form-1environmentclearance.nic.in/writereaddata/modification/previoustor/... · facilities for...

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 [email protected]

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)


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?


quantities / rates wherever possible)


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?




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.


No?


quantities/rates, wherever possible)


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.


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


No?




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?




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.


No?




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


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


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


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


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


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


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


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


(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


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


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


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


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


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


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)


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.


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


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


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


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


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


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,


CPCB/GPCB Authorized

Vendor

7 Empty Bags 200

Nos./

Year

100

Nos./

Year

300 Nos./

Year

33.3 Collection, Storage,


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.


� 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.


� Dyke wall


procedure.

� SCBA sets available .

� Flame proof plant,


process, etc.



� Fencing and No

Smoking and prohibited

area.


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,


process, etc.


� Dyke wall


procedure.




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.



� Fencing and No


area.


procedure.



� Hydrant system

NB, PNT, ONT, Plant

Toluene 40KLX4 Nos

Tank Total : 160 KL

U/G Tank

MS



process, etc.


� Dyke wall


procedure.




process, etc.



� Fencing and No


area.


procedure.



� 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



to all employees

Sulphuric

Acid 20KLX 1 No

Tank MS A/G

Tank ATP Corrosive

PNT

(P-

NitroToluene

)

200KLX1No

Tank

MS A/G

Tank



process, etc.


� Dyke wall


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


� Fencing and No


area.


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




to all employees



Acid storage tank






for the same to all

employees.




plant area.



acid handling.



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




to all employees



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





for the same to all

employees.




plant area.



acid handling.



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,


process, etc.



� Hydrant system


� Fencing and No


area.


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,


process, etc.


� Dyke wall



� Hydrant system


� Fencing and No


area.


procedure.


� Safety Showers provided





provided



to all employees

Hydrochloric

Acid

25 KL X 03 Nos A/G HDPE

Tank

Atmospheri

c Ambient

Corrosive � Safety Showers provided





provided



to all employees

TC plant (PROPOSED)

75

Thyonile

chloride 150KL X 03 Tank SS

A/G

Bullet

Atmospheri

c

Ambient




to all employees



Acid storage tank






for the same to all

employees.




plant area.



acid handling.



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






provided



to all employees

Chlorinated Paraffin Wax CPW (PROPOSED)

HNP 65KLX 04 TANK MS Tank Atmospheri

c Ambient

Flammable � Safety Showers provided





provided



to all employees

76

HCL 75KLX 6 TANK HDPE

TANK Atmospheri

c

Ambient






provided



to all employees

Chlorinated

Paraffin oil

20 KLX 03 FRP Atmospheri

c Ambient






provided



to all employees

Furnace Oil/

LDO 27 KLX 2 Nos

U/G tanks MS Tank Atmospheri

c Ambient

Fire � Flame proof plant,


process, etc.



� Hydrant system


� Fencing and No


area.


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.

form-1environmentclearance.nic.in/writereaddata/modification/previoustor/... · facilities for...

Documents