Environment Management System in Chemical Unit-II (Pyridine & its Derivatives and Speciality Chemicals)

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1 Environment Management System in Chemical Unit-II (Pyridine & its Derivatives and Speciality Chemicals) 1. Air Emission Management: Odour Management There will not be any specific source of air emission however, because of the nature of raw materials and processes involved, there are potential for various types of air emission from the process equipment mainly vents of the reactors and storage tanks. Depending on the type and nature of emission, the following approach has been adopted for minimising odour emissions from the proposed plant: a) Major Odourous Vents Pyridine recovery vents are connected to 2 No s Thermal oxidizer where the vent gasses are incinerated. The flue gasses are then passed through a Waste Heat Recovery Boiler is then wherein steam is generated to the tune of 4 TPH. b) Other Odourous vents Minimise emission by nitrogen blanketing / chilled water condenser/ scrubbing system in Pyridine storage tanks. (Effluent generated from scrubber will be recycled in the process) c) Mildly Odourous vents Provision for demister / knock out pots / chilled water condenser / scrubbing system in the vents. (Effluent generated from scrubber will be recycled in the process). d) Mildly odourous tankages vents Provision for breather valves / condensers. e) Fugitive emissions Condenser height reduced from 33 to 24 /27 to improve cooling water circulation system in order to prevent fugitive emissions into atmosphere. Scrubber capacity enhanced in 4DMAP plant to prevent fugitive emission into atmosphere. Cold trap provided before hot well during toluene distillation to prevent toluene exposure into atmosphere. Bund walls to restrict occasional leakages / accidental spillages. State of the art double mechanical seal pumps for material transfer.

2 Schematics of vent chiller / condenser & nitrogen blanketing is enclosed for reference Chiller to reduce the emission so as to reduce vent losses from the tank PRV for Nitrogen Blanketing SRV for N2 Blanketing Breather Valve

3 NITROGEN BLANKETING SYSTEM ON STORAGE TANKS In additions to this VOC detector has been installed at main gate to detect VOC levels in ambient air. SCHEME FOR VENTS CONTAINING TRACES OF PYRIDINE To common vent gas manifold for thermal oxidation CHWR Pyridine column CHWS Pyridine NO column Equalization Pot Beta NO column Residue column Ejector vent Py. column feed tank To RPT Py NO Feed vessel Beta NO feed vessel To RPT Residue feed tank Wet cut tank

4 2. Effluent Management: Process effluent The effluent generated from manufacturing of Pyridine and derivatives is organic/inorganic in nature and is known as raffinate. The organic raffinate is non biodegradable in nature and hence it can be treated through incineration only. We have options of treatment of raffinate. 1. In house incineration : Being adopted at present.. 2. Co incineration at cement kilns : The same is optional and under trial. Presently we are treating the effluent inhouse where organic raffinate is sent for concentration in the existing 02 nos. Multi Effect Evaporator (MEE) & condensate recovered from evaporators is used as make-up water in cooling tower. The concentrate from the MEE is incinerated in the state-of-the-art 3 nos. Liquid Waste Incinerators provided with waste heat recovery system, cyclones, scrubbers and spray dryer etc. We are in the process of conducting the trial for co incineration of same at cement kilns. The scheme of treatment is as below: The Aqueous Organic Raffinate shall be Co-incinerated in Cement Kilns at temperatures above 900 Deg C, by spraying it as fine Mist into the flue gas from the Cement kiln, before it enters Pre-Claciners for pre-calcining of lime. In the process, the water in the raffinate (>97%) is evaporated, Volatile Organic contents are destructed and Fixed salts are calcined into Cement thereby permanently fixed in cement. The above process will substantially reduce the resource, environment and Carbon foot print from the operations of Multiple Effect Evaporator, Coal fired boilers, Flue gases emitted through stack, Odour emissions, Ground water extraction for steam generation and GHG emissions. The process flow sheet for Cement Co-incineration is as attached.

5 Details of Treatment Facilities MEE I & II m³/d and 528 m³/d capacity respectively. Liquid Waste Incinerators I, II & III - 90 m³/d, 90 m³/d and 108 m³/d capacity respectively. Installed Production Capacity of Pyridine and Picoline- 152 TPD. Existing norm for raffinate generation is 2.8 KL per MT of Pyridene and Picoline production. Organic raffinate generation will be = 2.8*152 = m³/d approx... After concentration in existing evaporators the concentrate available for incineration = Kl/d. In organic raffinate generation from Pyridine derivatives and other speciality molecules will be approximately eq. to 55 Kl/d. Hence overall raffinate generation 425 Kl/d (organic) 55 kl/d (inorganic). The Inorganic raffinate from Pyridine derivatives is spray dried in Spray drier of capacities 24 KLD and 240 KLD provided with solid waste incinerator and liquid waste incinerator-iii respectively.

6 Inorganic raffinate eq. to 55 kl/d max. is being spray dried in spray driers and spray dried solids disposed in captive secured fill. The same will also be outsourced for treatment ie: incineration / co incineration / spray drying through govt. approved agencies ( Moef&CGG and SPCB ) as a alternate method and source of treatment to take care during any adverse conditions.

7 Complete Effluent treatment scheme of Chemical Unit-2..

8 Domestic Effluent treatment scheme The domestic effluent from colony and plant is collected in sewage collection tank from where it is transferred to aeration tank after passing through bar screen chamber. Aeration tank has diffusers for air supply to micro organism and here effluent is decomposed into its simple chain compounds. Effluent from aeration tank reaches to clarifier hydraulically where sludge settles and clear treated effluent reaches to final collection tank after passing through sand and carbon filter as tertiary treatment. After disinfection through chlorination, treated effluent utilized for horticulture process. Sludge generated during treatment process is collected in sludge drying beds which after drying disposed accordingly..

9 Utility Effluent management : Cooling Tower Blow down Tr. System The cooling towers blow down from Chemical Unit-1, Chemical Unit-2, Distillery Unit and Power plant of Jubilant Life Sciences Limited and 35.0 m3 per day from JACPL Unit ( 8.0 m3/day from Polymer Unit & 27.0 m3/day from Estergum plant ) meets all requirements of utilization in horticulture purposes. The same will be utilized in Horticulture process in non monsoon season and same will be treated through reverse osmosis process during monsoon season. Permeate from RO plant will be again utilized in cooling tower make up where as reject will be utilized for ash conveying / Spray drying. Cooling Tower blow down/boiler Blow down & Demin wash from JLL and C.T.Blow down from JACPL Reverse Osmosis Plant T. capacity : 1200 M3/day Permeate Approx 80.0 % of total feed Reject App % of feed. Wet Ash Conveying./ Spray drying Cooling Tower makeup / other purposes as per requirement. Thus total process effluent is treated adequately and complete Zero liquid Discharge status is being maintained FROM Chemical Unit-II.

10 3. Solid Waste Management: The incinerable wastes generated in various processes are treated in the existing solid waste incinerator, now we are engaged in co-incineration with MoEF approved agency. For environmentally sound disposal of non-incinerable wastes and incineration ash a Secured Land Fill has been commissioned within the premises. Details are given below: 175 TPA: Lutidine Nutch Filter :- Captive Incineration / Co Incineration / Co processing at authorised agency. TPA: Kettle distillation residue from 3 CP plant :- Captive Incineration / Co Incineration / Co processing at authorised agency. 170 TPA: Spent Solvent :- Reuse/Sale to authorised buyer 120 TPA: Amino pyridine residue from MPP :- Captive Incineration / Co Incineration / Co processing at authorised agency. 150 TPA: Contaminated plastic:- Captive Incineration / Co Incineration / Co processing at authorised agency KLA: Liquid residue from pyridine derivatives incineration/ Co incineration/used as fuel in captive Liquid waste incinerators. 273 TPA: Incineration ash is collected in drums and will be disposed off in captive SLF in the premises of JLL TPA: Spray dried solids are collected in drums and will be disposed off in existing SLF in the premises of JLL. 7 TPA : Spent Catalyst is collected in drums and will be disposed off in captive SLF. 50 TPA: 2HMP residue from pyridine derivatives:- Captive Incineration / Co Incineration / Co processing at authorised agency. 290 TPA: Distillation residue from pyridine derivatives :- Captive Incineration / Co Incineration / Co processing at authorised agency. 48 TPA: Waste charcoal from pyridine derivatives:- Captive Incineration / Co Incineration / Co processing at authorised agency 93 TPA: Spent catalyst from pyridine plant:- Captive Incineration / Co Incineration / Co processing at authorised agency.

11 4. Stacks details of Chemical Unit-II: 5. For Furnaces of Chemical unit II : Details of Fuel consumption in Metric Tones per day (MT/d) 1. Daily consumption in Tones 2. Calorific value (kcal/kg) 3. Ash content (%) 4. Sulphur content (%) 5. Others (specify) Coa l Oil (LDO/HSD ) 6 kl/day <1 Diesel (RFO+Resid ue) Wood Biogas/Coal gas Nm 3 /day / Nm 3 /day (for Inc I,II, III and other furnaces) 4000Kcal/Nm 3 / 1200 Kcal/Nm 3 Others (specify)

12 6. Details of Raw Materials : Raw Material Unit Qty PYRIDINE & PICOLINE ACH KG/KG FORMALIN KG/KG 2.57 NH3 KG/KG 0.49 CAT CONS ZEOLITE KG/MT 1.8 BENZENE KG/KG CYNO PYRIDINE B PICOLINE KG/KG AMMONIA KG/KG 0.62 BENZENE KG/KG ,3 LUTIDINE OXALIC ACID KG/KG % 3,5 LUTIDINE KG/KG 10

13 7. Product List of Chemical Unit-II Name of the Products Capacity (TPA) Pyridine and derivatives and Specialty chemicals Pyridine and Picoline and derivatives Cyano Pyridine 8030 Fine Chemicals MPP Products Lutidine & collidine and 1190 derivatives Amino pyridine and deivatives 1600 Piperidine and derivatives 860 Pyridine carboxylic acids and 1825 derivatives Chloro/Fluoro/Bromo/Hydroxyl 2920 Pyridine and derivatives Pyrazine and derivatives 1095 Vinyl Pyridines Catalyst for pyridine carboxylic acids Pyridine ethanol/aldehydes & Ketone derivatives Cyclo alkino pyridine & derivatives and aliphatic derivatives List of By Products By Product Quantity (TPA) Specialty Chemicals KCl rich salt 720

14 8. Details of Steam and Power production: The steam generated at power plant & other units is used during manufacturing of products at Jubilant, Gajraula The overall steam generation scenario for the Gajraula complex is given below; S. No Detail Installed Cap TPH Operating Cap TPH 1 90 TPH - 1Coal Fired AFBC Boiler TPH - 1Coal Fired AFBC Boiler TPH Coal Fired Boiler TPH Coal Fired Boiler TPH Coal Fired Boiler TPH Biogas Fired Boiler TPH Incinerator Waste Heat Recovery Boiler 8 25 TPH Slop Fired Boiler Total It may be observed that since steam requirement is in tune of 250 TPH, the other old Boilers viz. 34 TPH, 35 TPH and 25 TPH Coal fired boilers are now in standby mode. The overall power generation scenario for the Gajraula complex is given below; Sr No. Details Installed Capacity, Operating Capacity, MW MW 1 TG-1, Back Pressure Turbine TG-2, Back Pressure Turbine TG-3, Ext. Cum Condensing turbine TG-4, Back Pressure Turbine TG-5, Back Pressure Turbine DG sets (3 nos) Total It may be observed that since power requirement is being fulfilled by the Captive power plant, the DG sets will remain in stand by mode for back up. The steam generated will also be utilized in production of various products in Chem. Unit -II

15 9. LIST OF ANALYTICAL INSTRUMENTS S.No. Name of Instrument S.No. Name of Instrument 1. BOD Incubator 15. Gas chromatograph 2. Centrifuge 16. Water bath 3. ph meter 17. Oxygen Meter 4. Hot air oven 18. Handy Sampler 5. BOD analyser 19. APM-410/411 High Volume Sampler 6. Bacteriological Incubator 20. APM-415/411 High Volume Sampler 7. Single Pan Balance 21. APM-610 Stack Monitoring Kit 8. COD digital unit 22. APM-620 Stack Monitoring Kit 9. Atco Balance 23. H2S Monitor 10. Spectrophotometer 24. DO Meter 11. COD appratus 25. Respirable Dust Sampler 12. Refrigerator 26. Multiworn instrument 13. Muffle furnace 27. Desicator 14. Orset appratus 28. Distillation & Double Distillation Set

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