LIST OF PRODUCTS (PROPOSED) Sr.No. Name of Product Existing Total after expansion 1 Benzyl Acetate 20 50 2 Benzyl Benzoate 20 50 3 Benzyl Alcohol 20 50 4 Benzyl Cyanide 20 50 5 Phenyl Acetic Acid 20 50 6 Benzyl Salicylate 20 50 7 Naphthalene Acetic Acid (Tech) and Sodium Salt 5 30 8 Sodium Acetate 6 0 9 Sodium Benzoate 6 0 10 Para Methoxy Phenyl Aceto nitrile 0 50 11 Para Methoxy Phenyl Acetic Acid 0 10 12 Naphthalene Acetamide 0 10 13 Dibenzyl Ether (High boiler of Benzyl Alcohol) 0 30 14 High boiler of Benzyl Benzoate 0 10 15 High boiler of Benzyl Acetate 0 15 16 Trading (Repacking) Benzyl Acetone 1 Acetyl Naphthalene Benzyl Acetate 0 150 The existing manufacturing capacity of the plant is 137 MT/Month. The Total Manufacturing capacity of the plant after expansion will be 205 MT/Month. The total manufacturing capacity for Benzyl Acetate / Benzyl Benzoate / Benzyl Alcohol / Benzyl cyanide / Phenyl Acetic Acid / Benzyl Salicylate will be 50 MT/Month. Trading activities will be carried out for Benzyl Acetone, 1-Acetyl Naphthalene and Benzyl Acetate. The total quantity for trading will be 150 MT/Month.
Raw Material : Raw Materials Existing Qty Proposed Qty Benzyl Chloride 27.50 68.50 Benzyl Cyanide 21.50 53.50 Beta Napthol 0.00 10.00 Catalyst 0.50 0.85 Caustic Soda Lye 0.00 23.00 Caustic Lye 7.50 19.00 HCl 24.00 60.00 Liq. Ammonia 0.00 19.00 MCA 0.00 14.00 Napthlene Acetic Acid 6.00 36.00 N-Hexane 0.00 14.00 Para Anisyl Alcohol 0.00 54.50 Paraformaldehyde 1.65 10.00 Refined Naphthalene 6.65 40.00 Soda Ash 13.60 34.00 Sodium Acetate 1.30 3.50 Sodium Benzoate 15.50 39.00 Sodium Cyanide 9.50 24.00 Sulfuric Acid 1.75 10.50 Thionyl Chloride 0.00 10.50 Toulene 0.00 46.20 Trimethyl Amine 0.20 0.75 Zinc Chloride 0.30 1.50
Details of each Product: 1) Benzyl Acetate : Name Existing Production Proposed Production Product Benzyl Acetate 20 50 Raw material consumption per Month Material Existing Proposed Benzyl Chloride 18.0 45 Sodium Acetate 1.27 3.18 Catalyst 0.22 0.55 Brief process: Benzyl chloride and Sodium Acetate is reacted in presence of catalyst for 8 hours. The temperature is maintained and then the reacted mass is cooled, washed. The crude is separated, distilled under high vaccum Chemical Reaction: CH2.Cl CH 2 COOCH 3 + Na. COO CH 3 + NaCl C 6 H 5 CH 2.Cl + Na.COOCH 3 C 6 H 5 CH 2.COOCH 3 + NaCl Benzyl Chloride Sodium Acetate Benzyl Acetate
Flowchart with Mass Balance: BENZYL ACETATE HEAT BENZYL CHLORIDE 1000 kgs SODUIM ACETATE 700 kgs CATALYST 12 kgs REACTOR CRUDE BENZYL ACETATE WATER 3000 KGS WASHING WASHING TO ETP 3000 KGS VACCUM DISTILLATION High Boiler of Benzyl Acetate BENZYL ACETATE 1100 KGS
2) Benzyl Benzoate : Name Existing Production Proposed Production Product Benzyl Benzoate 20 50 Raw material consumption per Month Material Existing Proposed Benzyl Chloride 13.4 33.5 Sodium Benzoate 15.5 38.75 Catalyst 0.34 0.85 Brief process: Benzyl chloride and sodium benzoate is reacted in presence of catalyst at elevated temperature for 12 hours. After the reaction, the mass is washed and layer separated to get Benzyl Benzoate crude. The separated crude is washed under high vacuum to get pure Benzyl Benzoate. Chemical Reaction : CH 2 Cl CH 2 COOC 6 H 5 + NaCOOC 6 H 5 + NaCl C 6 H 5 CH 2 Cl + NaCOOC 6 H 5 Benzyl Chloride Sodium Benzoate C 6 H 5 CH 2.COOC 6 H 5 + NaCl Benzyl Benzoate
Flowchart with Mass Balance: BENZYL BENZOATE HEAT BENZYL CHLORIDE 670 kgs SODUIM BENZOATE 775kgs CATALYST 17 kgs REACTOR CRUDE BENZYL BENZOATE WATER 2500 KGS WASHING WASHING TO ETP 2500 KGS VACCUM DISTILLATION HIGH BOILER OF BENZYL BENZOATE BENZYL BENZOATE 1000 KGS
3) Benzyl Alcohol : Name Existing Production Proposed Production Product Benzyl Alcohol 20 50 Raw material consumption per Month Material Existing Proposed Benzyl Chloride 27.3 68.25 Soda Ash 13.6 34.0 Brief process: Benzyl chloride is hydrolysed with dilute soda ash for 12 hours at an elevated temperature. The mass is washed and the layer is separated to get crude Benzyl Alcohol. The crude is distilled under high vacuum at normal temperature to get pure Benzyl Alcohol. Chemical Reaction : CH 2 Cl CH 2 OH + Na 2 CO 3 + NaCl + CO 2 C 6 H 5 CH 2 Cl + Na 2 CO 3 C 6 H 5 CH 2 OH + NaCl + CO 2 Benzyl Chloride Sodium Ash Benzyl Alcohol
Flowchart with Mass Balance BENZYL ALCOHOL HEAT BENZYL CHLORIDE 1365 kgs SODA ASH 680 KGS REACTOR CRUDE BENZYL ALCOHOL WATER 10000 KGS WASHING WASHING TO ETP 10000 KGS VACCUM DISTILLATION HIGH BOILER OF BENZYL ALCOHOL BENZYL ALCOHOL 1000KGS
4) Benzyl cyanide : Name Existing Production Proposed Production Product Benzyl Cyanide 20 50 Raw material consumption per Month Material Existing Proposed Benzyl Chloride 24.2 60.5 Sodium Cyanide 9.44 23.6 Brief process: Benzyl Chloride and Sodium Cyanide is reacted in presence of catalyst for 10~12 hours. After reaction layer is separated and after proper washing, Benzyl Cyanide crude is separated. The crude is distilled under high vacuum to get the final product. Chemical Reaction : CH 2 Cl CH 2 CN + NaCN + NaCl C 6 H 5 CH 2 Cl + NaCN C 6 H 5 CH 2 CN + NaCl Benzyl Chloride Sodium Cyanide Benzyl Cyanide
Flowchart with Mass Balance : BENZYL CYANIDE BENZYL CHLORIDE 1210 kgs SODUIM CYANIDE 472 kgs HEAT REACTOR CRUDE BENZYL CYANIDE WATER 2500 KGS WASHING WASHING TO ETP 2500 KGS VACCUM DISTILLATION RESIDUE FOR INCINERATOR BENZYL CYANIDE 1000 KGS
5) Phenyl Acetic Acid: Name Existing Production Proposed Production Product Phenyl Acetic Acid 20 50 Raw material consumption per Month Material Existing Proposed Benzyl Cyanide 21.3 53.25 Caustic Lye 7.5 18.75 HCl 24.0 60.0 Brief process: Benzyl Cyanide is hydrolised with strong alkali solution and acidified with dilute HCl. The slurry formed is then centrifuged. The centrifuged cake is dried to get Phenyl Acetic Acid powder or flakes. Chemical Reaction : CH 2 CN CH 2 COOH + NaOH C 6 H 5 CH 2 CN + NaOH C 6 H 5 CH 2 COOH. Benzyl Cyanide Sodium Hydroxide Phenyl Acetic Acid
Flow Chart with Material Balance: Phenyl Acetic Acid BENZYL CYANIDE (1065 kgs) WATER CAUSTIC LYE (375 kgs) HCl (1200 kgs) CHARCOAL (1200 kgs) REACTOR REACTOR CENTRIFUGE &DRYING, PACKING P.A.A.
5) Naphthalene Acetic Acid: Name Existing Production Proposed Production Product Naphthalene Acetic Acid 5 30 Raw material consumption per Month Material Existing Proposed Refined Naphthalene 6.65 40.0 Paraformaldehyde 1.65 10.0 Zinc Chloride 0.245 1.5 Sodium Cyanide 2.67 16.0 Soda Ash 0.125 0.75 Trimethyl Amine 0.125 0.75 Caustic Lye 5.75 34.5 Sulfuric acid 1.75 10.5 Brief process: Chloromethylation: Refined Naphthalene and paraformaldehyde is reacted with HCl to produce Chloromethyl Naphthalene. Nitrilation: The chloromethyl naphthalene is nitriled and hydrolysed with strong alkali. Distillation: Nitriled crude is distilled to remove any unreacted material. The mass is diluted in large volume for acidification. Acidified material is centrifuged and dried to get Naphthyl Acetic Acid. Chemical Reactions CH 2 Cl CH 2 CN Naphthalene Chloromethyl CH 2 COOH Naphthalene Acetic Acid
Flow Chart with Material Balance: NAPHTHALENE ACETIC ACID HCl 4250 KGS WATER 1500 KGS REFINED NAPHTHOIENE 1330 KGS PARAFORMALDEHYDE 530 KGS ZINC CHLORIDE 49 KGS WATER 4000 KGS SODUIM CYANIDE 534 KGS SODA ASH 25 KGS TRIMETHYL AMINE 25 KGS CHLORO METHYL REACTION NITRILE REACTION NITRILE DISTILLATION WATER 25000 KGS CAUSTIC LYE 1150 KGS HYDROLYSIS SULFURIC ACID 350 KGS ACIDIFICATION WATER 25000 KGS CENTRIFUGE MOTHER LIQUOR TO ETP DRYER IN FLUID BED DRYER NAPHTHALENE ACETIC ACID 1000 KGS
Sodium Salt of Naphthalene Acetic Acid: Product Name Sodium Salt of Naphthalene Acetic Acid Existing Production Proposed Production 5 30 Raw material consumption per Month Material Existing Proposed Naphthalene Acetic Acid 6.0 36.0 Caustic Lye 2.0 12.0 Brief process: Naphthalene Acetic Acid, caustic lye and water are added in a reactor and the material is spray dried to get Sodium salt of Naphthalene Acetic Acid Flowchart with Mass Balance: SODUIM SALT OF NAPHTHALENE ACETIC ACID NAPHTHANE ACETIC ACID 1200 KGS CAUSTIC LYE 400 KGS WATER 3000 KGS REACTOR SPRAY DRIER Na. SALT OF NAPHTHALENE ACETIC ACID 1000 KGS
6) Para Methoxy Phenyl Aceto Nitrile: (New Product) Product Name Para Methoxy Phenyl Aceto Nitrile Existing Production Proposed Production --- 50 Raw material consumption per Month Material Existing Proposed Para Anisyl Alcohol --- 54.55 Toulene --- 39.5 Soda Ash --- 1.0 Brief process: Para Anisyl Alcohol and toluene are chlorinated with HCl in a reactor. The reacted mass is cynated by addition of sodium cyanide in presence of soda ash and toluene. The mass is distilled under vacuum to get the product. Flowchart with Mass Balance: PARA METHOXYL PHENYL ACETO NITRILE PARA ANISYL ALCOHOL 1800 KGS TOLUENE 650 KGS CHLORINATION HCl 3500 KGS PARA ANISYL CHLORIDE SODA ASH 34 KGS TOLUENE 650 KGS SODIUM CYANIDE CYANATION 750 KGS 4- METHOXYLPHENYL ACETO NITRILE (CRUDE) DISTILLATION RESIDUE FOR INCINERATION 4- METHOXYLPHENYL ACETO NITRILE 1650 KGS
6) Beta Naphthoxy Acetic Acid: (New Product) Product Name Beta Naphthoxy Acetic Acid Existing Production Proposed Production --- 10 Raw material consumption per Month Material Existing Proposed MCA --- 13.5 Caustic Soda Lye --- 23.1 Beta Napthol --- 10.0 HCl --- 15.4 Toulene --- 46.2 Brief process: MCA, Caustic Soda Lye and water are mixed in a reactor to form salt of MCA. Then Beta Napthol is added in presence of caustic soda lye to form salt of Beta Naphthol. Then HCl is added to form salt of Beta Naphthoxy Acetic acid. The crude is dried and recrystallized in presence of toluene. The pure Beta naphthol acetic acid which is centrifuged, dried and packed. Chemical Reaction :
Flowchart with Mass Balance: MCA (440 KGS) CAUSTIC SODA LYE (400 KGS) WATER REACTOR SALT OF MCA BETA NAPHTOL (325 KGS) CAUSTIC SODA LYE (350 KGS) WATER REACTOR SALT OF BETA NAPHTHOL HCl (500 KGS) REACTOR SALT OF BETA NAPHTHOXY ACETIC ACID CENTRIFUGE, DRYING OF CRUDE ML TO ETP TOULENE (1500 KGS) RECRYSTALLISATION OF CRUDE DISTILLATION CENTRIFUGE, DRYING OF BETA NAPHTHOXY ACETIC ACID (325 KGS) RECYCLED BACK TO PROCESS RESIDUE FOR INCINERATION
7) Naphthalene Acetamide: (New Product) Name Existing Production Proposed Production Product Naphthalene Acetamide --- 10 Raw material consumption per Month Material Existing Proposed Naphthalene Acetic Acid --- 11.1 Thionyl Chloride --- 10.5 N- Hexane --- 14.0 Liquor Ammonia --- 19.0 Brief process: Naphthalene acetic acid, N-Hexane and Thionyl Chloride are charged in a reactor. Then liquor ammonia is added to the reactor. After the completion of the reaction, the material is centrifuged, dried and packed. Chemical Reaction: CH2COOH CH2COCl + Cl 2 OS + HCl + SO 2 CH2COCl CH2CONH2 + NH 3 + HCl
Flowchart with Mass Balance: NAPHTHALENE ACETIC ACID 1110 KGS THIONYL CHLORIDE 1050 KGS N - HEXANE 1400 KGS REACTOR LIQ. AMMONIA 1900 KGS REACTOR CENTRIFUGE ML TO ETP RECRYSTALLIZATION AND CENTRIFUGE DRYING, BLENDING & PACKING NAPHTHALENE ACETAMIDE (1000 KGS)
SITE PLAN & LAYOUT PLAN
1. DETAILS OF WATER CONSUMPTION. 2. DETAILS OF WASTE WATER GENERATION.
Details of water consumption: Source of water: GIDC Water Supply Sr. No. Breakup Existing Water Consumption (M 3 /Day) Proposed Water Consumption (M 3 /Day) 1. Domestic 2 10 2. Industrial a) Process 31 105 b) Boiler Makeup 2 10 c) Cooling tower make up 2 10 3 Washing 1 15 4 Gardening 1 2 Total 39 152 Waste Water Generation Details : Sr. No. Breakup Existing Waste Water Generation (M 3 /Day) Proposed Waste Water Generation (M 3 /Day) 1. Domestic 1 8 2. Industrial a) Process 17 70 b) Boiler Blowdown 0.5 3 c) Cooling Tower Blow Down 0.5 2 d) R.O. Reject - 30 3. Washing 1 15 Total 20 128 Total waste water generation from the plant will be 128 KL/Day, of which 8 KL/Day will be from domestic activities and rest 120 KL/Day from industrial activities. 120 KL/Day will be taken to ETP plant for its treatment and further disposed to CETP of NIA.
EFFLUENT TREATMENT SCHEME.
Effluent Treatment Scheme: Domestic waste water and industrial waste water will be sent to the effluent treatment plant for treatment. The treated waste water will be sent to CETP of NIA, GIDC, Nandesari for its further disposal after meeting its inlet norms. PROPOSED TREATMENT SCHEME : The waste water from the plant will be collected in the waste water collection tank. The composite COD will be about 8500 mg/l. As per the recommendation received from the CETP of Nandesari Industries Association, we will be installing the hydrodynamic cavitation process for the treatment of the waste water. The setup for the hydrodynamic cavitation reactor is given in the figure below: The waste water is equalised over organic matter and flow. The ph of the waste water is raised to 10 by hydrated lime and filtered. The waste water is then pumped through a venturi. At the suction side, chlorine is injected to achieve hydrodynamic cavitation. This is a batch process and the system is kept under recirculation till the COD is reached to desired limit. This is again filtered in the filter press and the filtered waste water will be sent to the CETP.
DETAILS OF AIR EMISSIONS
Details on Existing Air Emissions: Sources of gaseous emissions Existing Thermic Fluid heater No. 1 Existing Thermic Fluid heater No. 2 Capacity 4 lac KCL/HR 4 lac KCL/HR Fuel used Piped Natural Gas Agro waste/ briquette / wood of fuel 350 SCM/Day 5 MT/day Type of emissions NOx, PM SO2, NOx, PM Stack height 11 meters 11 meters Stack diameter at top 13 inches 13 inches APC Provided None Built in Particulate Matter collection Mechanism Details of the New Thermic Fluid Heater
Flowchart of Dust collector From the firing in the combustion chamber (furnace), Gas will travel to radiative heat exchanger through Dust collector and from there to preheater to ID fan and Chimney. All the dust is collected in Dust collector through bottom connective heat exchanger.
Other sources of Utility Emissions There is no change in other utility emissions. Sources of gaseous emissions Existing Boiler DG Set (used only in case of power failure) Fuel used Wood / Briquettes HSD of fuel 10 MT/day 200 lts/month Type of emissions SO2, NOx, PM SO2, NOx, PM Stack height 11 meters 3 meters Stack diameter at top 13 inches 4 inches APC Provided Cyclone None Cyclone in the existing boiler Details of Existing Process Emissions Process emission Vent attached to Scrubber No.1 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches
Details of Proposed Air Emissions : Process emission Vent attached to Scrubber No. 2 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches Process emission Vent attached to Scrubber No. 3 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches Process emission Vent attached to Scrubber Gas Scrubbed Ammonia Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Water Stack height 15 meters Stack diameter at top 6 inches
DETAILS OF HAZARDOUS WASTE GENERATION AND DISPOSAL.
Details of hazardous waste generation and disposal: Sr. No. 1 2. 3. 4. Waste Details ETP Sludge Waste / Residue Waste Category Existing Total Volume Proposed Total Volume to be disposed Mode of Disposal to be disposed 34.3 180 MT/Yr 400 MT/Yr Collection, storage, transportation and disposal to TSDF, NECL for landfilling 28.1 18 MT/Yr 30 MT/Yr Collection, storage, transportation and disposal to CHWI, NECL for incineration Used Oil 5.1 0.5 MT/Yr 1 MT/Yr Applied on MS structures for corrosion control or will be sent to NECL for incineration Liner Bags and discarded containers 1 MT/year 1.5 MT/Yr Used for filling of ETP Sludge and Process residue or is Sold to registered recyclers