Annexure-I List of Products

Transcription

1 Annexure-I List of Products Sr. No. Name of Products Quantity (MT/Month) 1. Mono Chloro Acetic Acid (MCA) Chloro Acetyl Chloride (CAC) Tri Chloro Acetyl Chloride (TCAC) Aluminum Chloroide Feric Chloride 500 Total 1450 By product 1. Mother Liquor of MCA Hydrochloric Acid (30%), sold or captive 1710 consumption 3. Sodium bi Sulphite (20 30%) Sodium hypochlorite (20%) 25 Total byproduct 2130 M/s. Karan Intermediates Pvt. Ltd. -0-

2 List of Raw Materials Sr. No. Name of Raw Materials Quantity (MT/Month) Mono Chloro Acetic Acid (MCA)-300 MT/month 1 Acetic Acid Acetic Anhydride Chlorine Sulphur mono chloride Chloro Acetyl Chloride (CAC)- 150 MT/month 1 Mono chloro acetic acid Sulphur mono chloride/thionyl chloride Chlorine Tri Chloro Acetyl Chloride (TCAC)-150 MT/month 1 Acetic Acid Sulphur Mono Chloride Chlorine 315 Aluminum Chloroide 350 MT/month 1. Aluminum hydroxide Hydrochloric acid Feric Chloride-500 MT/Month 1. Fe (Scrap) Hydrochloric acid Chlorine 110 M/s. Karan Intermediates Pvt. Ltd. -1-

3 Annexure -II Manufacturing Process 1. Mono Chloro Acetic Acid (MCA): Charge Acetic acid in the reactor. Heat the reactor to C through hot water circulation and start chlorination. Acetic acid is converted into Mono chloro Acetic acid in presence of suitable catalyst. During the process, HCl gas is generated, which is scrubbed through scrubber and dissolved in water to convert 30% HCl liquor. After completion of reaction, the mass is transferred in buckets for crystallization where natural crystallization followed by induced cooling systems. After around 70 hrs, pure MCA crystals are recovered though centrifuging; MCA product is ready for packing. The Mother liquor (ML) generated from centrifuge is separated out and sold as ML of MCA. Chemical Reaction: CH 3 COOH + Cl > ClCH 2 COOH + HCl Acetic Acid Chlorine Monochloro acetic Acid Hydrochloric Acid M/s. Karan Intermediates Pvt. Ltd. -2-

4 Mass balance and process flow diagram:, Mono Chloro Acetic Acid Input kg output kg Acetic Acid 865 Sulphur mono Chloride 35.5 GLR HCl 629 Liq. Chlorine 895 (Convert to byproduct 30%)- for sell Acetic Anhydride 18.5 Crystallization Centrifuge Mother Liquor of MCA 185 (by product for sell) Packing MCA 1000 Total 1814 Total 1814 M/s. Karan Intermediates Pvt. Ltd. -3-

5 2. Chloro Acetyl Chloride (CAC): The MCA is directly taken to CAC reactors. At the desired temperature, gradual addition of sulphur mono chloride. Then start chlorination. On the completion of the reaction crude product is formed. The vent gases evolved during the process sent to the scrubbing system for recovery of by product and control the emission. The crude CAC thus formed is distilled, condensed, collected and packed. Chemical Reaction: 4ClCH 2 COOH + S 2 Cl 2 + 3Cl > 4ClCH 2 COCl + 2SO 2 + 4HCl Monochloro acetic Acid Sulphur Mono Chloride Liquid Chlorine Chloro Acetyl Chloride Sulphur Dioxide Hydrochloric Acid Mass balance and Process Flow Diagram: Chloro Acetyl Chloride Input Kg Output Kg Mono Chloro Acetic Acid 935 CAC Reactor Hydrochloric Acid (g) 566 Sulphur Mono Chloride 340 Sulphur Dioxide (g) 320 Chlorine 615 to APC System to Mfg. SBS Distillation Residue 4 CAC 1000 Total M/s. Karan Intermediates Pvt. Ltd. -4-

6 3. Tri Chloro Acetyl Chloride (TCAC): The acetic acid is taken into the TCAC reactor. At the desired temperature gradual addition of sulphur mono chloride is carried out and chlorination is started. On the completion of the reaction, crude product TCAC is formed. The vent gases evolved during the process is sent to the scrubbing system for recovery of by product and control of emission. The crude product formed in TCAC is distilled out and the vapours of the final products are condensed and collected in separate drums and then packed for dispatch. Chemical Reaction: 4CH 3 COOH + 15Cl 2 + S2Cl > 4CCl 3 COCl + 16HCl + SO 2 Acetic Acid Mass balance: Liquid Chlorine Sulphur mono Chloride Tri Chloro Acetyl Chloride Hydrochloric Acid Sulphur Dioxide Tri Chloro Acetyl Chloride Input Kg Output Kg Acetic Acid 510 Glass Lined HydroChloric Acid (g) 1610 Sulphur Mono Chloride 235 Reactors Sulphur Dioxide to 230 Liquid Chlorine 2100 APC System to Mfg. SBS Distillation Residue 5 TCAC 1000 Total 2845 Total 2845 M/s. Karan Intermediates Pvt. Ltd. -5-

7 4. ALUMINIUM CHLORIDE: Aluminum chloride solution is formed directly by the digestion of aluminum hydroxide and hydrochloric acid. The reaction is carried out at a temperature between 100 and 110 C. After the reaction, insoluble aluminum hydroxide is removed by filtration and is used again at the beginning of the process. The clear liquid is conditioned with water to get the finished product of a well defined quality. Al(OH) 3 + 3HCl AlCl 3 + 3H 2 O The process flow diagram for the manufacture of aluminium chloride solution is given Al(OH) KG Reactor HCl(30%) 2750 KG Un reacted Al (OH) 3 Recycled Filtration 3340 KG AlCl 3 (Solution 33 34%) 1000 KG AlCl 3 (Dehydrate) M/s. Karan Intermediates Pvt. Ltd. -6-

8 5. Ferric chloride: FeCl 2 is produced by the reaction of scrap iron with hydrochloric acid at a temperature of 80 C, hydrogen being released to the atmosphere. This solution is converted into ferric chloride (FeCl 3 ) by Chlorination. Reactions: 1. Fe + 2HCl FeCl 2 + H 2 2. FeCl 2 + ½ Cl 2 (g) FeCl 3 Flow Diagram Fe (Scrap) 445 KG HCl(30%) 1500 KG Reactor ML Recycle Filtration 100 kg Sludge Cl KG Chlorination 2065 KG FeCl 3 solution 1000 KG FeCl 3 (100% basis) M/s. Karan Intermediates Pvt. Ltd. -7-

9 Annexure-III Water Balance Total Raw Water Consumption 12.0* (fresh) KLD Domestic 5 KLD Utility 45 Process Nil Scrubber 12*+66.5 KLD Greenbelt 7 KLD 4.5 KLD Soak pit Reject Water treatment 45 HCl 65 KLD Sodium Hypochlorite 1 KLD Sodium Bi-Sulphite 12.5 KLD Blow down Boiler 20 Bleed off Cooling 20 Effluent =12.0* All by products No waste water generation M/s. Karan Intermediates Pvt. Ltd. -8-

10 Sr. No. Type of Waste 1. Distillation Residue Annexure -IV Details of Hazardous/Solid waste Category of Waste as per HWM Rules 2008 Quantity Disposal facility MT/month Collection, Storage, Transportation & Disposal to CHWI facility for incineration. 2. Used Oil kl/year Collection, Storage & Reused for internal lubrication purpose. In case of excess sold to registered re-processors. 3. Discarded Containers, Bags Nos./month 150 kg/month Selling to Authorize recyclers. M/s. Karan Intermediates Pvt. Ltd. -9-

11 Annexure-V Source of Air Emissions Sr. Stack Fuel Stack APC Probable emission No. attached to Type Height measures Flue Gas Stacks 1 Steam boiler (1000 kg/hour) 2 Thermic Fluid Heater (4 lac Kcal/hr) 3 D.G. set (200 kva) Bio Fuel 30 m Cyclone & Bag Bio Fuel filter HSD 11 m -- PM<150 mg/nm 3 SO 2 <100 mg/nm 3 NO x <150 mg/nm 3 Process Gas stack 1 Reaction vessels (MCA) 2 Reaction vessels (CAC & TCAC) m 3 Stage water scrubber followed by alkali scrubber m 3 Stage water scrubber followed by alkali scrubber HCl<20 mg/m 3 Cl 2 <09 mg/m 3 HCl<20 mg/m 3 Cl 2 <09 mg/m 3 SO 2 <40 mg/m 3 M/s. Karan Intermediates Pvt. Ltd. -10-