Ushanti Colour Chem Pvt. Ltd.

Transcription

1 Enclosure: 1 Product Detail Quantity MT/Month Sr. o. Product ame CI ame Total After Exiting Proposed Expansion 1 Manufacturing of SO Dyes & Pigment 1. Reactive Turquoise Blue H5G Blue Direct Turquoise Blue 86 Blue Reactive Turquoise Blue 72 Blue Reactive Blue G Blue Direct Turquoise Blue FBL Blue Copper Phthalocyanine Pigment Blue 15: Alpha Blue Pigment Blue 15: Beta Blue Pigment Blue 15: Ammonium Carbonate (Generate during manufacturing of Copper Phthalocyanine ) 2 Spray Drying Activity of SO Dyes

2 Enclosure: 2 Packing & Final Use of Product Sr. o. Product ame CAS O. Manufacturing of SO Dyes & Pigment 1 Reactive Turquoise Blue H5G Direct Turquoise Blue Reactive Turquoise Blue Reactive Blue G Direct Turquoise Blue FBL Copper Phthalocyanine Alpha Blue Beta Blue Ammonium Carbonate 9 (Generate during manufacturing of Copper Phthalocyanine ) Spray Drying Activity of SO Dyes Final Application of Product Used in Textile Industries, Dyes & Intermediates etc. Used in Dyes & Pigment Manufacturing. Used in Paint & Inks, in Plastic Industries as a colorant in textile industries. Used in Pharmaceuticals Industries Type of Packing 20 kg, 25 kg, HDPE bag including liner

3 Enclosure: 3 Detail of Raw Material with his Quantity Direct Turquoise Blue 86 Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Copper Phthalocyanine) Oleum Caustic Flakes Direct Turquoise Blue FBL (Blue -199) Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Copper Phthalocyanine) CSA (Chloro Sulphonic Acid) PCl3 (Phosphorus tri chloride) Liquid Ammonia Reactive Blue G (Blue-21) Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Copper Phthalocyanine) CSA (Chloro Sulphonic Acid) PCl3 (Phosphorus tri chloride) VS (Vinyl Sulphon) Sodium Bi Carbonate

4 Reactive Turquoise Blue H5G (Blue-25) Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Copper Phthalocyanine) CSA (Chloro Sulphonic Acid) Beta Chloro Liq. Ammonia HCl (Hydrochloric Acid) Soda Ash Reactive Blue 72 Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Chloro Sulphonic Acid) CSA (Chloro Sulphonic Acid) MPDSA (2,4 Di amino, Benzene Sulphonic Acid) Cynuric Chloride Liq. Ammonia Beta Blue Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Chloro Sulphonic Acid) Solvent Caustic Flakes Surfactant

5 Alpha Blue Sr.o. Raw Material Quantity MT/MT MT/Month 1 CPC (Chloro Sulphonic Acid) Salt Sulphuric Acid H 4 OH Solution (Ammonium Hydroxide) Emulsifier Caustic Flakes Copper Phthalocyanine Sr.o. Raw Material Quantity MT/MT MT/Month 1 Phthalic Anhydride Technical Grade Urea Cuprous Chloride Ammonium Molyblate Solvent Spent Acid

6 Overall List of Raw Martial Sr. o. 1 CPC Raw material Chemical ame CAS o. (SP-4-1)-[29 H,31Hphthalocyaninato (2-)- 29, 30, 31, 32 ]Copper Existing MT/Month Proposed Total After Expansion Oleum Fuming Sulphuric Acid Caustic Flakes Sodium Hydroxide CSA Chloro Sulphonic Acid PCl3 Phosphorus Tri Chloride Liquid Ammonia Ammonium Hydroxide VS Vinyl Sulphone Sodium Bi Carbonate 9 Beta Chloro Ethene, 1,1 - sulphonylbis Ethylamine, 2-Chloro- Ethylamine Hydrochloride HCl Hydrochloric Acid Soda Ash Sodium Carbonate MPDSA 2,4 Di amino, Benzene Sulphonic Acid Cynuric Chloride 2,4,6 Tri Chloro Triazene Solvent Solvent Surfactant Surfactant Salt Sodium Chloride Sulphuric Acid Sulphuric Acid Emulsifier Emulsifier Phthalic Anhydride 1,3 - Isobenzofurandione Technical Grade Carbamide, Urea Carbonyldiamine Cuprous Chloride Cuprous Chloride Ammonium Molyblate Molybdic Acid

7 Enclosure: 4 Chemical ame & Physical form of raw material with his storage facility Sr. o. Raw Material Physical form Type of Packing MOC Max. at a time storage capacity MT 1 CPC Solid Bag LDPE/HDPE 20 2 Caustic Flakes Solid Bag HDPE 10 3 VS Solid Bag LDPE/HDPE 20 4 Sodium Bi Carbonate Solid Bag LDPE/HDPE 20 5 Soda Ash Solid Bag LDPE/HDPE 20 6 MPDSA Solid Bag LDPE/HDPE 1 7 Cynuric Chloride Solid Drum MS 1 8 Salt Solid Bag LDPE/HDPE 10 9 Phthalic Anhydride Solid Bag LDPE/HDPE Technical Grade Urea Solid Bag LDPE/HDPE Cuprous Chloride Solid Bag LDPE/HDPE 5 12 Ammonium Molyblate Solid Bag LDPE/HDPE Oleum Liquid Tank MS CSA Liquid Tank MS PCl3 Liquid Tank/Drum MS Liquid Ammonia Liquid Carboys/Tank HDPE 5 17 Beta Chloro Liquid Carboys HDPE 1 18 HCl Liquid Carboys HDPE 9 19 Solvent Liquid Drum/Tank HDPE/MS 3 20 Surfactant Liquid Drum HDPE 2 21 Sulphuric Acid Liquid Tank MS Emulsifier Liquid Tank MS -

8 Enclosure: 5 Property of Raw Material Sr. o Product Phthalic Anhydride Vinyl Sulphone Cyanuric Chloride Physical & Chemical Composition B.P. F.P. LEL TLV Chemical Formula State MW o C o C % ppm or mg/nm 3 LD 50 mg/kg Sp.Gr. (Water=1)at V.D. at (air=1) Odor Threshold ppm, mg/m 3 Solubility in Water C 8H 4O 3 Solid A A A A Soluble C4-H6-O2-S Solid A A A A C3Cl33 Solid A A A A Insoluble 4 Soda Ash a 2 CO 3 Solid 106 A A A A A A Soluble 5 Sodium Hydroxide AOH Liquid A A 2 A 2.12 A A Soluble 6 Sodium Bi Carbonate ahco 3 Solid A A A A A A Soluble 7 Salt acl Solid A A A A A Soluble 8 Technical Grade Urea H 2 COH 2 Granules A A A A A Soluble 9 Ammonium (H 4 ) 6 Mo Molyblate 4H 2 O Solidas A A A A A A a Soluble 10 Sulphuric Acid H 2 SO 4 Liquid A A A A Soluble 11 Oleum H 2 SO % SO 3 Liquid A A A A Soluble 12 Chloro Sulphonic ClSO 3 H Liquid A A A A Soluble Acid 13 Cuprous Chloride CuCl Solid A A A A A Soluble In cold water

9 Enclosure: 6 Detail of Hazardous Chemicals The Raw materials, which are termed as hazardous Chemicals as per the Manufacturing, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989 are as listed below Table: Sr. o ame of Hazardous chemicals Chloro Sulphonic Acid Cuprous Chloride Hydrochloric Acid 4 Oleum Reference in MSIHC Sr.o. 136 (Schedule 1 of MSICR, 1989) Threshold Quantity (MT) Sc-2 Sc Maximum Storage Capacity (MT) Sr.o. 146 (Schedule 1 of MSICR, 1989) Sr. o. 313 (Sch-1 of MSIHC, 1989) Sr.o. 444 (Sch 1 of MSIHCR, 1989) Phosphorus tri chloride Sr.o. 506 (Schedule 1 of MSICR, 1989) Phthalic Anhydride Sr.o. 508 (Schedule 1 of MSICR, 1989) Sodium Hydroxide Sr. o. 571 (Sch-1 of MSIHC, 1989) Sulphuric Acid Sr.o. 591 ( Schedule 1 of MSICR, 1989)

10 Enclosure: 7 Manufacturing Process, Chemical Reaction & Mass Balance REACTIVE TERQUOISH BLUE H5G Manufacturing Process & Chemical Reaction 1. Charging of CPC: Copper Phthalo cyanine is taken in a MS vessel and Chloro Sulphonic acid is charged gradually. The temperature is maintained at 40ºc by chilled water circulation. Then the mass is stirred for 1 hour. 2 Sulphonation: The temperature of the mass is maintained at 100ºc for 1 hour. Then the temperature is raised up to 137ºc and maintained for hours. 3. PCL3 charging: The mass is cooled to 70ºc by chilled water circulation and PCL 3 was added. Then the material is heated up to 100ºc & the temperature is maintained for 2 hours. 4. Dumping in ICE: The dumped mass is filtered though press filter. Mixed liquor is separated collected. Then mass is given chilled water washing using fresh water and ice. 5. Condensation: Betachloro is taken in the condensation reactor. Then add water and then ice to reduce the temperature up to 5 0 c. Ammonia and sodium bi carbonate is added to maintain ph. Simultaneously rise temperatures up to 40º c. Then the mass is stirred for 2hours. Maintaining the above ph. 6. Isolation: Isolate the mass with HCl. 7. Spray Drying The solution produced is spray dried and packed.

11 Direct Turquoise Blue-86 Charge 250 Kgs CPC in vessel with 800 Kgs Oleum 23 %. Maintain temperature 80 0C for 06 hrs. This Sulphonated mass is dumped in MSRL vessel which contains Ice. Then filter the material in filter Press. The generated filtrate is known as spent acid. The wet cake is neutralized with soda ash or caustic soda. Further addition of salt water and stirr the mass for hrs. The filter the mass. The generated filtrate is sent to ETP for further treatment. The wet cake slurry is sent for spray drying activity to obtain finished product in powder form

12 REACTIVE TERQUOISE BLUE-G 1. Sulphonation: Copper Phthalo cyanine is taken in a MS vessel and Chloro Sulphonic Acid are charged gradually. The temperature is maintained at 40ºc by chilled water circulation. Then the mass is stirred for 1 hour. 2. PCL3 Charging: The temperature of the mass is maintained at 100ºc for 1 hour through indirect steaming. Then the temperature is raised up to 128ºc and maintained for hours. Then the mass is cooled to 70ºc by chilled water circulation and PCL3 was added. Then the material is heated up to 100ºc and the temperature is maintained for 2 hours. Then the mass is cooled up to 70ºc. 3. Dumping in ice. The slurry formed is charged into ice maintaining at 0ºc. 4. FILTRATIO & WASHIG: The dumped mass is filtered through press filter. Then mass is given chilled water washing using fresh water. 5. Condensation with VS: VS is taken in the condensation rector and a clear solution is made by the addition of soda ash and water. Then ice is added to reduce the temperature up to 5ºc. Then filtered cake is added gradually. Then the ph is maintained at 6 by the addition of soda bi- carbonate & ammonia. Then the mass is stirred for 2 hours maintaining the above ph. 6. Then the mass is sending for spray drying job work.

13 Direct Turquoise Blue FBL (Blue-199): 1. Charging of Copper Phthalo Cyanine: Chloro Sulphonic Acid & PCl3 is taken in a MS vessel and CPC are charged gradually. The temperature is maintained at 40ºc by chilled water circulation. Then the mass is stirred for 1hour. 2. Sulphonation: The temperature of the mass is maintained at 100ºc for 1 hour. Then the temperature is raised up to 115ºc and maintained for 1.5 hours. Gradually temperature of the mass is raised up to 122ºc and maintained for 2.5 hours. This mass is then cooled down to 50ºc. 3. Dumping in ICE: The slurry formed is charged into ice maintaining the temperature at 0ºc. 4. Filtration & Washing: The dumped mass is filtered through Filter through Filter Press. ML is collected. Then mass is given chilled water washing using fresh water and ICE. 5. Condensation: Take water in condensation reactor. Add ice in this vessel. Maintain Ph to 8 to 8.5 by addition of Ammonia. Maintain this ph for 12 hour. Increase temperature gradually up to 40ºc. 6. Spray Drying: The solution produced is spray dried and packed.

14 CPC BLUE Stage: 1 Charge Di Chloro Toluene in Glass lined reactor. Then add Urea, Phthalic Anhydride, Cuprous Chloride and Ammonium Molyblate to it. Raise the temperature up to C. During decomposition of urea ammonia gas as well as carbon dioxide gas is produced. We are controlling it by providing two stage water scrubber and then after acid scrubber. From the water scrubber we can obtain ammonium Carbamate as a by product. After maintaining sufficient time dump the batch in M.S.Ventulator for vacuum distillation of solvent. By that 95 % of the solvent will be recovered. And transfer the remaining crude in Drawning vessel containing water. Stage: 2 Take above heated crude material into dumping vessel with spent Sulphuric acid (mother liquor from Alpha Blue). Then start heating up to 95 0 C and maintain for three hours. Then filter in filter press, wash, neutralize, dry and pack the final product as a CPC Blue. After filtration process whatever mother liquor will be generated that contains 6-8 % of Sulphuric Acid. We will treat it into our adequate ETP to become neutral. Then after we will discharge it into CETP, Vatva.

15 Alpha Blue Stage: 1 (ACID PROCESS) Take Sulphuric acid (98 %) in a reaction vessel. Then slowly charge Copper Phthalocyanine slowly from ball mil. Maintaining temperature just below 85 0 C so as to dissolve it to completely. The mass is transferred to Drawning vessel stirred further for 2-3 hrs at 60 0 C and then cooled to room temperature. The CPC separate out in the required form and is filtered off. After filtration process whatever mother liquor generated that contains approximate 20 % of Sulphuric acid. We are using that liquor (H 2 SO 4 ) into the manufacture of CPC Blue. Stage: 2 (PIGMET PROCESS) The CPC cake is charged in another vessel and washed with water and stirred with fresh water. The aqueous slurry is neutralized to ph 8 to 8.5 using caustic lye and stirred with emulsifier agent at 60 0 C 90 0 C for 02 hours. The above slurry is filtered and the cake is washed with large amount of fresh water. The wet cake is dried to obtain Alpha Blue 15. The aqueous filtrate goes to ETP. Then after it is discharge it into CETP, Vatva.

16 Beta Blue Beta Blue is manufactured in two stages. Stage 1: Milling Stage 2: Pigmentation. Milling: Charge CPC (98 %) in ball mill of capacity 10,000 Liter. Mill the contents for 24 hrs. After grinding discharge the milled blue for stage II (Pigmentation) Pigmentation: Charge above milled blue into MS vessel, contains caustic water, surfactants and solvent. Reflux whole mass under stirring for 02 hrs. Then recover the solvent. Filter the pigmented mass through filter press; wash with water till neutral ph. Dry the pressed cake in spin flash dryer at the rate of 150 Kg/Hr.

17 DIRECT BLUE SULPHOATIO: + 2H 2 S OLEUM MW = 178 Cu COPPER PHTHALOCYAIE: MW = 576 SO 3 H Cu + 2H 2 SO 4 SO 3 H DIRECT BLUE MW = 736

18 2. CODESATIO: SO 3 H + 2 aoh Cu EUTRALIZATIO SO 3 H DIRECT BLUE MW = 736 SO 3 a Cu SO 3 a DIRECT BLUE - 86 MW = 780

19 REACTIVE BLUE-G 1. SULPHOATIO: + 2CLSO 3 H CSA MW = Cu COPPER PHTHALOCYAIE: MW = 576 SO 3 H Cu + 2HCl SO 3 H DIRECT BLUE MW = 736

20 2. CODESATIO:+ SO 3 H H 2 Cu + SO 3 H SO 2 CH 2 CH 2 OSO 3 H VIYL SULPHOE MW = 281 DIRECT BLUE MW = 736 SO 2 H 2 Cu SO 2 CH 2 CH 2 OSO 3 + H2O HSO 2 REACTIVE BLUE-G MW = 1262 SO 2 CH 2 CH 2 OSO 3 H

21 DIRECT BLUE SULPHOATIO: + 2ClSO 3 H PCl3 Cu CSA MW = COPPER PHTHALOCYAIE: MW = 576 SO 3 H Cu + 2HCl SO 3 H DIRECT BLUE MW = 736

22 2. CODESATIO: SO 3 H Cu SO 3 H DIRECT BLUE-199 MW = 736 SO 3 H Cu SO 3 H DIRECT BLUE MW = 736

23 REACTIVE BLUE H5G 1. SULPHOATIO: + 2CLSO 3 H CSA MW = Cu COPPER PHTHALOCYAIE: MW = 576 SO 3 H Cu + 2HCL SO 3 H DIRECT BLUE MW = 736

24 2. CODESATIO: SO 3 H Cu + 2 CLCH 2 CH 2 H 2 HCL B-CHLORO MW = SO 3 H DIRECT BLUE MW = 736 SO 3 CLCH 2 CH 2 H 2 HCL Cu + 2HCL HCLCH 2 CH 2 H 2 CLSO 3 REACTIVE BLUEH5G MW = 895

25 CHEMICAL REACTIO FOR CPC BLUE 4C 8 H 4 O 3 Phthalic Anhydride + 12CO 2 H 4 Urea + Cu M.W. 148 x 4 M.W. 60 * 12 = 720 C 32 H 16 CU 8 Copper Phthalocyanine + 16H 3 + M.W. = 17 * 16 = CO M.W. = * Clarification regarding side reaction:- The main raw material for manufacturing of Copper Phthalocyanine is Phthalic Anhydride, Urea and Cuprous Chloride. Excess quantity of Phthalic anhydride and urea are forming Phthalimide and isoindoline derivatives. Excess of Cuprous Chloride is generating Cupric Chloride and that is finding their way in the effluent. Molyblate used as catalyst also goes in the effluent. Alkali and Acidic washes are removing the impurities from the product and taking them in the liquid effluent. Excess of Sulphuric Acid in the effluent is neutralized by lime in primary ETP and calcium Sulphate is precipated. In this calcium Sulphate sludge, Phthalimide and isoindoline derivatives, copper and molybdenum are also present.

26 CHEMICAL REACTIO FOR ALPHA BLUE & BETA BLUE The manufacture of Alpha Blue & Beta Blue from CPC Blue does not involve a chemical process except reorientation and crystallization of copper Phthalocyanine Alpha Blue. CPC Crude ALPHA BLUE / BETA BLUE Polymorphic form of CPC 1100 Kgs of crude CPC produces 1050 Kgs of Copper Phthalocyanine Alpha Blue. About 50 Kgs of impurities, undercover and lost copper Phthalocyanine is left in the effluent. Due to reorientation and Crystallization the structure and molecular product of CPC Blue, Alpha Blue & Beta Blue are same. Loss of CPC in spent Sulphuric Acid can be minimized by optimizing temperature, Concentration of Sulphuric Acid and quantity of water.

27 4. Reactive Turquoise Blue H5G Mass Balance CPC: 290 Kg CSA: 1230 Kg Vessel SO 2, HCl gas scrubbed in one water Scrubber + Two Alkali Scrubber: 200 Kg Ice: 5880 Kg Dumping Vessel HCl as a By Product: 1000 Liter Water: 290 Liter Filtration Spent Acid: 18 % Liter Spent Acid: 7 % Liter Beta Chloro: 88 Kg Condensation Liq. H 3: 440 Kg eutralization HCl: 290 Kg Water: 290 Liter Isolation Filtration Effluent Liter Soda Ash: 58 Kg eutralization Spray Drying M/c. Removal: 3540 Liter Reactive Turquoise Blue H5G: 1000 Kg

28 1. Direct Blue Turquoise Blue 86 CPC: 500 Kg Oleum: 2750 Kg Vessel Ice: 5000 Kg Dumping Vessel Water: 2500 Liter Filtration Spent Acid: 18 % Liter Spent Acid: 7 % Liter Caustic Flakes: 375 Kg eutralization Spray Drying M/c. Removal: 2107 Liter Blue 86: 1000 Kg

29 5. Reactive Blue 72 CPC: 490 Kg CSA: 1960 Kg Vessel SO 2, HCl gas scrubbed one water Scrubber + Two Alkali Scrubber: 100 Kg Ice: 6154 Kg Dumping Vessel HCl as a By Product: 1000 Liter Water: 3077 Liter Filtration Spent Acid: 18 % Liter Spent Acid: 7 % Liter MPDSA: 310 Kg Coupling CYCl 3 : 610 Kg Cynuration Liquid Ammonia: 380 Kg Condensation Spray drying M/c. Removal: 2342 Liter Reactive Blue 72: 1000 Kg

30 3. Reactive Blue G (Blue-21) CPC: 350 Kg CSA: 1320 Kg PCl 3 : 164 Kg Vessel SO 2, HCl gas scrubbed in one water Scrubber + Two Alkali Scrubber: 231 Kg Ice: 5200 Kg Dumping Vessel HCl as a By Product: 1026 Liter Water: 1026 Liter Filtration Spent Acid: 18 % Liter Spent Acid: 7 % Liter Ice: 205 Kg VS : 308 Kg Condensation SBC: 206 Kg eutralization Spray Drying M/c. Removal: 2348 Liter Blue 21: 1000 kg

31 2. Direct Turquoise Blue FBL (Blue 199) CPC: 580 Kg CSA: 2350 Kg PCl 3 :100 Kg Vessel SO 2, HCl gas scrubbed in one water Scrubber + Two Alkali Scrubber: 353 Kg Ice: 9411 Kg Dumping Vessel HCl as a By Product: 1176 Liter Water: 2353 Liter 3. Filtration Spent Acid: 18 % Liter Spent Acid: 7 % Liter Ice: 1000 Kg Liq. H 3 : 540 Kg eutralization Spray Drying M/c. Removal: 5570 Liter Blue199: 1000 kg

32 8. Copper Phthalocyanine Pht hallic Anhydride: 1087 Kg Technical Grade Urea: 1494 Kg Cuprous chloride: 190 Kg Ammonium Molyblate: 3 Kg Solvent: 1667 Kg Glass Lined Reactor Vacuum Distillation H 3 & CO 2 gas scrubbed in to scrubber system: 1170 kg Solvent Recover: 1617 Kg Ammonium Carbonate 2600 Kgs Sulphuric Acid 18 % Kg Wash ing with water: 4333 Liter MSRL Vessel Filtration Spent Acid 15 % Kg Effluent: 4333 Liter goes to ETP Drying M/c. Loss: 654 Kg CPC Blue 1000 kg

33 7. Alpha Blue CPC: 1050 Kg Salt: 160 Kg Ball Milling Sulphuric Acid: 7360 Kg (98 %) M.S. Reactor Water: Liter Drawning Vessel 1 st Wash with H 4 OH: 2100 Liter 2 nd wash: 5263 Liter with water Filtration Spent Acid: Kg H 4 SO 4: 1895 Kg Effluent: 5263 Liter goes to ETP Water: 5263 Liter Emulsifier: 20 Kg Caustic Flakes: 30 Kg Vessel Washing: 8420 Liter Filtration Effluent: Liter to ETP Spin Flash Dryer M/c. removal: 456 Kg Alpha Blue: 1000 Kg

34 6. Beta Blue CPC: 1020 Kg Ball Milling Water: 2040 liter Solvent: 1780 Liter Caustic: 05 Kg Surfactant: 20 Kg Reaction Vessel Distillation Vessel Solvent Recovery: 1755 Liter Water recovery: 1020 Liter Water: Liter Filter Press Effluent goes to ETP: Liter Spin Flash Dryer M/c. Removal: 1600 Liter Beta Blue: 1000 Kg

35 Enclosure: 8 Detail of Water Consumption & Waste Water Generation Existing of Unit-1 (Plot o. 88/7) Water Consumption In Lit /Day Effluent Generation Lit/Day Domestic Industrial Process Boiler Scrubber Washing Total Existing of Unit-2 (Plot o. 88/8) Water Consumption In Lit /Day Effluent Generation Lit/Day Domestic Industrial Process il il Boiler 0.5 il Washing 2 2 Total 3 2.4

36 After Expansion & Merge Unit 1&2 (Plot o. 88/7 & 8) Water Consumption KL/Day Waste Water Generation KL/Day Existing Proposed Total Existing Proposed Total Domestic Domestic Industrial Industrial Process Process Boiler Boiler Scrubber Scrubber Cooling Cooling Washing Washing Gardening Gardening Total Total Total water consumption will be KLPD. Domestic water consumption will be 3 KLPD & Industrial water consumption will be KLPD. Domestic 2.75 KLPD will be disposed to soak pit system. Industrial effluent KLPD will be treated in Effluent treatment Plant and finally 8.75 KLPD Discharged to CETP Vatva & 83.5 KLPD send to MEE. Source of Water:- GIDC Water Supply

37 Water Balance Diagram All the Figures are in KL/Day Water Consumption Industrial Domestic 3 Domestic Effluent goes to septic tank 2.75 Process 84 Gardening 2 Scrubber 2 Washing 7.5 Boiler 5 Cooling 3 Spent Acid Effluent 83 Effluent 1 Washing Effluent 7.5 Blow Down 0.45 Effluent Spent Acid use in CPC 17 Spent Acid to OVEL 36 Spent Acid sell to authorized recycler 49.6 Ammonical Effluent Generated From Rec. Blue 25 & Alpha Blue Process (2 nd Filtration effluent) send to ETP 35 Low COD Effulent send to ETP CETP Vatva 8.75 MEE 83.5

38 Existing of Unit-1 (Plot o. 88/7) Enclosure: 9 Detail of Effluent Treatment Plant SR.O AME OF THE UIT O. OF UIT CAPACITY (KL) 1 Collection Tank 1 25 KL 2 eutralization Tank 1 25 KL 3 Carbon Filter Final collection tank for CETP 1 25 KL 5 ovel discharge Tank 2 10 KL + 30 KL 6 Filter Press 1 52 plates,36 inches 7 Settling Tank 1 21 KL 8 eutralization cum Ammonia Aeration Tank with HAG 2 with fix line to H 3 recovery. 20 KL of each 9 Copper recovery vessel 1 20 KL Existing of Unit-2 (Plot o. 88/8) Sr. o. Unit os. Capacity(KL) 1. Collection Cum eutralization Tank Filter utch 1 == 3. Overhead tank 1 20

39 After Expansion & Merge Unit 1&2 (Plot o. 88/7 & 8) Sr. o. Unit ame os. Capacity For Low Concentration Effluent 1 Collection tank 1 25 KL 2 Vessel-1 (eutralization Tank) 1 15 KL 3 Vessel-2 (eutralization Tank) 1 10 KL 4 Vessel-3 (eutralization Tank) 1 15 KL 5 Vessel-4 (eutralization Tank) 1 10 KL 6 Filter press 1 52 plates, 36 inches 7 Settling Tank 1 20 KL 8 Cartridge (Holding Tank) Collection Tank for CETP 1 25 KL Ammonical Effluent 1 Vessel-1 (eutralization Tank) 1 7 KL 2 Aeration Tank 1 70 KL For Spent Acid Collection 1 Spent Collection Tank KL

40 ETP Flow Diagram 1. Low Concentration Effluent Effluent Collection Tank Vessel (4 os.) Filter Press Settling Tank Cartridge/ Holding Tank Collection Tank for CETP 2. Ammonical Effluent Effluent Vessel (os. 5) Aeration Tank Single Acidic Scrubber Spray Dryer/MEE

41 3. Spent Acid Spent Acid Collection Tank ovel Discharge Reuse in Process Sell to authorized recycler

42 Enclosure: 10 Detail of Flue Gas Emission & Process Gas Emission with APCM System Flue Gas Emission Detail: Existing of Unit-1 (Plot o. 88/7) Stack o. Stack Attached to 1 Boiler 2 Hot Air Generator Stack Height in (m) 12 Permissible Limit Particulate Matter: 150 mg/m 3 SOx: 100 mg/m 3 Ox: 50 mg/m 3 Existing of Unit-2 (Plot o. 88/8) Stack o. Stack Attached to 1 Steam Boiler 2 Thermic Fluid Heater Stack Height in (m) 15 Permissible Limit Particulate Matter: 150 mg/m 3 SOx: 100 mg/m 3 Ox: 50 mg/m 3

43 After Expansion & Merge Unit 1&2 (Plot o. 88/7 & 8) Stack o. 1 2 Existing Steam Boiler (1 MT) Steam Boiler-2 (1 MT) Stack Attached to Proposed -- Stack Height in (m) Thermic Fluid Heater Hot Air Generator Hot Air Generator Hot Air Generator Hot Air Generator-4 10 Permissible Limit Particulate Matter: 150 mg/m 3 SOx: 100 mg/m 3 Ox: 50 mg/m 3

44 Process Gas Emission Detail: Existing of Unit-1 (Plot o. 88/7) Stack o. Stack Attached to Stack Height in (m) Air Pollution Control System Permissible Limit SOx: 40 mg/m 3 1 Reaction Vessel (os. 4) 18 Three Stage Scrubber System H 3 : 20 mg/ m 3 HCL: 20 mg/ m 3 Existing of Unit-2 (Plot o. 88/8) Stack o. Stack Attached to Stack Height in (m) Air Pollution Control System Permissible Limit 1 Spray Dryer 15 Cyclone Separator followed by Water Scrubber Particulate Matter: 150 mg/m 3

45 After Expansion & Merge Unit 1&2 (Plot o. 88/7 & 8) Stack o. Stack Attached to Stack Height in (m) 1 Reaction Vessel Reaction Vessel-2 12 Air Pollution Control System Permissible Limit Three Stage Scrubber System SOx: 40 mg/m 3 Three Stage Scrubber System HCL: 20 mg/ m 3 3 Reaction Vessel-3 18 Two Stage Scrubber System SOx: 40 mg/m 3 H 3 : 20 mg/ m 3 4 Reaction Vessel-4 5 Spray Dryer 18 Cyclone Separator followed by Water Scrubber Particulate Matter: 150 mg/m 3 Fuel Consumption Detail: Quantity Scm/Month Sr. o. Fuel ame Total After Existing Proposed Expansion 1. atural Gas

46 Existing of Unit-1 (Plot o. 88/7) Enclosure: 11 Detail of Hazardous Waste Management Sr. o. Type of Waste Category Quantity Management 1 ETP Waste Cat. o.: Spent Oil/Used Oil Cat. o.: Discarded Containers Liners Carboys 4 Spent Acid 5 Ammonium Carbonate Cat. o.: 33.3 Cat o.: Class D- 2, Sch-II MT/Month 20 L/Year 180 os./month 6000 os./month 120 os./month 11 KL/Month 30 MT/Month Collection, Storage, Transportation & Disposed at TSDF site. Collection, Storage, Transportation & Disposed by selling to Registered refiners or reuse as lubricant. Collection, Storage, Transportation & Disposed by selling to registered reuser/recyclers. Collection, Storage, Transportation & Disposed by selling to authorized recycler. Collection, Storage, Transportation & Disposed by selling to authorized user.

47 Existing of Unit-2 (Plot o. 88/8) Sr. o. Type of Waste Quantity Category Management 01. ETP Sludge 0.05 MT/Year 35.3 Collection, Storage, Transportation, Disposal at TSDF 02. Used Oil 25 L/Year 5.1 Collection, Storage, Transportation, Disposal by Selling to Registered reprocess

48 After Expansion & Merge Unit 1&2 (Plot o. 88/7 & 8) Sr. o. Type of Waste Category Quantity Existing Proposed Total Management 1 ETP Waste Cat. o.: MT/Month 28 MT/Month 40 MT/Month Collection, Storage, Transportation & Disposed to safe TSDF site, GESCSL, Vatva. 2 Spent Oil/Used Oil Cat. o.: L/Year 5 L/Year 50 L/Year Collection, Storage, Transportation & Disposed by selling to Registered refiners or reuse as lubricant. 3 Discarded Containers Liners Carboys 4 Spent Acid 5 Ammonium Carbonate 6 Hydrochlori c Acid Cat. o.: 33.3 Cat o.: Class D-2, Sch-II Cat. o.:sch-2, C1 180 os./month 6000 os./month 120 os./month 11 MT/Month 30 MT/Month Cat. o.: D2,Sch os./month 2000 os./month 280 os./month 2129 MT/Month -30 MT/Month MT/Month 600 os./month 8000 os./month 400 os./month 2140 MT/Month MT/Month Collection, Storage, Transportation & Disposed by selling to registered reuser/recyclers. Collection, Storage, Transportation & Disposed by selling to authorized recycler. Collection, Storage, Transportation & Disposed by selling to authorized user. Collection, Storage, Transportation & Disposed by selling to authorized rule 9 user.

49 Enclosure: 12 ame & Address of Director Sr. o. ame of Directors Address Contac Detail 17, Someshwar Bunglow, 1 Mr. Maunal Gandhi 2 Mr. Minku Gandhi r. Bidiwala park, Satelite, Ahmedabad. 4, Vanshree Villa, Opp. Vraj Villa, B/h. Iscon Mall, B/h. Rajpath club, Satelite, Ahmedabad. (MO) (MO)

50 Enclosure: 13 Land Supporting Document

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54 Enclosure: 15 CA Certificate

55 Enclosure: 16 SSI Certificate

56 Enclosure: 17 Membership Certificate

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59 Existing OC of Unit-1 (Plot o. 88/7) Enclosure: 18 Existing CCA

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63 Existing CCA of Unit-2 (Plot o. 88/8)

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