Annexure-1 Location Map

Transcription

1 ANNEXURES

2 Annexure-1 Location Map District Map: Bharuch 1

3 Annexure -2 Google Image Showing Location of the Project Site 2

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5 Annexure - 3 Plan Layout ONGC 4

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7 Annexure 4 Break-up of Land Area Requirement Description Area (m 2 ) Existing Proposed Plant [a] [b] (Epoxy ) ECH Plant EPOY Plant CPVC Plant d) Open land area ** Greenbelt (33% of the total plot area) 33% of the Total Plot area will be used for green belt development Total Area (m 2 ) ** Existing Facility will be used Note : It may be noted that the total land area of the company is 567 acres, out of which Existing plant area is 35 acres [ m 2 ] and 9 acres [ m 2 ] of land will be utilized for proposed expansion of ECH and Epoxy plant. Total 33 % of plot area will be utilized for the greenbelt development Total after proposed expansion [a+b] Manufacturing Process Area Storage for Raw Materials ** Storage for Products ** Storage for Fuel nil ** nil 28.4 Storage for Water ** ** ** Storage for Hazardous/Solid Waste Storage for Hazardous Chemical ** ** ** Effluent Treatment Plant ** ** Utilities ** 1020 ** Approach Road(s) ** Other (Substation & Pipe Rack) ** a) Office ** ** [Administration + Security] ** b) Parking ** 500 c) Canteen **

8 Annexure 5 Details of Products and Raw Materials (A) DETAILS OF PRODUCTS Name of Product Project Activity as per EIA Notification As per EC Production Capacity (MT/Annum) Existing As per CTE/CC&A PRODUCT MIX Proposed For Expansion/ EC Total [a] [b] [a+b] Epichlorohydrin (ECH) Epichlorohydrin 36500** 0.0** Hydrochloric acid (20% Technical grade) as 20% 5(f) 4247** 0.0** NaCl (20%) Refined Glycerin (75%) Chlorinated Poly Vinyl Chloride (CPVC) CPVC (f) Hydrochloric acid Epoxy Plant Liquid Epoxy Resin Formulated Resin 9000 Powder Coating Can Coating Resin 5(f) Solution Cut Resins 5000 Hardeners Reactive diluents Salt Hydrochloric acid Note :** It may be noted that we have obtained Environmental Clearance for the manufacture of Epichlorohydrin MT/Annum and generated Hydrochloric Acid 20% 4247 MT/Annum. Due to the market scenario company dropped the manufacturing of ECH and obtained CTE and CC&A -Product Mix for the increase in the total capacities of Epoxy Generation of HCl from HCl scrubber attached to kiln in proposed Epoxy Resin Plant (Solvent less process) 6

9 (B) DETAILS OF RAW MATERILAS Name of Raw Material Existing As per CC&A Product Mix MT/Annum Proposed For EC Total (a+b) (a) (b) For manufacture of Epichlorohydrin (ECH) Crude Glycerin HCl (100%) Catalyst NaOH (32%) Water Oxidizer For manufacture of CPVC PVC Resin Chlorine For manufacture of Liquid Epoxy Resin * ECH** 54943** Bisphenol-A Caustic Soda 48-50% Caustic Butyl Cellulose S1(Solvent) For manufacture of Formulated Resins* Reactive diluents Liquid Epoxy resin For manufacture of Hardeners D IPDA PACM T BDMA 0.0 ECA-100 NC 0.0 MXDA TEPA 0.0 Benzyl Alcohol 0.0 Salicylic Acid 0.0 D HHPA 0.0 MTHPA 0.0 MHHPA 0.0 BTEAC 0.0 Omecure 0.0 THPA 0.0 NPG 0.0 MPG 0.0 ETPPBR 0.0 Methanol 0.0 7

10 Name of Raw Material Existing As per CC&A Product Mix MT/Annum Proposed For EC Total (a+b) (a) (b) Methyl Amidazole 0.0 Sodium methaoxide 0.0 HYCAT 3100 S 0.0 ARADURE (various grade) 0.0 CRAYAMIDE (various grade) 0.0 N-AEP 0.0 Nonyl Phenol 0.0 Acronal 0.0 Phenol O-Cresol 0.0 SBH 0.0 MDA 0.0 LN 0.0 BTMAC 0.0 Various pigment color For manufacture of Powder Coating * YD Bisphenol-A For manufacture of Can Coating Resin* YD BPA PTBP For manufacture of Solution Cut Resin * YD BPA Xylene For manufacture Reactive Diluents 1.4BD Toluene ,6 HD ECOROL ECH Caustic Soda- 50% Catalyst Note: * The stated raw material consumption is based on maximum production of any Product at a time ** Currently purchased from outside 8

11 Annexure 6 1) Epichlorohydrin Epichlorohydrin through Glycerin route Epichlorohydrin is produced by the following two steps. 1. Chlorination of glycerin (1, 3 dichorohydrin) 2. Epichlorohydrin Process Chlorination of glycerin (1, 3 dichlorohydrin) 1,3 dichorohydrin is produced as a first stage intermediate in the manufacture of ECH Preheated glycerin and hydrochloric gas are reacted at high temperatures (100 ºC) to produce 1,3 dichlorohydrin. Glycerin and hydrochloric gas is feed to reactor and reaction carried out in presence of catalyst (Acid catalyst). Catalyst C 3H 5(OH) 3 + 2HCl C 3H 5 OH Cl 2 + 2H 20 During this reaction first reaction of glycerin with hydrochloric acid and form monochlorohydrin subsequent reaction of monochlorohydrin with hydrochloric gas form dichlorohydrin. Dichlorohydrin sent to stripping column. From stripping column Dichlorohydrin sent to saponification column. Epichlorohydrin Process The Dichlorohydrins are further reacted with 19% NaOH solution in saponification column to produce crude ECH which is having impurities such as DCPA/TCPA/Tetrachloro propyl ethers and small quantity of unconverted DCH. C 3H 5 OH Cl 2 + NaOH C 3H 5OCl + NaCl + H 2O + By Products The crude ECH is then purified in two distillation columns which removes the lighter and heavier impurities respectively. Pure ECH of 99.9 % min is produced from the last distillation column. Block diagram: 9

12 Incinerator All inerts and all of gas from process are fed into the Off Gas drum where water are separated from the bottom. Part vapour is passed through the carbon absorber. Heavy ends, AC light Ends, ECH light ends, ECH heavy ends and organics drain from process are fed into the Liquid Waste Drum where the liquids are separated from the bottom into the incinerator. Mass Balance Input T/T Output T/T Crude Glycerine 2.0 ECH 1.0 HCl (100%) 0.98 Treated Brine (NaCl-20%) Catalyst Refined Glycerine 0.40 NaOH (32%) 1.5 HCl (20%) 0.10 Water 1.33 Washwater (for recovery from utilities) 0.83 Oxidiser 0.15 Evaporation losses from cooling tower 1.17 losses from incinerator 0.66 Incineration waste 0.08 Total

13 2. Chlorinated PVC Manufacturing process of CPVC Process Flow Diagram Mass Balance: Input T/T Output T/T PVC 0.75 CPVC 1.0 Chlorine 0.48 HCl 0.23 Total 1.23 Total

14 3. EPOXY RESIN (Existing Process) LIQUID EPOXY RESIN (LER) Main raw materials used in the production process are Epichlorohydrin (ECH), Bisphenol-A and Caustic Soda (C. Soda or NaOH). Pre-reaction Section Excessive quantity of Epichlorohydrin is reacted with prescribed quantity of Bisphenol-A by using NaOH as catalyzer. As result of this reaction, Bisphenol-A chlorohydrins intermediate is generated. Reaction Section Bisphenol-A chlorohydrins intermediate generated from the pre-reaction section is changed to liquid epoxy resin by reaction with NaOH. Automatic control of the reactor maintains optimum process conditions. This minimizes the hydrolysis of ECH and formation of by-product waste polymer and enables the production of high quality epoxy resin of the required viscosity at high yields. 12

15 ECH Detachment Section After the reaction process, excessive quantities of unrelated ECH are separated from the product and recovered through a vapourizer and returned to the ECH day tank for reuse. The crude epoxy is then supplied to the next refining section. The crude epoxy is then supplied to the next refining section. Vaporization of ECH through the vaporizer is done under vacuum conditions, at the lowest possible temperature and in the shortest possible time in order to protect the epoxy resin from thermal effect. Refining In this section, toluene is added to dissolve resin in it and salt solution is separated from the resin manually by adding water. The resin stays in the upper layer & NaCl water in the lower layer. Again DM water is added to wash the resin and remove the traces of salt from it. Filtration After refining, filtration is done to remove the impurities viz. suspended particles and rest of waste polymer by passing through the multilayer paper filter. De solvent In this section, dissolvent is done to remove the solvent, toluene from the resin by passing through falling film thin evaporator & Rotary film thin evaporator under vacuum. Product Finishing Section Epoxy resin is finally filtered to remove impurities and is sent to the product tank. ECH Stripping ECH Evaporated during reaction contains ECH and water, water is stripped off in the distilled unit, pure ECH is recycled. ECH Distillation ECH vapors from the ECH detachment section are recovered and distilled in this section to recover pure ECH which is recycled. 13

16 Proposed Epoxy (Solvent less) Process for 1, 00,000 TPA Liquid Epoxy Resin (LER) Main raw materials used in the production process are Epichlorohydrin (ECH), Bisphenol-A and Caustic Soda (C. Soda or NaOH). Pre-reaction Section Excessive quantity of Epichlorohydrin is reacted with prescribed quantity of Bisphenol-A by using NaOH as catalyzer. As result of this reaction, Bisphenol-A chlorohydrins intermediate is generated. O HO HO + CH 3 CH 3 CH 2 CH2 Cl CH Bis Phenol A NaOH Epichlorohydrin Cl OH OH Cl CH 2 CH CH 2 O O CH2 CH CH 2 CH 3 CH 3 Intermediate Reaction Section Bisphenol-A chlorohydrins intermediate generated from the pre-reaction section is changed to liquid epoxy resin by reaction with NaOH. Automatic control of the reactor maintains optimum process conditions. This minimizes the hydrolysis of ECH and formation of by-product waste polymer and enables the production of high quality epoxy resin of the required viscosity at high yields. O NaOH O CH 2 CH CH2 O O CH 2 CH CH2 CH3 CH 3 Resin + 2 NaCl + 2H 2O 14

17 Salt Separation Section After the reaction process finished, the composite of Resin, ECH and salt is sent to next section where salt is separated from Resin and ECH for further process. Filtration At this section, mixture of resin and ECH passes through the filter to remove the traces of impurities viz. suspended particles and rest of waste polymer. De-ECH In this section, de-ech is done to remove the ECH from resin by passing through falling film thin evaporator followed by stripping column and flash drum under vacuum. Product Finishing Section Epoxy resin is finally filtered to remove races of impurities and is sent to the product tank through mixing tank. ECH Stripping ECH Evaporated during reaction contains ECH and water, water is stripped off in the distilled unit, pure ECH is recycled for next batch. 15

18 Manufacturing Process Flow Diagram [for 274 MT/Day ( TPA)] BPA NaOH ECH Pre Reaction VSF ETP Treated water to VSF ETP % NaOH Reaction Reaction Water ETP Treatment Sludge Salt Separation Salt Salt Packaging Filter Aid/paper Solid Waste (Waste Polymer) Resin Solid Disposal Product -1.0 Mass Balance Input T/T Output T/T BPA Product 1 NaOH Salt ECH Solid Waste (Waste Polymer) % NaOH Reaction Water 0.33 Filter Aid/paper Solid waste Total Total FORMULATED RESIN Liquid Epoxy is mixed with various type of additives and Reactive Diluents to meet specific applications of composite customers and other special application. The customer is supplied with a system consist of modified epoxy and appropriate hardener (we make various type for different applications) 16

19 Process Flow Diagram of Formulated Resin 5- HARDNER (Existing Process) The epoxide group of DGEBA (diglycidyl ether of Bisphenol A) reacts with one of the amino groups of the amine compound e.t. Isophorone diamine (IPD) and forms the adduct. The adduct is then diluted with non-reactive diluents such as benzyl alcohol. An accelerator such as tertiary amine is added to the adduct to facilitate ease of curing. The added accelerator forms a complex with the DGEBA-IPDA adduct. A flexibilizer is added to the hardener when required to improve the toughening properties of epoxy systems. The flexibilizer is normally a rubber modified compounds that adds strength to the cured epoxy systems. The mass is cooled, filtered through cartridge filter and drummed out. 17

20 Manufacturing process of proposed Hardner (10,000 TPA) HARDENER/ANHYDRITES: Main raw materials used in manufacturing of Hardeners/Anhydrates grades are various amines and anhydrates as mentioned below: IPDA/D-230/BDMA/ECA-100 NC / MXDA/TEPA/BENZYL ALCOHOL/SALICILIC ACID/T-403/D-400/TETA/HHPA/MTHPA/MHHPA/BTEAC/PPG-400/ OMECURE /THPA /NPG/ MPG/ETPPBR/ METHYL AMIDAZOLE/ ACRONAL/ SODIUM METHOXIDE / METHANOL/ HYCATE/ ARADUR/ CRAYAMIDE/N-AEP/NONYL PHENOL Process steps involved are RAW MATERIALS & CHEMICALS CHARGING MIXING & HEATING SAMPLING FILTRATION DRUMMING/STORINING Raw-Materials & Chemicals Charging Raw materials for production of various grades of Hardener mainly are amines and anhydrates which are charged into the reactors as per specified quantity mentioned in the SOP/PFD. Raw material quantity charging is based on batch size & grades. During charging N2 flow should be on. Mixing & Heating After charging of first raw materials into the reaction, immediately start agitator & keep N 2 flow on. Heating should be done as per SOP. Sampling Sampling of product to be done to check the quality of product & if desired quality achieved, sent the material to the filtration section. Product Finishing Section Finally hardener grades resin is filtered by cartridge filter to remove traces of impurities and is sent to the product tank. 18

21 Process Flow Diagram Various Amine/ Anhydrites group 0.9 MT Reactor Various Accelerator MT Mixing/Heating Color Pigment MT Mixing /Heating Filtration Final Product 1 MT Mass Balance Input T/T Output T/T Various Amine/ Anhydrites group 0.9 Product 1.0 Various accelerator Colour Pigment Total 1.0 Total

22 5 POWDER COATING Liquid Epoxy resin is mixed with Bisphenol - A to meet specific applications of composite customers and other special application. The customer is supplied with a system consist of modified epoxy and appropriate hardner (we make various type for different applications) 6 CAN COATING RESIN Low Molecular Weight epoxy solid resin is mixed with Bisphenol A to meet specific applications of composite customers and other special application. Process Flow Diagram of Can Coating Components Qty (MT) YD BPA Heating & Reaction Solid waste PTBP Total Flaking Can Coating 1.00 MT 20

23 7. SOLUTION CUT RESIN Low Molecular Weight epoxy solid resin is mixed with BPA & various type of additives to meet specific applications of composite customers and other special application. Manufacturing Process Flow Diagram Solution Cut Resin 1.0 MT 8. Reactive Diluents Pre-reaction Raw material for producing Reactive Diluents is charged into the Main Reactor through Intermediate Charging Vessels. Catalyst is charged directly in the Main reactor.after completion of Catalyst addition, calculated quantity of ECH is added into mass at stipulated rate. The reaction is controlled by the instruments as per the set point. Typical Example of one Reactive Diluents 21

24 Reaction After completion of the Pre-reaction, the mass is heated up and mixed to complete the reaction. The reaction is carried out under vacuum by adding Caustic Soda at regular feed rate and the same time the water of reaction formed is being removed by azeotropic distillation using the vent condensers to condense the vapour and separate out the water medium. Reaction temperature and the flow control is controlled by the instruments. Refining The reacted mass is washed with water to remove the NaCl water. Here solvent is also added to make the separation easy. This NaCl water pumped to biological treatment plant for further treatment. De solvent In this section, de solventing is done by Evaporating solvent under vacuum and then stripping by Nitrogen and steam. Filtration Finally resin is filtered to remove suspended particles from resin. 22

25 Process Flow diagram of Reactive Diluents 1,4 BD S Catalyst ECH NaOH Water Pre Reaction & Reaction Water Recovered S Phase Separation/ Filtration/ De ECH/ Dissolventing Waste Water Water to ETP Solid Waste Filtration Filter Aid Reactive Diluents-1.00 Input T/T Output T/T 1, 4 BD product 1 S S1 recovered Catalyst wastewater ECH Solid waste NaOH Water Filter Aid Water Total OR 23

26 1,6 HD-0.5. Catalyst ECH-0.8 NaOH-0.31 Water Pre Reaction & Reaction Water Phase Separation/ Filtration/ De ECH/ Dewatering Waste Water Water to ETP Solid Waste Filtration Filter Aid Reactive Diluents-1.0 Input T/T Output T/T 1,6 HD 0.5 product 1 Catalyst wastewater 23.3 ECH 0.8 Solid waste NaOH 0.31 Water Filter Aid Water Total OR 24

27 Ecorol Catalyst ECH NaOH Water Pre Reaction & Reaction Water Phase Separation/ Filtration/ De ECH/ Dewatering Waste Water Water to ETP Solid Waste Filtration Filter Aid Reactive Diluents 1.0 Input T/T Output T/T Ecorol 0.78 product 1 Catalyst wastewater ECH Solid waste NaOH Water Filter Aid Water 15.9 Total

28 Annexure 7 Details of Storage Facilities for Product and Raw Material Sr. No. Name of Products Solid/ Liquid/ Gas Temp. (C) Pressure Storage Quantity and parameters Material of Construction Storage Capacity Existing Storage Capacity Proposed 1. ECH Purified Liquid Ambient Atmospheric SS316L Not Applicable 2 x 150 Tons 2. HCl (20%) Liquid Ambient Atmospheric Ambient Not Applicable CS-PTFE lined/cs-rl 3. CPVC Solid Ambient Atmospheric SS 304 Not Applicable 2000 Tons 4. Refined Glycerin Tank USP Grade Liquid Ambient Atmospheric SS 316 L/S317 Not Applicable 3 x 300 Tons 5. Liquid Epoxy Resin Liquid Ambient Atmospheric SS MT 5 X 100 MT 6. Formulated Resin Liquid Ambient Atmospheric SS Existing will be used 7. Powder Coating Solid Ambient Atmospheric PP (Bag) 300 Existing will be used 8. Can Coating Resin Solid Ambient Atmospheric PP (Bag) 100 Existing will be used 9. Solution Cut Resins Liquid Ambient Atmospheric SS Existing will be used 10. Hardeners Liquid Ambient Atmospheric SS X 50 MT 11. Reactive Diluents Liquid Ambient Atmospheric SS X 50 MT 26

29 Sr. No. Name of Chemicals Solid/ Liquid Temp. (K) Pressure (kg/cm 2 ) Storage Quantity and parameters Material of Construction Storage Capacity Existing Storage Capacity Proposed Total After proposed expansion 1. Crude Glycerine Liquid Ambient Atmospheric SS 316 L/SS MT 2000 MT 2. HCl (100%) Gas Ambient 5 Hastalloy B MT 300 MT 3. Catalyst Solid Ambient Atmospheric Ambient m 3 40 m 3 4. NaOH (32%) Liquid Ambient Atmospheric CPVC-FRP 1000 Ton x Ton x2 5. PVC Resin Solid Ambient Atmospheric SS MT MT 6. Chlorine Through pipeline from -- existing CA plant 7. ECH** Liquid Ambient Atmospheric SS Ton Nil 2500 MT (Existing will be used) 8. Bisphenol-A Solid Ambient Atmospheric Jumbo Bags 1600 Ton 1600 Ton 3200 MT 9. Caustic Soda 50% Liquid Ambient Atmospheric SS Ton 150 Ton 300 MT 10. Reactive diluents Liquid Ambient Atmospheric SS Ton 50 Ton 350 MT 11. Liquid Epoxy resin Liquid Ambient Atmospheric SS Ton 500 Ton 3500 MT 12. D 230 Liquid Ambient Atmospheric M.S 50 Ton NA 50 Ton 13. IPD Liquid Ambient Atmospheric HDPE 40 Ton NA 40 Ton 14. PACM Liquid Ambient Atmospheric M.S 5 Ton NA 5 Ton 15. BDMA Liquid Ambient Atmospheric M.S NA 5 Ton 5 Ton 16. ECA-100 NC Liquid Ambient Atmospheric M.S NA 30 Ton 30 Ton 27

30 17. MXDA Liquid Ambient Atmospheric M.S NA 5 Ton 5 Ton 18. TEPA Liquid Ambient Atmospheric M.S NA 25 Ton 25 Ton 19. Benzyl Alcohol Liquid Ambient Atmospheric M.S NA 25 Ton 25 Ton 20. Salicylic Acid Liquid Ambient Atmospheric M.S NA 1 Ton 1 Ton 21. D-400 Liquid Ambient Atmospheric G.I. Drum NA 25 Ton 25 Ton 22. HHPA Solid Ambient Atmospheric G.I. Drum NA 20 Ton 20 Ton 23. MTHPA Liquid Ambient Atmospheric G.I. Drum NA 20 Ton 20 Ton 24. MHHPA Liquid Ambient Atmospheric M.S NA 5 Ton 5 Ton 25. BTEAC Solid Ambient Atmospheric M.S NA 1 Ton 1 Ton 26. Omecure Liquid Ambient Atmospheric M.S NA 0.5 Ton 0.5 Ton 27. THPA Liquid Ambient Atmospheric Fibre NA NPG Liquid Ambient Atmospheric M.S NA MPG Liquid Ambient Atmospheric M.S NA 1 Ton 1 Ton 30. ETPPBR Solid Ambient Atmospheric M.S NA 1 Ton 1 Ton 31. Methanol Liquid Ambient Atmospheric M.S NA 0.25 Ton 0.25 Ton 32. Methyl Amidazole Liquid Ambient Atmospheric M.S NA 1 Ton 1 Ton 33. Sodium methaoxide Solid Ambient Atmospheric M.S NA 0.01 Ton 0.01 Ton 34. HYCAT 3100 S Liquid Ambient Atmospheric M.S NA 1 Ton 1 Ton 28

31 35. ARADURE (various grade) Liquid Ambient Atmospheric M.S NA 30 Ton 30 Ton 36. CRAYAMIDE (various Liquid Ambient Atmospheric M.S NA 2 Ton 2 Ton grade) 37. N-AEP Liquid Ambient Atmospheric M.S NA 2 Ton 2 Ton 38. Nonyl Phenol Liquid Ambient Atmospheric MS NA 1 Ton 1 Ton 39. Phenol Solid Ambient Atmospheric HDPE NA 0.02 Ton 0.02 Ton 40. O-Cresol Liquid Ambient Atmospheric MS NA 1 Ton 1 Ton 41. SBH Liquid Ambient Atmospheric M.S NA 0.5 Ton 0.5 Ton 42. MDA Solid Ambient Atmospheric Bag NA 1 Ton 1 Ton 43. LN Solid Ambient Atmospheric M.S NA 0.01 Ton 0.01 Ton 44. BTMAC Solid Ambient Atmospheric M.S NA 0.01 Ton 0.01 Ton 45. Various pigment color Liquid Ambient Atmospheric HDPE NA 1 Ton 1 Ton 46. Acronal Liquid Ambient Atmospheric MS NA 1 Ton 1 Ton 47. Low Molecular Solid Ambient Atmospheric LDPE Bag 1 Ton NA 1 Ton Weight Epoxy Solid Resins 48. Xylene Liquid Ambient Atmospheric SS Ton NA 40 Ton 49. ECOROL Liquid Ambient Atmospheric SS Ton Exiting will be used 100 Ton BD Liquid Ambient Atmospheric SS Ton Exiting will be used 100 Ton 51. Toluene Liquid Ambient Atmospheric SS Ton 50 Ton 100 Ton 52. 1, 6 HD Solid Ambient Atmospheric HDPE 30 Ton Exiting will be used 30 Ton 29

32 Annexure-8 Water Consumption and Wastewater Generation WATER CONSUMPTION Sr. Description No. Water Consumption Quantity (kl/day) Existing (1) PROPOSED (2) Total (1 + 2) CPVC ECH Epoxy CPVC ECH Epoxy a. Domestic b. Industrial Process (59*+597 # ) (50**+440 ## ) 1546 (509***+1037 ### ) Cooling - makeup Washing Others Sub-total (b) c. Greenbelt TOTAL(a+b+c) Note: Steam will be obtained from our sister unit/ existing unit. * : Raw water pond: 59 kl # : Water from Caustic & Reaction water (60) + Steam condensate (488) + DM water (49) 597 kl ** : Raw water pond :50 kl ## : Water from Caustic & Reaction water (90)+ Steam condensate (350) 440 kl *** : Total process water from Raw water pond : = 509 kl ### : Total process water from Water from Caustic & Reaction water (150)+ Steam condensate (838)+DM water (49) 1037 : Total water requirement would be kl out of which approx kl will be obtained from existing plant unit (i.e. from Caustic & Reaction water + Steam condensate + DM water) and remnant approx kl ( ) from raw water pond.

33 WASTEWATER GENERATION Sr. Description No. Wastewater Generation Quantity (kl/day) Existing (1) PROPOSED (2) Total (1 + 2) CPVC ECH Epoxy CPVC ECH Epoxy a. Domestic b. Industrial From Process Cooling Purge Washing Others Sub-total (b) c. Greenbelt TOTAL(a+b+c)

34 TOTAL WATER BALANCE DIAGRAM AFTER THE PROPOSED EXPANSION (For Existing + Proposed Epoxy, CPVC & ECH Plant) Water from GIDC Total Water Balance EPOXY, CPVC & ECH Plant kl/day 1 st day water requirement from 2 nd day onwards 2847 kl/day ( ### ) 109 (recycle) Gardening (Fresh) Domestic Industry From Existing Plant Unit 1037 ### For EPOXY & CPVC Plant Fresh water kl/day ( ### ) Evaporation Loss For ECH Plant Fresh water 600 kl/day ( ) 350 (recycle) 109 (Fresh water) 600 (Fresh) (350 recycled) Process (109*** ### ) = 1146 From Process 558 Loss 871 Cooling make-up 1585 Cooling Purge 714 Other 285 From other 95 Washing 120 From Washing 120 Cooling make-up 450 ( ) Cooling Purge 100 Water from Raw materials (caustic 32% & glycerin) 350 Process 400 From Process 750 ( ) Washing 100 From Washing 100 To STP All Units in kl/day 250 *** : Total process water(epoxy&cpvc) from Raw water pond : 59+50= 109 Kl ### : Total process water from Water from Caustic & Reaction water (150)+ Steam condensate (838)+ DM water (49) 1037 kl (for : Total industrial water requirement (Epoxy&ECH) would be 3136 kld out of which approx kld will be obtained from existing plan unit (i.e. from Caustic & Reaction water + Steam condensate + DM water) and remnant approx kld from raw water pond. Total Effluent from Epoxy &CPVC 1487 TO Existing ETP 2437[Epoxy & CPVC (1487) + ECH (950)] Total Effluent from ECH (EPOXY & CPVC) after treatment will be discharged to Vilayat-Dahej U/G Pipeline ECH PLANT ZERO DISCHARGE 350 (recycle)

35 Mode of Disposal Domestic effluent Domestic effluent will be treated in Sewage Treatment Plant and treated wastewater will be used for gardening purposes. Industrial Effluent The waste water from the Epoxy-ECH plant contains biologically degradable components and inorganic salts required to be treated prior discharge to the sea. The treatment system is described in brief as below: Effluent from the Epoxy-ECH plant is segregated first and high TDS effluent will collect in receiving tanks. The content of the receiving tanks are kept agitated by means of jet mixer. From the receiving tank the effluent is pumped by means of a pump to a pre-treatment section, where ph adjustment will be done and solids will be separated by DAF (Dissolved Air Floatation). Solid sludge from DAF will pass through filter press and solid will be disposed as solid waste. The supernatant liquid from the DAF will be taken to MEES (Multiple Effect Evaporation System), where inorganic salts (NaCl) are removed by evaporation fallowed by PUSHER centrifuge. Other streams, including condensate from MEES contains low TDS will collect in equalization tanks and kept in agitation by means of jet mixer. From the equalization tank effluent will fed to the aeration tank. In aeration tanks, the effluent is inoculated with bacteria and nutrients. The effluent has enough retention time, during which the COD/BOD loadings get reduced. The liquid from the aeration system flows into a clarifier. In the clarifier the sludge is separated and thickened from the effluent by using Decanter. The supernatant liquid is undergoing contact with Chlorine then passed through Multi Grade Filter (MGF) and Activated Carbon Filter (ACF). The treated effluent from the MGF & ACF flows into treated effluent storage tank. The treated effluent from this tank is discharged to the sea through a common effluent pipe line. The above treatment system ensures that the organic Loadings are reduced by treatment to acceptable limits before discharge. 32

36 33

37 EFFLUENT TREATMENT PLANT 34

38 Sr. No. Name of Waste Annexure 9 Details of Hazardous/Solid Wastes and its Mode of Disposal ** As per CC&A product mix Sch/ Cat. Quantity per MT /Annum Existing ** Proposed Total after Expansion Mode of Storage & Disposal [a] [b] [a+b] 1. Waste Residues I Collection, storage, (Not made with animal or vegetable material) 2. Chemical Sludge from wastewater treatment 3. Discarded containers/ bags/ liners contaminated with hazardous waste/chemicals transportation, disposal at Ambuja Cement Ltd. for pre-processing, co-processing/ incineration I Collection, storage, transportation, disposal of landfill waste at TSDF and incinerable waste by preprocessing, co-processing/ incineration I Collection, storage, transportation, disposal by selling to authorized vendors. 4. Used or Spent Oil I Collection, storage, transportation, disposal by selling to registered recycler 5. Waste or residue containing oil 6. Incinerator waste/residue I Collection, storage, transportation, disposal by selling to registered recycler I Collection, storage, transportation, disposal of landfill waste at TSDF 35

39 Annexure 10 Details of Stack/Vent, Fuel and Air Pollution Control Measures Flue Gas Stack Details Sr. No. Stack attached to Type & Quantity of Fuel Diameter of the Stack (m) Height of the Stack (m) Expected Emission (A). EXISTING Flue Gas Emission ** D.G. Set PM < 150 mg/nm 3 1. (2000 kva) HSD SO 2 < 100 ppm NO x< 50 ppm (B). PROPOSED Flue Gas Emission 2 Incinerator Hydrogen PM < 150 mg/nm Nm 3 /Hr SO 2 < 100 ppm NO 2< 50 ppm Note: ** As per CC & A Product Mix HCl < 20 mg/nm 3 Air Pollution Control Measures Not Applicable Caustic Scrubber Process Stack details Sr. No. Vent attached to Height of the Vent (m) Diameter of the Vent (m) Existing Stack As Per CC&A Product-Mix Epoxy Plant Expected Emission Air Pollution Control Measures ISBL ECH Tank VOC Guard Condenser, Scrubber, PRV, Flame Arrester ISBL Toluene Tank VOC Guard Condenser, PVRV, (Integrated Flame Arrester) OSBL ECH Tank VOC Scrubber, PRV, Flame Arrester Remarks Liquid Epoxy Resin Plant (ECH Vent) Liquid Epoxy Resin Plant (Toluene Vent) Liquid Epoxy Resin tank (ECH Vent) 4. PESO Toluene Tank VOC 5. Toluene Tank VOC Underground tank, PVRV (Integrated flame arrestor) Guard Condenser, PVRV, (Integrated Flame Arrester) Liquid EPOXY Resin Tank (Toluene Vent) Reactive Diluents Plant (Toluene) 36

40 Sr. No. Vent attached to Height of the Vent (m) Diameter of the Vent (m) Expected Emission 6. Reactor VOC 7. Solution Cut Tank VOC 8. PESO Xylene Tank VOC Proposed Stack ECH Plant 1 HCl Vent Scrubber HCl <20 mg/nm 3 Cl 2 < 09 mg/nm 3 CPVC Plant 1 HCl synthesis HCl < 35 mg/nm 3 2 CPVC Reactor and Degassing Vessel Cl2 < 9 mg/nm 3 3 PVC Conveying to Cl2 < 9 Silo mg/nm 3 4 PVC Conveying to PM 150 Oxygen mg/nm 3 5 Degassing PM 150 mg/nm3 6 Conveying PM 150 Degassing Vessel mg/nm 3 to Hopper 7 Evacuation of air PM 150 mg/nm 3 8 Conveying CPVC from PVC Reactor PM 150 mg/nm 3 Air Pollution Control Measures Guard Condenser, PVRV, (Integrated Flame Arrester) PVRV, (Integrated Flame Arrester) Underground tank, PVRV (Integrated flame arrestor) Scrubber Remarks Solution Cut Plant (Xylene) Solution Cut Tank Farm (Xylene) Xylene Tank (PESO Tank Farm) Emergency vent Scrubber Absorption tower -- using water as an absorption media Alkaline scrubber -- Bag filter -- Bag filter -- Bag filter -- Bag filter -- Bag filter -- Bag filter -- Fuel Consumption: Type of fuel Existing Consumption Proposed Total [Existing +Proposed ] Source HSD 10 kl/year 0 10 kl/year Local Supplier Hydrogen Nm 3 /Hr Power Consumption 200 Nm3/Hr From Chlor-alkali plant ECH Plant Epoxy Plant CPVC 2 MW 1.5 MW 3 MW Total 5.5 MW 37