Existing Quantity (MT/Month) Silver refining

Transcription

1 LIST OF PRODUCTS: ANNEXURES TO FORM-1 Sr.No. Name of Product Existing Additional Total after expansion Formaldehyde Hexamine Paraformaldehyde Hexalye Urea / Melamine Formaldehyde (liquid Resin) Powder Resin (Urea / Melamine Formaldehyde) Urea Formaldehyde Concentrate Methylal Foundry Resins (Powder / liquid) and sand quoted resin PF Resin (liquid) PF Resin (powder) Silver refining Hexamine Hardner Hexamine Tablet

2 Details of each Product: 1) FORMALDEHYDE: Name Existing Proposed Total Product Formaldehyde Methanol Water Raw Material Requirement Manufacturing Process: It is a three step continues process which includes reaction, absorption & distillation. Stream containing methanol, air and water is fed to the reactor continuously where catalytic conversion takes place to formaldehyde. The reactor gas is absorbed in multiple stage absorber columns. The product from the column goes to distillation for recovery of excess methanol, which is totally recycled back to the plant. The bottom of the column is pure product, which goes to finished product tank. Chemical Reaction: CH3 OH + ½ O Oxidation HCHO + HO > Methanol Formaldehyde Water Reduction CH3OH > HCHO + H Methanol Formaldehyde

3 Flow Chart with Material Balance: Methanol Recovery N and other organic matter sent to boiler 110 kg i i Water 75 kg Methanol kg Air 850 kg Water - 60 kg Reactor Carburator (Oxidation & Absorber Distillation Reduction) Formaldehyde 1000 kg Mass Balance: Input Qty in kgs Operation Output Qty in kgs Methanol 0.47 Reaction Formaldehyde 1.00 Air 0.85 Water N & organic matter to boiler Total Total 1.655

4 ) HEXAMINE: Name Existing Proposed Total Product Hexamine Raw Material Requirement Qty Formaldehyde 5758 Ammonia 808 Water 85 Manufacturing Process: Formaldehyde and ammonia are reacted in a batch reactor. The reactor material goes to storage tank for evaporation and crystallization. In crystallization, water is evaporated and the mass is centrifuged. Hexamine crystals are obtained and mother liquor is recycled. Chemical Reaction: 6HCHO + 4NH3 (CH)6N4 + 6 HO Formaldehyde Ammonia Hexamine Flow Chart with Material Balance: Cooling^ Tower Water vapor DM Water 50 kg Water Cooling Tower 3490 (37%) kg Formaldehyde Ammonia kg * Reaction 3980 kg Evaporation kg Centrifuge ML Recycle Dryer ^ Hexamine 1000 kg Mass Balance: Input Qty in Operation Output Qty in kgs kgs Formaldehyde 3.49 Reaction Hexamine 1.00 Ammonia 0.49 Evaporated water 3.03 recycled to cooling tower Water 0.05 Total 4.03 Total 4.03

5 3) HEXALYE: Name Existing Proposed Total Product Hexamine Raw Material Requirement Qty Formaldehyde Ammonia Manufacturing Process: Formaldehyde and ammonia are reacted in a batch reactor. The reaction mass is checked for ph and other product parameters. The reaction mass is cooled with cooling water in jacket of heat exchanger. The mass is then stored in a storage tank for Hexalye finished product. Chemical Reaction: 6HCHO + 4NH3 (CH)6N4 + 6 HO Formaldehyde Ammonia Hexalye Flow Chart with Material Balance: Formaldehyde 3490 Kg (37 %) Ammonia- 490 Kg Reaction Hexalye storage tank Kg (5% soln.) Mass Balance: Input kg/kg Output kg/kg Formaldehyde 0.87 Hexalye 1.00 Ammonia 0.13 Total

6 4) PARA FORMALDEHYDE: Name Existing Proposed Total Product Paraformaldehyde Raw Material Qty Requirement Formaldehyde 5376 Manufacturing Process: Formaldehyde is evaporated to achieve concentration of 60 to 70 % under catalytic condition. The distillate which contains 18 to 0 % F.D. is valuable product and returned to the formaldehyde plant. The concentrated mass is taken to dryer where it is dried to final specification. Further the dried mass is taken to silo for packing. Chemical Reaction: No Chemical Reaction. Flow Chart with Material Balance: 390 Kg (as 37% formaldehyde) Formaldehyde (37 %) 4950 Kg > Evaporator Dryer Silo Packing Para Formaldehyde * 1000 Kg Mass Balance: Input kg/kg Output kg/kg Formaldehyde 4.95 Paraformaldehyde 1.00 Formaldehyde 3.95 Total

7 5) Liquid Resin (Urea /Melamine / Phenol Formaldehyde) Name Product Liquid Resin (Urea/ Melamine / Phenol) Existing Proposed Total Raw Material for Urea Qty Formaldehyde (liquid Resin) Formaldehyde 875 Urea 1500 Caustic Soda 7.5 Formic Acid 0.5 Manufacturing process Urea Formaldehyde resins, Melamine Formaldehyde and Phenol Formaldehyde resins are manufactured in similar batch processes. The equipment consists of steel jacketed Reaction Vessel equipped with an agitator and condenser, followed by a Blender, Product Storage tanks and Filling stations. Formaldehyde, Amino compound (Urea / Melamine) and a Catalyst are charged to a stirred tank jacketed reactor commonly referred to as a Resin Kettle. The ph is adjusted and the mixture is heated. Since the reaction is exothermic, close temperature control is necessary. The progress of reaction is monitored by checking samples of viscosity. The equipment / machinery for production of UF as well as MF liquid resins are identical and can have common usage by running batches with downstream common Dryer in which powder production campaigns can be run. One or more methylol groups per molecule are produced, depending on the amount of formaldehyde used. The second step is the condensation of the monomer units resulting in polymer chain formation and elimination of water. Melamine Formaldehyde resins are produced by condensation reaction of Formaldehyde with the amino groups of Melamine. Chemical Reaction HN-CO-NH + HCHO HOCHNH-CO-NHCHOH C3H6N6 + HCHO C4H8N6

8 Flowchart: Water Vapour Catalyst Urea / Phenol Melamine Reactor 1 * Blender Product filled in tankers/ Sent to Dryer Heating / Cooling Mass Balance: Urea Formaldehyde Input kg/kg Output kg/kg Formaldehyde 1.15 Urea Formaldehyde (liq. Resin) 1 Urea 0.6 Water from condenser 0.45 Caustic Soda Water vapour loss Formic Acid Total Total Melamine Formaldehyde Input kg/kg Output kg/kg Formaldehyde 1.15 Melamine Formaldehyde 1 (liq. Resin) Melamine 0.8 Water from condenser Caustic Soda Water vapour loss Total Total Phenol Formaldehyde Resins The Phenol Formaldehyde Resins are manufactured with Formaldehyde to Phenol molar ratio greater than one, normally in the range 1.4 to 1.6. The resulting Resin has more than one Methylol group attached to each aromatic ring and these can be used for cross linking. These Resins are made by the simple condensation of the starting materials in a stainless steel or glass lined vessel fitted with a condenser arranged both to reflux and distill. The usual catalyst is an alkaline material viz. Caustic Soda, etc. Whilst the reaction will take place under either acid or alkaline conditions, acid catalysis is

9 generally too violent for commercial d production. The final product may be liquid, a solution in an added solvent (Ketones and Alcohols are most common) or, occasionally a solid. The production of solid Resin is a hazardous business since the point at which the molecular weight is sufficiently high for the product to be solid and that at which it is effectively cross-linked and intractable are very close. Solid Resins are emptied from the reactor in the molten state into a box filled with chilled plates, or a similar shock cooling device, where it freezes rapidly and the reaction stops. Chemical Reaction: C6H6O + HCHO C7H8O Flowchart: Catalyst Water Vapour A Phenol Formaldehyde i Reactor A Blender Product filled in tankers/ Sent to Dryer Heating / Cooling Mass Balance: Input kg/kg Output kg/kg Formaldehyde Phenol Formaldehyde 1.00 Phenol 0.1 Caustic Soda Water 0.07 Total Total 1.00

10 6) Powder Resin Name Product Powder Resin (Urea/ Melamine / Phenol) Existing Proposed Total Manufacturing Process: The liquid resin is dried through spray drier. Input kg/kg Output kg/kg Melamine Formaldehyde.000 Melamine Formaldehyde (liquid resin) (powder resin) Evaporation loss (drying) Total.000 Total.000 Input kg/kg Output kg/kg Phenol Formaldehyde.73 Phenol type powder resin 1.00 (liquid resin) Evaporation loss 1.7 Total.73 Total.7

11 7) Methylal : Name Existing Proposed Total Product Methylal Raw Material Requirement Qty Formaldehyde 68 Methanol 1806 Manufacturing Process: Methanol and Formaldehyde are pumped into the fixed bed Catalytic Reactor in appropriate proportions. The reaction temperature is controlled at 60~85 o C. The obtained mixing solution of Methylal, Methanol and water is heated for evaporation by the re-boiler steam at the bottom of distillation column. The compositions with low volatility are collected at the top through screen packing, while the heavy fraction remains at the column bottom. The azeotropic fraction of Methylal and Methanol from the column top is condensed and sent to the reflux tank. Part of it returns to the top of the tower for circulation, and part of it is collected as 9% Methylal solution, which is pumped to multipressure Distillation Column with a pressure range of 1. Mpa to 1.5Mpa. The temperature at the top of the Distillation Column is controlled at 10 o C, while temperature at the bottom is controlled at 135 o C. High concentration Methylal is withdrawn from the Column bottom, and fractions from the top are refluxed to reactor and pressure Distillation Column. Chemical Reaction : Flowchart: CH3OH + HCHO C3H8O Methanol Methanol Formaldehyde > Reactor > Distillation Column 1 Distillation Column Methylal Catalyst

12 Mass Balance: Input kg/kg Output kg/kg Formaldehyde 1.08 Methylal 1.00 Methanol 0.86 Excess reaction water 0.94 Total 1.94 Total 1.94

13 8) Hexamine Hardener: Name Existing Proposed Total Product Hexamine Hardener Raw Material Requirement Qty Hexamine 35 Calcium Stearate 175 Manufacturing Process: Hexamine and Calcium Stearate is mixed in blender, grinded in air classifier. It is then screened and packed for despatch. Flowchart: Hexamine Calcium Sterate (650 kgs) (350 kgs) I Blender Air Classifier Screening & Packing Hexamine Hardener (1000 kgs)

14 9) Hexamine Tablet: Name Existing Proposed Total Product Hexamine Tablet Raw Material Requirement Qty Hexamine 400 Camphor 100 Manufacturing Process: Hexamine and Camphor is mixed in blender, grinded in air classifier. It is then screened and packed for despatch. Flowchart: Hexamine (800 kgs) Camphor (00 kgs) Blender Grinding Tableting and packing Hexamine Tablet (1000 kgs)

15 i I List of Machinery for the New Plant Sr.No. I Description I FD Plant Equipment Reactor- 500 mm dia x 8000mm long I Evaporator-45 KL Capacity ' Absorbers mm dia x 10 mtr Heat Exchangers Pumps Hexamine Plant Reactor I Heat Exchangers Evaporator - Multieffects I Centrifuge ^ Crystallizers- 6 KL Capacity Dryers. Pumps Para Formaldehyde Plant Agitator Thin Film Evaporator Heat Exchangers Holding Vessels RVD Pumps Absorbers Hexalye - I Reactor Heat Exchangers PF/Urea/Melamine liquid/powder reactor Heat Exchangers Holding Vessels Spray Dryer ' Pumps Sulphonated Naphthalene (Liquid/Powder) Reactor Heat txchanger Holding vessels I Vaccum Dryer I Pumps Foundary Resins-(Powder/Liquid) Reactor Heat Exchanger Dryers Mixer Pumps MOC QTY SS do 1 -do- 5 -do- 15 -do- 5 SS do - do 1 3 -do do -do- -do do- -do- 10 -do -do 1 -do 5 -do- 4 -do 15 -do 6 -do- 4 - do do 10 -do -do- 1 - do - -do -do do -do- do - do 6 do- -do- -do- 10

16 " O pps?? p ;? ffp??? p??ffp??? pe?? p? 5?P 5^ 5^ ^p? 5^1^? JTJTI^? <?j?[^>?? ^ PJTP^E <7j7 ^> JST5 J j ;??T5 fs E X P A N S I O N c $3 A R E A 0) D TO J7$7PE>^ Ol jir^ /J TO 3 a Methanol Tank 500 KL. D Methanol Tank io_o T. K. Plgtforr i Gate o R O A D 3?!^; Gate O ' Gate 5? p 5 Ammonia Storage Tanks R O A D Unloading Co sor Fire hydrant [0] ooo Tanker Platform Storage tank Caustic Storane tank Storage Gate Solid Waste Sti o Boiler House R O A D 5 O o ^ ' Q Clarifier -urn < HOU! o PFD = L Q Godown o boqlifu Tower Plant CO ct < o * o DM/RO cc Plant < < 1DJ Q Q_ LU ETP < Road X a: LU < ^ o oa )e D G. Set o or FTI^? Eli?oorff Godown Q < o or o fdl o DOO o iioiage lanks HEXfc =>lant «oo o o F.H. Point Weighing Scale o- o- F.D. Plant Gate Sate 5 ^ 5?P JTJTP^ Office Block S ate <D D O) E Q < O or o < O GARDEN or 5 <r> MGVCL Transforra Q 5 TO Time Office Parking Gate Plant Layout

17 Water Consumption Details (KL/day) No. Usages Existing Water Consumption (m 3 /day) Proposed Water Consumption (m 3 /day) Total Water Consumption (m 3 /day) 1 Domestic 6 8 Gardening Industrial RO + DM Water a) Process b) Boiler c) Washing d) RO Reject SW Water a) Cooling Tower b) Backwash & Regeneration Total Industrial Total Effluent Generation (KL/day) No. Usages Existing Wastewater generation (m 3 /day) Proposed Wastewater generation (m 3 /day) Total Wastewater generation (m 3 /day) 1 Domestic 6 8 Gardening -- Industrial RO + DM Water a) Process b) Boiler c) Washing d) RO Reject SW Water a) Cooling Tower b) Backwash & Regeneration Total Industrial Total The total waste water quantity generated will be about 705 m 3 /day. This will be passed through filter press and stored in treated water tank. Then it will be passed through RO unit to recover the waste water. 175 m 3 /day will be recycled back to the plant and 530 m 3 /day having high TDS will be sent to CETP

18 Details of Existing ETP Diagram of Effluent Treatment Plant: Cooling tower blowdown y 5700 > R.O. Reject & Softner Back Wash > 1 Pump V ^ 4 4 Boiler blowdown y P-1 > Treated Effluent to CET Nandesari through pipeline Surface Aerator / T m 3 i Details of ETP Units: Retention Sr. Capacity Description Size Time No. (m 3 ) For 180 KL 1 Settling Pits (3 Nos.) 1. x 1.0 x 1.88m SWD m F.B hr Intermediate 3.5 x 1.5 x 1.88m Depth m F.B. 8.3 Collection Tank 1.1 hr 3 Equalization Tank 5.7 x 3.3 x.33m SWD m F.B hr 4 Aeration Tank 3.86m o x 3.5m SWD + 0.3m F.B hr 5 Setting Tank 3.0m 0 x 3.6m SWD + 0.3m F.B hr 6 Intermediate holding hr 3.48 x 3.10 x 1.94m SWD + 0.3m F.B. tank 7 Treated Collection 50 15m x 5m x 3.5m Depth Tank 8 Sludge Drying Bed 3.90 x.35 x 1.80m Depth 16.50

19 Proposed ETP: The present ETP tanks will be dismantled and a new ETP will be constructed The characteristics of the waste water is given below: Parameters Concentration (mg/l) except ph 1) ph 6.3 ~ 6.8 ) COD 100 ~ 150 3) BOD 35 ~ 50 4) SS 30 ~ 50 For the expansion, the old treatment units will be demolished and in its place a new ETP will be constructed. The layout of the new ETP is given below: RO Unit m3-530 m3 100 m m3 recyled '' Filter Press - Nos (48" x 48" x 50 plates) To CETP Treated water CollectionTank via CollectionTank (1m x 1m x 4.5m) Pipeline (1m x 1m x 4.5m - Nos) The total waste water quantity generated will be about 705 m 3 /day. This will be passed through filter press and stored in treated water tank. Then it will be passed through RO unit to recover the waste water. 175 m 3 /day will be recycled back to the plant and 530 m 3 /day having high TDS will be sent to CETP The permission to discharge into CETP of NIA, has been taken. The details are given below:

20 NANDESARI INDUSTRIES ASSOCIATION (COMMON EFFLUENT TREATMENT PLANT) 153/A, G.I.D.C. Nandesari, Dist. Baroda Phone No. : / / website : nia.net.in nia_cetp@yahoo.co.in NIA/CETP/0MLD/SCIL/017-18/001 0/0/018 To, Simalin Chemical Industries Ltd. Plot No. 13, GIDC, Nandesari Vadodara Subject: Provisional McmLersliIjj Certificate of the CETP in 1-0 MLD Expansion Slot. Dear Sir, The CLI P of NIA, GIDC, Nandesari has a valid CC&A vide no. AWH dated 15/1/017 for 1 MLD treatment and discharge capacity. Now the CETP is applying for expansion from 1 MLD to 0 MLD. The discharge capacity of the CETP will remain the same as 1 MLD and the extra 8 MLD of treated Waste water will be recycled b^ck to the industries by using the Forward Osmosis technology or Thermal Desalination. In this regard, we will in position to provide membership in the 1 ~ 0 MLD slot and accept your additional ellluent ol 350 KL/day alter the CETP has received the permission for 0 MLD. This certificate has been issued to you so that you can apply lor EC/NOC. The expansion of your ETP should be in consultation with the CETP authorities. You will have to abide by all our terms and conditions and you will have to treat the effluent as per the inlet norms of the CETP issued by us in consultation with GPCB. Yours faithfully, For Nandesari Industries Association Common Effluent Treatment Plant? 11 B. C. Patel (Chairman) CCTO: L RO, GPCB, VADODARA. UNIT HEAD-VADODARA, GPCB, GANDHINAGAR ISO WO I Reg. Office : 134/1, Opp. Shopping Centre, G.I.D.C. Nandesari, Dist. Baroda Phone No , Fax No. : nia ndsr@yahoo.co.in

21 Air Emission Details: Flue Gas Emission: Sr. No. Stack Attached to Fuel Existing fuel Consumption Stack Height (m) Stack dia. (mm) Existing Flue gas stack 1 Boiler (GT-7019) LG/ scm/hr 31 mts 1500 Capacity 10 TPH FO or 10 KL/day Boiler (GT-597) FO 8.0 KL/day 30 mts 750 Capacity 4 TPH 3 DG Set (1500 KVA) HSD 50 Lt/hr 7.5 mts DG Set (50 KVA) HSD 50 Lt/hr 7.5 mts 400 Proposed Flue gas stack 5 Boiler 10 TPH NG/ scm/hr 31 mts 1500 FO or 10 KL/day 6 Boiler 4 TPH FO 8.0 KL/day 30 mts 750 LG Lean Gas There are no other process gas emissions.

22 Hazardous Waste Generation Sr No Waste Description Cat. Existing Proposed Expansion ETP Sludge MT/Year MT/Year Filter Cloth MT/Year Discarded Bags & containers MT/Year Used Oil KL/Year Activated Carbon 1.44 MT/Year 8.96 MT/Year 1.94 KL/Year Total 5.76 MT/Yr 1.9 MT/Yr 0 MT/Yr 5 MT/Yr 10 MT/Yr 35 MT/Yr Mode of Disposal Collection, Storage, Transportation and disposal at TSDF, Nandesari. Collection, Storage, Transportation and disposal by incineration at CHWI. Collection, Storage, Decontamination to authorized vendor. KL/Yr Collection, Storage, Transportation and disposal to registered recycler Collection, Storage, Transportation and disposal at TSDF, Nandesari. The membership to discharge additional hazardous waste into NECL, Nandesari has been taken. The details are given below:

23 NANDESARI ENVIRONMENT CONTROL LTD. necl SURVEY NO. : 519/P, G.I.D.C. ESTATE, NANDESARI , DIST : VADODARA. PHONE : (065) FAX : (065) necl tsdf@yahoo.co.in T o M/s.Simalin Chemical Industries Pvt.Ltd 13.GIDC.Industrial Estate Nandesari,Dist.Baroda Sub: Consent for Acceptance of Hazardous Waste Dear Sir With reference to your letter dt we are ready quantity of hazardous waste as given details to accept your additional ETP Waste : 1.44 MT + Filter Cloth : 0.48 MT MT = 5.76 MT/year 1.44 MT = 1.9 MT/year lhe acceptance criteria of above material subject to the authorization Control Board as well as our Terms & Conditions of Pollution For & on behalf of: Nandesari Environment Control Ltd o Nair. ^rtfefag Manager:ftdm Common Solid Waste Disposal and Incineration Facility