LIST OF ANNEXURE Annexure-1 Location of the project site Annexure-2 Layout plan Annexure-3 Break up of land area requirement Annexure-4 Details of products and raw materials and storage facility for the same Annexure-5 Details of manufacturing processes Annexure-6 Details of water consumption and wastewater generation Annexure-6 A Water balance diagram Annexure-7 Details of effluent treatment Annexure-8 Details of solid/hazardous waste and mode of disposal Annexure-9 Details of electricity and fuel Annexure-10 Details of stacks Annexure-11 NOC from Principal Chief Conservator of Forest
Gujarat map showing Gandhinagar district: ANNEXURE -1 Location Map District: Gandhinagar
District map showing talukas: Taluka: Kalol
Kalol taluka map showing village Rakanpur Village: Rakanpur
Google Earth Image: Latitude: 23 06 06.82 N Longitude: 72 28 39.99 E
ANNEXURE -2 Layout Plan 1 1 4 5 1 3 2 2 9 1 1 1 2 2 17 1 1 1 2 26 1 2 6 Gound Floor Lay out 7 8 2 No Area No Area No Area 1 Reaction area 10 Solvent room 19 Rejected FP store 2 Drying Area 11 Solvent room 20 Rejected RM & PM store 3 Drying Area 12 Solvent room 21 Drying Area 4 Steam boiler area 13 Office 22 Security room 5 Hot air generator 14 Finished product room 23 Pulverization & sifting 6 ETP evaporator 15 Electric room 24 Pulverization & sifting 7 ETP filtration tank 16 Maintenance room 25 Liquid store 8 Pre-Filtration tank 17 R & D room 26 Liquid store 9 Chemist room 18 R & D room
Production Area F1 F2 F3 F4 F8 F5 F6 F7 Terrace First Floor Lay out plan No Area No Area F1 RM store room F5 RM retain room F2 PM store room F6 Instrument room F3 Microbial testing Lab F7 Quality control room F4 Media Preparation room F8 Production Area
ANNEXURE-3 Details of Land Area Description Area (in Square Meters) 1. Manufacturing process area 1000 2. Storage (raw materials) 400 3. Storage (products) 100 4. Storage (fuel) 100 5. Storage (water) 50 6. Storage (hazardous/solid waste) 50 7. Storage (hazardous chemicals) 80 8. ETP area 50 9. Road 300 10. Green belt 1047 (33%) Total Area of the Project 3177
ANNEXURE-4 List of Products, Raw Materials and Storage Details Products: No Product 1 Methacrylic Acid Copolymers Existing MT/Month Proposed Total after Expansion i Methacrylic Acid Copolymers Type-A 5.0 ii Methacrylic Acid Copolymers Type-B 2.5 iii Methacrylic Acid Copolymers Type-C 0.5 19.5 2.5 iv Methacrylic Acid Copolymers Aqueous Dispersion 2 Acrylic Acid Polymers 10.0 i Acrylic Acid Homopolymers 0.5 30.0 30.5 ii Acrylic Acid Copolymers Nil 5.3 5.3 iii Acrylic Acid Interpolymers Nil 3.0 3.0 3 Sodium Starch Glycolate i Sodium Starch Glycolate (Maize) 47.1 5.0 53.7 ii Sodium Starch Glycolate (Potato) 11.6 4 Croscarmellose Sodium 1.0 45.6 46.6 5 Methyl Paraben 4.4 6 Propyl Paraben 1.3 1.0 21.8 7 Sodium Methyl Paraben 11.5 8 Sodium Propyl Paraben 5.6 9 Sodium Stearyl Fumarate Nil 3.9 3.9 10 Polacrillin Potassium Nil 8.9 8.9 11 Polyoxyl Hydrogenated Castor Oil Nil 5.8 5.8 Total 8.0 197.5 205.5
Raw Materials: S. Name Consumption per month (MT) 1 Starch Maize 40.7 2 Caustic Soda* 16.2 3 Monochloro Acetic Acid* 9.5 4 Methanol* 7.8 5 Starch Potato 10.0 6 Sodium Carboxy Methyl Cellulose 48.4 7 Hydrochloric Acid* (30% w/v) 3.6 8 Acrylic Acid 37.8 9 Allyl Ether of Polyalcohol 0.4 10 Ethylene Dihloride 19.6 11 Alkyl Methacrylate* 0.4 12 Methacrylic Acid 9.6 13 Methyl Methacrylate* 4.3 14 Ethyl Acrylate 1.3 15 Methacrylic Acid Copolymer Type-C 6.0 16 Polysorbate 80 0.5 17 Sodium Lauryl Sulphate 0.1 18 Stearyl Alcohol 2.7 19 Maleic Anhydride* 1.0 20 Acetone* 1.4 21 p-hydroxy Benzoic Acid 5.0 22 1-Propanol* 0.8 23 Methyl Paraben 10.0 24 Propyl Paraben 5.0 25 Divinyl Benzene 2.6 26 Caustic Potash 1.7 27 Hydrogenated Castor Oil 4.0 28 Ethylene Oxide* 2.2 *Hazardous chemicals as per Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and Amendment Rules.
Storage Facility for Raw Materials: No Raw material state Type of container of containers Total storage at a time (MT) 1 Starch Maize Solid HDPE 400 bags x 25 kg 10.0 2 Caustic Soda Solid HDPE 100 bags x 50 kg 5.0 3 Mono Chloroacetic Acid Solid HDPE 40 bags x 50 kg 2.0 4 Methanol Liquid HDPE 500 drums x 200 kg 10.0 5 Starch Potato Solid Paper 80 bags x 25 kg 2.0 6 7 Sodium Carboxy Methyl Cellulose Hydrochloric Acid Solution Solid Paper 200 bags x 25 kg 5.0 Liquid HDPE 5 drums x 200 kg 1.0 8 Acrylic Acid Liquid HDPE 25 drums x 200 kg 5.0 9 Allyl Ether of Polyalcohol Liquid HDPE 1 drum x 200 kg 0.2 10 Ethylene Dichloride Liquid HDPE 75 drums x 200 kg 15.0 11 Alkyl Methcrylate Liquid HDPE 5 drums x 200 kg 1.0 12 Methacrylic Acid Liquid HDPE 20 drums x 200 kg 4.0 13 Methyl Methacrylate Liquid HDPE 10 drums x 200 kg 2.0 14 Ethyl Acrylate Liquid HDPE 10 drums x 200 kg 2.0 15 Methacrylic Acid Copolymer Type C Solid HDPE 80 drums x 25 kg 2.0 16 Polysorbate 80 Liquid HDPE 2 drums x 200 kg 0.4 17 Sodium Lauryl Sulphate Solid HDPE 5 bags x 50 kg 0.25 18 Stearyl Alcohol Solid HDPE 10 bags x 50 kg 0.5 19 Maleic Anhydride Solid Paper 4 bags x 25 kg 1.0
20 Acetone Liquid HDPE 10 drums x 160 kg 1.6 21 P-Hydroxy Benzoic Acid Solid Paper 80 bags x 25 kg 2.0 22 1-Propanol Liquid HDPE 10 drums x 160 kg 1.6 23 Methyl Paraben Solid HDPE 40 bags x 25 kg 1.0 24 Propyl Paraben Solid HDPE 20 bags x 25 kg 0.5 25 Divinyl Benzene Liquid HDPE 2 drums x 250 kg 0.5 26 Caustic Potash Solid HDPE 2 bags x 50 kg 0.1 27 Hydrogenated Castor Oil Liquid HDPE 5 drums x 200 kg 1.0 28 Ethylene Oxide Gas MS 5 cylinder x 100 kg 0.5
1. Methacrylic Acid Copolymers ANNEXURE-5 Details of Manufacturing Processes i. Manufacturing Process of Methacrylic Acid Copolymer, Type-A Methacrylic Acid along with Methyl Methacrylate are dissolved in Ethylene Dichloride and cooked in presence of a catalyst at a temperature between 45 o C to 200 o C for a period of 2 to 12 hrs. After the reaction over, the whole mass is allowed to cool at room temperature. The solid product is separated by filtration. The organic solvent is recovered by distillation. The solid product obtained is dried and pulverized to a desired particle size. The product is analyzed and packed. Material Balance:- Input 1 Methacrylic Acid Liquid kg 250.00 2 Methyl Methacrylate Liquid kg 250.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid litre 3500.00 Output Quantity/ 1 METHACRYLIC ACID COPOLYMERS TYPE-A Solid kg 500.00 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00 Flow Diagram:- Methyl Methacrylate Ethylene Dichloride Distillation Methacrylic Acid Reaction Filtration Solid Product Analysis & Packing Pulverization Drying
ii. Manufacturing Process of Methacrylic Acid Copolymer, Type-B Methacrylic Acid along with Methyl Methacrylate are dissolved in Ethylene Dichloride and cooked in presence of a catalyst at a temperature between 45 o C to 200 o C for a period of 2 to 12 hrs. After the reaction over, the whole mass is allowed to cool at room temperature. The solid product is separated by filtration. The organic solvent is recovered by distillation. The solid product obtained is dried and pulverized to a desired particle size. The product is analyzed and packed. Material Balance:- Input 1 Methacrylic Acid Liquid kg 150.00 2 Methyl Methacrylate Liquid kg 350.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid litre 3500.00 Output 1 METHACRYLIC ACID COPOLYMERS TYPE-B Solid kg 500.00 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00 Flow Diagram:- Methyl Methacrylate Ethylene Dichloride Distillation Methacrylic Acid Reaction Filtration Solid Product Analysis & Packing Pulverization Drying
iii. Manufacturing Process of Methacrylic Acid Copolymer, Type-C Methacrylic Acid along with Ethyl Acrylate are dissolved in Ethylene Dichloride and cooked in presence of a catalyst at a temperature between 45 o C to 200 o C for a period of 2 to 12 hrs. After the reaction over, the whole mass is allowed to cool at room temperature. The solid product is separated by filtration. The organic solvent is recovered by distillation. The solid product obtained is dried and pulverized to a desired particle size. The product is analyzed and packed. Material Balance:- Input 1 Methacrylic Acid Liquid kg 250.00 2 Ethyl Acrylate Liquid kg 250.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid kg 3500.00 Output 1 METHACRYLIC ACID COPOLYMERS TYPE-C Solid kg 500.00 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00 Flow Diagram:- Ethyl Acrylate Ethylene Dichloride Distillation Methacrylic Acid Reaction Filtration Solid Product Analysis & Packing Pulverization Drying iv. Methacrylic Acid Copolymers Aqueous Dispersion Methacrylic Acid Copolymers Type-C, Polysorbate 80, Sodium Lauryl Sulphate and water are mixed to form an aqueous dispersion of Methacrylic Acid Copolymers.
Material Balance:- Quantity Input / 1 Methacrylic Acid Copolymers Type-C Solid kg 600.00 2 Polysorbate 80 Liquid kg 46.00 3 Sodium Lauryl Sulphate Solid kg 14.00 4 Water Liquid kg 1400.00 1 Output METHACRYLIC ACID COPOLYMERS AQUEOUS DISPERSION Flow Diagram:- Quantity / Solid kg 2060.00 Methacrylic Acid Copolymers Type-C Polysorbate 80 Sodium Lauryl Sulphate Water Mixing Methacrylic Acid Copolymers Aqueous Dispersion 2. Acrylic Acid Polymers i. Manufacturing Process of Acrylic Acid Homopolymers Acrylic acid along with Allyl ether of polyalcohols, are dissolved in ethylene dichloride and in presence of a catalyst, are heated at a temperature between 40 o C to 200 o C for a period of 2 to 12 hrs. The whole mass cooled at a room temperature, after the reaction over. The solid product is separated by filtration and washed with fresh solvent. The organic solvent is recovered by distillation. The solid product is dried and pulverized to a desired particle size. Finally product is analyzed and packed.
Material Balance:- Input 1 Acrylic Acid Liquid kg 1008.00 2 Allyl Ether of Polyalcohols Liquid kg 10.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid kg 6048.00 Output 1 ACRYLIC ACID HOMOPOLYMERS Solid kg 1018.08 2 Ethylene Dichloride (Solvent) Liquid kg 5745.60 3 Solvent Loss Liquid kg 302.40 Flow Diagram: Allyl Ether of Polyalcohols Ethylene Dichloride Distillation Acrylic Acid Reaction Filtration Solid Product Analysis & Packing Pulverization Drying ii. Manufacturing Process of Acrylic Acid Copolymers: Acrylic acid, alkyl methacrylate, along with allyl ether of polyalcohols, are dissolved in ethylene dichloride and in presence of a catalyst, are heated at a temperature between 40 o C to 200 o C for a period of 2 to 12 hrs. The whole mass is cooled at a room temperature, after the reaction over. The solid product is separated by filtration and washed with fresh solvent. The organic solvent is recovered by distillation. The solid product is dried and pulverized to a desired particle size. Finally product is analyzed and packed.
Material Balance:- Input 1 Acrylic Acid Liquid kg 504.00 2 Alkyl Methacrylate Liquid kg 25.20 3 Allyl Ether of Polyalcohols Liquid kg 5.00 4 Catalyst Solid kg Q.S. 5 Ethylene Dichloride (Solvent) Solid kg 3500.00 Output 1 ACRYLIC ACID COPOLYMERS Solid kg 534.17 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00 Flow Diagram: Allyl Ether of Polyalcohols Ethylene Dichloride Distillation Acrylic Acid Reaction Filtration Alkyl Methacrylate Solid Product Analysis & Packing Pulverization Drying iii. Manufacturing Process of Acrylic Acid Interpolymers: Acrylic Acid, Alkyl methacrylate, along with allyl ether of polyalcohols, are dissolved in ethylene dichloride and in presence of a catalyst, are heated at a temperature between 40 o C to 200 o C for a period of 2 to 12 hrs. The reaction mass then bubbled with Ethylene Oxide. The whole mass cooled at a room temperature, after the reaction over. The solid product is separated by filtration and washed with fresh solvent. The organic solvent is recovered by distillation. The solid product is dried and pulverized to a desired particle size. Finally product is analyzed and packed.
Material Balance:- Input 1 Acrylic Acid Liquid kg 504.00 2 Alkyl Methacrylate Liquid kg 21.00 3 Ethylene Oxide Gas kg 70.00 4 Allyl Ether of Polyalcohols Liquid kg 5.00 5 Catalyst Solid kg Q.S. 6 Ethylene Dichloride (Solvent) Liquid kg 3500.00 Output 1 ACRYLIC ACID INTERPOLYMERS Solid kg 600.04 2 Ethylene Dichloride (Solvent) Liquid kg 3150.00 3 Solvent Loss Liquid kg 350.00 Flow Diagram: Allyl Ether of Polyalcohols Ethylene Dichloride Distillation Acrylic Acid Reaction Filtration Alkyl Methacrylate Ethylene Oxide Solid Product Analysis & Packing Pulverization Drying 3. Manufacturing Process of Sodium Starch Glycolate (Maize & Potato) To the methanolic solution of Caustic Soda, Monochloro Acetic Acid and Maize / Potato starch is added slowly and cautiously. The whole mass, in presence of suitable catalyst, is cooked at reflux temperature for a period of 3 to 5 hrs. After completion of reaction, ph is adjusted & the solid product obtained on filtration is washed with Methanol and dried. The dried product is sifted and oversize particles are pulverized. The sample is sent for
analysis. The finished product is packed in drums / boxes. The Methanol is recovered by distillation. Material Balance of Sodium Starch Glycolate (Maize):- Input 1 Starch Maize Solid kg 1506.00 2 Caustic Soda Solid kg 240.00 3 Mono Chloroacetic Acid Solid kg 283.50 4 Methanol (Solvent) Liquid kg 4518.00 Output 1 SODIUM STARCH GLYCOLATE (MAIZE) Solid kg 1746.00 2 Sodium Chloride Solid kg 175.50 3 Water Liquid kg 108.00 4 Methanol (Solvent) Liquid kg 4292.10 5 Solvent Loss Liquid kg 225.90 Material Balance of Sodium Starch Glycolate (Potato):- Input 1 Starch Potato Solid kg 1004.00 2 Caustic Soda Solid kg 160.00 3 Mono Chloroacetic Acid Solid kg 189.00 4 Methanol (Solvent) Liquid kg 3012.00 Output 1 SODIUM STARCH GLYCOLATE (POTATO) Solid kg 1164.00 2 Sodium Chloride Solid kg 117.00 3 Water Liquid kg 72.00 4 Methanol (Solvent) Liquid kg 2861.40 5 Solvent Loss Liquid kg 150.60
Flow Diagram:- Maize / Potato Starch Caustic Soda Methanol Reaction Distillation Mother Liquor Filtration Chloro Acetic Acid Catalyst Solid Product Pulverization Sifting Drying Analysis Packing 4. Manufacturing Process of Croscarmellose Sodium To the Methanol, Sodium salt of Carboxy Methyl Cellulose is charged in the reactor. The ph is adjusted using inorganic acid and\or alkali. The whole mass, in presence of suitable catalyst, is cooked for a period of 3 to 5 hrs. After complete reaction, ph is adjusted & the solid product obtained on filtration is purified by using Methanol and dried. The sample is analyzed and material is packed. Methanol is recovered by distillation. Material Balance:- Input 1 Sodium Carboxy Methyl Cellulose Solid kg 968.00 2 Hydrochloric Acid (30.0 % W/V) Liquid kg 73.00 3 Caustic Soda Solid kg 80.00 4 Methanol (Solvent) Liquid kg 2904.00 Output 1 CROSCARMELLOSE SODIUM Solid kg 932.00 2 Sodium Chloride Solid kg 117.00 3 Water Liquid kg 72.00 4 Methanol (Solvent) Liquid kg 2758.80 5 Solvent Loss Liquid kg 145.20
Flow Diagram:- Hydrochloric Acid Aqu. solution Methanol Distillation Sodium Carboxymethyl Cellulose Reaction Filtration Solid Product Analysis & Packing Pulverization Drying 5. Manufacturing Process of Methyl Paraben Parahydroxyl Benzoic Acid is charged in the reactor and, dissolved in excess Methyl Alcohol. Suitable catalyst is added and the whole mass is heated to a temperature between 50 o C to 250 o C for about 10 hrs. After the complete reaction, the solution is allowed to cool slowly. The solid product obtained after filtration is re-crystallized in Methanol and dried in dryer. The product is packed after analysis. Material Balance:- Input 1 p-hydroxy Benzoic Acid Solid kg 503.70 2 Methanol Liquid kg 116.80 3 Catalyst Solid kg Q.S. 4 Methanol (Solvent) Liquid kg 2500.00 Output 1 METHYL PARABEN Solid kg 554.80 2 Water Liquid kg 65.70 3 Methanol (Solvent) Liquid kg 2375.00 4 Solvent Loss Liquid kg 125.00
Flow Diagram :- p-hydroxy Benzoic Acid Methanol Distillation Catalyst Reaction Filtration Solid Product Analysis & Packing Pulverization Drying 6. Manufacturing Process of Propyl Paraben Parahydroxyl Benzoic Acid is charged in the reactor and, dissolved in excess 1-Propanol. Suitable catalyst is added and the whole mass is heated to a temperature between 50 o C to 150 o C for about 4 hrs. After the complete reaction, the solution is allowed to cool slowly. The solid product obtained after filtration is re-crystallized in 1-Propanol and dried in dryer. The product is packed after analysis. Material Balance:- Input 1 p-hydroxy Benzoic Acid Solid kg 503.70 2 1-Propanol Liquid kg 219.00 3 Catalyst Solid kg Q.S. 4 1-Propanol (Solvent) Liquid kg 2000.00 Output 1 PROPYL PARABEN Solid kg 657.00 2 Water Liquid kg 65.70 3 1-Propanol (Solvent) Liquid kg 1800.00 4 Solvent Loss Liquid kg 200.00
Flow Diagram :- p-hydroxy Benzoic Acid 1-Propanol Distillation Catalyst Reaction Filtration Solid Product Analysis & Packing Pulverization Drying 7. Manufacturing Process of Sodium Methyl Paraben Methyl Paraben is charged in the reactor and caustic soda dissolved in Methanol is added slowly and stepwise with cooling till the desired ph is obtained. The excess solvent is recovered by distillation. The product obtained is transferred to the dryer. Once dried, the material is pulverized and analyzed before packing. Material Balance:- Input 1 Methyl Paraben Solid kg 500.08 2 Caustic Soda Solid kg 131.60 3 Catalyst Solid kg Q.S. 4 Methanol (Solvent) Liquid kg 1000.00 Output 1 SODIUM METHYL PARABEN Solid kg 572.46 2 Water Liquid kg 59.22 3 Methanol (Solvent) Liquid kg 950.00 4 Solvent Loss Liquid kg 50.00
Flow Diagram :- Methyl Paraben Methyl Alcohol Distillation Caustic Soda Reaction Semi Solid Mass Analysis & Packing Pulverization Drying 8. Manufacturing Process of Sodium Propyl Paraben Propyl Paraben is charged in the reactor and Caustic Soda dissolved in Methanol is added slowly and stepwise with cooling till the desired ph is obtained. The excess solvent is recovered by distillation. The product obtained is transferred to the dryer. Once dried, the material is pulverized and analyzed before packing. Material Balance:- Input 1 Propyl Paraben Solid kg 500.40 2 Caustic Soda Solid kg 111.20 3 Catalyst Solid kg Q.S. 4 Methanol (Solvent) Liquid kg 1000.00 Output 1 SODIUM PROPYL PARABEN Solid kg 561.56 2 Water Liquid kg 50.04 3 1-Propanol (Solvent) Liquid kg 950.00 4 Solvent Loss Liquid kg 50.00
Flow Diagram :- Propyl Paraben Methanol Distillation Caustic Soda Reaction Semi Solid Mass Analysis & Packing Pulverization Drying 9. Manufacturing Process of Sodium Stearyl Fumarate Add Stearyl Alcohol and Maleic Anhydride to the reactor. The whole mass, in presence of suitable catalyst, is cooked at reflux temperature for a period of 3 to 5 hrs. After the reaction, Solvent Acetone is charged in the reactor. Thereafter, the desired ph is adjusted with caustic soda & the solid product obtained on filtration is purified by using Acetone and dried. The sample is analyzed and material is packed. Solvent Acetone is recovered by distillation. Material Balance:- Input 1 Stearyl Alcohol Solid kg 540.00 2 Maleic Anhydride Solid kg 196.00 3 Catalyst Solid kg Q.S. 4 Caustic Soda Solid kg 80.00 5 Acetone (Solvent) Liquid kg 5400.00 Output 1 SODIUM STEARYL FUMARATE Solid kg 780.00 2 Water Liquid kg 36.00 3 Acetone (Solvent) Liquid kg 5130.00 4 Solvent Loss Liquid kg 270.00 Flow Diagram:-
Stearyl Alcohol Acetone Distillation Maleic Anhydride Reaction Filtration Caustic Soda Solid Product Analysis & Packing Pulverization Drying 10. Manufacturing Process of Polacrillin Potassium:- Pump solvent Ethylene Dichloride in reactor. Charge Methacrylic Acid and Divinyl Benzene. Charge catalyst and close the main hole. Slowly heat to reflux temperature. Continue heating to a reflux temperature 80 o C for 4 hrs. Stop heating and cool the reaction mass to room temperature. Centrifuge the slurry, wash with Ethylene Dichloride. Dry the cake at temperature below 80 o C. Pulverize & sift the product. Material Balance:- Input 1 Methacrylic Acid Liquid kg 510.00 2 Divinyl Benzene Liquid kg 260.00 3 Catalyst Solid kg Q.S. 4 Caustic Potash Solid kg 170.00 5 Ethylene Dichloride (Solvent) Liquid kg 3500.00 Output 1 POLACRILLIN POTASSIUM Solid kg 890.00 2 Water Liquid kg 50.00 3 Ethylene Dichloride (Solvent) Liquid kg 3150.00 4 Solvent Loss Liquid kg 350.00
Flow Diagram:- Methacrylic Acid Ethylene Dichloride Distillation Divinyl Benzene Reaction Filtration Solid Product Analysis & Packing Pulverization Drying 11. Manufacturing Process of Polyoxyl Hydrogenated Castor Oil:- Hydrogenated Castor Oil is charged into the reactor. Charge catalyst & purge Ethylene Oxide slowly with stirring taking care that internal temperature does not exceed 40 o C. The whole mass is then cooked at a temperature at 30 o C to 60 o C for a period of about 4 hrs. Discharge viscous liquid into the carboys. Allow to cool to room temperature when it will become semisolid at temperature below 20 o C. Material Balance:- Input 1 Hydrogenated Castor Oil Liquid kg 400.00 2 Ethylene Oxide Gas kg 176.00 3 Catalyst Solid kg Q.S. 1 Output POLYOXYL HYDROGENATED CASTOR OIL Semi Solid kg 576.00
Flow Diagram:- Hydrogenated Castor Oil Catalyst Ethylene Oxide Reaction Product Analysis & Packing
ANNEXURE-6 Details of water consumption and wastewater generation Water Consumption (2 nd day onwards) Source of water: Borewell Description Existing Water Consumption (kl/day) Total after Proposed Expansion A Domestic 0.75 0.5 1.25* B Gardening Nil 5.4 5.4 C Industrial 1 Process 0.2 0.4 0.6 2 Evaporative water loss during condensation Nil 0.3 0.3 3 Boiler 2.0 12.0 14.0 (2.2 recycled + 11.8 fresh) 4 Cooling Tower 0.1 0.5 0.6 5 Floor & Equipment Washing 0.2 0.2 0.4 Total C (1 to 5) 2.5 13.4 Total (A+B+C) 3.3 19.3 15.9 (2.2 recycled + 13.7 fresh) 22.6 (2.2 recycled + 20.4 fresh) *25 persons x 50 litre/day
Wastewater Generation Description Wastewater Generation (kl/day) Total after Existing Proposed Expansion A Domestic 0.6 0.4 1.0 B Gardening Nil Nil Nil C Industrial 1 Process 0.16 0.34 0.5 2 Evaporative water loss during condensation Nil Nil Nil 3 Boiler 0.1 1.3 1.4 4 Cooling Tower Purge Nil 0.1 0.1 5 Floor & Equipment Washing 0.2 0.2 0.4 Total C (1 to 5) 0.46 1.94 2.4 Total (A+B+C) 1.06 2.34 3.4 Water balance diagram is attached as Annexure-6A
ANNEXURE-6 A Water Balance Diagram after Expansion (2 nd day onwards) Total Water Consumption 20.4 (fresh) Domestic 1.25 Industrial 13.7 Gardening 5.4 Septic tank/soak pit 1.0 Process 0.6 Evaporative water loss while condensation of solvents 0.3 Boiler 11.8 Cooling 0.6 Floor and Equipment Washing 0.4 From Process 0.5 Blow down 1.4 Cooling Tower Purge 0.1 From Washing 0.4 Treated Water for Re-Use 2.2 Effluent Treatment Plant 2.4 All figures are in kilo litre/day
ANNEXURE-7 Details of Effluent Treatment Domestic wastewater: Domestic wastewater will be disposed off by means of septic tank /soak pit system. Industrial wastewater The industrial wastewater from the unit will be collected in a collection tank. Then it will be pumped to a settling tank where settling of solids will take place. The supernatant effluent will be transferred to a storage tank from where it will be pumped to a distillation unit. The sludge from the settling tank will be allowed to go to a nutch filter. The sludge remaining on the filter will be dried and collected in HDPE bags for disposal to TSDF site. The filtrate from the nutch filter will be taken to the storage tank before distillation. Distilled water will be collected in a recycling water tank from where it will be recycled to the plant. The residue left in the distillation/evaporation tank will be dried and stored for disposal. Flow diagram of the Effluent Treatment Plant is given in the next page.
Schematic Flow Diagram of Effluent Treatment Plant
Types of Waste Category as per Schedule-1 of HW Rules ANNEXURE-8 Details of Hazardous Waste and its Disposal Quantity (MT/Year) Existing Proposed Total after Expansion Disposal Details ETP Sludge 34.3 3.6 5.4 9 Will be collected, stored and transported to a TSDF site for disposal. Waste Lubricating Oil Discarded Drums/ Bags Process Waste (consisting of inorganic salts) 5.1 Nil 0.12 0.12 Will be collected, stored and reused within the premises and excess will be sold to authorized recyclers. 33.3 6.0 64 70 Will collected, stored and reused within the premises and excess will be sold to authorized recyclers. 28.1 0.3 140.7 141 Will be collected, stored and transported to a TSDF site for disposal.
ANNEXURE-9 Details of Electricity and Fuel Electricity: Connected Load Source Competing Users Existing Proposed Total after Expansion Uttar Gujarat Vij Co. Ltd. Nearby industries 95 kva 50 kva 145 kva Fuel: Consumption (MT/day) Description Source Existing Proposed Total after Expansion Wood Domestic 1.1 Nil Nil Saw Mill Wooden Chips / White Coal Domestic Nil 22 22
ANNEXURE-10 Details of EXISTING Stacks / Vents Stack attached to Existing Fuel Pollutant Height of stack from ground level (m) Diameter of stack (m) Air pollution control unit Flue gas stacks attached to 1 2 Steam Boiler (1 TPH) Wood (1.1 MT/day) Hot Air Generator SPM SO 2 NOx SPM SO 2 NOx Note: There is no any existing process vent. 12 0.1 12 0.1 Multi Cyclone Separator Multi Cyclone Separator Details of PROPOSED Stacks / Vents There will be no additional stacks / vents due to the proposed expansion. Saw mill wooden chips / white coal will be used as a fuel to the tune of 22 MT/day in Steam Boiler and Hot Air Generator.
ANNEXURE-11 NOC from Principal Chief Conservator of Forest