List of Annexure Form 1 Nipur Chemicals Ltd.

Transcription

1 List of Annexure Form 1 Nipur Chemicals Ltd. Annexure Number I II III IV V VI VII VIII Name of Document Google Image of the Project MIDC possession letter Soil Analysis Report Manufacturing Process flow Charts ETP Details STP Details Stack Monitoring Reports CETP Membership

2 Annexure I Google Image Latitude: 19 ' "N, Longitude: 72 43'.50.16"E

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5 Annexure III - Soil Analysis Report

6 Annexure IV Manufacturing Process Flow Charts 1. Manufacturing Process Flow Chart for Acetanalide INPUT 680 Kgs - ANILENE 382 Kgs - ACETIC ACID 99% 224 KGS SPENT ACETIC ACID (RECOVERY) ACETYLATION OUTPUT SCRUBBER SYSTEM- FOR SPENT ACETIC ACID RECOVERY FOR RECYCLESY (REUSE/SALE) Kgs FLAKING MACHINE WATER EVAPORATION- 38 Kgs PACKING MACHINE ACETANALIDE FLAKES Kgs

7 2. Manufacturing Process Flow Chart for Amido G Acid INPUT OUTPUT 750 Kgs - BETA NAPTHOL 800 Kgs - SULPHURIC ACID (98%) 1300 Kgs - OLEUM(23%) 2000 Kgs - WATER 800 Kgs - P-SALT SULPHONATION ISOLATION FILTER NEUTSCH HCl ACID Kgs RECOVERY FOR SALE SPENT ACID Kgs CENTRIFUGE SPENT ACID Kgs PACKING G-SALT Kgs 1003 Kgs - G SALT 200 Kgs - SODIUM BI SULPHITE 300 Kgs - LIQUOR AMMONIA AMINATION CONCENTRATION AMMONIA RECOVERY (REUSED/RECYCLED) Kgs - SPENT ACID CRYSTALLIZATION FILTRATION & CENTRIFUGING Waste water for MEE DRYING Water evaporation Kgs AMIDO G ACID 1000 Kgs

8 3. Manufacturing Process Flow Chart for Benzoyl H Acid H ACID 800 WATER 500 Caustic Soda 200 Banzoyl Chloride 500 REACTION VESSEL HYDROLYSIS TEMP: 95 *C Hydro Chloric Acid Kgs ACIDIFICATION FILTRATION Water evaporation Kgs SPRAY DRYING WATER EVAPORATION Kgs PRODUCT Benzoyl H ACID-1000 Kgs 4. Manufacturing Process Flow Chart for Bronner s Acid 910 Kgs - BETA NAPTHOL 1100 Kgs - SULPHURIC SULPHONAT 2590 Kgs - WATER ISOLATION FILTER CENTRIFUGE Spent Acid Kgs Spent Acid- 385 Kgs Recycle in Acidification process PACKING Schaeffer's acid Kgs 1000 Kgs Shaeffer s Acid 350 Kgs - Ammonia (23%) Ammidiation Ammonia recovery 250 Kgs 800 Kgs - Caustic soda Alkali Fusion 3600 Kgs (Spent Acid - Recovered) Acidification Filtration & Centrifuging Waste water Kgs MEE for salt recovery Bronner's acid Kgs PACKING

9 5. Manufacturing Process Flow Chart for Chromotropic Acid INPUT OUTPUT 485 Kgs - NAPTHALENE 900 Kgs - SULPHURIC ACID (98%) 1450 Kgs - OLEUM (65%) 100 Kgs - WATER SULPHONATION SOx GAS WET SCRUBBER - 5 Kgs SBS RECOVERY SYSTEM (SALE) 460 Kgs - NITRIC ACID (60%) NITRIFICATION NOx GAS WET SCRUBBER- 3 Kgs RECOVERY/RECYCLED (SALE) 2000 Kgs - RECYCLED WASTE WATER 2000 Kgs - GLAUBER'S SALT (RECOVERED) 2500 Kgs - LIME STONE POWDER DE-NOXIFICATION NEUTRALISATION NITRIC ACID RECOVERY- RECYCLED CO2 GAS (WET) Kgs 3000 Kgs - RECYCLED WATER WATER NITRO RECOVERY GYPSUM FOR SALE Kgs STEAM 500 Kgs - C.I POWDER 125 Kgs - SPENT ACID (RECOVERED) REDUCTION WATER EVAPORATION Kgs 150 Kgs - SODA ASH SODATION & FILTRATION WATER EVAPORATION -145 Kgs 2500 Kgs - WATER AMINO IRON OXIDE FOR SALE Kgs 450 Kgs- SPENT ACID/RECYCLED HCI ACID 250 Kgs- Sodium Nitrite Chromotropic ACID ISOLATION FILTRATION WASTE WATER TO MEE Kgs SALT RECOVERY AND RECYCLE SPRAY DRYING PACKING WATER EVAPORATION Kgs CHROMOTROPIC ACID FINISHED PRODUCT (1000 Kgs)

10 6. Manufacturing Process Flow Chart for DASA 641 Kgs - ACETANILIDE 2945 Kgs - CHLORO SULPHONIC ACID HCl ACID (SALE) Kgs SULPHONATION REDUCTION 590 Kgs - PNA 650 Kgs - WATER 190 Kgs - HCL 650 Kgs - IRON PDR 3298 Kgs - ICE DRAWNING SODATION 130 Kgs - SODA ASH 3600 Kgs - WATER WASH FILTRATION NEUSTCH FILTER FILTRATION FILTER PRESS IRON OXIDE FOR SALE Kgs 4000 Kgs - WATER ASC PPD 415 Kgs - SODA ASH CONDANSATION 500 Kgs - CS FLAKES HYDROLYSIS 7916 Kgs - SPENT SULPHURIC ACID ISOLATION ACIDIFICATION FILTRATION &CENTRIFUGING EFFLUENT TO ETP Kgs DRYING & PACKING DASA Kgs

11 7. Manufacturing Process Flow Chart for Black 5 Synthesis REACTION VESSEL DIAZOTIZATION TEMP: 0-5 *C SPRAY DRYER WATER EVAPORATION-1858Kgs BLACK -5 PRODUCT BLACK Kgs

12 8. Manufacturing Process Flow Chart for EK Acid 1250 Kgs - NAPTHALENE 2900 Kgs - SULPHURIC ACID (98%) 4500 Kgs - OLEUM (65%) 300 Kgs - WATER SULPHONATION SOx GAS WET SCRUBBER - 6 Kgs SBS RECOVERY SYSTEM(SALE) 1200 Kgs - NITRIC ACID (60%) NITRIFICATION NOx GAS WET SCRUBBER- 3 Kgs RECOVERY/RECYCLED (SALE) 9000 Kgs - WATER DE-NOXIFICATION NITRIC ACID RECOVERY/RECYCLED 5500 Kgs - GLAUBER'S SALT(RECOVERED) 7000 Kgs - LIME STONE POWDER NEUTRALISATION CO2 GAS (WET) Kgs Kgs - WATER NITRO RECOVERY GYPSUM FOR SALE Kgs 2000 Kgs - STEAM 1100 Kgs - C.I POWDER 200 Kgs - SPENT ACETIC ACID REDUCTION WATER EVAPORATION Kgs 400 Kgs - SODA ASH SODATION WATER EVAPORATION Kgs 5000 Kgs - WATER AMINO RECOVERY IRON OXIDE FOR SALE Kgs AMINO CONCENTRATION WATER EVAPORATION Kgs REUSED IN BOILER FEED WATER 2500 Kgs - CAUSTIC SODA FLAKES ALKALI FUSION MeOH RECOVERY Kgs - SPENT SULPHURIC ACID (FROM VINYL SULPHON PROCESS PLANT ) ACIDIFICATION SO2 GAS TO SCRUBBER Kgs SBS RECOVERY SYSTEM(SALE) 1000 Kgs - WATER FILTERATION EFFLUENT (TREATMENPLANT) (Glouber's Salt recovery) & SSRP PLANT Kgs CENTRIFUGING CENTRIFUSE ML RECYCLE SPRAY DRYING WATER EVAPORATION EK-ACID DRY POWDER 1000 Kgs 1000 Kgs

13 9. Manufacturing Process Flow Chart for G Salt & Gamma Acid 730 Kgs - BETA NAPTHOL 804 Kgs - SULPHURIC ACID(98%) 1280 Kgs - OLEUM(23%) SULPHONATION 2190 Kgs - WATER 890 Kgs - P-SALT ISOLATION HCl ACID Kgs RECOVERY FOR SALE FILTER NEUTSCH CENTRIFUGE SPENT ACID Kgs SPENT ACID Kgs RECYCLED/ REUSED FOR R-SALT (COMPLEX) PRODUCTION PACKING G-SALT NETT WT Kgs REAL QTY - (1000 Kgs) RAW MATERIAL FOR GAMMA ACID 2130 Kgs - G SALT 240 Kgs - SODIUM BI SULPHITE 410 Kgs - LIQUOR AMMONIA AMINATION 218 Kgs - C SODA FLAKES DISTILATION AMMONIA (RECOVERED/REUSED IN AMINATION)/RESYCLED 978 Kgs - C SODA FLAKES FUSION FUSION HOLDER 6260 Kgs -SPENT SULPHURIC ACID Filtrate of R-Complex (Salt) Plant RECYCLED ISOLATION 1544 Kgs - WATER (WASHING) FILTER NEUTSCH CENTRIFUGE EFFLUENT Kgs EFFLUENT Kgs RECYCLED WASTE WATER TREATMENT PLANT DRYER WATER Kgs EVAPORATION PULVERISOR & PACKING GAMMA ACID NETT WT Kgs

14 10. Manufacturing Process Flow Chart for H Acid 833 Kgs - NAPTHALENE 1666 Kgs - SULPHURIC ACID (98%) 2500 Kgs - OLEUM (65%) 125 Kgs - WATER SULPHONATION SOx GAS WET SCRUBBER - 4 Kgs SBS RECOVERY SYSTEM (SALE) 800 Kgs - NITRIC ACID (60%) NITRIFICATION NOx GAS WET SCRUBBER- 2 Kgs RECOVERY/RECYCLED (SALE) 6000 Kgs - WATER DE-NOXIFICATION NITRIC ACID RECOVERY/RECYCLED 3600 Kgs - GLAUBER'S SALT(RECOVERED) 4600 Kgs - LIME STONE POWDER NEUTRALISATION CO2 GAS (WET) Kgs Kgs - WATER NITRO RECOVERY GYPSUM FOR SALE Kgs 2000 Kgs - STEAM 850 Kgs - C.I POWDER 200 Kgs - SPENT ACETIC ACID REDUCTION WATER EVAPORATION Kgs 300 Kgs - SODA ASH SODATION WATER EVAPORATION Kgs 4000 Kgs - WATER AMINO RECOVERY IRON OXIDE FOR SALE Kgs AMINO CONCENTRATION WATER EVAPORATION Kgs REUSED IN BOILER FEED WATER 1700 Kgs - CAUSTIC SODA FLAKES 100 Kgs - METHANOL ALKALI FUSION MeOH RECOVERY METHANOL RECOVERY/RECYCLED 7516 Kgs - SPENT SULPHURIC ACID (FROM VINYL SULPHON PROCESS PLANT) ACIDIFICATION SO2 GAS TO SCRUBBER Kgs SBS RECOVERY SYSTEM (SALE) 500 Kgs - WATER FILTERATION EFFLUENT (TREATMENPLANT) (Glouber's Salt recovery) & SSRP PLANT Kgs CENTRIFUGING CENTRIFUSE ML RECYCLE SPRAY DRYING WATER EVAPORATION H-ACID DRY POWDER 1000 Kgs 1000 Kgs

15 11. Manufacturing Process Flow Chart for J Acid Synthesis 1210 Kgs -TOBIAS ACID 3630 Kgs -OLEUM (23%) SULPHONATION 4850 Kgs - WATER ISOLATION WATER EVAPORATION Kgs FILTER CENTRIFUGING FILTRATE Kgs (Recycled in J-Acid) AIG Kgs PURITY 68% 2085 Kgs - AIG 1515 Kgs- CAUSTIC SODA 270 Kgs- CAUSTIC POTASH 6635 Kgs -FILTRATE OF AIG (Recycled) 1100 Kgs -WASH WATER FUSION ISOLATION FILTER CENTRIFUGING SO2 GAS Kgs (WET) (SBS RECOVERY- SALE) EFFLUENT (ETP)-7880 Kgs FILTRATE RECYCLE DRYING WATER EVAPORATION 200 KGS PACKING J-ACID 1000 Kgs

16 12. Manufacturing Process Flow Chart for K Acid Synthesis 540 Kgs - BETA NAPTHOL 1000 Kgs - SULPHURIC ACID (98%) 1550 Kgs - OLEUM (65%) SULPHONATION TO SCRUBBER- 5 Kgs 3000 Kgs - WATER 2200 Kgs - AMMONIA 23% ISOLATION FILTER NEUTSCH CENTRIFUGE SPENT ACID Kgs RECYCLE /REUSED IN K-ACID ISOLATION 660 Kgs AMMONIA 23% AMMINATION AMMONIA RECOVERY Kgs 7075 Kgs - SPENT ACID REUSED/RECYCLED K-ACID ISOLATION FILTRATION & CENTRIFUGING FILTRATE TO ETP- SALT RECOVERY PLANT 5745 Kgs DRYING WATER EVAPORATION- 400 Kgs PACKING K- ACID NETT WT Kgs

17 13. Manufacturing Process Flow Chart for Koch Acid 485 Kgs - NAPTHALENE 900 Kgs - SULPHURIC ACID (98%) 1450 Kgs - OLEUM (65%) 100 Kgs - WATER SULPHONATION SOx GAS WET SCRUBBER - 5 Kgs SBS RECOVERY SYSTEM (SALE) 460 Kgs - NITRIC ACID (60%) NITRIFICATION NOx GAS WET SCRUBBER- 3 Kgs RECOVERY/RECYCLED (SALE) 2000 Kgs - RECYCLED WASTE WATER DE-NOXIFICATION NITRIC ACID RECOVERY- RECYCLED 2000 Kgs - GLAUBER'S SALT(RECOVERED) 2500 Kgs - LIME STONE POWDER NEUTRALISATION CO2 GAS (WET) Kgs 3000 Kgs - RECYCLED WATER WATER NITRO RECOVERY GYPSUM FOR SALE Kgs STEAM 500 Kgs - C.I POWDER 125 Kgs - SPENT ACID (RECOVERED) REDUCTION WATER EVAPORATION Kgs 150 Kgs - SODA ASH SODATION & FILTRATION WATER EVAPORATION Kgs 2500 Kgs - WATER AMINO RECOVERY IRON OXIDE FOR SALE Kgs 450 Kgs- SPENT ACID/RECYCLED HCI ACID 750 Kgs- RECOVERED SALT KOCH ACID ISOLATION FILTRATION WASTE WATER TO MEE Kgs SALT RECOVERY AND RECYCLE SPRAY DRYING WATER EVAPORATION Kgs PACKING KOCH ACID (65%) Kgs FINISHED PRODUCT (1000 Kgs)

18 14. Manufacturing Process Flow Chart for R Complex 5957 Kgs - SPENT ACID OF G SALT 703 Kgs - COMMON ISOLATION FILTER NEUTSCH CENTRIFUGE SPENT ACID Kgs REUSED IN GAMMA ACID PLANT PACKING R-COMPLEX NETT WT Kgs 15. Manufacturing Process Flow Chart for Shaeffer s Acid 910 Kgs - BETA NAPTHOL 1100 Kgs - SULPHURIC ACID (98%) SULPHONATI 2000 Kgs - WATER 700 Kgs - Caustic ISOLATION FILTER Waste water Kgs MEE for salt recovery CENTRIFUGE Waste water Kgs PACKING Schaeffer's acid Kgs

19 16. Manufacturing Process Flow Chart for Sulpho Gamma Acid 1600Kgs - K-ACID 1600 Kgs - CAUSTIC SODA FLAKES ALKALI METAL FUSION 7980 Kgs - SPENT SULPHURIC ACID (SPENT SULPHURIC FROM SULPHO TOBIAS ACID SYNTHESIS) ISOLATION PRECIPITATION SOx GAS WET SCRUBBER Kgs (SBS RECOVERY SYSTEM (SALE) FILTRATION & CENTRIFUGING WASTE WATER TO ETP Kgs MEE (SALT RECOVERY PLANT) DRYING WATER EVAPORATION Kgs SULPHO GAMMA ACID DRY POWDER Kgs (FINISHED PRODUCT) 17. Manufacturing Process Flow Chart for Sulpho Tobias Acid 780Kgs - BETA-NAPHTHOL 2420 Kgs - OLEUM (23%) SULPHONATION SOx GAS WET SCRUBBER - 5 Kgs SBS RECOVERY SYSTEM (SALE) 4000 Kgs - ICE 600 Kgs - WATER 680 Kgs - GLAUBER SALT/SODIUM SALT ISOLATION PRECIPITATION FILTRATION & CENTRIFUGING SPENT SULPHURIC ACID- (FOR RECYCLE TO SULPHO GAMMA ACID) Kgs Kgs DRYING WATER EVAPORATION Kgs SULPHO TOBIAS ACID DRY POWDER - (FINISHED PRODUCT) 1000 Kgs

20 18. Manufacturing Process Flow Chart for Vinyl Sulphone 641 Kgs - ACETANILIDE 2945 Kgs - C.S.A. SULPHONATION HCL RECOVERY - 400Kgs 3298 Kgs - ICE DRAWNING 5000 Kgs - WATER FILTRATION & WASHING SPENT SULPHURIC ACID Kgs (REUSE/SALE/RECYCLE TO H-ACID) 451 Kgs - SODIUM BI SULPHITE 973 Kgs - CAUSTIC SODA LYE REDUCTION 256 Kgs - ETHYLENE OXIDE ETHOXILATION 1000 Kgs - WASH WATER FILTRATION & WASHING CONCENTRATED STREAM Kgs TO MEE (SALT RECOVERY PLANT) FILTRATE TO ETP (WEAK STREAM) Kgs CENTRIFUGING FILTRATE TO ETP Kgs (WEAK STREAM) DRYING WATER EVAPORATION Kgs 340 Kgs - SULPHURIC ACID (98%) ESTERIFICATION SPENT ACETIC ACID (95%) Kgs PULVERISING & PACKING VINYL SULPHONE Kgs

21 Annexure V Effluent Treatment Plant Effluent Treatment Plant: Nipur Chemicals Ltd. has provided ETP of 5m 3 /hr capacity to treat industrial effluent using the Fenton s primary treatment mechanism of physical processes involving super oxidation, coagulation and flocculation with chemical dosing followed by settling using tube settler that follows secondary or advanced oxidation process treatments using TiO 2 photochemical activation using UV and finally polishing the secondary treated effluent using tertiary process of filtrations. Ozonation for quaternary oxidation is also added to take care of remains of recalcitrant COD. Layout of ETP is presented below; Layout of ETP Description of Units Sr. No. Units Capacity 1 Collection Tank 180 m 3 x 2 2 Effluent Transfer pump 2 HP x 2 3 Tube settler 15 m 3 x 2 4 Clarifier 12 m 3 5 Filter feed pump 7.5 HP 6 Sludge return pump 2 HP 7 Pressure sand filter Ø 2500 x Activated carbon filter Ø 2500 x Filter water holding tank 10 m 3 10 Sludge drying bed 1.5 m 3 x Air blowers 25 HP x 2

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24 HIGH TDS EFFLUENT TREATMENT/HANDLING PROCESS SHEET- DAILY BASIS INPUT 2,58,000 Kgs Acidic ML from plant (18% TDS as sodium sulphate) NIPUR CHEMICALS LTD. PLOT NO-D- 17, MIDC, TARAPUR BOISAR COLLECTION / HOLDING TANK OUTPUT Kgs. Lime Stone powder 860 Kgs Hydrated Lime powder ML NEUTRALISATION Hot Water For Washing ML RECOVERY ( Filteration) GYPSUM 25,800 Kgs. CONTINEOUS CRYSTALISER Water Evap kgs. GLOUBER'S SALT RECOVERY PUSHER CENTRIFUSE G.SALT Kgs ( Recovery) Condensate Recycle MEE.EVAPORATOR Water Evap Kgs. Condensate Recovery to Boiler feed SPRAY DRYER Water Evaporation Kgs. SALT RECOVERY SYSTEM Spent H. Acid Sold to User Ind./ Disposal CHWS Kgs TOTAL Kgs. TOTAL Kgs.

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26 STEPS TECHNIRON LIMITED 101 SINCHAN, NEW LINK ROAD, OFF VEERA DESAI ROAD, ANDHERI (WEST), MUMBAI INDIA TEL : / FAX : steps.techindia@gmail.com Web Site : Annexure VI Details of Sewage Treatment Plant TREATMENT SCHEME Sewage Treatment Plant: Primary Treatment: Raw sewage generated will be passed through Screen Chamber (Civil) and Oil & Grease Trap. Bar screens will be provided in Civil for removing any type of floatable matter in the raw sewage which will be scrapped out and collected in drums. Oil skimmer will remove floatable oil in raw sewage. Clear sewage will be collected in Equalization/ Collection Tank for equalizing the sewage. Flash Mixers will be provided for mixing purpose. Equalized sewage will be sent to Mixing Tank for further treatment. Secondary Treatment: The AOT Tank will be Dozed with the specified quantity of bio-cultures made of light Organic Elements material to enhance the surface area for bio-growth. Oxygen required for the bacterial growth will be supplied through Rapid Oxidizer Micro2. The system envisages better oxygen because of Liquid Dozing and increased contact with the sewage. The overflow from aeration tank will be gravitating to Secondary Settler. The Alum dosing will be done for settling. This unit is provided to arrest the sludge from leaving the system. The arrested sludge will be pumped backed to the Sludge Holding Tank. Collected sludge will be pumped to the Manual Filter Press for de-watering. The filtrate from filter press will be taken to the equalization cum collection tank. Clear overflow from tube settler will be gravitated to further tertiary treatment. Tertiary Treatment: Overflow from the tube settler will be gravitated to Disinfection Contact Tank where provision will be made for Probio - M dosing as required for disinfection. Dosing will be done by pumping. Treated sewage will be pumped to Pressure Sand Filter followed by Activated Carbon Filter.

27 PROCESS FLOW DIAGRAM

28 STP Layout

29 PROCESS CALCULATION/ EQUIPMENT SIZING CIVIL UNITS: A. Screen Chamber: Quantity : 2 nos Retention Time : 12 min each Capacity : 5 m 3 Dimension : 2.0m x 2.0m x 1.25m SWD MOC : MS angels with PVC mesh B. Equalization cum Collection Tank : Quantity : 2 nos Retention Time : 6 hrs. Capacity : 5 m 3 Dimension : 2.0 m x 2.0x 1.25m SWD MOC : RCC C. AOT Tank : Quantity : 2 Retention Time : 4.0 hrs. Capacity : 5 m 3 Dimension : 2.0 m x 2.0 m x 1.25 m SWD MOC : RCC D. Disinfection Contact Tank: Quantity : 2 Retention Time : 1.0 hr. Capacity : 5 m 3 Dimension : 1.5m x 1.5m x 0.5m SWD MOC : RCC MECHANICAL EQUIPMENT DETAILS: A. Raw Sewage Transfer Pumps: Quantity Capacity Head MOC Make B. STEPSSORB MEDIA : Quantity MOC Make C. Sludge Return Pumps: Quantity Capacity Head MOC Make : 2 nos. (1W+1S) : 1.5 m 3 /hr : 15 Mtrs : CI : Kirloskar/ equivalent : Packaged unit (Inbuilt Mechanism) : Proprietery : Steps : 1 nos. : 1.5 m 3 /hr : 15 Mtrs : CI : Kirloskar/ equivalent

30 D. Filter Feed Pumps: Quantity Capacity Head MOC Make E. Pressure Sand Filter: Quantity Diameter MOC Make F. Activated carbon Filter: Quantity Diameter Height of Straight MOC Make G. Dosing Tank: Quantity Capacity MOC Make H. Dosing Pump: Quantity Capacity MOC Make : 1 nos. : 1.5 m 3 /hr : 25 Mtrs : CI : Kirloskar/ equivalent : 1 (Packaged Unit) : Capacity 1.5 M3/hr : MSEP : Steps : 1 (Packaged unit) : capacity 1.5 M3/hr : 2000 mm : MSEP : Steps : 1 no. : 200 lit. : HDPE : Sintex : 1 no. : 0-5 lph : PP : Asia LMI

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33 Annexure VII - Stack Monitoring Report

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