2 PROPOSED TERMS OF REFERENCE

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1 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC TERMS OF REFERENCE 2 PROPOSED TERMS OF REFERENCE Purpose of bifurcation of EC "The proposed business requires petrochemical segment specialization with dedicated team to meet the goal of the company. We have created different company with the focused team on board. It's need on an hour to have experts on different board. The different group of people will be handling the total petrochemical business under the guidance of principal promoter of the company." As it is bifurcation of existing EC No. SEIAA/EC/5(f), 4(d), 1(d)/ 120/2014 dated 6th August 2014 into Deepak Nitrite Limited (DNL) and Deepak Phenolics Limited (DPL). So there is no Terms of Reference. KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

2 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE 3 ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

3 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 1: Production Details Table 1: Details of Products for EC S. No. Final Products for EC DNL DPL 1 2 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cumidine, (Para & Ortho) Nitration Plant- Any one Product at a time Nitro Toluenes (ONT, PNT, MNT) Nitrochlorobenzenes (ONCB, PNCB) O- Nitroxylenes (3 NOX & 4NOX) M- Nitroxylenes (2, 4 NXL & 2,6 NXL) Ethyl Hexyl Nitrate (EHN) Nitrocumenes (PNC) 3 Monochlorobenzene (MCB) 4 Dichlorobenzene DCB (Byproduct) 5 30% HCl (Byproduct) 6 DASDA 7 Sodium Sulphate (Byproduct) 8 Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc. 9 Hydrogen (Byproduct) (Nm3/ hr) 10 Power 11 Steam 12 Phenol 13 Cumene 14 Acetone 15 Alpha Methyl Styrene (AMS) 16 Benzene Rich Cut 17 Crude Phenol Column Bottoms Table 2: Production Details after Bifurcation S. No. Name of Final EC Product 1 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cyclohexanone, Cumidine, (Para & Ortho) 2 Nitration Plant- Any one Product at a time EC Received (MT/Month) Capacity (MT/Month) DNL DPL Nitro Toluenes (ONT, PNT, MNT) Nitrochlorobenzenes (ONCB, PNCB) O- Nitroxylenes (3 NOX & 4NOX) M- Nitroxylenes (2, 4 NXL & 2,6 NXL) Ethyl Hexyl Nitrate (EHN) Nitrocumenes (PNC) Monochlorobenzene (MCB) KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

4 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE S. No. Name of Final EC Product EC Received (MT/Month) Capacity (MT/Month) DNL DPL 4 Dichlorobenzene DCB (Byproduct) % HCl (Byproduct) DASDA Sodium Sulphate (Byproduct) Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc Hydrogen (Byproduct) (Nm3/ hr)# Power 42 MW Steam* 125 TPH Phenol Cumene Acetone Alpha Methyl Styrene (AMS) Benzene Rich Cut Crude Phenol Column Bottoms #Note: Hydrogen (Byproduct) (Nm 3 / hr) production will be reduced *Note: EC application was done for 125 TPH, however in EC it is 100 TPH. Hence, in total capacity 125 TPH is mentioned. Table 3: After bifurcation Final Products of Deepak Nitrite Limited (DNL) S. No. Name of Final EC Product Capacity (MT/Month) 1 2 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cyclohexanone, Cumidine, (Para & Ortho) Nitration Plant- Any one Product at a time 750 Nitro Toluenes (ONT, PNT, MNT) 2500 Nitrochlorobenzenes (ONCB, PNCB) 2500 O- Nitroxylenes (3 NOX & 4NOX) 2160 M- Nitroxylenes (2, 4 NXL & 2,6 NXL) 2160 Ethyl Hexyl Nitrate (EHN) 1800 Nitrocumenes (PNC) Monochlorobenzene (MCB) Dichlorobenzene DCB (Byproduct) % HCl (Byproduct) DASDA Sodium Sulphate (Byproduct) Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc. on active substance basis. 9 Hydrogen (Byproduct) (Nm3/ hr)# Steam KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

5 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 2: Existing Environmental Clearance KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

6 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

7 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

8 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 3: Existing Consent to Establish KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

9 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

10 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

11 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

12 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

13 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 4: Site Location Map KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

14 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 5: Site Layout Plan KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

15 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Total Area in the existing EC is m 2. Area of Deepak Nitrite Limited (DNL) is m 2. Area of Deepak Phenolics Limited (DPL) is m 2. Table 4: Area Breakup of Deepak Nitrite site (DNL) S. No. Title Total Area in m 2 % of Total Area 1 Production Storage 2 Product Storage Raw Material Drum Storage Boiler Substation DG Room Security Room Cooling Tower Office Effluent Treatment Plant Road & open area Green belt Area Fire water tank Raw Water Process water/ DM water Chilled water Substation/CCR Engg Store Coal storage N2 storage Other Garden/ Assembly point Total KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

16 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 6: Storage Details Table 5: Raw Material Storage Details for EC Received for DNL S. No. Chemicals State Consumption (MT/Month) Hazard Involved Means of Storage Operating Condition (Storage) Press Kg/Cm 2 Capacity of Vessel / Bag 1 Hydrogen ( via Pipeline) Gas 252 Flammable Cylinder Temp ºC No. of Vessels / bag Storage Area Dedicated area 2 Toluene Liquid 1708 Flammable Drum Atm. Ambient Warehouse O-Xylene Liquid 1540 Flammable Tank Atm. Ambient 50 3 Tankfarm M-Xylene Liquid 1540 Flammable Tank Atm. Ambient 50 3 Tankfarm Ethyl Hexyl Alcohol (EHA) Liquid 1344 Flammable Tank Atm. Ambient 50 3 Tankfarm Cumene Liquid 1316 Flammable Tank Atm. Ambient 50 3 Tankfarm Sulfuric Acid Liquid 1120 Corrosive Tank Atm. Ambient 50 2 Tankfarm Nitric Acid Liquid 130 Tank Atm. Ambient 20 1 Tankfarm 14 9 Benzene Liquid 1876 Flammable Tank Atm. Ambient Tankfarm Chlorine Gas 190 Corrosive Turner Atm. Ambient Dedicated area 11 30% Oleum Liquid 3656 Corrosive Tank Atm. Ambient Tankfarm Caustic Lye Liquid 1004 Flammable & Corrosive 15 Cyanuric Chloride Solid 1274 Corrosive Storage Capacity (MT/m 3 ) Tank Atm. Ambient 50 2 Tank farm 108 Jumbo bag Atm. Ambient 50 3 Warehouse Aniline Liquid 420 Poison Drum Atm. Ambient 20 2 Warehouse Aniline 2-5 Disulphonic Acid Solid 53 Bag Atm. Ambient 10 1 Warehouse 6 18 Baykanol 16 Bag Warehouse 2 19 Baypure CX100 Solid 0.6 Bag Warehouse Caustic Potash Solid 120 Corrosive Bag Warehouse DiisoPropanolamine Liquid 5 Combustible Drum Atm. Above Warehouse KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

17 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE S. No. Chemicals State Consumption (MT/Month) Hazard Involved Means of Storage Operating Condition (Storage) Press Kg/Cm 2 Capacity of Vessel / Bag No. of Vessels / bag Storage Area 22 Defoamer Liquid 5 Drum Atm. Ambient 5 1 Warehouse 1 23 Diethyl amine Liquid 10 Drum Atm. Ambient 5 1 Warehouse 1 24 Diethanolamine Liquid 537 Combustible Drum Atm. > Warehouse Morpholine Liquid 233 Flammable Drum Atm. Ambient 20 1 Warehouse Monoethylene Glycol Liquid 12.6 Drum Atm. Ambient 5 1 Warehouse 1 27 Polyethylene Glycol Liquid 8 Combustible Drum Atm. > Warehouse 1 28 Triethanol amine Liquid 11 Drum Atm. Ambient 5 1 Warehouse 1 29 Glutaraldehyde Liquid 12 Drum Atm. Ambient 5 1 Warehouse 1 30 Sulphanillic Acid Liquid 342 Carboys Atm. Ambient 10 4 Warehouse Hyflow Supercell Solid 16 Bag Atm. Ambient 5 1 Warehouse 2 Temp ºC Storage Capacity (MT/m 3 ) KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

18 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 7: Details of Water Consumption Water will be sourced from GIDC water supply. Details for water consumption are given as following; Table 6: Details of Water Consumption S. No. Source Quantity of Water Consumption, KLD EC Received Deepak Nitrite Ltd Deepak Phenolics Ltd 1 Process Boiler Cooling & Chilling Washing Domestic Gardening Total Water Requirement Recovery Net Water Requirement Table 7: After Bifurcation Water Consumption of Deepak Nitrite Limited S. No. Source Quantity of Water Consumption, KLD 1 Process Boiler Cooling & Chilling Washing Domestic 88 6 Gardening 38 Total Water Requirement Recovery Net Water Requirement 5608 KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

19 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 8: Details of Wastewater Generation Table 8: Wastewater Generation Details S. No. Source Quantity of Waste Water Generation, KLD EC Received Deepak Nitrite Ltd Deepak Phenolics Ltd 1 Process Boiler Cooling & Chilling Washing Domestic Total Wastewater Generation Water to MEE for Recovery Total Water to ETP & thereafter to GIDC Drain for disposal to deep sea Table 9: After Bifurcation Waste Water Generation of Deepak Nitrite Limited S. No. Source Quantity of Waste Water Generation, KLD 1 Process Boiler Cooling & Chilling Washing Domestic Total Wastewater Generation Water to MEE for Recovery Total Water to ETP & thereafter to GIDC Drain for disposal to deep sea KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

20 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 9: Effluent Treatment Plant of Deepak Nitrite Limited Brief Description of Multi Effective Evaporator Plant to be started in following sequence generally. Later after the stabilized run and independent operation on the effluent streams amendment in startup procedure is possible based on the individual experience of the plant personnel. Check for availability of feed, utilities manpower etc. Start cooling water tower, cooling tower fan & cooling water pump. Establish the water circuit in the barometric condenser SC-01(HE-1908) and SCS-01 (HE-1902) Start the vacuum pump VP-01 (VP-1912) and wait till vacuum reaches to 300 mm Hg. Check the sealing water flow and temperature in vacuum pump. Transfer the feed from main feed storage tank to feed tank FT-01 (T-1905). Start the feed pump FP-01(P- 1909) and establish circulation through stripper section with maintaining level 50% in PC-01 (C-1901) with FP-01 (P-1909) VFD. After sample analysis of stripper section start transferring to Evaporator section and take % level in VLS-01(V-1903) by CV-PL-01 (LCV-12927) Start the transfer pump TP-01 (P-1905) and transfer liquid to the VLS-02 (V-1905) and take the same level as in VLS-01 (V-1903) by means of CV-PL-02 (LCV-12935) Start the Axial flow pump RPE-01 (P-1907) and transfer liquid to the VLS-03 (V-1907) and take the % level by means of CV-PL-03 (LCV-12955) Start the Axial flow pump RPE-02 (P-1908) and transfer liquid to the VLS-04(V-1909) and take the same level as in VLS-03 (P-1907) Now start the recirculation pump and establish circulation in last effect of Evaporator unit. Slowly start steam by means of CV-ST-02 (PCL-12919) in to the thermo compressor and make the pressure at about 8 Kg/cm2-g. This steam will heat the first Calandria. Vapor & liquid will be separated in to VLS-01 (V-1903). A small part of steam from calandria-1 will heat the feed in PH-01 (HE-1903) The vapor from VLS-01 (V-1903) will heat second Calandria. Vapor & liquid will be separated in VLS-02 (V- 1905). Partial flow of Vapor from VLS-02 (V-1905) will heat the third Calandria and part will go to the thermo compressor.vapor from VLS-03 (V-1907) will heat forth Calandria and vapor from VLS-04(V-1909) will be condensed in surface condenser. Keep watch on the condensate levels in all four Calandria and 50% for flash tank & accordingly start condensate pump CP-01(P-1910) and adjust the level by means of VFD KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

21 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Due to evaporation in all four Calandria, level will start falling down in all vapor liquid separator. Now start the feed pump slowly and adjust the flow and also start transferring liquid from 1st effect to second, from second to third effect and third to fourth. Now slowly increase the steam pressure and accordingly the feed flow and make it to the rated capacity. Meanwhile start cooling water supply to SC-03 (HE-1909) & 04 (HE-1910) and make ready ATFD section. Start steam by means of CV-ST-04 (PCL-12988) in to the ATFD and allow steam for 10 to15 minutes. Start the product pump PP-01(P-1911) as concentration of slurry reached to 50 % (W/W).and start transferring slurry to the ATFD (A-1901) & (A-1902) slowly. As we get product out from the bottom of ATFD (A-1901) & (A-1902) check product quality and raise feed rate to the rated capacity. Process Flow Diagram of Effluent Treatment Plant KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

22 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Brief description of ETP (700 m 3 /day) All non-toxic and biodegradable effluent streams from factory is collected in Raw effluent Tanks.From Raw effluent Tanks it Pumped to Equalization cum neutralization tank Effluent is continuously agitated with air diffusers, where air is supplied with two numbers of blowers here the continuous addition and stirring of lime, acid, Alum, poly Electrolyte, is done to maintain the ph of wastewater. The effluent is pumped to Primary clarifier. In the Primary clarifier suspended solids are allowed to settle down and decanted effluent passes to multi Stage Aeration Tank. Domestic wastewater shall be added to AT-1, if required. Here, biodegradation of organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the AT-1, AT2, AT- 3 and AT 4 for that oxygen shall be supplied by Surface Aerators were also keep MLSS in suspension. We can run Aeration tank separately as per COD, if COD load is low we can run single Aeration tank & if COD load is high we can run multiple Aeration tank Over Flow of aeration tank goes to Secondary clarifier, clear supernatant from Secondary clarifier shall go to Partially Treated water Sump by gravity from where effluent is pumped to Flash Mixer one where PH is maintain by adding lime & acid, over flow of flash mixture one over flow goes to flash Mixer two here we add Alum for better sludge settling. Over Flow of flash Mixer goes to final clarifier clear supernatant from final clarifier shall go to Treated water Sump by gravity from where effluent is pumped to sand filter. Treated effluent is then goes to GIDC drain through TOC meter, water flow meter & PH meter, we also install one five KL HDPE tank for sampling near boundary wall as per GIDC guide line. The suspended solids from Primary clarifier Tanks, secondary clarifier, and final clarifier are pumped to Sludge Sump. Sludge is then pumped to Filter Press where dewatering is carried out before storage of sludge in Hazardous Waste Storage Area and ultimate disposal to TSDF. Proposed Effluent treatment plant (700 m3/day) flow diagram is given in Figure and list of units with their size are given in following table. KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

23 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Size of the ETP (700 m 3 /day) KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

24 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Figure 1: Effluent Treatment Plant (700 m 3 /Day) Flow Diagram KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

25 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Figure 2: Multiple Effect Evaporator Flow Diagram KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

26 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 10: Details of Fuel Consumption Fuel Consumption details are given as below; Table 10: Details of Fuel Consumption S. No. Stack Attached to Boiler for Hydrogenation, Nitration & Chlorination Plant (22TPH) Thermic Fluid Heater for Chlorination Plant Boiler for DASDA Plant (32 TPH) Thermic Fluid Heater for DASDA Plant Scrubber for FBRS of DASDA Plant Boiler for OBA Plant (16 TPH) Boiler for ECH Plant (30 TPH) Cogen Plant Boiler (100 TPH) DG Set (1 no. of 1500 kva) Boiler for Phenol & cumene plant (100 TPH) Type of Fuel used Indian/ Imported Coal Fuel consumption (Kg/ hr.) EC Received DNL DPL 3806/ / 2530 Furnace Oil Indian/ Imported Coal 5536/ / 3680 Indian Coal Saw Dust Indian/ Imported Coal Indian/ Imported Coal Indian/ Imported Coal 2768/ / / / HSD 500 lit/hr. 500 lit/hr. - Indian/ Imported Coal 21000/ / Incinerator for Vent gas Gas 25 m3/ hr - 25 m3/ hr 12 Hot Air Generating Unit 13 DG Set (1 no. of 1500 kva) Indian/ Imported Coal 1950/ 1500 Note: DG set will be used intermittently and only during power failure. 1950/ 1500 HSD 500 lit/hr lit/hr. CPP (Cogen Plant Boiler) will be installed later and after that the present boilers will be stopped. Table 11: After Bifurcation Fuel Consumption of Deepak Nitrite Limited S. No. 1 Stack Attached to Boiler for Hydrogenation, Nitration & Chlorination Plant (22TPH) Type of Fuel used Fuel consumption (Kg/ hr.) Indian/ Imported Coal 3806/ Thermic Fluid Heater for Chlorination Plant Furnace Oil Boiler for DASDA Plant (32 TPH) Indian/ Imported Coal 5536/ Thermic Fluid Heater for DASDA Plant Indian Coal Scrubber for FBRS of DASDA Plant Saw Dust Boiler for OBA Plant (16 TPH) Indian/ Imported Coal 2768/ KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

27 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE S. No. Stack Attached to Type of Fuel used Fuel consumption (Kg/ hr.) 7 DG Set (1 no. of 1500 kva) HSD 500 lit/hr. 8 Hot Air Generating Unit Indian/ Imported Coal 1950/ 1500 KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

28 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 11: Details of Stacks Flue gas and process vent details are given as following; Table 12: Stack Details S. No. EC Received Source of Emission/ Stack Attached to DNL DPL 1 Boiler for Hydrogenation, Nitration & Chlorination Plant (22 TPH) 2 Thermic Fluid Heater for Chlorination Plant 3 Boiler for DASDA Plant (32 TPH) 4 Thermic Fluid Heater for DASDA Plant 5 Boiler for OBA Plant (16 TPH) 6 Cogen Plant Boiler (100 TPH) 7 DG Set (1 no. of 1500 kva) 8 Boiler for phenol & Cumene 100 TPH 9 Incinerator for 304 Nm 3 /hr. Vent gas 10 Hot Air Generating Unit (OBA Plant) 11 DG Set (1 no. of 1500 kva) Table 13: Details of Flue Gas Stacks for Deepak Nitrite Limited S. No. Source of Emission/ Stack Attached to Stack Height (m) Pollutants Pollution Control measures Boiler for Hydrogenation, Nitration & Chlorination Plant (22 TPH) Thermic Fluid Heater for Chlorination Plant Boiler for DASDA Plant (32 TPH) Thermic Fluid Heater for DASDA Plant 52 PM, SOx, NOx Electro Static Precipitator (ESP) & Adequate Stack Height 15 PM, SOx, NOx Adequate Stack Height 58 PM, SOx, NOx 5 Boiler for OBA Plant (16 TPH) 48 PM, SOx, NOx 6 Hot Air Generating Unit (OBA Plant) ESP & Adequate Stack Height 30 PM, SOx, NOx Adequate Stack Height 52 PM, SOx, NOx ESP & Adequate Stack Height ESP with adequate stack height will be provided 7 DG Set (1 no. of 1500 kva) 25 PM, SOx, NOx Adequate Stack Height Table 14: Details of Process vent Deepak Nitrite Limited S. No. Stack Attached to Air Pollution Control measures provided Stack Height (m) Pollutants 1 Hydrogenation Reactor of Hydrogen Plant Vent Scrubbing System for H2 gas 20 Hydrogen 2 Nitration Reactor of Nitration Plant NOx Scrubber with water as scrubbing media 16 NOx Vapours <40 mg/ Nm3 3 Chlorination Reactor of Chlorination Plant HCl absorption column with water as scrubbing media 20 HCl Vapours <20 mg/ Nm3 KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

29 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE S. No. Stack Attached to Air Pollution Control measures provided Stack Height (m) Pollutants 4 Drowning Reactor of DASDA Plant 5 Oxidation Vats of DASDA Plant SO2 Vent scrubbing system 15 Vent scrubbing system for Oxidation vats 20 SO2 Vapours <40 mg/ Nm3 Air with minor organics 6 Reactors of OBA Plant CO2 vent scrubbing system 20 CO2 Vapours 7 Process Plant of OBA Plant Scrubber 37 HCl Fumes 8 Spray Dryer of OBA Plant - 29 PM, SO2, NOx KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

30 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Annexure 12: Hazardous Waste Generation Details Details of Hazardous waste generation are given as following; Table 15: Details of Hazardous waste S. No Type of Waste ETP Sludge Salt Generation from ECH & OBA & DASDA Process Waste Waste Residue Spent Catalyst for regeneration Hazardous Waste Category Hazardous Waste Generation in MT/Month EC Received a) 395 b) 3728 a) 105 b) 368 Deepak Nitrite Ltd. a) 135 b) 3728 a) 105 b) 368 Deepak Phenolics Ltd. a) Used Oil Lit/ Month 100 Lit/ Month 250 Lit/ Month 5 Boiler Ash (if Indian coal) or 1807 if imported coal) 3650 (Indian Coal) (Indian Coal) 6 Spent Carbon Iron Sludge Discarded Container/ bags No./ Month 1000 No./ Month 1000 No./ Month Treatment / Disposal Collection, Storage, Transportation and Disposal at TSDF site. Salt Sale/ TSDF Site Collection, Storage & disposal by Incineration at approved incinerator site Regenerated & Reused or sent to third party for recovering precious metal Collection, storage, Transportation & Disposal by selling to Registered Re-processor Collection, storage, Transportation & Disposal by selling to brick manufacturer or cement industry Collection, Storage, Transportation and Disposal at TSDF site. Sold to approved registered vendors/ cement manufacturers Collection, decontamination, storage, transportation & sell to registered vendor KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

31 DEEPAK NITRITE LTD EXISTING PLANT AT DAHEJ GIDC ANNEXURE Table 16: After Bifurcation Hazardous Waste Generation of Deepak Nitrite Limited S. No. 1 2 Type of Waste ETP Sludge Salt Generation from ECH & OBA & DASDA Process Waste Waste Residue Hazardous Waste Category Hazardous Waste Generation in MT/Month a) 135 b) 3728 a) 105 b) Spent Catalyst for regeneration Used Oil Lit/ Month 5 Boiler Ash (Indian Coal) 6 Spent Carbon Iron Sludge Discarded Container/ bags Treatment / Disposal Collection, Storage, Transportation and Disposal at TSDF site. Salt Sale/ TSDF Site Collection, Storage & disposal by Incineration at approved incinerator site Regenerated & Reused or sent to third party for recovering precious metal Collection, storage, Transportation & Disposal by selling to Registered Re-processor Collection, storage, Transportation & Disposal by selling to brick manufacturer or cement industry Collection, Storage, Transportation and Disposal at TSDF site. Sold to approved registered vendors/ cement manufacturers Collection, decontamination, storage, transportation & sell to registered vendor KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

32 Kadam Environmental Consultants w w w. k a d a m e n v i r o. c o m E n v i r o n m e n t for Dev e l o p m e n t CONTACT DETAILS Vadodara (Head Office) 871/B/3, GIDC Makarpura, Vadodara, India E: kadamenviro@kadamenviro.com; T: ; F: Delhi / NCR Spaze IT Park, Unit No. 1124, 11 th Floor, Tower B-3, Sector 49, Sohna Road, Gurgaon, India E: delhi@kadamenviro.com; T/F :

33 DEEPAK NITRITE LIMITED Prefeasibility Report for Bifurcation of Existing EC and EC on Name of Deepak Nitrite Limited on Plot No. 12/B, GIDC Dahej, Taluka Vagra, District Bharuch OCTOBER 2015 Kadam Environmental Consultants w w w. k a d a m e n v i r o. c o m E n v i r o n m e n t for Dev e l o p m e n t

34 DEEPAK NITRITE LIMITED EXISTING PLANT EXECUTIVE SUMMARY DEEPAK NITRITE LIMITED Prefeasibility Report for EC Amendment for Bifurcation of Existing Plant at Plot No. 12/B, GIDC Dahej, Taluka Vagra, District Bharuch Kadam Environmental Consultants ( Kadam ), October 2015 This report is released for the use of the M/s. Deepak Nitrites Limited (DNL), Regulators and relevant stakeholders solely as part of the subject project s Environmental Clearance process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam. PROJECT DETAILS Name of Publication Prefeasibility Report for EC Amendment for Bifurcation of Existing Plant at Plot No. 12/B, GIDC Dahej, Taluka Vagra, District Bharuch Project Number Report No. 1 Version 1 Released October 2015 Prepared & Managed By Dhara Patel Released By Jitixa Upadhyay CONTACT DETAILS Vadodara (Head Office) 871/B/3, GIDC Makarpura, Vadodara, India E: kadamenviro@kadamenviro.com; T: ; F: Delhi / NCR SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall, Sohna Road, Gurgaon (Haryana) E: delhi@kadamenviro.com; T: ; M: DISCLAIMER Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation. KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

35 DEEPAK NITRITE LIMITED EXISTING PLANT EXECUTIVE SUMMARY CONTENTS 1 EXECUTIVE SUMMARY PLANT FEATURES AND PRODUCTION CAPACITY INTRODUCTION BRIEF DESCRIPTION OF THE PROJECT NEED FOR THE PROJECT AND IT S IMPORTANCE TO REGION DEMAND SUPPLY GAP IMPORT VS. INDIGENOUS PRODUCTION EXPORT POSSIBILITY EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT PROJECT DESCRIPTION TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT LAY OUT) WITH COORDINATES DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED SIZE OR MAGNITUDE OF OPERATION PROJECT DESCRIPTION WITH PROJECT DETAILS (A SCHEMATIC DIAGRAM / FLOW CHART SHOWING THE PROJECT LAYOUT, COMPONENTS OF THE PROJECT ETC SHOULD BE GIVEN) RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIALS AND FINISHED PRODUCT RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND THEIR SOURCE Fuel QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT /DISPOSAL Waste Water Generation, Treatment and Disposal Effluent Treatment Plant of Deepak Nitrite Limited (DNL) Flue gas and process vent details are given as following; Hazardous Waste Generation Details Schematic Representations of the Feasibility Drawing which give Information of EIA Purpose SITE ANALYSIS CONNECTIVITY LAND FORM, LAND USE AND LAND OWNERSHIP TOPOGRAPHY (ALONG WITH MAP) EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

36 DEEPAK NITRITE LIMITED EXISTING PLANT EXECUTIVE SUMMARY HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN EXISTING INFRASTRUCTURE SOIL CLASSIFICATION CLIMATIC DATA FROM SECONDARY SOURCES Temperature Wind Rainfall Cloud Cover Humidity SOCIAL INFRASTRUCTURE AVAILABLE PLANNING BRIEF PROPOSED INFRASTRUCTURE INDUSTRIAL AREA (PROCESSING AREA) RESIDENTIAL AREA (NON-PROCESSING AREA) GREEN BELT SOCIAL INFRASTRUCTURE CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC) By Road By Rail By Air By Water DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) SEWAGE SYSTEM INDUSTRIAL WASTE MANAGEMENT SOLID WASTE MANAGEMENT POWER REQUIREMENT & SUPPLY/ SOURCE REHABILITATION AND RESETTLEMENTS (R& R) PLAN POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) PROJECT SCHEDULE AND COST ESTIMATE LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT ANALYSIS OF PROPOSAL KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

37 DEEPAK NITRITE LIMITED EXISTING PLANT EXECUTIVE SUMMARY 1 EXECUTIVE SUMMARY 1.1 Plant Features and Production Capacity Deepak Nitrite Limited (DNL) is one of the medium sized producers of intermediate chemicals in India. DNL has been serving the Asian & European markets for the past four decades. DNL has one of the largest nitration facilities in India & their manufacturing portfolio includes products such as Sodium Nitrite, Sodium Nitrate, Nitro aromatics, Nitro Chloro benzene etc. They also manufacture various derivatives of nitro aromatics that are used as intermediates in optical brightener & dyes & inks. They are vertically integrated in some of their products streams with the raw materials coming from one of the other companies in the group. As it is bifurcation of existing EC No. SEIAA/EC/5(f), 4(d), 1(d)/ 120/2014 dated 6th August 2014 into Deepak Nitrite Limited (DNL) and Deepak Phenolics Limited (DPL) S. No. Final Products for EC DNL DPL 1 2 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cumidine, (Para & Ortho) Nitration Plant- Any one Product at a time Nitro Toluenes (ONT, PNT, MNT) Nitrochlorobenzenes (ONCB, PNCB) O- Nitroxylenes (3 NOX & 4NOX) M- Nitroxylenes (2, 4 NXL & 2,6 NXL) Ethyl Hexyl Nitrate (EHN) Nitrocumenes (PNC) 3 Monochlorobenzene (MCB) 4 Dichlorobenzene DCB (Byproduct) 5 30% HCl (Byproduct) 6 DASDA 7 Sodium Sulphate (Byproduct) 8 Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc. 9 Hydrogen (Byproduct) (Nm3/ hr) 10 Power 11 Steam 12 Phenol 13 Cumene 14 Acetone 15 Alpha Methyl Styrene (AMS) 16 Benzene Rich Cut 17 Crude Phenol Column Bottoms #Note: Hydrogen (Byproduct) (Nm3/ hr) production will be reduced KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

38 DEEPAK NITRITE LIMITED EXISTING PLANT EXECUTIVE SUMMARY *Note: EC application was done for 125 TPH, however in EC it is 100 TPH. Hence, in total capacity 125 TPH is mentioned. Production Details of Deepak Nitrite Limited (DNL) S. No. Name of Final EC Product Capacity (MT/Month) 1 2 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cyclohexanone, Cumidine, (Para & Ortho) Nitration Plant- Any one Product at a time KADAM ENVIRONMENTAL CONSULTANTS OCTOBER Nitro Toluenes (ONT, PNT, MNT) 2500 Nitrochlorobenzenes (ONCB, PNCB) 2500 O- Nitroxylenes (3 NOX & 4NOX) 2160 M- Nitroxylenes (2, 4 NXL & 2,6 NXL) 2160 Ethyl Hexyl Nitrate (EHN) 1800 Nitrocumenes (PNC) Monochlorobenzene (MCB) Dichlorobenzene DCB (Byproduct) % HCl (Byproduct) DASDA Sodium Sulphate (Byproduct) Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc. 9 Hydrogen (Byproduct) (Nm3/ hr)# Steam 25 Area of the Project Total Area in the existing EC is 2,31, m 2. Area of Deepak Nitrite Limited (DNL) is 91, m 2. Water Consumption Total fresh water consumption in the existing EC is 7656 KLD. Total fresh water consumption in Deepak Nitrite Limited (DNL) is 5608 KLD. Water is sourced from the GIDC water supply. Wastewater Disposal Total waste water generation in the existing EC is 3319 m 3. Total waste water generation in Deepak Nitrite Limited (DNL) is After treated in MEE waste water KLD wastewater generated which is treated in ETP and disposed to the deep sea through GIDC Pipeline after meeting the disposal mode described by State Pollution Control Board. Power Power supply from Grid: DNL connection load is 3.5 MW supplied by Dakshin Gujarat Vij Company Ltd. (DGVCL). DNL Backup: DG Set (1 No.) of Capacity of 1500 kva 3750

39 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION 2 INTRODUCTION 2.1 Brief Description of the Project Deepak Nitrite Limited (DNL) is one of the medium sized producers of intermediate chemicals in India. DNL has been serving the Asian & European markets for the past four decades. DNL has one of the largest nitration facilities in India & their manufacturing portfolio includes products such as Sodium Nitrite, Sodium Nitrate, Nitro aromatics, Nitro Chloro benzene etc. They also manufacture various derivatives of nitro aromatics that are used as intermediates in optical brightener & dyes & inks. They are vertically integrated in some of their products streams with the raw materials coming from one of the other companies in the group. DNL has manufacturing locations in India with ample scope for expansion & has considerable experience in implementing & managing large scale projects. DNL's senior management team is fully committed to support both financially & by providing the necessary technical resources for expansion of our product portfolio. 2.2 Need for the project and it s importance to region It is bifurcation of existing EC No. SEIAA/EC/5(f), 4(d), 1(d)/ 120/2014 dated 6th August 2014 into Deepak Nitrite Limited (DNL) and Deepak Phenolics Limited (DPL). "The proposed business requires petrochemical segment specialization with dedicated team to meet the goal of the company. We have created different company with the focused team on board. It's need on an hour to have experts on different board. The different group of people will be handling the total petrochemical business under the guidance of principal promoter of the company." 2.3 Demand Supply Gap Not Applicable 2.4 Import vs. Indigenous Production Not Applicable 2.5 Export Possibility Not Applicable 2.6 Employment Generation (Direct and Indirect) due to the project. Not Applicable KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

40 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION 3 PROJECT DESCRIPTION 3.1 Type of Project including interlinked and interdependent projects, if any No 3.2 Location (map showing general location, specific location and project boundary & project lay out) with coordinates 3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted Not Applicable 3.4 Size or Magnitude of Operation As it is bifurcation of existing EC No. SEIAA/EC/5(f), 4(d), 1(d)/ 120/2014 dated 6th August 2014 into Deepak Nitrite Limited (DNL) and Deepak Phenolics Limited (DPL) Table 3-1: Total Products for EC S. No. Final Products for EC DNL DPL 1 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cumidine, (Para & Ortho) KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

41 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION S. No. Final Products for EC DNL DPL 2 Nitration Plant- Any one Product at a time Nitro Toluenes (ONT, PNT, MNT) Nitrochlorobenzenes (ONCB, PNCB) O- Nitroxylenes (3 NOX & 4NOX) M- Nitroxylenes (2, 4 NXL & 2,6 NXL) Ethyl Hexyl Nitrate (EHN) Nitrocumenes (PNC) 3 Monochlorobenzene (MCB) 4 Dichlorobenzene DCB (Byproduct) 5 30% HCl (Byproduct) 6 DASDA 7 Sodium Sulphate (Byproduct) 8 Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc. 9 Hydrogen (Byproduct) (Nm3/ hr) 10 Power 11 Steam 12 Phenol 13 Cumene 14 Acetone 15 Alpha Methyl Styrene (AMS) 16 Benzene Rich Cut 17 Crude Phenol Column Bottoms #Note: Hydrogen (Byproduct) (Nm3/ hr) production will be reduced *Note: EC application was done for 125 TPH, however in EC it is 100 TPH. Hence, in total capacity 125 TPH is mentioned. Table 3-2: Production Details of Deepak Nitrite Limited (DNL) S. No. Name of Final EC Product Capacity (MT/Month) 1 2 Hydrogenation Toludine (Ortho, Para, Meta), Xylidine (2-4,2-6,3-4,2-3), Cyclohexanone, Cumidine, (Para & Ortho) Nitration Plant- Any one Product at a time Nitro Toluenes (ONT, PNT, MNT) 2500 Nitrochlorobenzenes (ONCB, PNCB) 2500 O- Nitroxylenes (3 NOX & 4NOX) 2160 M- Nitroxylenes (2, 4 NXL & 2,6 NXL) 2160 KADAM ENVIRONMENTAL CONSULTANTS OCTOBER Ethyl Hexyl Nitrate (EHN) 1800 Nitrocumenes (PNC) Monochlorobenzene (MCB) Dichlorobenzene DCB (Byproduct) % HCl (Byproduct) DASDA 1875

42 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION S. No. Name of Final EC Product Capacity (MT/Month) 7 Sodium Sulphate (Byproduct) Various Optical Brightening Agents (OBA) such as DMA-X Conc., UP liq., UP Conc., SRK, BMK, AS liq., HF liq., ABP liq., SI liq., BOP, MST liq., 2B Type etc. 9 Hydrogen (Byproduct) (Nm3/ hr)# Steam Project Description with Project details (A Schematic Diagram / Flow Chart Showing the Project Layout, components of the Project etc should be given) Not applicable as it is bifurcation of existing EC. 3.6 Raw material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw materials and finished product. Not applicable as it is bifurcation of existing EC. 3.7 Resource optimization / recycling and reuse envisaged in the project, if any. Not applicable as it is bifurcation of existing EC. 3.8 Availability of water its source, energy/power requirement and their source Water will be supplied by GIDC. Table 3-3: Water Consumption Details S. No. Source Quantity of Water Consumption, KLD EC Received Deepak Nitrite Ltd Deepak Phenolics Ltd 1 Process Boiler Cooling & Chilling Washing Domestic Gardening Total Water Requirement Recovery Net Water Requirement Table 3-4: Details of Water Consumption by Deepak Nitrite Limited (DNL) S. No. Source Quantity of Water Consumption, KLD 1 Process Boiler Cooling & Chilling Washing Domestic 88 KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

43 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION 6 Gardening 38 Total Water Requirement Recovery Net Water Requirement Fuel Source of Power Supply: Dakshin Gujarat Vij Company Ltd. For backup DG set will be installed. DNL Connected Load: 3.5 MW. Table 3-5: Details of Fuel Consumption S. No. Stack Attached to Type of Fuel used Boiler for Hydrogenation, Nitration & Chlorination Plant (22TPH) Thermic Fluid Heater for Chlorination Plant Boiler for DASDA Plant (32 TPH) Thermic Fluid Heater for DASDA Plant Scrubber for FBRS of DASDA Plant 6 Boiler for OBA Plant (16 TPH) 7 Boiler for ECH Plant (30 TPH) 8 Cogen Plant Boiler (100 TPH) Indian/ Imported Coal Fuel consumption (Kg/ hr.) EC Received DNL DPL 3806/ / 2530 Furnace Oil Indian/ Imported Coal 5536/ / 3680 Indian Coal Saw Dust Indian/ Imported Coal Indian/ Imported Coal Indian/ Imported Coal 2768/ / / DG Set (1 no. of 1500 kva) HSD 500 lit/hr. 500 lit/hr Boiler for Phenol & cumene plant (100 TPH) Indian/ Imported Coal 21000/ / / Incinerator for Vent gas Gas 25 m3/ hr - 25 m3/ hr 12 Hot Air Generating Unit Indian/ Imported Coal 13 DG Set (1 no. of 1500 kva) HSD 500 lit/hr lit/hr. 1950/ Note: DG set will be used intermittently and only during power failure / CPP (Cogen Plant Boiler) will be installed later and after that the present boilers will be stopped. Table 3-6: Details of Fuel Consumption for Deepak Nitrite Limited S. No. 1 Stack Attached to Boiler for Hydrogenation, Nitration & Chlorination Plant (22TPH) Type of Fuel used 1500 Fuel consumption (Kg/ hr.) Indian/ Imported Coal 3806/ Thermic Fluid Heater for Chlorination Plant Furnace Oil KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

44 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION S. No. Stack Attached to Type of Fuel used Fuel consumption (Kg/ hr.) 3 Boiler for DASDA Plant (32 TPH) Indian/ Imported Coal 5536/ Thermic Fluid Heater for DASDA Plant Indian Coal Scrubber for FBRS of DASDA Plant Saw Dust Boiler for OBA Plant (16 TPH) Indian/ Imported Coal 2768/ DG Set (1 no. of 1500 kva) HSD 500 lit/hr. 8 Hot Air Generating Unit Indian/ Imported Coal 1950/ Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal Waste Water Generation, Treatment and Disposal Table 3-7: Total Wastewater Generation S. No. Source Quantity of Waste Water Generation, KLD EC Received Deepak Nitrite Ltd Deepak Phenolics Ltd 1 Process Boiler Cooling & Chilling Washing Domestic Total Wastewater Generation Water to MEE for Recovery Total Water to ETP & thereafter to GIDC Drain for disposal to deep sea Table 3-8: Waste Water Generation Details for Deepak Nitrite Limited (DNL) S. No. Source Quantity of Waste Water Generation, KLD 1 Process Boiler Cooling & Chilling Washing Domestic Total Wastewater Generation Water to MEE for Recovery Total Water to ETP & thereafter to GIDC Drain for disposal to deep sea Effluent Treatment Plant of Deepak Nitrite Limited (DNL) Brief Description of Multi Effective Evaporator KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

45 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION Plant to be started in following sequence generally. Later after the stabilized run and independent operation on the effluent streams amendment in startup procedure is possible based on the individual experience of the plant personnel. Check for availability of feed, utilities manpower etc. Start cooling water tower, cooling tower fan & cooling water pump. Establish the water circuit in the barometric condenser SC-01(HE-1908) and SCS-01 (HE-1902) Start the vacuum pump VP-01 (VP-1912) and wait till vacuum reaches to 300 mm Hg. Check the sealing water flow and temperature in vacuum pump. Transfer the feed from main feed storage tank to feed tank FT-01 (T-1905). Start the feed pump FP-01(P- 1909) and establish circulation through stripper section with maintaining level 50% in PC-01 (C-1901) with FP-01 (P-1909) VFD. After sample analysis of stripper section start transferring to Evaporator section and take % level in VLS-01(V-1903) by CV-PL-01 (LCV-12927) Start the transfer pump TP-01 (P-1905) and transfer liquid to the VLS-02 (V-1905) and take the same level as in VLS-01 (V-1903) by means of CV-PL-02 (LCV-12935) Start the Axial flow pump RPE-01 (P-1907) and transfer liquid to the VLS-03 (V-1907) and take the % level by means of CV-PL-03 (LCV-12955) Start the Axial flow pump RPE-02 (P-1908) and transfer liquid to the VLS-04(V-1909) and take the same level as in VLS-03 (P-1907) Now start the recirculation pump and establish circulation in last effect of Evaporator unit. Slowly start steam by means of CV-ST-02 (PCL-12919) in to the thermo compressor and make the pressure at about 8 Kg/cm2-g. This steam will heat the first Calandria. Vapor & liquid will be separated in to VLS-01 (V-1903). A small part of steam from calandria-1 will heat the feed in PH-01 (HE-1903) The vapor from VLS-01 (V-1903) will heat second Calandria. Vapor & liquid will be separated in VLS-02 (V- 1905). Partial flow of Vapor from VLS-02 (V-1905) will heat the third Calandria and part will go to the thermo compressor.vapor from VLS-03 (V-1907) will heat forth Calandria and vapor from VLS-04(V-1909) will be condensed in surface condenser. Keep watch on the condensate levels in all four Calandria and 50% for flash tank & accordingly start condensate pump CP-01(P-1910) and adjust the level by means of VFD Due to evaporation in all four Calandria, level will start falling down in all vapor liquid separator. Now start the feed pump slowly and adjust the flow and also start transferring liquid from 1st effect to second, from second to third effect and third to fourth. Now slowly increase the steam pressure and accordingly the feed flow and make it to the rated capacity. KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

46 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION Meanwhile start cooling water supply to SC-03 (HE-1909) & 04 (HE-1910) and make ready ATFD section. Start steam by means of CV-ST-04 (PCL-12988) in to the ATFD and allow steam for 10 to15 minutes. Start the product pump PP-01(P-1911) as concentration of slurry reached to 50 % (W/W).and start transferring slurry to the ATFD (A-1901) & (A-1902) slowly. As we get product out from the bottom of ATFD (A-1901) & (A-1902) check product quality and raise feed rate to the rated capacity. Process Flow Diagram of Effluent Treatment Plant Brief description of ETP (700 m 3 /day) All non-toxic and biodegradable effluent streams from factory is collected in Raw effluent Tanks.From Raw effluent Tanks it Pumped to Equalization cum neutralization tank Effluent is continuously agitated with air diffusers, where air is supplied with two numbers of blowers here the continuous addition and stirring of lime, KADAM ENVIRONMENTAL CONSULTANTS OCTOBER

47 DEEPAK NITRITE LIMITED EXISTING PLANT INTRODUCTION acid, Alum, poly Electrolyte, is done to maintain the ph of wastewater. The effluent is pumped to Primary clarifier. In the Primary clarifier suspended solids are allowed to settle down and decanted effluent passes to multi Stage Aeration Tank. Domestic wastewater shall be added to AT-1, if required. Here, biodegradation of organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the AT-1, AT2, AT- 3 and AT 4 for that oxygen shall be supplied by Surface Aerators were also keep MLSS in suspension. We can run Aeration tank separately as per COD, if COD load is low we can run single Aeration tank & if COD load is high we can run multiple Aeration tank Over Flow of aeration tank goes to Secondary clarifier, clear supernatant from Secondary clarifier shall go to Partially Treated water Sump by gravity from where effluent is pumped to Flash Mixer one where PH is maintain by adding lime & acid, over flow of flash mixture one over flow goes to flash Mixer two here we add Alum for better sludge settling. Over Flow of flash Mixer goes to final clarifier clear supernatant from final clarifier shall go to Treated water Sump by gravity from where effluent is pumped to sand filter. Treated effluent is then goes to GIDC drain through TOC meter, water flow meter & PH meter, we also install one five KL HDPE tank for sampling near boundary wall as per GIDC guide line. The suspended solids from Primary clarifier Tanks, secondary clarifier, and final clarifier are pumped to Sludge Sump. Sludge is then pumped to Filter Press where dewatering is carried out before storage of sludge in Hazardous Waste Storage Area and ultimate disposal to TSDF. Proposed Effluent treatment plant (700 m3/day) flow diagram is given in Figure and list of units with their size are given in following table. KADAM ENVIRONMENTAL CONSULTANTS OCTOBER