sold out.
Reduction:
Sodium Bi Sulphite slurry is prepared in the reactor. The pH is maintained by adding Caustic
Lye and ASC wet cake under controlled temperature and pH. After addition is over the
temperature is raised up to 50 °C. The mass is then filtered and transferred to condensation
vessel.
Condensation:
The reduction mass in condensation vessel is maintained at 50°C. Ethylene Oxide is slowly
added. The pH is maintained to 5-7 by adding dilute sulphuric acid. The material after
condensation is transferred to the Nutsch Filter. The Mother liquor is chilled to precipitate
sodium sulphate which is then filtered to recover sodium sulphate which is used or sold out
and the filtrate is collected in storage tank. The condensed product is then washed and
dried.
Esterification:
The condensed product is charged in esterification reactor. Concentrated Sulphuric Acid is
added. The temperature is then raised and maintained at 160°C for 4 hours. Vacuum is
applied to take out acetic acid vapors and being condensed to acetic acid which is sold or
used. The product vinyl sulphone is then collected and naturally cooled to achieve room
temp. It is pulverized and packed in PVC bags.
28
Chemical Reaction
135 119 116.5 233.5 36.5 98
233.5 40 104 98
44
243
142 58.5
243 98
281
60
VS Condense
Acetyl Sulpho Chloride
29
Mass Balance
Acetanilide 545.5CHLOROSULPHONIC
ACID 1970.5
3091
Ice 3636.25 DUMPING(ICE)
6727.25
FILTERATION(Notch) H2SO4 (25-35%)
3091 3636.25
SOD. BISULPHITE
SLURRY(30%) 1636.25
CAUSTIC LYE 545.5
5272.75
PRODUCT FROM FILT
ETHYLENE OXIDE 254.5
H2SO4 567.25 6094.5
Salt
FILTER 4438.25
SODIUM SULPHATE
SALT
(BYPRODUCT)2074.75
1656.25
Incinerator
CONDENSED PRODUCT 2363.5
1656.25
565.5 MOISTURE LOSS
DRYER
1090.75
PRODUCT FROM
Dryer
H2SO4 363.75 ESTERIFICATION
1454.5 ACETIC ACID
454.5
VINYL SULPHONE
1000.0
CHLOROSULPHONATION
REDUCTION
ETHOXYLATION
MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE
HCL (30-32%)
Sulphanilic Acid
T.C. - 625
50
30
260°C
2 CH3OH CH3-O-CH3 + H2O
Catalyst(Al2O3)
Methanol Dimethyl Ether
2 x 32 46 18
CH3-O-CH3 + SO3 (CH3)2SO4
Dimethyl Sulphate
46 126
9 Dimethyl Sulphate
Manufacturing Process
Methanol from day tank in the plant is taken through metering pump passed through heat
exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum
catalyst, further it is reacted with liquid SO3. The ration of consumption of methanol + SO3
for DMS produced is as follows:
SO3 = 0.70 MT and Methanol = 0.55 MT.
The moisture shall be collected out of Methanol and sent to ETP. After reaction of SO3 +
Methanol gas in a closed reaction, which will have chilled water circulation in jacket. The
crude DMS formed is having a high acidity. The distilled acid thus produced is 98% Sulphuric
Acid. This is a byproduct and will be sold or use in plant.
Chemical Reaction
Mass Balance
80
659.66 Liq SO3
DME Gas
379.33
508 Methanol Day TankHeat
Exchanger
Reactor
Containing
Al2O3
Catalyst(260°C)
Reactor
128.66 Water To ETPCondensation
Tank
Pure Dimethyl Sulphate 1000 Distillation
39
98% Spent Sulfuric Acid
MASS BALANCE OF DIMETHYL SULPHATE
31
High Pressure Steam
45 kg/cm2
410°C
Exhaust
0.1 kg/cm2
100 °C
Condenser Condensate back to
Boiler feed water
Turbine
Generator
Set
10 Power Plant
Manufacturing Process
(2.5 MW – Existing)
For power generation steam is generated from the boiler, which is then sent to steam
turbine to generate the power. At the outlet of the turbine steam goes to condenser to
recover the water utilized and further sent back to the boiler. The fuel utilized for the boiler
will be Coal.
To generate 2.5 MW, a steam of 8 MTD required, which is generated from the FO based
boiler. The FO consumption for the required steam would be approximately 1700 Lit/Day.
Total Consumption
(10 MW –Proposed)
For power generation steam will be generated from the boiler, which is then sent to steam
turbine to generate the power. At the outlet of the turbine steam goes to condenser to
recover the water utilized and further sent back to the boiler. The fuel utilized for the boiler
will be Coal.
To generate 10 MW, a steam of 40 MTD required, which is generated from the coal based
boiler. The coal consumption for the required steam would be approximately 10 MTD.
For Power plant, separate coal yard will be made in which coal will be stored, from coal yard
the coal will be sent to crusher. The crushed coal is then sent to silo for ultimate feed in to
the combustion chamber.
Process Flow Chart
32
11 Sulphuric Acid, Oleum (23% & 65%) and Liquid SO3
Manufacturing Process
The process for the manufacture of sulphuric acid comprises the following steps:
Solid Sulphur after weighment is fed to sulphur melter which is provided with steam coils.
The ash content of the molten sulphur settles in the melter cum settler and molten sulphur
free of impurities is pumped to the sulphur burner where it is burnt with air. Sulphur is
converted in to SO2 in the sulphur burner as per the following reaction
S + O2 � SO2
SO2 is further converted to SO3 in presence of Vanadium Pentoxide catalyst in the
converter as per the following reaction:
SO2 + ½ O2 � SO3
The conversion of SO2 to SO3 is carried out in stages in all the five pass of the converter. The
conversion is optimized by intermediate cooling of gases between the different stages and
also by interpass absorption of SO3 after 3rd
pass of the converter.
The gas from the 3rd
& 5th
pass of the converter containing SO3 is cooled & then fed to the
interpass & final absorption tower where SO3 is removed by circulating Sulphuric Acid in the
absorption towers. The concentration of sulphuric acid is controlled by addition of water in
the pump tank.
Air for sulphur burner is routed through Air Filter to drying tower and further to suction side
of Centrifugal Air Blower. 98.5% acid is circulated through drying tower at 70°C, thus heating
to 125°C before entering sulfur burner. This system helps to increase generation of steam
and hence power generation.
SO2 emission during start up of the plant is controlled by a Venturi Scrubber using alkali as
scrubbing medium. The plant therefore does not cause any pollution either during start up
or during normal operation.
33
The process as described above has been divided into five main sections described as
follows:
Sulphur Circuit
The weighed quantity of sulphur of about 99.5% purity is fed to the first compartment of
sulphur melter. The heat for melting sulphur is provided through steam coils. The optimum
pressure to be maintained for melting sulphur in the first compartment is upto 7 kg/cm2 G.
The molten sulphur flows from compartment no. 1 to pumping compartment through
underflows/overflows. The sulphur pumps for feeding sulphur are fitted in pumping
compartment. The total time of retention in the compartments corresponds to more than
72 hrs at normal rated production capacity of the plant. In order to achieve optimum
results, it is necessary that the feeding of sulphur to the melter should be maintained at
specified temperature of 135 °C. All compartments are fitted with steam coil to provide the
necessary heat for maintaining the temperature of molten sulphur at the desired level.
Molten sulphur from the pumping compartment is pumped to the sulphur burner through
one of the submersible type sulphur pumps through specially designed sulphur feeding gun.
The rate of feed of sulphur to the sulphur burner is controlled by operation of sulphur feed
control valve. Drain lines have been provided in the molten sulphur discharge line at two
different points.
The optimum steam pressure for coils located in 2nd
, 3rd
, 4th
through pumping
compartments of the sulphur melter is around 4 kg/cm2 G. This regulated steam pressure is
achieved through pressure reducing valve. Molten sulphur line starting from the discharge
flange of the sulphur pump to the inlet of the sulphur burner is suitably steam jacketed to
maintain correct temperature of molten sulphur fed to the sulphur burner.
SO2 Scrubber
It is very important that SO2 emission during plant startup is controlled within permissible
limits. This is achieved by use of a alkali scrubber located after the final absorption tower
where gas is scrubbed with circulating alkali solution.
34
DM and Water Softening Plants
For generation of steam of high quality DM water is required for this purpose RO plant and
DM plant will be installed.
The plant is provided with data logging system through DCS control circuits for control of
parameters like Acid concentration control, pump tank level control, Boiler feed water level
control, boiler feed water from Deaerator temperature control. All the output signals are
fed to a computer and output data is collected based on reports to be prepared including
log sheets.
Chemical Reaction
S + O2 SO2
SO2 + 1/2O2 SO3
SO3 + H2O H2SO4
Overall
S 3/2O2 + H2O H2SO4
M.W 32 48 18 98
35
Oleum & Liquid SO3
Oleum (23%)
Oleum 23% is manufactured by absorbing SO3 gas with Sulphuric Acid.
H2SO4 + SO3 H2S2O7
Oleum 23% means free SO3 in the product is 23%, which is equivalent to 105.17% Sulphuric
Acid. This way 23% Oleum is equivalent to 1.07 of 98% Sulphuric Acid. The sulphur required
for 1 ton of 23% Oleum is 0.326 x 1.07 = 0.349 ton.
Oleum (65%)
Oleum 65% means, the free SO3 in this product is 65% which is equivalent to 114.626%
sulphuric acid. This way the Oleum 65% is equivalent to 1.17 times of 98% sulphuric acid.
The sulphur required for 1 ton of 65% Oleum 0.326 x 1.17 = 0.381 ton
Liquid SO3
Liquid SO3 is = 1.25 times of 98% Sulphuric Acid. The Sulfur required for 1 ton of liquid SO3 =
0.326 x 1.25 = 0.41 ton.
36
Mass Balance
Sulphur
Metler
(135°C)
326.5 Kg
1808.682 M 3
Air Drying Tower Furnace
(1100°)
(Oxygen: 490 Kg)
Water
WHB Steam Steam Turbine to Generate
4 MW Power
Convertor
(upto 3rd pass)
200 Kg
DM Water
H2SO4 (98.5%)
Acid Pump Tank P
IPAB(Inter Pass
Absorption
Tower
99%
H2SO4
Convertor
(4th pass)
Oleum
Storage
(23% or 65%)
99% H2SO4
H2SO4
(98.5%) Storage
Final Absorption
Tower
Alkali
Scrubbe
r
Vent to
Atmosphere
Wastewater
1000 Kg 1.6
Oleum
Tower
Oleum
Pump Tank
(Oleum 23%
or 65%)
PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)
14.9 Kg
Condenser SO3 Liquid
1000
Oluem Pump
Tank (23%)
1076
Oleum
Tower
(23%)
SO3
Convertor
(132 °C)
76
37
SO3 + HCl ClSO3H
(l) (g) (l)
80 36.5 116.5
11 Chloro Sulphonic Acid
Manufacturing Process
The HCl gas is refrigerated and cleaned in gas cleaning tower. The dry HCl is reacted with liq
SO3 to get Chloro Sulphonic Acid. The unconverted gas is scrubbed in caustic scrubber.
Chemical Reaction
Mass Balance
313.4 Kg HCl Chilling
313.4 Kg
Chilled HCl
H2SO4Gas
Cleaning Bleed
313.4 Kg
Dry HCl 99.90%
686.6 Kg Liq SO3 Reactor
100.00% Gas to Stack
Caustic
Scrubber
0.16 Caustic Solutions Wastewater to ETP
10% 0.16
1000 Kg
Chlorosulphonic Acid
MASS BALANCE OF CHLOROSULPHONIC ACID
38
13 Thionyl Chloride
Process Description:
Sulphur is charged in sulfur mono chloride reactor along with chlorine in measured quantity
and reacted over a period of 12 hours to Sulphur Monochloride (SMC), which is stored for
further reaction. Thionyl Chloride reacted is fed with SMC, SO3 and Chlorine. Reactor is
fitted with fractionating column. TC gas thus produced is passed through 3 condensers, out
of which first condenser used cooling water and other two condensers use chilled water.
Crude TC is then sent to Distillation column as reflux. A part of crude TC is reacted with
sulfur to get pure Thionyl Chloride.
Alkali Scrubber is provided to absorb SO2 when required if not used captivally to
manufacture SBS; similarly chlorine scrubber removes traces of chlorine. Byproduct is
recycled back to sulfuric acid plant, where it is converted to Sulphur Trioxide for reuse in TC
Plant.
Chemical Reaction
2S + Cl2 S2Cl2
Sulphur Chlorine Sulphur Monochloride (SMC)
64 71 135
S2Cl2 + 2SO3 + Cl2 2SOCl 2 + 2SO 2
135 160 71 238 128
SMC Sulphur Trioxide Chlorine TC
Overall Chemical Reaction:
2S + 2Cl2 + 2SO3 2SOCl 2 + 2SO 2
64 142 160 238 128
39
Mass Balance
272.66 Sulphur
296.66 Chlorine
569.33 681.33 SO3 To Sulfuric Acid & SBS plant (Recycle)
296.66 Chlorine 542.33
1005
800
Product
200
Product
5
Total Product 1000
MASS BALANCE OF THIONYL CHLORIDE
SMC Reactor
TC Reactor
Condenser
Distillation
Column
40
14 Sodium Bisulphite
Manufacturing Process
Sodium Carbonate and Water is charged in the reactor. Sulphur Dioxide is then passed
slowly to the reactor. The mass is then allowed for continuous mixing. The material thus
prepared is Sodium Bi Sulphite.
Chemical Reaction
Mass Balance
Na2CO3 + 2SO2 + H2O 2NaHSO3 + CO2 106 128 18 208 44
Sodium SBSCarbonate
CO2Sodium Carbonate 509 211
SO2 615
Water 87
1000
Reactor
MASS BALANCE OF SODIUM BI SULPHITE
41
15 Calcium Chloride
Manufacturing Process
Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride.
Chemical Reaction
CaCO3 +2HCl 2CaCl2 + H20 + CO2
100 73 111 18 44
Mass Balance
3
40 Kg
Water
1000 Kg Lime Stone Ventury Scrubber (Alkali)
ETP
800 Kg HCl 40 Kg
1800 Kg
Sludge to ETP
200 Kg
1600 Kg CaCl2
Clear Liquid
600 Kg Moisture Loss
1000 Kg
Dry CaCl2
Product
Reactor
Filter Press
MASS BALANCE OF CALCIUM CHLROIDE
Evaporator
42
2S + Cl2 S2Cl2
Sulphur Chlorine Sulphur Monochloride (SMC)
64 70 134
16 Sulphur Monochloride
Manufacturing Process
Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a reactor.
Chemical Reaction
Mass Balance
477.5 Kg Sulphur
522.5 Kg Chlorine
1000 Kg
MASS BALANCE OF SULPHUR MONOCHLORIDE
SMC Reactor
43
17 Sulphuryl Chloride
Manufacturing Process
Sulphur, Chlorine & Sulphur Trioxide is reacted together to get Sulphuryl Chloride.
Chemical Reaction
S + 3Cl2 + 2SO3
3SO2Cl2
32 213 160 405
Sulphuryl Chloride
Mass Balance
80 Sulphur
87.5 Chlorine
167.5
400 SO3
447.5 Chlorine
1015
950
Product
65
Residue Product 50
15
Reactor
Reactor
Condenser
Distillation
Column
MASS BALANCE OF SULPHURYL CHLORIDE
44
18 Aluminium Sulphate (ALUM)
Manufacturing Process
Aluminium Sulphate is manufactured by the reaction of Alumina Hydrate and Bauxite with Sulphuric
Acid.
Bauxite is ground in the Pulveriser to 90% passing through 200 meshes and elevated to batch hopper
through bucket elevator. Measure quantity of water is added in the lead bonded reactor and slowly
sulphuric acid is to be added in the reactor. After getting the required temperature in the reactor,
slowly ground bauxite i.e added. After the addition of measure quantity of bauxite/alumina hydrate,
the agitator is kept on for about 45 minutes; solution is then dumped in to the settling tank.
The decanted solution of Aluminium Sulphate is then taken to the reactor and the required quantity
of sulphuric acid is added after getting the required temperature Hydrated Alumina is added slowly.
After addition, Aluminum Sulphate is molded in the trays with the help of tray filling arrangements.
The slabs after cooling are to be taken out from the trays and stacked in the store.
Chemical Reaction
2Al(OH)3 + 3H2SO4
Al2(SO4)3 + 6H2O
156 294 342 108
Mass Balance
Water
485 Alumina Hydrate/Bauxite
257 Sulphuric Acid 742
742
258 Sulphuric Acid
Moulding
in to Slab
Reactor
Settling Tank
Reactor
MASS BALANCE OF ALUM
1000 Kg
45
98
178
o-Nitro Toluene Sulphonated Sulfuric Acid
o-NT
137 217 98
CH3NO2
H2SO4
H2S2O7
CH3NO2
SO3H
+ H2SO4
+ H2S2O7 + H2SO4
Tobias Acid (TA) STA (Sulfo Tobias Acid)
223 178 303 98
NH2
SO3H SO3H
NH2SO3H
19 Sulphonation of PNT, ONT, VS, Tobias, etc.
Manufacturing Process
Take o-NT/p-NT/tobias/VS, etc. in as sulfonator and charge 98% Sulphuric Acid and 65%
Oleum in it slowly. After completion of reaction blow sulfomass in another vessel containing
water, charge common salt, mix it, cool it and filter in neutsch. Material is then centrifuge.
Collect filtrate as Spent Sulphuric Acid for sale. Sulphonated ONT/PNT from centrifuge is
then packed in HDPE bags and sent for sale.
Chemical Reaction- Sulphonated o/p-NT
Chemical Reaction- Sulphonated Tobias Acid
46
Mass Balance
Sulphonation ONT/PNT
Sulphonation Tobias Acid
ONT 637H2SO4 455.7
H2S2O7 827.71920.45
Water 83.7Common Salt 544(NaCl) 2548.2
Spent Acid (25%)Filteration (Water+Salt+Sulfuric Acid)
1009 1539
Centrifuge 9.3(Recycle to Drowning Vessel)
Wet Cake1000
Sulfonator
Drowning Vessel
MASS BALANCE OF SULPHONATION ONT/PNT
Tobias Acid 735.9
H2S2O7 587.41323.3
Brine Water 59.4
1382.7Spent Acid (25%)
Filteration (Water+Salt+Sulfuric Acid)1006.5 376.2
Centrifuge 6.6(Recycle to Drowning Vessel)
Wet Cake1000
Drowning
Vessel
MASS BALANCE OF SULPHONATION TOBIAS ACID
Sulfonator
47
20 Benzene Sulphonyl Chloride
Manufacturing Process
Benzene is reacted with Chloro Sulphonic Acid in a agitated vessel at low temperature at
about 20 -25 °C. Chloro Sulphonic Acid is used in excess for the reaction. The reacted mass is
then kept under agitation for some time. It is then transferred to another vessel containing
chilled water. During the addition, the vessel is cooled up to desire temperature till the
addition complete. The contents are kept under agitation for some time. The mass is then
separated. The acid layer is transferred to the storage tank for sale. The organic layer is
washed, dried & distilled under vacuum to get the product. The HCl gas evolved during the
reaction & isolation is send to CSA plant for making Chloro Sulphonic Acid.
Chemical Reaction
C6H6 + 2HOSO2Cl � C6H5SO2Cl + HCl + H2SO4
Benzene CSA BSC Hydrochloric Acid Gas Sulphuric Acid
78 233 126.5 36.5 98
Mass Balance
Reactor
Isolation - 1570 Kg
Distillation -1010 Kg
Benzene 446.2 Kg
CSA 1332.54 Kg
HCl Gas 208.63 Kg
Dilute H2SO4 560.6 Kg
BSC – 1000 Kg
10Kg - Residue
48
PNT(137) 98 178 PNTSA (217)
+ 2HCl + 3H2O
2NaOCl +H2O
217 149 18 474 73 54
Fe/HCl
NH4Cl
(DNSDA) Di-Sodium Salt (Nitro form) Di-Sodium Salt (Amino form)
414
+ H2SO4
414 370DASDA
CH3
+
NO2
H2SO 4+ H2S2O7 2H2SO4
CH3
NO2
+SO3H
O2N
SO3Na
- C = C
- H H
SO
3N a
NO2 H2N
SO3Na
- C = C
- H H
SO
3N a
NH2
H2N
SO3Na
- C = C
- H H
SO
3N a
NH2 H2N
SO3H
- C = C
- H H
SO
3H
NH
CH3
NO2
+SO3H
2 O2N
SO3Na
- C = C
- H H
SO
3N a
NO2
21 DASDA
Manufacturing Process
Sulfuric Acid & Oleum (65%) are taken in Sulfonator, Para Nitro Toluene (PNT) is then
charged. The mass in then dumped in to the water, cooled and filtered in Neutsch filter. The
acid is then separated, the mass (PNTOSA) is then oxidized with sodium Hypochloride. After
completion of the reaction common salt is charged at the room temperature the mass is
then filtered in Neutsch Filter.
Then reduction of DNSDA is carried out with Fe, HCl and NH4Cl. Filter the reduction mass &
isolates the filtrate using dilute H2SO4 & filters it in Neutsch filter. Material thus prepared is
DASDA, Which is then centrifuged and packed in the HDPE bags.
Chemical Reaction
49
Mass balance
PNT 370.566
H2SO4 264.69
Oleum 482.32
1117.58
Water 117.64
Salt 88.23
1323.45
Neutsch Filter 341.16Spent Acid
982.29
Centrifuge 176.46
ML(Recycle)
805.83 Drowning
Common Salt 88.23
Soda Ash 105.88
NaOCl 405.86
Water 147
1552.85
Neutsch Filter 341.16 To ETP
1211.69
Centrifuge 29.41 ML(Recycle)
4182.30 Drowning
Fe 29.41
HCl 47
NH4Cl 88.23
1347
Sulfonator
Drowning
Vessel
Oxidation
Reduction
Vessel
50
22 Dimethyl Aniline
Manufacturing Process
Methanol from day tank in the plant is taken through metering pump passed through heat
exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum
catalyst, further it is reacted with Aniline. The product is then distilled to get Dimethyl
Aniline
The moisture shall be collected out of Methanol and sent to ETP.
Chemical Reaction
Mass Balance
DME Gas
Aniline
755.24
373
519.5 Methanol Day TankHeat
Exchanger
Reactor
Containing
Aluminium
Catalyst
Reactor
146.52 Water To ETP
Condensation
Tank
1128.20
1000 Pure Dimethyl Aniline Distillation
128.20
Wastewater to ETP
MASS BALANCE OF DIMETHYL ANILINE
260°C
2 CH3OH CH3-O-CH3 + H2O
Catalyst(Al2O3)
Methanol Dimethyl Ether
2 x 32 46 18
CH3-O-CH3 + C6H5NH2 (CH3)2C6H5N + H2O
Dimethly Aniline
46 93 121 18
51
23 Diethyl Sulfate
Manufacturing Process
Ethyl Alcohol and SO3 reacts in presence of catalyst Sodium Sulphate and Urea and formed
Ethyl Hydrogen Sulfate (EHS). This EHS mass is ammoniated by ammonia and EHS gets
converted into Diethyl Sulfate. Ammonia is passed in Ethyl Hydrogen Sulfate mass. The
product thus formed is crude Diethyl Sulphate.
Moisture content present in the Ethyl Alcohol reacts with SO3 and forms Sulphuric Acid.
Distillation of crude EHS takes place under vacuum. The pure DES is produced and
transported to the storage tanks.
Chemical Reaction
Mass Balance
596.73 Ethyl Alcohol
1037.62 SO3
235.26
1398.6
NH3
110.55
1509.64
Spent ST Tank
509.64
1000
Pure Diethyl Sulfate
MASS BALANCE OF DIETHYL SULFATE
Reactor (Catalyst:
Urea+Sod. Sulfate)
Cooler
Ammoniation Reactor
Distillation
2C2H5OH + 2SO3 2C2H5OSO3H
Catalyst
Ethyl Alcohol Ethyl Hydrogen Sulfate
92 160 252
2C2H5OSO3H+ 2NH3 (C2H5)2SO4 + (NH4)2SO4
EHS Ammonia Diethyl Sulfate Ammonium Sulfate
252 34 154 132
52
350 Urea Reactor
3300 SO3/Oleum
(23-25%) 3650
R/C Mother Liquor
Mixing
5150
Separation Spent Acid
2400 2750
100 Water Make -Up
2500
Cyrstallisation
1500
1000
Packing/Bagging
Figure are in Ton/Month
MASS BALANCE OF SULFAMIC ACID
24 Sulfamic Acid
Manufacturing Process
Urea & 23-25% Oleum are fed at controlled rates to reactor, which is cooled by chilled
water/brine and cooling water. The reaction products are diluted by mixing with recycled
mother liquor (available after separation of crystals of Sulfamic acid). Temperature is
controlled during mixing by chilled water/brine. Dilute acid streams (70% sulfuric acid) is
separated after the mixing operation and is sold to SSP/Alum manufacturer.
Chemical Reaction
NH2CONH2 + SO3 NH2CONHSO3H
NH2CONHSO3H + H2SO4 2NH2SO3H + CO2
Overall Reaction
NH2CONH2 + SO3 + H2SO4 2NH2SO3H + CO2
60 80 98 2 x 97 44
Mass Balance
1500
53
ANNEXURE-IV
DETAILS OF WATER CONSUMPTION, WASTEWATER GENERATION AND TREATMENT
WATER POLLUTION AND ITS CONTROL SYSTEM
Water requirement for the project is supplied by the GWIL (Gujarat Water Infrastructure
Limited) Narmada Pipeline Project. Presently the company has agreement with GWIL for
supply of maximum of 1210 KLD. The unit is also in process for obtaining permission of
maximum supply of 2500 KLD. The details of water requirement are given in Table 1.0. The
entire water requirement is Gujarat Water Infrastructure Limited for existing & proposed
scenario.
TABLE – 1.0
WATER CONSUMPTION
Sr.
No Category
Type of
Water
Existing
Water
Consumption,
KLD
Additional
Water
Consumption,
KLD
Total Water
Consumption,
KLD
1 Process + Washing Raw Water 603.8 700* 1303.8
2 Cooling Tower Raw Water 640 128 768
3 Boiler Raw Water 262 - 262
4 Gardening Raw Water 10 40 50
5 Domestic Raw Water 27 23 50
Total 1542.8 891 2433.8
Note: 80% water use in the Ice Plant in existing unit.
* Due to operation of MEE, the condensed water will be used in process.
54
Table – 1.0 (Contd.)
WASTEWATER GENERATION FROM THE PROJECT
Sr. No Category
Existing
Wastewater
Generation,
KLD
Additional
Wastewater
Generation,
KLD
Total
Wastewater
Generation,
KLD
Industrial
1 Process + Washing 50 700 750*
2 Cooling Tower 19 24 43
3 Boiler 24 0 24
4 Domestic 19.6 15.4 35
Total 112.6 739.4 852
* 750 m3/day of Process + Washing wastewater goes to MEE, then after 320 m
3/day of
condensate water from MEE will be reused and 125 m3/day will be incinerated.
Water Balance Flow Diagram
Raw Water: 2433.8 m3/Day
Process +
Washing:
1303.8 m3/Day
Cooling tower:
768 m3/Day
Gardening
50 m3/Day
Domestic:
50 m3/Day
750 m3/Day
Incinerator: 125 m3/Day
ETP: 817 m3/Day MEE
Boiler:
262
m3/Day
Soak Pit/
Septic Tank –
35 m3/Day
43 m3/Day 24 m
3/Day
MEE Salt – 173 m3/Day
Condensate - 320 m3/Day will
be used in gardening,
washing, flushing & cooling
tower make up, etc.
55
WASTEWATER MANAGEMENT
The wastewater generated will be segregated and treated separately. After proposed
expansion total of 817 KLD of Industrial & 35 KLD of domestic wastewater will be generated.
The industrial wastewater will be further segregated considering its pollution load and
finally be treated within premise.
SEGREGRATION OF THE WASTE STREAMS:
The Various Streams generated from the industrial activity will be as follows:
Stream A: Process wastewater from Vinyl Sulphone after recovery of sodium sulphate (30 –
40 %), which will have high concentration of COD which will go to Incinerator.
Stream B: Floor Wash water from Sulphonation plant, DASDA Plant, DMS Plant, DMA Plant,
Sulfamic Acid Plant which will go to ETP and then after MEE Unit. Condensate water will be
reused in gardening, washing, flushing & cooling tower make up, etc.
Stream C: Utility wastewater (viz Boiler blow down, Cooling water blow down and Washing)
which will go to ETP and then after MEE Unit.
Stream D: Domestic wastewater will go to soak pit or to maintain biomass in ETP.
The streams from the process will be conveyed to the equalization/ collection tank and is
given a primary treatment. The utility wastewater will be directly taken into the final
collection tank after the physical screening of the wastewater.
56
CHARACTERISTICS OF THE WASTEWATER STREAMS
TABLE 2.0
CHARACTERISTICS OF VARIOUS STREAMS OF WASTEWATER
Sr
.
N
o
Paramete
rs
Unit Characterist
ic of
Process
Streams-
Vinyl
Sulphone
Characteristi
cs of Other
Process
Streams
Characteristi
cs of Cooling
Tower Blow
down
Characteristi
cs of Boiler
Blow down
Analysis
Results
After
treatme
nt
Permissib
le Limits
1 Color pt
Co.
unit
s
- Turbid –Light
Yellow
Colorless Colorless Colorless 100 units
2 pH - 6.5-8.5 3.5-6.5 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5
3 COD mg/
L
8500-10000 1000-1200 100 100 <250 <250
4 BOD3 mg/
L
2000-4200 300-400 35 35 <100 <100
5 TDS mg/
L
8000-10000 2000-2500 4500 4500 <2100 <2100
Effluent Treatment Plant
1. Stream A: Process wastewater from Vinyl Sulphone after recovery of sodium sulphate
(50%), which will have high concentration of COD which will go to Incinerator.
The effluent from all plants is collected in the ETP, where effluent from VS plant is collected
in the separate tank and effluent from all other plant is collected separately.
The effluent collected from VS plant is send for Glauber salt recovery. After recovery of
Glauber salt, where as ML from recovery section is reused.
Incinerator Plant
Stream A containing high COD concentration will be processed for effluent reduction by
crystallization, evaporation process. The concentrated and reduced effluent will be
incinerated. The flow scheme of the same has been described below:
57
The ML is first collected in collection tank and then it is pumped to crystallizer for recovery
of Glauber Salt. The filtrate effluent is pumped to filter press. The filtrate is collected in
collection tank from where it is pumped to the multi effect evaporator for reduction in
volume.
The concentrated ML is collected in other collection tank from where it is pumped to the
incinerator.
The total volume of effluent to be passed through effluent reduction process is 50 KLD. The
reduced mass after the evaporation will be 20 KLD, which will be sent to incinerator for the
final incineration process.
Process Effluent & EO Condensate
Collection Tank Crystallizer
Glauber Salt
Filter Press
Washing Water
Washing Chilled Water
Crystallizer
Liquid Effluent Tank
Multiple Effective Evaporators
Conc. Effluent Incineration
58
TABLE 3.0
SPECIFICATON OF INCINERATOR (EXISTING)
Sr. No. Description Details
1 Type Vertical
2 Capacity 2000 Lit/Hr
3 Size - Diameter 1.0 meter
4 Height 5.0 meter
5 Inlet feed rate 2000 Lit/Hr
6 Fuel Consumption 250 Lit/Hr
7 Fuel LDO
8 LDO Feed System Pumping
9 Nozzle
LDO
Mother liquor
Lap – 1 (2 Nos.)
Lap – 2 (2 Nos.)
10 Operating Temperature 800-1100 °C
11 Scrubber Ventury Scrubber
2. Stream B & Stream C containing lesser pollution load will be collected in collection &
equalization tank and physico chemical treatment followed with Tertiary Treatment. The
treatment scheme is as under.
Effluent from plant feed into the chlorinator where it is mixed with chlorine water. After the
effluent water send to equalization tank-I and the equalization tank-II. This effluent feed to
the neutralizer, to maintain the pH by addition of Soda ash/lime solution then passes to the
clarifier for removing the Suspended solid particles and collect the effluent into
underground sump. This effluent is pumped into the sand filter for removing rust of
suspended solid particles and passes through to the activated carbon bed for color and COD
reduction. Then effluent is send to Multiple Evaporator for removal of TDS.
Condensate from MEE approx. 70 KL is use for gardening, washing, flushing & cooling tower
make up in existing scenario. Condensate from MEE approx. 230 KL will be reuse for
gardening, washing, flushing & cooling tower make up in proposed scenario.
59
Effluent Treatment Plant Units:
Table 4.0
Sizing of ETP Units
Sr.
No. Name of Units Size (m x m x m)
No.
1 Collection Tank 4.5 x 4.5x 2.1 1
2 Equalization tank 3.0 x 3.25x 3.7 2
3 Lime Slurry Tank 2.7 x 1.7 x2.0 2
4 Neutralization Tank 3.0 ф X 3.0 depth 1
5 Primary Clarifier 4.8 ф X 2.7 depth 1
6 Final Water Tank 6.6 x 3.2.1 2
60
Flow Diagram:
Plant Washing
Water
Collection
Tank
Equalization
Tank
Neutralization
Tank
Primary
Clarifier
Sludge Bed Water Collection
Tank
Multiple
Evaporators
Reuse in
Plant
Salt
Incinerator
61
Multiple Effective Evaporator
62
Specification of MEE
63
3. Septic Tank & Soak Pit
Domestic waster will be generated to the tune of 40KLD. The entire sewage will be disposed
off in to the septic tank and soak pit.
64
ANNEXURE-V
DETAILS OF HAZARDOUS WAST GENERATION & DISPOSAL
Sr.
No. Type of Hazardous
Waste
Existing Additio
nal
Total After
Proposed
Expansion Hazardo
us Waste
Category
Storage, Collection
& Disposal MT/
Month MT/
Month MT/
Month
1 ETP Sludge 31.7 - 31.7 34.3 Collection, Storage ,
Transportation &
Disposal to TSDF or Sold
to Actual Users (i.e.
cement mfg. industries)
2 Process Sludge 800 - 800 - Collection, Storage ,
Transportation & sell to
Fertilizer
Industries/Cement
Industries/agriculture
3 Distillation Residue 0.2 0.43 0.63 20.3 Collection, Storage ,
Transportation &
Disposal to Incineration
or Sold to Actual Users
(i.e. cement mfg.
industries)
4 Incineration Ash 12 48 60 36.2 Collection, Storage ,
Transportation &
Disposal to TSDF
5 Used Oil/Spent Oil 0.2 0.092 0.292 5.1 Collection, Storage,
Transportation & Sell to
GPCB Authorized
Reprocessor
6 Empty
Drums/Container
25
Nos./ Year
50
Nos./ Year
75 Nos./
Year
33.3 Collection, Storage,
Transportation & Sell to
CPCB/GPCB Authorized
Vendor
7 Empty Bags 200
Nos./
Year
100
Nos./
Year
300 Nos./
Year
33.3 Collection, Storage,
Transportation & Sell to
CPCB/GPCB Authorized
Vendor
8 Salt from MEE - 5190 5190 34.3 Collection, Storage ,
Transportation & Sold to
End Users
Note: The empty drums generated are basically from dry powder raw material. The drums
are then stored at separate hazardous waste storage are finally be given to the approved
vendor. Hence, no decontamination is required at the site.
65
ANNEXURE-VI
DETAILS OF STACK AND VENTS
DETAILS OF EMISSION FROM STACK AND VENT
* Mark indicates permissible limits
Stack Attached To:
1. Thermic Fluid Heater Boiler (I, II, III & IV) (Existing)
2. D.G.Set – 1500 KVA (Existing)
3. Steam Boiler (Existing)
4. Incinerator-I (Existing)
5. Incinerator-II (Existing)
6. MCB Plant (Existing)
7. VS Plant (Existing)
8. SA Plant (Existing)
9. Power Plant (Existing)
10. Thionyl Chloride (Existing)
11. Sulphur Mono Chloride (Existing)
12. Reactor of CSA Plant (Existing)
SR.
NO.
OPERATING
PARAMETER
UNIT SOURCE OF EMISSION (EXISTING)
1 2 3 4 5 6 7 8 9 10 11 12
1. Stack height Meter 30 30 30 30 30 22 20 50 30 26 26 20
2. Stack
diameter at
top
Meter 1.2 0.8 1.2 1.2 1.2 0.6 0.6 1.0 1.2 0.8 0.8 0.6
3. Flue gas exit
velocity
m/s 7.0 7.5 7.2 7.1 7.2 4.0 5.1 5.0 7.0 5.2 5.0 4.5
4. Emission
concentration
PM
SO2
NOx
HCl
Cl2
mg/Nm3
mg/Nm3
mg/Nm3
mg/Nm3
mg/Nm3
131.5
104.3
14.3
--
--
90.5
18.2
7.4
--
--
138.5
108.4
14.4
--
--
122.7
86.0
9.2
--
--
124.6
93.0
9.6
--
--
--
--
--
8
--
--
--
--
6.1
--
--
6.5
--
--
--
--
10.5
1.2
--
--
--
10.1
--
--
6.2
--
--
--
--
8.1
--
20.3
--
--
--
5. Flue gas
temp.
0K 435 423 438 443 443 318 325 318 440 325 325 323
6. Ambient
temp.
0K 298 298 298 298 298 298 298 298 298 298 298 298
7. Wind Speed m/s 1.92 1.92 1.92 1.92 1.92 1.92 1.92 1.92 1.92 1.92 1.92 1.92
66
Details of Emission from Stack and Vent
* Mark indicates permissible limits
Stack Attached To: 1. BSC Plant (Proposed)
2. DASDA Plant (Proposed)
SR.
NO
.
OPERATING
PARAMETER
UNIT SOURCE OF
EMISSION
(PROPOSED)
1 2
1. Stack height
Meter 20 26
2. Stack diameter at
top
Meter 0.6 0.8
3. Flue gas exit
velocity
m/s 5.1 5.3
4. Emission
concentration
PM
SO2
NOx
HCl
mg/Nm3
mg/Nm3
mg/Nm3
mg/Nm3
--
40*
--
20*
--
40*
--
20*
5. Flue gas temp. 0K 325 318
6. Ambient temp. 0K 298 298
7. Wind Speed m/s 1.92 1.92
67
Air Pollution & its Control
There shall (12 Existing + 6 Proposed) source of air pollution at M/s. Kutch Chemical Ind. Ltd.
i.e. stack attached to boiler, Incinerator and process vents. Required Scrubber system shall
be installed to prevent air pollution.
Details of Air Pollution Control Measures
Bag Filter
Boiler
68
Scrubber for SO2
Scrubber for HCl
NRV
PG
DILUTE NaOH
Water
PACKED
COLUMN
SCRUBBER
VENTURY
SCRUBBER
BLOWER
STACK
reactor
1
69
ANNEXURE-VII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
NAME OF
HAZARDOUS
SUBSTANCE
MAX. STORAGE
CAP.[Qty.]
PLACE
OF IT’S
STORAGE
OPERATIN
G
PRESSURE
AND TEMP.
TYPE OF
HAZARD
CONTROL
MEASURE PROVIDED
Vinyl Sulphone Plant
Ethylene
Oxide
25 KL X 1 bullet
15 KL X 1 bullet
Licenced
Premises A/G SS
10 Kg/ cm2
Ambient
Fire
/Explosion/
Toxic
� Double Safety Valve
� Nitrogen Blanketing
� Double Static earthing
� Dyke wall
� Scrubber provided
� Jumper clips on flanges
� Hydrant system
� Fire extinguishers
� Fencing and No Smoking
and prohibited area.
� Tanker unloading
procedure.
� Shed provided on
bullets.
� Sprinkler provided on
bullets.
� SCBA sets available.
� Safety shower.
Chloro
Sulfonic Acid
45 KL X 6 Nos
Tank
Tank farm
area A/G MS
ATP
Ambient
Corrosive � Level gauge provided.
� Scrubber provided
� Required PPEs provided
to all employees
� Double drain valve will
be provided to sulfuric
Acid storage tank
� Full body protection will
be provided to operator.
� Caution note and
emergency first aid will
be displayed and train
for the same to all
Chloro
Sulfonic Acid
(Proposed)
200 MT X 3 Nos. Do ATP Ambient
Corrosive
Caustic Lye 25 KL X 2Nos
Tank Tank farm
area
A/G MS
ATP Ambient
Corrosive
Caustic Lye 40 KL X6 Nos
Tank Do ATP
Ambient Corrosive
Sulfuric Acid 20 KL X 1Nos
Tank
Do ATP
Ambient
Corrosive
70
Hydrochloric
Acid 30 KL X 3Nos
Tank Tank farm
area
A/G HDPE
ATP Ambient
Corrosive employees.
� Safety shower and eye
wash will be provided in
storage tank area and
plant area.
� Total close process will
be adopted for Sulfuric
acid handling.
� Dyke wall will be
provided to storage tank
Acetanilide Plant
Acetanilide 600 MT Godown ATP,
Ambient
Combustible � Flame proof plant,
pumping transfer, close
process, etc.
� Double Static earthing
� Dyke wall
� Tanker unloading
procedure.
� SCBA sets available .
� Flame proof plant,
pumping transfer, close
process, etc.
� Jumper clips on flanges
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� Flame arrestor provided
on vent line of the tank
Aniline 100 KL X 1 No
Tank Tank farm
area
A/G MS
ATP,
Ambient Flammable
Aniline 200 KL X 1 No
Tank Do ATP,
Ambient Flammable
Acetic Acid 100 KL X 2 No
Tank
Do ATP,
Ambient
Corrosive/
Flammable
Dil. Acetic
Acid
25 KL X 2 No
Tank
Do ATP,
Ambient
Corrosive
Ethyl Acetate 25 KL X 1 No
Tank
15 KL X 1No
Tank
Do ATP,
Ambient Flammable
MCB, ODCB, PDCB, DCB Plant
Chlorine 209 Tonners Storage
Shed 10 Kg/cm2 Ambient
Toxic � Chlorine Kit, Caustic Pit,
SBA sets, Cl2 Shed, Cl2
Hood, EOT, etc.
Provided. Chlorine 200 Tonners Storage
Shed
10 Kg/cm2
Ambient
Toxic
Benzene 40KLX4 Nos
Tank
Total : 160 KL
U/G Tank MS
ATP Fire � Flame proof plant,
pumping transfer, close
process, etc.
� Double Static earthing
� Dyke wall
� Tanker unloading
procedure.
� SCBA sets available .
� Flame proof plant,
pumping transfer, close
Monochloro
Benzene
(MCB)
200KLX2Nos
Tank
Tank farm
area A/G MS
ATP Fire
PNCB 90KLX 2 Nos
Tank
DO ATP Fire
ONCB 200KLX 1 No
Tank
DO ATP Fire
71
Dichloro
Benzene
(DCB)
200KLX 1 No
Tank Tank farm
area
A/G MS
ATP Fire process, etc.
� Jumper clips on flanges
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� Flame arrestor provided
on vent line of the tank
� Hydrant system
NB, PNT, ONT, Plant
Toluene 40KLX4 Nos
Tank Total : 160 KL
U/G Tank
MS
ATP Fire � Flame proof plant,
pumping transfer, close
process, etc.
� Double Static earthing
� Dyke wall
� Tanker unloading
procedure.
� SCBA sets available .
� Flame proof plant,
pumping transfer, close
process, etc.
� Jumper clips on flanges
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� Flame arrestor provided
on vent line of the tank
� Hydrant system
Benzene 40KLX4 Nos
Tank
Total : 160 KL
U/G Tank
MS
ATP Fire
Nitric Acid 20KLX3 Nos
Tank
MS A/G
Tank
ATP Corrosive � Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
Sulphuric
Acid 20KLX 1 No
Tank MS A/G
Tank ATP Corrosive
PNT
(P-
NitroToluene
)
200KLX1No
Tank
MS A/G
Tank
ATP Fire � Flame proof plant,
pumping transfer, close
process, etc.
� Double Static earthing
� Dyke wall
� Jumper clips on flanges
ONT O- Nitro
Toluene
200 KLX 1 No
Tank MS
A/G(V)
Tank
ATP Fire
72
MNT (Meta Nitro
Toluene)
90KL X1 No
Tank
200KLX 1 No
Tank Total : 290 KL
MS A/G
(H) Tank
MS
A/G(V)
Tank
ATP Fire � Hydrant system
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� Flame arrestor Provided. NB (Nitro
Benzene)
150KLX 1 No
Tank ATP Fire
Sulphuric Acid Plant
Sulfur
powder 5000 MT Storage
yard ATP Fire � Separate storage area.
� Monitors provided
surrounding the storage
area.
� Automatic conveyer
system for charging in
melter.
Oleum 65 % 250 MT X2 Nos
Tank
MS A/G
Tank
Atmospheri
c Ambient
Corrosive � Level gauge provided.
� Scrubber provided
� Required PPEs provided
to all employees
� Double drain valve will
be provided to sulfuric
Acid storage tank
� Full body protection will
be provided to operator.
� Caution note and
emergency first aid will
be displayed and train
for the same to all
employees.
� Safety shower and eye
wash will be provided in
storage tank area and
plant area.
� Total close process will
be adopted for Sulfuric
acid handling.
� Dyke wall will be
provided to storage tank
Oleum 23% 250 MT X 1No
Tank MS A/G
Tank
Atmospheri
c
Ambient
Corrosive
Oleum 65 % 100 MT X 2 Nos. MS A/G
Tank
Atmospheri
c Ambient
Corrosive
Liq Sulphur
Trioxide MS A/G
Tank
Atmospheri
c
Ambient
Corrosive
Sulphuric
Acid 98 %
1000 MT X 2
Nos. tank
MS A/G
Tank
Atmospheri
c Ambient
Corrosive
CSA Plant
Chloro
sulphonic
Acid
50 KLX 3 Nos
Tank 140 KL X 01
Tank
MS A/G
Tank
Atmospheri
c Ambient
Corrosive � Level gauge provided.
� Scrubber provided
� Required PPEs provided
to all employees
� Double drain valve will
be provided to sulfuric
Acid storage tank
Chloro
sulphonic
Acid
2000 MT X 2
Nos Tanks MS A/G
Tank
Atmospheri
c
Ambient
Corrosive
73
Dimethyl
Sulfate
(DMS)
200 MTX 3 Nos.
MS A/G
Tank
Atmospheri
c
Ambient
Fire � Full body protection will
be provided to operator.
� Caution note and
emergency first aid will
be displayed and train
for the same to all
employees.
� Safety shower and eye
wash will be provided in
storage tank area and
plant area.
� Total close process will
be adopted for Sulfuric
acid handling.
� Dyke wall will be
provided to storage tank
Dimethyl
Aniline
(DMA)
100 MTX 2 Nos.
MS A/G
Tank
Atmospheri
c
Ambient
Fire
Diethyl
Sulfate (DES)
200 MTX 2 Nos.
MS A/G
Tank
Atmospheri
c Ambient
Fire
Benzene
Sulphonyl
Chloride
100 MTX 2 Nos.
MS A/G
Tank
Atmospheri
c
Ambient
Fire
DASDA
100 MTX 2 Nos. MS A/G
Tank
Atmospheri
c Ambient
Fire
Methanol 60KLX 4 Nos
Tank MS A/G
Tank
Atmospheri
c Ambient
Fire � Flame proof plant,
pumping transfer, close
process, etc.
� Double Static earthing
� Jumper clips on flanges
� Hydrant system
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� Flame arrestor Provided.
Ethanol 200 KL X 1 No.
tank
MS A/G
Tank
Atmospheri
c Ambient
Fire
74
Ammonia
Anhydrous
( Liquefied )
50 MT X 1 No.
Bullet MS bullet 35
0 C
4 to 10
kg/cm2
Toxic � Flame proof equipment,
pumping transfer, close
process, etc.
� Double Static earthing
� Dyke wall
� Scrubber provided
� Jumper clips on flanges
� Hydrant system
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� SCBA sets available .
� Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
Hydrochloric
Acid
25 KL X 03 Nos A/G HDPE
Tank
Atmospheri
c Ambient
Corrosive � Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
TC plant (PROPOSED)
75
Thyonile
chloride 150KL X 03 Tank SS
A/G
Bullet
Atmospheri
c
Ambient
Corrosive � Level gauge provided.
� Scrubber provided
� Required PPEs provided
to all employees
� Double drain valve will
be provided to sulfuric
Acid storage tank
� Full body protection will
be provided to operator.
� Caution note and
emergency first aid will
be displayed and train
for the same to all
employees.
� Safety shower and eye
wash will be provided in
storage tank area and
plant area.
� Total close process will
be adopted for Sulfuric
acid handling.
� Dyke wall will be
provided to storage tank
Chlorine 140 Toner Storage
Shed 10 Kg/cm2 Ambient
Toxic � Chlorine Kit, Caustic Pit,
SBA sets, Cl2 Shed, Cl2
Hood, EOT, etc.
Provided.
� Scrubber provided .
Sulpher
trioxide
100 MT X 02
Tank
MS Tank Atmospheri
c Ambient
Corrosive � Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
Chlorinated Paraffin Wax CPW (PROPOSED)
HNP 65KLX 04 TANK MS Tank Atmospheri
c Ambient
Flammable � Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
76
HCL 75KLX 6 TANK HDPE
TANK Atmospheri
c
Ambient
Corrosive � Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
Chlorinated
Paraffin oil
20 KLX 03 FRP Atmospheri
c Ambient
Corrosive � Safety Showers provided
� Caution note provided
� Dyke wall provided
� Level gauge provided.
� Double drain valve
provided
� Scrubber provided
� Required PPEs provided
to all employees
Furnace Oil/
LDO 27 KLX 2 Nos
U/G tanks MS Tank Atmospheri
c Ambient
Fire � Flame proof plant,
pumping transfer, close
process, etc.
� Double Static earthing
� Jumper clips on flanges
� Hydrant system
� Fire extinguishers
� Fencing and No
Smoking and prohibited
area.
� Tanker unloading
procedure.
� Flame arrestor Provided.
HSD 21 KL Tank MS Tank Atmospheri
c Ambient
Fire
79
ANNEXURE-VIII
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
The manpower requirement for the proposed expansion project is being expected to
generate some permanent jobs and secondary jobs for the operation and maintenance of
plant. This will increase direct / indirect employment opportunities and ancillary business
development to some extent for the local population.
This phase is expected to create a beneficial impact on the local socio-economic
environment.
2) INDUSTRIES
Required raw materials and skilled and unskilled laborers will be utilized maximum from the
local area. The increasing industrial activity will boost the commercial and economical status
of the locality, to some extent.
3) PUBLIC HEALTH
The company regularly examines, inspects and tests its emission from sources to make sure
that the emission is below the permissible limit. Hence, there will not be any significant
change in the status of sanitation and the community health of the area, as sufficient
measures have been taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION
Since the existing factory is having proper linkage for the transport and communication, the
development of this project will not cause any additional impact.
In brief, as a result of the expansion there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be
taken under the EMP. The proposed expansion is not expected to make any significant
change in the existing status of the socio - economic environment of this region.
80
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