Feasibility Report on the Proposed Expansion in Manufacturing Capacity of Synthetic Organic Chemicals Manufacturing at M/s DBS Chemicals

Transcription

1 Feasibility Report on the Proposed Expansion in Manufacturing Capacity of Synthetic Organic Chemicals Manufacturing at M/s DBS Chemicals Sanghvi-Shirwal [PIN ] Taluka: Khandala, Dist. Satara August,

2 Contents 1. Purpose Background Industry Details Environmental Policy of DBS Chemicals Site Location Plant Layout Processes carried out in the plant Water consumption Manufacturing process and flow diagram for Para Amino Azo Benzene (PAAB) 13 Product Name: Para Amino Azo Benzene (PAAB) / Solvent Yellow Raw Materials Manufacturing Process: Process Flow details for 1000 kg PAAB Material Balance for 1000 kg PAAB Treatment and disposal of by-products Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow 1, Effluent and other outputs in kg from PAAB production Analysis Report of treated effluent Proposed scale-up and Additional Products Material Balance of Proposed PAAB 1500 kg batch Material Balance in kg for Proposed Scale up of PAAB Manufacturing process and flow diagram for Fast Garnet GB base /Ortho Amino Azo Toluene (OAAT) Manufacturing process Chemical Reaction of OAAT Process flow chart of OAAT Waste Management for Scale-up Effluent Treatment Proposed Effluent Treatment: Air Pollution Control Hazardous Waste Management Justification for Environmental Clearance

3 Figures Figure 1: Schematic Details of Village Sanghvi... 8 Figure 2: Schematic Layout Plan of DBS Chemicals... 9 Figure 3: Schematic Layout showing plant equipment Figure 4: Water Supply Diagram Figure 5: PAAB Chemical Reaction Figure 6: Process flow chart PAAB Figure 7: OAAT Chemical reaction Figure 8: Process flow diagram of OAAT Figure 9: Process Flow Chart of Yellow Dye Figure 10: Proposed Zero Liquid Discharge Scheme Tables Table 1: Industry Details... 6 Table 2: Room wise measurements (dimensions in feet) Table 3: List of Plant & Machinery Table 4: Material Balance (for 1000 kg PAAB) Table 5: Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow 1 16 Table 6: Effluent and other outputs in kg from PAAB production Table 7: Other Water Consumption/effluent generation in kg per month Table 8: Treated Effluent Analysis Table 9: Material Balance of Proposed for PAAB 1500 kg Table 10: Material Balance in kg for Proposed Scale up of PAAB Table 11: Material Balance for 1000 kg OAAT batch Table 12: Scale up - Ortho Amino Azo Toluene (OAAT) Table 13: Material Balance for 800 kg OAAT batch Table 14: Material Balance for 1600 kg OAAT batch Table 15: Input Raw Material Quantity Details OAAT / Garnet

4 Table 16: Other Water Consumption Table 17: Material Balance Yellow Dye Table 18: Monthly production Yellow Dye Table 19: Proposed Effluent generation from PAAB Table 20: Proposed Effluent generation from OAAT / Garnet Table 21: Proposed Effluent generation from Yellow Dye Table 22: Other water consumption Pictures Picture 1: Google image of Village Sanghvi in Shirwal area... 8 Picture 2: Google image showing DBS Chemicals... 9 Picture 3: Coiled Jacketed Reactor Picture 4: Distillation Vessel and Tray Picture 5: Centrifuges Picture 6: Tray Dryer and Finished Product Picture 7: Solvent Storage Tanks Picture 8: Finished Product Storage Picture 9: Neutralisation Tank Picture 10: Tertiary Treatment

5 1. Purpose DBS Chemicals is engaged in the manufacture of Synthetic Organic Chemicals and has been in operation since DBS Chemicals are operating their Manufacturing facility at Plot. No. 285, 286/4, 287 notified Shirwal Industrial Area, Sanghvi, Taluka: Khandala, Shirwal , Dist. Satara in Maharashtra and operate with a valid Consent to Operate No.BO/AST/RO-Pune/EIC NO.PN /10436 dated 20/12/2013 for production of 8MT/Month Para Amino Azo Benzene (PAAB). (Copy of Consent to Operate is given under Sr.No.14). This facility has an installed capacity to manufacture 80MT/Month PAAB and within the same capacity can manufacture 120MT/Month Garnet (GB Base)/Solvent yellow 3/ or Ortho Amino Azo Toluidine (OAAT) or 5MT/Month Yellow Dye either singly or in combination with minor modification to existing manufacturing installation. The present activity at site is only in one shift of 6 hrs during the day which is proposed to be extended to three shifts of 8hrs a day with scaling up of the batch to the max possible batch size per shift, and hence it is proposed to amend the existing 8MT/Month production capacity of PAAB in the Consent to Operate to 80MT/Month of PAAB with addition of 120MT/Month Garnet/OAAT and 5MT/Month Yellow Dye. The Consent to Establish for this same has been obtained from MPCB vide consent order no. B. O/MPCB/AST/EIC.No-PN /E/CC-8523 dated: (Copy of Consent to Establish is given under Sr.No.15). The justification for amendment to Consent is detailed below under Annexure Background Late Mr. G.V. Utgi a double graduate with M.Sc. (Tech) by research from UDCT Mumbai in 1963 was the founder member of the organization. 5

6 DBS Chemicals is the first Manufacturers of Para Amino Azo Benzene (PAAB), a synthetic organic chemical, in India since 1982 and have carried a reputation of manufacturing quality Para Amino Azo Benzene for last 34 years with installed manufacturing capacity of 80MT/month at their plant at Sanghvi in Satara District. DBS Chemicals is one of the largest manufacturers of PAAB in India. This product being an import substitute big reputed companies like Sandoz India Ltd., Colorchem Ltd., Atul Ltd, who used to import this product from Germany & Japan now use the product manufactured by DBS Chemicals. DBS Chemicals have setup a well-equipped laboratory to help in development and testing of online process parameters, Raw materials and finished products.the laboratory has testing instrument like Gas Chromatograph, Automatic Titrator, UV Spectrophotometer, Karl Fisher Moisture Meter for finding purity and strength of dyes Intermediates. Muffle Furnace, Lab Oven, Vacuum Pump, Small Distillation Unit, Digital ph Meter, Electronic Weighing Balance, and various other equipments for finding different characteristics of Dyes & Chemicals. The effort and emphasis of the DBS Chemicals is to ensure consistent high quality products with a commitment to regular and scheduled supplies. 3. Industry Details Following Table 1 gives the industry details. Table 1: Industry Details Sr. Details No. 1. Name & Address of the Industry: Description M/s DBS Chemicals, Plot No. 285, 286/4, 287 notified Shirwal Industrial Area, Sanghvi Shirwal Taluka Khandala, Dist. Satara 2. Contact Details Shri Devdatta Utgi, Managing Director, Cell No / E mail: info@dbschemicals.com 6

7 3. Type & Category Chemical Unit in Red SSI Sector 4. Consent to Operate Validity up to : Products i. Manufactured: Para Amino Azo benzene [PAAB] 8MT/ month ii. Proposed under Amendment: Combined product manufacturing capacity shall not exceed 205 MT per month comprising (a) Synthetic Organic Chemicals such as Methylene Yellow N (Dye Yellow), (b) Synthetic Organic Chemicals such as PAAB and (c) Fast Bases such Garnet GB based Garnet (OAAT). Note: Depending upon the market demand, above products will be manufactured singly or in combination in batch process. 4. Environmental Policy of DBS Chemicals Environmental Policy of DBS Chemicals states that DBS CHEMICALS uncompromisingly commits itself to conserving the environment, besides protecting it. We would first look at each and every business of ours from the perspective of Environmental friendliness for prevention of pollution. We assure compliance with all applicable environmental legislations and other statutory requirements. We will adopt Environmental friendly technologies and ensure minimum waste generation and strive simultaneously to develop effective methods for waste treatment to improve the quality of wastewater generated from our process. We will always operate our factory and office in a healthy atmosphere and ensure a high degree of safety for employees and the general public. We are committed to conserving water. 7

8 5. Site Location DBS Chemicals plant is located at Plot No. 285, 286/4, 287 notified Shirwal Industrial Area, Sanghvi Shirwal Taluka Khandala, Dist. Satara. Picture 1 below shows Google image of Sanghvi Area and Figure 1 below shows the schematic details of Sanghvi village. The plant is surrounded by other SMEs such as Hy-Tech, Paranjape Auto cast Pvt. Ltd. on the east and north side and there is existing agricultural land on the west side and some more SMEs on the south side. The plant surrounding area can be seen from the Google image Picture 2 below. Picture 1: Google image of Village Sanghvi in Shirwal area Figure 1: Schematic Details of Village Sanghvi 8

9 Picture 2: Google image showing DBS Chemicals 6. Plant Layout Figure 2 below shows the schematic of Plant layout and Figure 3 below shows the schematic of equipment layout. Figure 2: Schematic Layout Plan of DBS Chemicals 9

10 Figure 3: Schematic Layout showing plant equipment Table 2 below gives the sizes of areas allocated in the plant for different equipment and Table 3 below gives the details of Plant and Machinery. Table 2: Room wise measurements (dimensions in feet) Sr. No. Description Length Width Height 1 Old plant changing room to dispatch room 2 Boiler room Acid Tank shade Sodium Nitrite & Caustic Shade Old bathroom, office, store, lab Hazardous tanks New plant New office to worker room D. G. set room Canteen

11 Table 3: List of Plant & Machinery Sr. No. Name of equipment Make Capacity Quantity (Nos) 1 Reaction Kettle/ Reactor (SS316L limpet coil, Thickness SS 316 L 7 KL 3 9 MM, Gear Box, Stirrer) RK-1, RK-2, RK-3. 2 Distillation Vessel / DV-1 (MS Make) Thickness-9mm MS 3.5 KL 1 3 Distillation Vessel / DV-2(MS limpet coil, Thickness 9 MS 7KL 1 MM, Gear Box, Stirrer) 4 Distillation Vessel / DV-3(For Solvent distillation) MS 1KL 1 Thickness-9mm 5 SS 316L Condenser With MS Jacket /C-1 SS/MS Length- 2 1 Mtr. 6 SS 316L Condenser With MS Jacket /C-2 SS/MS Length- 3 1 Mtr. 7 SS 316L Condenser With MS Jacket /C-3 SS/MS Length Mtr. 8 SS 316L Condenser With MS Jacket /C-4 (Spare) SS/MS Length-2Mtr. 1 9 Receiver-1 (Thickness 8 mm) MS 3.5KL 1 10 Receiver-2 (Thickness 8 mm) MS 6 KL 1 11 Receiver-3 (Thickness 8 mm) MS 1 KL 1 12 Cooling tank with Coil-1 MS 1.5 KL 1 13 Cooling tank with Coil-2 MS 2 KL 1 14 Vertical receiver -1 MS 1 KL 1 15 Vertical receiver -2 MS 1.5 KL 1 16 Vacuum pumps with Motors (All vacuum pumps are two stage oil cooled high vacuum pumps) JB VAC made. MS 24 No. 22 No. 19 No. 18 No Centrifuge / Hydro MS Steam Dryer with 4 Trolley & 100 Aluminium Trays. MS 800 kg 1 19 Cooling tower- 1 MS/PP Cooling tower- 2 MS/PP Cooling tower Water Tank- 1 & 2 Cement 2.5 KL 2 22 Ice Cooling Water Tank - 2 Cement 2.5 KL 1 23 Hot Water Tank - 2 MS 2.5 KL 1 24 Acid Tank -1, Thickness-8 mm FRP 0.6 KL 1 25 Acid Tank -2, Thickness-8 mm FRP 1.5 KL 1 26 O.T. storage tank (Big) MS 30 KL 3 27 Aniline storage tank MS 20 KL 3 28 O.T. storage tank (Small) MS 15 KL 3 29 Hot Water Tank - 2 MS 2.5 KL 1 30 Pulveriser With Air Bags MS 3 KL 2 31 Scrubber Unit PP 1 31 DM Plant PP 7 kl/hr 1 32 Water storage tank (Big) PP 5 KL 3 33 Water storage tank (Small) PP 0.5 KL 3 34 Water storage tank Cement 10 KL 1 35 ETP Plant MS/PP ETP Ground Storage Tank Cement 2 KL 10 KL 10 KL 37 Batch crude tray (Big) MS 1 KL 1 38 Batch crude tray (Medium) MS 0.8 KL 2 39 Batch crude tray (Small) MS 0.2 KL 4 40 Sewing Machine MS SS316L Autoclave with Magnetic Stirrer (SS limpet coil, SS316L 1.5 KL 1 Thickness 40 MM, Gear Box, Stirrer) 42 Purification reactor/ssr(ss limpet coil,thickness 9 SS316L 5 KL 1 MM, Gear Box, Stirrer) 43 HDPE Black Tank with coil & Gear Box, Stirrer HDPE 3 KL

12 44 Filter Press with 26 plates PP 1 45 Centrifuge (36 Rubber lined) MS/Rubber 36 1 lined 46 Air compressor MS 1 47 Hot Oil System(Thermic Fluid Heater) MS 2LacKcal/hr 1 48 Expansion Tank Unit. MS 1 49 Steam Dryer with 2 Trolley & 100 PP Trays. MS/FRP 1 50 SS Multi-miller SS Diaphragm pump PP 2 52 PP Tray PP 0.2 KL 1 53 LDO Storage tanks MS 0.5 KL 1 54 Cartridge Filter PP Weighing balance MS IBR Boiler with Cyclone, ID Fan Unit (No.- MR 15480) MS 1 MT 1 57 MS Water storage Tank for Boiler MS 1 KL 1 58 Chimney with Lightening Arrester- 100 MS L- 100 Ft Chimney MS L- 45 Ft Chimney MS L- 25 Ft Scrubber Chimney PP L- 25 Ft Hazardous Waste Storage Tank MS 8 KL 1 63 DG Set 125 KVA MS 125 KVA 1 7. Processes carried out in the plant Main process reaction is nitration which involves Diazotization Vacuum distillation Coupling 8. Water consumption Water consumption and supply to various activities on the plant premises are shown in Figure 4 below. 12

13 Figure 4: Water Supply Diagram BOREWELL ON SITE STORAGE TANK 500L MAIN WATER SUPPLY TANK 10kL ICE WATER 5kL COOLING TOWER SOFTENER PLANT DM PLANT WASHROOM TANK BOILER 1kL STORAGE TANK 5kL X 2Nos LAB & WASHROOMS HOT WATER 500L NITRITE SOLUTION PREPARATION CAUSTIC SODA SOLUTION PREPARATION AND REACTION KETTLE CLEANING YELLOW SS REACTOR PRODUCTION FLOOR WASHING JACKETED VACUUM PUMP 9. Manufacturing process and flow diagram for Para Amino Azo Benzene (PAAB) Product Name: Para Amino Azo Benzene (PAAB) / Solvent Yellow 1 Raw Materials Aniline Oil (Pure) Sodium Nitrite NaNO 2 Hydrochloric Acid HCL 30-35% Pure Caustic Soda NaOH (Flakes) Toluene (Nitration Grade Pure) Manufacturing Process: Aniline is reacted with hydrochloric acid to form aniline hydrochloride. This reacts with Sodium Nitrite to form phenyldiazonium chloride. This product reacts with aniline to form di-amino benzene at low temperature. This di-amino benzene with aniline and aniline hydrochloride at temperature of C for specific time forms Para Amino Azo Benzene (PAAB). Sodium Hydroxide is added in access to neutralise hydrochloric acid. The final ph is 09 to

14 Aniline + crude PAAB is taken to the distillation vessel where aniline is condensed and it goes to receiver. Water layer + other by products are separated and are transferred to ETP. Then crude PAAB is transferred to the centrifuge to remove Tar & other liquid impurities soluble in aniline. PAAB crystals are separated and dried in a dryer and then taken to pulveriser to get PAAB powder. Chemical Reaction of PAAB Figure 5 below shows the chemical reaction involved in manufacturing of PAAB. Figure 5: PAAB Chemical Reaction Process Flow details for 1000 kg PAAB Following Figure 6 shows the process flow for 1000kg per batch of PAAB 14

15 Figure 6: Process flow chart PAAB HCL kg NaNO 2-400kg Aniline 1350 Lit Water 1300 Lit HNO 2 fumes Water Scrubber Nitric Acid Plant for neutralisation (400Lit) Jacketed reaction kettle Reaction Vessel NaOH kg Water 100 Lit Crude PAAB + Aniline Distillation Vessel Condensation Aniline Receiver Effluent 1440 Lit Salts 80 kg Crude PAAB Semi liquid ETP Centrifuge Liquid TAR impurities 50 kg PAAB Crystal Dryer Pulveriser Final Product PAAB powder 1000kg Material Balance for 1000 kg PAAB Following Table 4 shows the Material balance for 1000kg PAAB batch. Table 4: Material Balance (for 1000 kg PAAB) Sr. No. Input Quantity Unit Output Quantity Unit 1 Aniline 1350 kg PAAB 1000 kg 2 NaNO kg Effluent Water 1440 kg 3 Water for 400 kg HNO kg dissolving NaNO 2 4 HCl 950 kg Water evaporation 450 kg 5 NaOH 120 kg Tar 50 kg 6 Water for 100 kg Waste salts 80 kg dissolving NaOH Total Reactants 3320 kg Total Output 3320 kg 7 Toluene 130 kg Recovered Toluene 130 kg 8 Water 900 kg 9 Ice Blocks 35 kg 10 Cold Water 3350 kg 11 Fire wood for Boiler 1350 kg 15

16 Treatment and disposal of by-products 1. HNO 2 fumes are sent to scrubber, thus HNO 3 is scrubbed out and taken to ETP for neutralisation. 2. Tar is taken to storage tank then sent to CHWTSDF at Ranjangaon near Pune for disposal L water containing dissolved salts is transferred to ETP. Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow 1, Effluent and other outputs in kg from PAAB production Following Table 5 shows the Material Balance for existing scale of manufacturing of 750kg per batch and Table 6 below shows the Effluent and other outputs from PAAB or Garnet manufacture. Other water consumption and effluent generation is shown in Table 7 below. Table 5: Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow 1 Sr. No. Input Quantity Unit Output Quantity Unit 1 Aniline 1013 kg PAAB 750 kg 2 NaNO kg Effluent Water 1080 kg 3 Water for 300 kg HNO kg dissolving NaNO 2 4 HCl 712 kg Water evaporation 338 kg 5 NaOH 90 kg Tar 37 kg 6 Water for 75 kg Waste salts 60 kg dissolving NaOH Total Reactants 2490 kg Total Output 2490 kg 7 Toluene 100 kg Recovered Toluene 100 Kg 8 Water 675 kg 9 Ice Blocks 25 kg 10 Cold Water 2500 kg 11 Fire wood for Boiler 1000 kg Table 6: Effluent and other outputs in kg from PAAB production Sr. No. Particulars PAAB Per batch Daily Monthly 1 Alkaline effluent from reaction Vacuum Pump oil water o C oil water Production floor washing Reactor & equipment wash water 50 16

17 Table 7: Other Water Consumption/effluent generation in kg per month Sr.No. Particulars Quantity 1 Road Cleaning Laboratory, Shade Floor Cleaning Gardening 3000 Following are the pictures of plant equipment and installations as detailed below: Picture 3 Coiled Jacketed Reactor in which the main reaction is carried out, Picture 4 Distillation Vessel from where the solvent, water are removed and the tray in which the reaction product is collected, Picture 5 Centrifuge to remove excess water, Picture 6 Tray Dryer for drying the product, Picture 7 - Solvent Storage area and Solvent Storage Tanks, Picture 8 Finished products storage area, Picture 9 Neutralisation Tank at ETP area, Picture 10 Tertiary Treatment Plant at ETP. Picture 3: Coiled Jacketed Reactor 17

18 Picture 4: Distillation Vessel and Tray Picture 5: Centrifuges Picture 6: Tray Dryer and Finished Product 18

19 Picture 7: Solvent Storage Tanks Picture 8: Finished Product Storage Picture 9: Neutralisation Tank 19

20 Picture 10: Tertiary Treatment 20

21 10. Analysis Report of treated effluent Treated effluent analysis report of sample drawn on is given in following Table 8. Table 8: Treated Effluent Analysis Sr. No Parameter Unit Results 1 ph Oil & Grease mg/l Suspended mg/l Solids 40 4 BOD mg/l 18 5 COD mg/l TDS mg/l Sulphates mg/l Chlorides mg/l Percent sodium % Proposed scale-up and Additional Products The proposed scale-up of existing manufacturing volumes taking advantage of installed capacity of the plant is detailed in Table 9 below showing input and output material balance. Material Balance of Proposed PAAB 1500 kg batch Material Balance of proposed 1000kg batch PAAB is given in Table 9 below. Table 9: Material Balance of Proposed for PAAB 1500 kg Sr. No. Input Quantity Unit Output Quantity Unit 1 Aniline 2025 Kg PAAB 1500 Kg 2 NaNO Kg Effluent Water 2160 Kg 3 Water for 600 Kg HNO Kg dissolving NaNO 2 4 HCl 1425 Kg Water evaporation 675 Kg 5 NaOH 180 Kg Tar 75 Kg 6 Water for 150 Kg Waste salts 120 Kg dissolving NaOH Total 4980 Total Output 4980 kg Reactants Kg 7 Toluene 200 Kg Recovered Toluene 200 kg 21

22 8 Water 1350 Kg 9 Ice Blocks 50 Kg 10 Cold Water 5000 Kg 11 Fire wood for Boiler 2000 Kg Material Balance in kg for Proposed Scale up of PAAB The total monthly quantity of production after the proposed scale-up of PAAB with 750 kg PAAB per batch and 2 batches per day in Reaction Kettle 1 as being carried out and with 1500 kg per batch and 2 batches per day in Reaction Kettle 2 will be carried out utilising plant installed capacity and in three shifts per day. Following Table 10 shows the proposed monthly material balance for PAAB production. Table 10: Material Balance in kg for Proposed Scale up of PAAB Sr. Raw material RK 1 (750 kg) RK 2 (1500 kg) No. Current production line Proposed production line Per batch Daily Monthly Per Daily Monthly (25days) batch (25days) 1 Aniline NaNO Water for dissolving NaNO 2 4 HCl NaOH Water for dissolving NaOH Total Reactants Toluene Water Ice Blocks Cold Water Fire wood for Boiler Total PAAB Salt Water (water softening)

23 Manufacturing process and flow diagram for Fast Garnet GB base /Ortho Amino Azo Toluene (OAAT) 1. Product Name: Ortho Amino Azo Toluene (OAAT) / Fast Garnet GB base Solvent Yellow 3 2. Required quantity 120 MT/month 3. Raw Materials Ortho Toluidine Liquid Sodium Nitrite NaNO 2 Hydrochloric Acid (30-35%) Caustic Soda - NaOH (Flakes) Manufacturing process Ortho Toluidine (OT) liquid is reacted with hydrochloric acid to form orthotoluidine hydrochloride. This reacts with sodium nitrite to form phenyldiazoniumchloride. This product with Ortho toluidine form diaminoazo toluene at low temperature. This di-aminoazo toluene with Ortho toluidine and ortho toluidine hydrochloride form ortho amino azo toluene at 40 C-50oC in specific time. Sodium hydroxide is added in excess to neutralise hydrochloric acid and final ph is OT + crude OAAT is taken to the distillation vessel where OT is condensed and then transferred to a receiver. Water layer + other by products are separated and transferred to ETP. Then crude OAAT is transferred to the centrifuge to remove TAR & other liquid impurities soluble in Ortho Toluidine. OAAT crystals are separated and dried in a dryer and then pulverised to get OAAT powder. Chemical Reaction of OAAT Figure 7 below shows the chemical reaction involved in manufacturing of OAAT. 23

24 Figure 7: OAAT Chemical reaction 24

25 Process flow chart of OAAT Process schematic flow diagram is shown below in Figure 8. Figure 8: Process flow diagram of OAAT HCL 900 kg HNO 2 fumes Water Scrubber Nitric Acid Plant for neutralisation (400Lit) NaNO kg NaOH 120 kg + Water 100 O.T 1300 lit Water 400 lit Jacketed reaction kettle Reaction Vessel Crude OAAT +O.T. Distillation Vessel Condensation Aniline Receiver Effluent 1420 Lit Salts 100 kg Crude OAAT Semi liquid ETP Centrifuge Liquid TAR impurities 40 kg OAAT Crystal Dryer Pulveriser Final Product OAAT powder 1000kg Material Balance for 1000 kg batch of OAAT/ Garnet /SY3 Following Table 11 gives the Material Balance of 1000kg batch of OAAT. Table 11: Material Balance for 1000 kg OAAT batch Sr. No. Input Quantity Unit Output Quantity Unit 1 Ortho Toluidine 1300 kg OAAT/Garnet 1000 kg 2 NaNO kg Effluent Water 1430 kg 3 Water for 400 kg HNO kg dissolving NaNO 2 4 HCl 900 kg Water evaporation 350 kg 5 NaOH 120 kg Tar 40 kg 6 Water for 100 kg Waste salts 100 kg dissolving NaOH Total 3220 Total Output 3220 kg Reactants kg 7 Toluene 130 kg Recovered Toluene 130 kg 25

26 8 Water 900 kg 9 Ice Blocks 35 kg 10 Cold Water 3350 kg 11 Fire wood for Boiler 1350 kg Treatment and disposal of by-products 1.HNO 2 fumes are sent to scrubber, thus HNO 3 is scrubbed out and taken to ETP for neutralisation. 2.Tar is transferred to storage tank then sent to TSDF at Ranjangaon Ltrs effluent water with dissolved salts is transferred to ETP. Scale up - Ortho Amino Azo Toluene (OAAT) / Fast Garnet GB base Solvent Yellow 3 Following Table 12 gives the Material Balance of Scale-up 1600kg batch of OAAT. Table 12: Scale up - Ortho Amino Azo Toluene (OAAT) Sr. No. Raw Material For 800 kg batch 1 Ortho Toluidine HCl (33%) Sodium Nitrite (NaNO 2 ) For 1600 kg batch 4 Sodium Hydroxide (NaOH) Toluene (solvent) Water Fire wood (boiler) Material Balance for 800 kg OAAT batch Material balance for 800kg OAAT batch is shown below in Table 13. Table 13: Material Balance for 800 kg OAAT batch Sr. No. Input Quantity Unit Output Quantity Unit 1 Ortho Toluidine 1040 kg OAAT/Garnet 800 kg 2 NaNO kg Effluent Water 1152 kg 3 Water for 320 kg HNO kg dissolving NaNO 2 4 HCl 720 kg Water evaporation 280 kg 5 NaOH 96 kg Tar 40 kg 6 Water for 80 kg Waste salts 64 kg dissolving NaOH Total 2576 Kg Total Output 2576 kg Reactants 7 Toluene 100 kg Recovered Toluene 100 kg 26

27 8 Water 720 kg 9 Ice Blocks 25 kg 10 Cold Water 2500 kg 11 Fire wood for Boiler 1000 kg Material Balance for 1600 kg OAAT batch Material balance for 1600kg batch is shown below in Table 14. Table 14: Material Balance for 1600 kg OAAT batch Sr. No. Input Quantity Unit Output Quantity Unit 1 Ortho Toluidine 2080 kg OAAT/Garnet 1600 kg 2 NaNO kg Effluent Water 2304 kg 3 Water for 640 kg HNO kg dissolving NaNO 2 4 HCl 1440 kg Water evaporation 560 kg 5 NaOH 192 kg Tar 80 kg 6 Water for 160 kg Waste salts 128 kg dissolving NaOH Total 5152 Total Output 5152 kg Reactants kg 7 Toluene 200 kg Recovered Toluene 200 kg 8 Water 1440 kg 9 Ice Blocks 50 kg 10 Cold Water 5000 kg 11 Fire wood for Boiler 2000 kg Input Raw Material Quantity Details for OAAT / Garnet/SY3 Input Raw material quantities for OAAT are given in Table 15 below. Table 15: Input Raw Material Quantity Details OAAT / Garnet Sr. Raw material RK 1 (800 kg) RK 2 (1600 kg) No. Current production Proposed production line line Per Daily Monthly Per Daily Monthly batch (25days) batch (25days) 1 Ortho Toluidine NaNO Water for dissolving NaNO 2 27

28 4 HCl NaOH Water for dissolving NaOH Total Reactants Toluene Water Ice Blocks Cold Water Fire wood for Boiler Total OAAT Salt Water (water softening) Other Water Consumption/effluent generation in kg per month Table 16 below shows other water consumption at the plant. Table 16: Other Water Consumption Sr.No. Particulars Quantity 1 Road Cleaning Laboratory, Shade Floor Cleaning Gardening 3000 Manufacturing process and flow diagram for Yellow Dye 1. Product Name: Yellow Dye 2. Required quantity 05 MT/month 3. Raw Materials Methanol Red 30 Dimethyl Sulphate Sodium Bromide Distilled Water Hydrochloric acid Sodium Chloride Sodium Carbonate (Soda Ash) Catalyst 28

29 Manufacturing process Red 30, methanol, di-methyl sulphate and sodium bromide are kept in an autoclave pressure of 35-45kg/inch2 for 20 hours. Then it is purified by water in reaction kettle. This acidic solution is neutralised by soda ash and is then filtered in filter press. The filtrate is then transferred to HDPE tank and precipitated by HCl and sodium chloride. This precipitate with filtrate is then filtered through a filter press to separate Dye Yellow. Water is then removed by centrifugation and the filtered dye is dried in a dryer and then powdered using a multi-mill. 4. End use: Pigments Process flow chart Yellow Dye / MYN / TT / CD Following Figure 9 shows the schematic process diagram for Yellow Dye Figure 9: Process Flow Chart of Yellow Dye Methanol 4600 lit Water lit Catalyst 30 kg Soda Ash 450kg Residue cake 700 kg DMS 850 kg HCl lit Nacl 900kg Red kg NaBr 380 kg Pressure vessel - Autoclave Purification Reactor Filter press HDPE tank Semi product ETP lit/batch Centrifuge Waste Water 200 lit Dryer Multi-miller Final Product Yellow Dye 1000kg 29

30 Material Balance for 100kg/day Yellow Dye Material balance for 100kg/d Yellow Dye is given in Table 17 below. Table 17: Material Balance Yellow Dye Sr. No. Quantity in kg Input Quantity in kg Output 1 Red Yellow Dye Methanol 460 Effluent Water DMS 85 Residue Cake 70 4 Sodium Water for 38 Bromide evaporation Catalyst 21 Other impurities Water Soda Ash 45 8 HCl NaCl 90 Total Monthly production of Yellow Dye Monthly production of Yellow Dye is shown in Table 18 below. Table 18: Monthly production Yellow Dye Sr. No. Input Quantity in kg Output Quantity in kg 1 Red Yellow Dye Methanol Effluent Water DMS 3400 Residue Cake Sodium 1520 Water for Bromide evaporation 5 Catalyst 840 Other impurities Water Soda Ash HCl NaCl 3600 Total Waste Management for Scale-up Effluent Treatment Proposed Effluent generation and other outputs in kg from PAAB, OAAT/Garnet, Yellow Dye production and other Water 30

31 Consumption/effluent generation in kg per month is given in the following Table 19, Table 20, Table 21 and Table 22. Small volume of alkaline effluent generated during PAAB manufacturing will be transferred to ETP. Any other effluent generated during washing etc. will also be transferred to ETP where it will be neutralised with HCL in Neutralisation tank along with the alkaline effluent and the neutralised effluent will be evaporated to separate the salt and the salt formed will be sent to CHWTSDF. Table 19: Proposed Effluent generation from PAAB Sr. No. Particulars PAAB Per batch Daily Monthly 1 Alkaline effluent from reaction Vacuum Pump oil water o C oil water Production floor washing Reactor & equipment wash water 100 Table 20: Proposed Effluent generation from OAAT / Garnet Sr. No. Particulars OAAT / Garnet Per batch Daily Monthly 1 Alkaline effluent from reaction Vacuum Pump oil water o C oil water Production floor washing Reactor & equipment wash water 100 Table 21: Proposed Effluent generation from Yellow Dye Sr. No. Effluent 100 kg batch/day 1 Acidic liquid 1,700 lit 2 Liquid waste from centrifuge 100 lit 3 Liquid waste from filter press 100 lit Total 1900 lit Table 22: Other water consumption Sr.No. Particulars Quantity 1 Road Cleaning Laboratory, Shade Floor Cleaning 1500 Waste solvents generated during the process will be distilled in the plant and the recovered solvent will be sold to authorised recyclers. 31

32 Proposed Effluent Treatment: Total effluent generation will be about KL per day (maximum) from existing and proposed amended production. Characteristics of acidic and alkaline raw effluent shall be as follows: Parameter Unit Acidic Effluent Alkaline Effluent ph BOD mg/l COD mg/l TSS mg/l TDS mg/l O&G mg/l 8 12 Chlorides mg/l Sulphate SO4 mg/l Phosphates mg/l Proposed Effluent Treatment Scheme Effluent Collection Effluent will be collected in aneffluent Collection Tankby gravity from all the sources. Tank is provided with 1 day holding capacity. Air is introduced for proper mixing of effluent. Neutralisation Effluent is then neutralised with addition of Alkali / Acid as required. Acid and Alkali dosing system with dosing pumps is provided for neutralisation. Coagulation / Flocculation After neutralisation, effluent is pumped to flash mixer for coagulation. Alum / PAC doing system are provided for enhancement of coagulation. Mixer is provided in coagulation tank for mixing of coagulant and effluent. Effluent then flows to flocculation tank. Flocculation tank is provided with slow speed agitator mixer. Flocks are formed in the tank. Fine flocks adhere to each other to form bigger flocks. 32

33 Sedimentation Effluent flows to sedimentation tank for settlement of flocks. Sludge from the bottom is withdrawn periodically. Treated Effluent Evaporation Treated effluent is then collected in a tank and then pumped to evaporator vessel. Excess steam available in the manufacturing process is used to evaporate the effluent by passing through jackets of vessel. Effluent is concentrated to suitable volume. Concentrated sludge is then collected in the tank and then disposed of at TSDF. Vapour is condensed and condensate is recycled in process. Sludge Disposal Sludge separated from sedimentation tank and from evaporator disposed of at TSDF. Figure 10: Proposed Zero Liquid Discharge Scheme 33

34 Air Pollution Control Nitrite gas generated during the reaction will be scrubbed through the wet scrubber with water recirculation and the scrubbed nitrite will be transferred to ETP for neutralisation with Caustic. Hazardous Waste Management All the Hazardous waste that will be generated from the process, ETP will be disposed of to CHWTSDF. Recovered solvents will be sold to authorised recycler. DBS Chemicals are members of CHWTSDF a Ranjangaon near Pune. 13. Justification for Environmental Clearance The proposed amendment to the existing 8MT/Month production capacity of PAAB in the Consent to Operate to Synthetic organic chemicals 80MT/Month of PAAB with addition of Synthetic Organic Chemicals 120MT/Month Garnet/OAAT and (SOD) 5MT/Month Yellow Dye is requested with the following justification. a. Additional land is not required. b. Additional plant & machinery is not required. c. Manufacturing process being "Batch Process", production is proposed to be increased by operating in three shifts instead of one shift as of today using fully the installed capacity & different possible product mix and combinations. d. Implementation of Zero Liquid Discharge. e. Water is not used in the manufacturing process anywhere, however waste water is generated only from washings of the vessels and same is sent to ETP and treated. f. Treated effluent being chemical in nature & in small quantity of less than 10cmd will be concentrated further and sent to CHWTSDF for incineration. 34

35 g. A small 1Ton per hour capacity wood fired boiler will be provided with 100 ft. stack height in compliance of air emission standards. h. Approximately kg/day Solid waste in the Hazardous Waste Category 20.3 and Chemical Sludge from ETP in the Hazardous Waste Category 34.3 will be sent to CHWTSDF at Ranjangaon near Pune. Membership obtained. i. Approximately m 3 /day Domestic waste water and wastes from floor washing will be sent to ETP. Sludge from ETP will be disposed to CHWTSDF as stated above. j. Existing capital investment as on date is Rs Cr. due to replacement of old boiler and reaction vessels. k. Bank Guarantee for Rs.1 lakh valid up to towards O & M and towards compliance of consent conditions shall be submitted to MPCB along with Consent Fees based on capital investment of Rs Cr. 14. Conclusions & Recommendations: In view of the scenario explained as above, proposed scheme of upgradation of the waste management systems (Zero Discharge) and technical justification, SEAC/SEIAA may consider the proposed environmental clearance as under: Combined product manufacturing capacity shall not exceed 205 MT per month comprising (a) Synthetic Organic Chemicals such as Methylene Yellow N, (b) Synthetic Organic Chemical such as PAAB and (c) Fast Bases such Garnet GB based (OAAT) Hazardous Wastes shall be sent to TSDF along with the HW sludge. Solvent recovered shall be sold to authorised recycler. Zero Liquid Discharge scheme shall be implemented for the remaining trade effluent. No land disposal is allowed. 35

36 Wood fired boiler of 1 MT capacity shall have minimum stack height as stipulated by MPCB in its Consent to Operate. (Devdatta Utgi) Pune, Enclosed: Copy of Consent to Operate, dated valid up to Copy of Consent to Establish, dated

37 37

38 38

39 39

40 40

41 41