ANNEXURE-1 TERMS OF REFERENCES TOR prescribed by MoEF & CC for this sector will be taken into account. M/s. RAMDEV CHEMICAL INDUSTRIES UNIT-(II)
ANNEXURE-2 Sr. Products No. LIST OF PRODUCTS Existing Quantity as per CCA- AWH 73496 (MT/Month) Quantity as per EC J- 11011/993/2 008-IA II (I)* (MT/Month) Additional Quantity (MT/ Month) Total Quantity after proposed Expansion (MT/Month) 1. CPC Blue Crude 45 360 655 700 2. Pigment Alpha Blue 7.5 160 97.5 105 (Blue 15.0 & 15.1) 3. Activated CPC Blue 100 300 830 930 (Only grinding process) 4. Phthalocyanine Beta Blue (Pigment Blue 15.3 & 15.4) 300 630 330 630 5. Phthalocyanine Beta Blue (Pigment Blue 15.3 & 15.4) (only grinding process) 6. Recovered Inorganic products (Ammonium Sulphate 100% base) OR Recovered Inorganic products (Ammonium Sulphate Solution ) 200 -- 0 200 60 305 665 725 315 3500 3815 7. Calcium Carbonate 45 -- 315 360 8. Copper salt -- -- 5.5 5.5 9. Ammonium Carbonate Solution (100%) OR Ammonium Carbonate Solution 40 270-40 -270 0 0 Total 797.5 2858 3655.5 *This EC is converted into CTE. (CTE No:-81416) M/s. RAMDEV CHEMICAL INDUSTRIES (UNIT-II)
ANNEXURE-2 AS PER CTE No: 81416 Sr. No. Products Existing Quantity as per CCA- AWH 73496 (MT/Month) Quantity as per granted CTE:-81416 1. CPC Blue Crude 45 360 2. Pigment Alpha Blue 7.5 00 (Blue 15.0 & 15.1) 3. Activated CPC Blue 100 930 (Only grinding process) 4. Pthalocyanine Beta Blue (Pigment Blue 15.3 & 15.4) (Solvent base, water base) 300 00 5. Pthalocyanine Beta Blue (Pigment Blue 15.3 & 15.4) (only grinding process) 6. Recovered Inorganic products (Ammonium Sulphate 100% base) OR Recovered Inorganic products (Ammonium Sulphate Solution ) 200 200 60 305 315 7. Calcium Carbonate 45 45 8. Ammonium Carbonate Solution (100%) OR Ammonium Carbonate Solution 40 270 0 Total 797.5 1840 *This CTE is not converted into CCA. M/s. RAMDEV CHEMICAL INDUSTRIES (UNIT-II)
ANNEXURE-3 LIST OF PARTNERS Sr. No. Name of the Partner Address Contact No. 1. Mr. Sureshkumar Mavjibhai Bhingaradia 2. Mrs.Manju S. Bhingaradia 3. Mrs. Viruben M. Bhingaradia 4. Mr. Mavjibhai M. Bhingaradia 507/3, Aavkar Society, G.I.D.C., New Colony, Ankleshwar- 393 002. 507/3, Aavkar Society, G.I.D.C., New Colony, Ankleshwar- 393 002. 507/3, Aavkar Society, G.I.D.C., New Colony, Ankleshwar- 393 002. 507/3, Aavkar Society, G.I.D.C., New Colony, Ankleshwar- 393 002. 02646-252828 02646-252828 02646-252828 02646-252828 M/s. RAMDEV CHEMICAL INDUSTRIES (UNIT-II)
16. MT. W I D E R O A D ² 20. MT. W I D E R O A D SITE PLAN SCALE - 1:500
ANNEXURE 5 NAME OF THE PRODUCT COPPER PHTHALOCYANINE BLUE CRUDE AMMONIUM SULFATE PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) EXISTING & PROPOSED PRODUCT RAW MATERIAL LIST NAME OF RAW MATERIALS QUANTITY MT/MT OF PRODUCT QUANTITY MT/MONTH Phthalic Anhydride 1.075 752.5 Carbamide Salt/NH3 gas 1.505 1053.5 Cuprous Chloride 0.193 135.1 Ammonium Molybdate 0.003 2.1 TCB/NB/ONT/ISOL 0.02 14 Spent Sulphuric Acid (30% to 40%) 2.00 1400 TOTAL 4.796 3357.2 Ammonium Carbonate Solution 3.9 2827.5 (20 to 22%) Dilute sulfuric from CPC filtrate 2.4 1740 (20 to 25%) Sulfuric Acid 70% 0.4 290 TOTAL 6.7 4857.5 CPC Blue Crude 1.03 648.9 Caustic Soda Flakes 0.011 6.93 Dilute Hydrochloric acid (HCl) 0.02 12.6 Xylene/IBA 0.01 6.3 Salt 0.1 63 TOTAL 1.171 737.73 PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1) CPC Blue Crude 1.1 115.5 Sulphuric Acid (98%) 4 420 Dispersing agent/additives 0.001 0.105 Caustic Flakes 0.1 10.5 ACTIVATED CPC BLUE TOTAL 5.201 546.1 CPC Crude 0.91 846.3 Common Salt 0.09 83.7 M/s. RAMDEV CHEMICAL INDUSTRIES (UNIT-II)
ANNEXURE 5 TOTAL 1.00 930 PTHALOCYANINE CPC Crude 1.00 200.00 BETA BLUE (PIGMENT BLUE TOTAL 1.00 200 15.3 & 15.4) (ONLY GRINDING PROCESS) COPPER SALT Acidic filtrate from CPC blue 312.5 1719 TOTAL 312.5 1719 M/s. RAMDEV CHEMICAL INDUSTRIES (UNIT-II)
ANNEXURE-6 MANUFACTURING PROCESS 1. COPPER PHTHALOCYANINE BLUE CRUDE MANUFACTURING PROCESS FOR CPC BLUE CRUDE Phthalic Anhydride,Carbamide salt/nh3 gas and solvent (TCB/NB/ONT/ISOL) are mixed in the vessel equipped with heating arrangement (by thermo pack boiler for circulation of high temperature oil) and stirrer. Cuprous chloride and ammonium molybdate are then added. - The Mixture is heated up slowly for 20 hours at 180 C. - Ammonia gas is liberated with the formation of phthalamide at 135 C. Formation of copper phthalocyanine takes place at a temp 185 C with release of ammonia gas and CO2 gas. - The ammonia gas and CO2 gas are scrubbed through scrubbers under water circulation. The generated ammonium carbonate solution is converted into ammonium sulfate. - The reaction mass is stirred till formation of copper phthalocyanine is completed. - The reaction mass is then transferred to rotary vacuum drier and solvent is recovered completely under vacuum from rotary vacuum drier. - The dried powder of Copper phthalocyanine is then purified in MSRL brick lined vessel by treating it with acidic effluent (diluted sulphuric acid) generated during manufacture of pigment Alpha Blue. - The resulting mixture is filtered in filter press and wet cake is washed with water. - Filtrate is transferred into collection tank and use for the manufacturing of ammonium sulfate. Washing water is treated in ETP. While the wet press cake of CPC blue is dried in dryer/spin flash dryer, pulverized and packed into HDPE bags.
ANNEXURE-6 CHEMICAL REACTION FOR CPC BLUE CRUDE: PROCESS FLOW DIAGRAM FOR CPC BLUE CRUDE: 1. Phthalic Anhydried 2. Carbamide Salt/NH 3 gas 3. Cuprous Chloride 4. Ammonium Molybdate 5. Solvent (ONT/TCB/NB/ISOL) Solvent Recovered Glass Lined Vessel Rotary Vacuum Dryer Ammonia (Gas) CO 2 Gas Water Scrubber Ammonium Carbonate solution Ammonium Sulfate Spent H2SO4 from Alpha Washing water MSRL Filter Press Filterate for Mfg of ammonium sulfate Washing water To ETP Drying (SFD) Packing
ANNEXURE-6 MASS BALANCE OF TYPICAL BATCH OF CPC BLUE CRUDE Input Kg. Output Kg. Phthalic Anhydride 1075 Mass 4126 (NH3) & CO2 gas to water 1505 Carbomide salt/ammonia gas scrubber REACTOR Cuprous Chloride 193 800 Ammonium Molybdate 3 ONT 2150 TOTAL 4926 TOTAL 4926 Input Kg Output Kg. Mass 4126 RVD Mass 1976 Recovered solvent 2130 Atmospheric solvent loss 20 TOTAL 4126 TOTAL 4126 Input Kg. Output Kg. Mass 1976 Slurry 4526.00 Live steam 550 Dilute sulfuric acid from Alpha MSRL-BL Blue Plant (30% to 40%) 2000 TOTAL 4526 TOTAL 4526.00 Input Kg. Input Kg. Slurry 4526 Mass 2100 Filterate (20%to 25%) for FILTER PRESS mfg of ammonium sulphate 2500 Water 2800 AND WASHING Water from MEE condenset 1780 Effluent water to ETP & MEE 4506 TOTAL 9106 TOTAL 9106 Input Kg. Output Kg. Mass 2100 Water loss 1100.00 SFD/DRYER Product 1000 TOTAL 2100 TOTAL 2100 MASS BALANCE ACROSS SCRUBBER Input Kg Output Kg Water from MEE condenset 3240 Water loss 40 (NH3) & CO2 gas 800 SCRUBBER Ammonium Carbonate solution(20 to 22 %) 4000 TOTAL 4040 TOTAL 4040
ANNEXURE-6 2. AMMONIUM SULPHATE MANUFACTURING PROCESS FOR AMMONIUM SULPHATE The Ammonium Carbonate solution is generated from the production of CPC Blue which is reacted with Spent Sulfuric acid/sulfuric Acid in the reactor. After the completion of reaction, mass is charged into distillation vessel/mee for the recovery of ammonium sulfate and condensate of MEE is reused into Scrubber/Process. CHEMICAL REACTION FOR AMMONIUM SULPHATE (NH4)2 CO3 + H2SO4 (NH4)2SO4 + H2O + CO2 AMMONIUM SULFATE Input Kg. Output Kg. Ammonium Carbonate Solution(20 to 22%) 4000 CPC filtrate (20 to 25%) after copper REACTOR Reaction Mass 6917 recovery 2492 Sulfuric Acid 70% 425 TOTAL 6917 TOTAL 6917 Input Kg Output Kg. Evaporation loss 882 Water to cpc Reaction Mass DISTILLATION/MEE manufacturing and scrubber 5000 6917 Ammonium Sulphate 1035 TOTAL 6917 TOTAL 6917
ANNEXURE-6 3. PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1) MANUFACTURING PROCESS FOR PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1) - CPC blue crude is to be charged in concentrated sulphuric acid and agitated in a suitable reactor in order to make a homogeneous mass. - The above reaction mass is to be drown slowly into ice cold water in a rubber lined brick lined reactor. - After 2 hours stirring, the slurry is to be filtered in a filter press and washed with water. - The filtrate, such obtained of around 30% to 40% Sulphuric Acid which is used in the manufacturing process of CPC Blue. - while the press cake from the filter press is unloaded and processed further by neutralizing them along with dispersing agent / additives and caustics soda to attain the highest color value and chemical properties like light fastness, chemical resistance and heat stability. - Such treated reaction mass (pigment slurry) is to be filtered in a filter press, washed with water and press cake is unloaded and dry in Dryer/SFD. - Finally, pigment Alpha Blue (Blue 15.0 & 15.1) is classified, Blended and packed in HDPE Bags/drums.
ANNEXURE-6 PROCESS FLOW DIAGRAM OF PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1) 98% H 2SO 4 CPC Blue Crude Reaction Vessels Water Drowning Vessel Filtration Washing Dilute H2SO4 30% to 40% Chill Water Dilute H 2SO 4 collection tank for CPC Blue TO ETP DRYER/SFD Pulverizing Packing
ANNEXURE-6 MATERIAL BALANCE FOR PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1) Input Kg Output Kg CPC blue crude 1111 Sulfuric acid(98%) 4000 REACTOR-1 Reaction mass 5111 Total 5111 Total 5111 Input Kg Output Kg Reaction Mass 5111 Reaction mass 9555 Chilled water 4444 DROWING Total 9555 Total 9555 Input Kg Output Kg Reaction mass 9555 Wet cake 2255 FILTER PRESS Dilute H2SO4 to CPC Water 6000 plant(30% to 40%) 13300 Total 15555 Total 15555 Input Kg Output Kg Reaction mass 2255 Reaction mass 2356 Dispersing agent/additives 1 REACTION VESSEL Caustic Flakes 100 TOTAL 2356 TOTAL 2356 INPUT KG OUTPUT KG Reaction mass 2356 WET CAKE 2255 FILTER PRESS AND water for washing 16900 EFFLUENT TO ETP 17001 WASHING TOTAL 19256 TOTAL 19256 Input Kg Output Kg Wet cake 2255 Alpha blue 1000 SFD/DRYER Evaporation loss 1255 TOTAL 2255 TOTAL 2255 PULVERISING & PACKING
ANNEXURE-6 4. ACTIVATED CPC BLUE (ONLY GRINDING PROCESS) MANUFACTURING PROCESS FOR ACTIVATED CPC BLUE CPC Blue Crude is to be charged with salt in the grinding mill. Where sheering, hammering and grinding process occurs and as a result finest particles of Activated CPC Blue is obtained, which is called Activated CPC Blue. In this process by which desired particles shape and size are attained. In this way after the physical process, such obtained Activated CPC Blue is to be discharged from the grinding mill and packed in HDPE Bags/Drums. PROCESS FLOW DIAGRAM FOR ACTIVATED CPC BLUE 1. CRUDE CPC BLUE 2. COMMON SALT BALL MILL ACTIVATED CPC BLUE PACKING
ANNEXURE-6 MATERIAL BALANCE FOR ACTIVATED CPC BLUE (GRINDING PROCESS) INPUT KG OUTPUT KG CPC Crude 1000 Activated CPC Blue 1100 BALL MILL Common salt 100 TOTAL 1100 TOTAL 1100 5. PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) (ONLY GRINDING PROCESS) MANUFACTURING PROCESS OF PHTHALOCYANINE BETA BLUE (ONLY GRINDING PROCESS) - CPC Blue Crude is to be charged in the grinding mill. Where sheering, hammering and grinding process occurs and as a result finest particles of pigment beta Blue is obtained, which is called Pigment Beta Blue. - In this process no chemical process or reaction is involved but it is a physical process by which desired particles shape and size are attained. - In this way, after the physical process, such obtained Beta Blue is to be discharged from the grinding mill and packed in HDPE Bags/Jambo. PROCESS FLOW DIAGRAM FOR PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) (ONLY GRINDING PROCESS) BALL MILL CPC BLUE CRUDE FINISHED PRODUCT
ANNEXURE-6 MATERIAL BALANCE OF PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) (ONLY GRINDING PROCESS) INPUT KG OUTPUT KG Pthalocyanine Beta Blue(only grinding BALL MILL CPC Crude 1000 process) 1000 TOTAL 1000 TOTAL 1000 6. PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) MANUFACTURING PROCESS FOR PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) CPC Blue Crude, is used for manufacturing of Beta blue. It is taken into Ball mill with salt for grinding. Here the particle size of the material gets reduced. Then the grinded material is taken into the reactor with Caustic Flakes. Caustic flakes are used to get alkaline ph. The alkaline ph results in better dispersion of particles for pigmentation. The mass is refluxed for pigmentation. Here the colour of the material gets enhanced due to fine tuning with IBA/xylene. This is only a physical process and does not involve any chemical reaction. After completion of reflux, the mass is distilled for recovery of IBA/xylene. After recovery of IBA/xylene, the mass is neutralized with hydrochloric acid to increase the particle size of beta blue. The whole mass is filtered and washed by water in filter press. Generated effluent from the filter press will be sent to ETP. Wet cake from filter press is dried in dryer/sfd. Dried cake is the pulverized and packed for dispatch.
ANNEXURE-6 CHEMICAL REACTION FOR PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4)
PROCESS FLOW DIAGRAM FOR PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) ANNEXURE-6 CPC Blue Salt Ball Mill IBA/Xylene Caustic Flakes Reflux/ Pigmentation Water Distillation Recovered IBA/Xylene HCl ph Adjustment Water Filtration & Washing TO ETP Dryer/SFD Pulverizing Packing Dispatch
ANNEXURE-6 MATERIAL BALANCE FOR PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) Input Kg Output Kg copper phthalocyanine Blue 1030 BALL MILL Reaction mass 1130 Salt 100 Total 1130 Total 1130 Input Kg Output Kg Mass 1130 Mass 3461 Dilute HCL 20 Caustic soda flakes 11 Water 1800 REACTION VESSEL IBA/Xyalene 500 Total 3461 Total 3461 Input Kg Output Kg Mass 3461 Mass 3281 live Steam 320 DISTILLATION Recovered IBA/Xylene 490 Atmosphere solvent loss 10 Total 3781 Total 3781 Input Kg Output Kg Mass 3281 Mass 2730 Water for washing 4930 FILTER PRESS Effluent to ETP 5481 Total 8211 Total 8211 Input Kg Output Kg Mass 2730 Pigment Beta Blue 1000 DRYER/SFD Evaporation loss 1730 Total 2730 Total 2730 PULVERIRE & PACKING
ANNEXURE-6 SOLVENT RECOVERY Solvents to be used: ONT/NB/TCB/ISOL/IBA/XYLENE Vapour Inlet Cooling water Outlet Primary condenser Vapour Inlet Cooling water Outlet Secondary condenser Cooling water Inlet Solvent vapour Cooling water Inlet Reflux line Distribution box Steam Inlet Reactor Vessel Steam Outlet Receiver Vessel
7 MANUFACTURING PROCESS OF COPPER SALT Manufacturing Process :- ANNEXURE-6 During the manufacturing process of CPC blue acidic filtrate is generated which will be sent into copper recovery system for recovery of copper salt. MATERIALBALANCE OF COPPER SALT:- Input Kg Output Kg Acidic filterate from CPC blue 2500 COPPR RECOVERY Copper salt 8.0 SYSTEM Acidic filtrate to amonium sulfate plant 2492 Total 2500 Total 2500
ANNEXURE-7 BRIEF DESCRIPTION OF GENERATED EFFLUENT FROM CPC BLUE During the manufacturing of CPC blue two types of stream are generated. 1) Acidic filtrate(ml) 2) Acidic washing water 1) Generated acidic filtrate is collected in collection tank and sent to ammonium salt manufacturing plant after copper recovery. 2) Generated acidic washing water is neutralized with lime into neutralization tank. After neutralization, treated effluent is sent to MEE for further treatment. During the neutralization process ETP waste is generated, which will be sent to TSDF site and generated MEE salt is also sent to TSDF site. MEE condensate will be reused into process. BRIEF DESCRIPTION OF GENERATED EFFLUENT FROM BETA BLUE, ALPHA BLUE AND OTHERS -Generated effluent form the beta blue, alpha blue and others (Boiler blow-down, Cooling tower blow-down, Soften water blow down etc) is neutralized with lime into neutralization tank and send into RO for further treatment. -During the neutralization generated sludge will be sent to TSDF site. -RO permeate will be recycled in process and RO rejected will be treated in conventional ETP. -After treatment in conventional ETP, treated effluent will be sent to NCTL through GIDC underground drainage system. ETP UNITS: Particulars No. Capacity in m 3 Oil and Grease Tank 1 6.9 Equalization/Neutralization Tank 2 72.8 Primary Settling Tank 1 47.2 Filter press 2 36x36 Aeration Tank 1 350 Secondary Settling Tank 1 52.8 Secondary Treated Collection Tank 1 22.5 Treated Water Tank 1 22.5 Pressure Sand Filter 1 1.5 Pressure Carbon Filter 1 1 Holding Tank 4 90 Final Discharge Tank 1 150 Multi Effect Evaporator 1 100 KL Copper recovery system 1 -- RO (2 stages) 1 200 + 100 KL
ANNEXURE-7 ETP FLOW DIAGRAM GENERATED SLUDGE TO TSDF SIDE COLLECTION CUM NUTRALAZINE TANK 1 2 FILTER PRESS MEE COLLECTION TANK (HOLDING TANK) 4 Nos. 2-Stage RO AERATION TANK RO reject SST TERTIARY TREATMENT FILTER PRESS MEE salt to TSDF GENERATED SLUDGE TO TSDF SIDE Ro permeate to recycle TRATED EFFLUENT STORAGE TANK COPPER RECOVER Y SYSTEM TREATED EFFLUENT TO FETP THROGH GIDC UNDER GROUND DRAINAGE EFFLUENT COMING FROM PLANT
ANNEXURE-7 CHARACTERISTIC OF EFFLUENT Sr. No. 1. ph Parameters 2. T.S.S in mg/l Before Treatment (at the ETP inlet) mg/l After Treatment (at the ETP outlet & FETP inlet) mg/l 0-2 6.5-8.0 6.5-8.5 200-250 100 ---- Standard Norms prescribed (FETP Inlet norms) mg/l 3. C.O.D. in mg/l 700-1000 < 300 1000 4. Ammonical Nitrogen in ppm <75 < 25 75
ANNEXURE-8 Sr. No Particulars DETAILS OF WATER CONSUMPTION Existing Water Consumption KL/Day (As per CCA- 73496 AWH ) Proposed Water Consumption KL/Day (As per proposed expansion) Total Water Consumption KL/Day Fresh Recycle Fresh Recycle Total Fresh Recycle Total 1. Domestic 2.5 --- 2.5 0 2.5 5 0 5 2. Gardening / Other use 0.5 --- 1.5 0 1.5 2 0 2 INDUSTRIAL WATER CONSUMPTION 3. Process 55.87 45.72 9.53 308.88 318.41 65.4 354.6* 420 4. Boiler 12 --- 10 0 10 22 0 22 5. Cooling 16.8 --- 13.2 0 13.2 30 0 30 6. Equip. & Floor Washing 7. Softener back wash Total (Industrial) TOTAL (Domestic + Industrial +Gardening) 2 --- 2 0 2 4 0 4 1 --- 1 0 1 2 0 2 87.67 45.72 35.73 308.88 344.61 123.4 354.6 478 136.39 (Fresh water=90.67+ Recycle water=45.72) 348.61 (Fresh water=39.73 + Recycled Water=308.88) 485 (Fresh water=130.4 + Recycled water=354.6) *Breakup of KL/Day : 354.6 KL/Day Recycle from MEE/RO : 237.6 KL/Day Internal Recycle (during the mfg of ammonium sulfate) : 117.0 KL/Day
ANNEXURE-8 Sr. No. Particulars DETAILS OF WASTE WATER GENERATION Existing Waste Water Generation KL/Day (As per CCA AWH -73496) Proposed Waste water Generation KL/Day Total Waste Water Generation after expansion KL/Day 1. Domestic 1 1 2 2. Industrial Process & Process washing 34 246 280 Boiler 2.5 0 2.5 Cooling 1.5 0 1.5 Equip. & Floor 2 2 4 Washing Softener back wash 1 1 2 Total Industrial 41 249 290 TOTAL (Domestic + Industrial) 42 250 292* *Existing industrial waste water discharge permission of the unit is 42 KL/Day which will be continued after proposed expansion.due to the proposed expansion additional effluent generation will be 250 KL/Day from which 9 MTD sludge and 3.4 MTD MEE salt will be generated. Unit will dispose it at available TSDF site. So due to the proposed expansion additional waste water generation will be 237.6** KLD which will be reused by the unit after treatment. **237.6 KLD WATER BIFURCATION:-1) 96.6 KLD MEE Condensate 2) 141.0 KLD RO permeate*** ***Unit is having booked permission of discharge into NCTL is 183 KLD. Unit will send this RO (additional 141 KLD) permeate into NCTL when NCTL will start to take our additional effluent as per booked quantity.
WATER BALANCE DIAGRAM & WASTE WATER GENERATION DIAGRAM TOTAL WATER REQUIREMENT (130.4 KL/DAY GIDC FRESH WATER+237.6 FROM RO&MEE+117 INTERANAL RECYCLE TOTAL PROCESS WATER (420 KLD) (65.4 FRESH+237.6 FROM RO&MEE+ 117 INTERNAL RECYCLE BOILER (22KLD FRESH Makeup) SOFT EN WATER (02 KLD) COOLING TOWER (30KLD) WASHING (04 KLD) GARDENING (02 KLD) DOMESTIC (05 KLD) Effluent generation from CPC (105 KLD) Effluent generation from Alpha and Beta (175 KLD) Internal recycle* (117 KL/DAY) LOSS (19.5 KLD) (02 KL/DAY) LOSS (28.5 KL/Day) LOSS (3 KL/Day) Primary Treatment (105 KLD) Sludge to TSDF (5 MTD) BLOW DOWN (2.5KL/DAY) BLOW DOWN (1.5KL/DAY) WASHING (04KL/DAY) MEE (100 KLD) (02 KL/Day) MEE permeate (96.6 KLD) MEE Salt (3.4 MT/Day) 2-STAGE RO (183 KLD) PRIMARY TREATMENT (187 KLD) Sludge (4 MTD) RO permeate 141 KLD RO rejected to ETP 42 KLD TREATED EFFLUENT TO FETP THROGH GIDC UNDER GROUND DRAINAGE (42 KL/DAY)
ANNEXURE 9 FUEL CONSUMPTION SR. FUEL QUANTITY QUANTITY TOTAL NO (As per current CCA- AWH-73496) (As per proposed expansion) 1. Natural Gas 8000 NM 3 /Day 2000NM 3 /Day 10000 NM 3 /Day 2. LDO/Diesel 400 Lit/Day 1600Lit/Day 2000 Lit/Day 3. Coal/Briquette --- Coal=6 TPD OR Coal=6 TPD OR Briquette=10 Briquette=10 TPD TPD POWER CONSUMPTION SR. NO POWER QUANTITY (As per current CCA- AWH-73496) QUANTITY (As per proposed expansion) TOTAL QUANTITY 1. Electricity 1900 KVA 2100 KVA 4000 KVA
ANNEXURE 10 LIST OF HAZARDOUS CHEMICALS Sr. List of Hazardous Chemicals No. 1. Phthalic anhydrides 2. Cuprous Chloride 3. Sulfuric acid 4. Xylene/IBA 5. ONT/NB/ISOL/TCB 6. Caustic Soda Lye/Flakes 7 Carbamide salt/nh3 gas 8 HCl M/S. SUBHASRI PIGMENTS PVT. LTD., ANKLESHWAR
ANNEXURE-11 HAZARDOUS WASTE GENERATION Sr. No. 1. ETP Sludge Waste Category Quantity/ Year (As per CCA- AWH-73496 Existing) 2. Discarded Bags/Liners, Discarded Container 3. Used/ Spent Oil Quantity/ Year (As per Proposed Expansion) 35.3 72-0 MT/Year 2500 MT/Year 5.1 24,000 Nos/Year 10000 Nos/Year 33.1 0.06 KL/Year 0.02 KL/Year Total 3220 MT/Year 34000 Nos/Year 0.08 KL/Year Facility Collection, storage, transportation, disposal at TSDF- BEIL Collection, storage, and decontamination Collection, storage, transportation, disposal by selling to register re-refiner or lubrication for nut bolt. 4. MEE Salt 35.3 1224 MT/Year -- 1224 MT/Year Collection, storage, transportation, Disposal by sell or by send to TSDF site. M/s. Jyoti Om Chemical Research Centre Pvt Ltd
ANNEXURE-12 Sr. No. Stack Attached To FLUE GAS EMISSION Stack Height (m) AS PER CCA No:-AWH-73496 1. Boiler (IBR)(4TPH) 2. 3. 4. Thermic Fluid Heater (2 Nos) (10 Lac Kcal/Hr) D.G.Set (For emergency use only)(125 KVA) Fuel Consumption APCM 11 Natural gas ---- 11 (for each) Natural gas ---- 9 Diesel ---- Boiler (IBR) (6 TPH) 21 Coal/Briquette Multi cyclone separator, Bag filter and Water scrubber AS PER PROPOSED EXPANSION D.G.Set (For 5. emergency use only) (600 KVA) 09 Diesel ---- Type of Emission PM SO2 NOx PM SO2 NOx PM SO2 NOx PM SO2 NOx PM SO2 NOx Permissible Limit 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 6. Thermic Fluid Heater (2 Nos) (10 Lac Kcal/Hr) 11 for each Natural gas ---- PM SO2 NOx 150mg/NM 3 100 PPM 50 PPM
ANNEXURE-12 AFTER PROPOSED EXPANSION Sr. No. 5. 3. 4. Stack Attached To 1. Boiler (IBR)(4TPH) 2. Thermic Fluid Heater (2 Nos) (10 Lac Kcal/Hr) D.G.Set (For emergency use only)(125 KVA) Stack Height (m) Fuel Consumption APCM 11 Natural gas ---- 11 (for each) Natural gas ---- 9 Diesel ---- Boiler (IBR) (6 TPH) 21 Coal/Briquette D.G.Set (For emergency use only) (600 KVA) Multi cyclone separator, Bag filter and Water scrubber 09 Diesel ---- Type of Emission PM SO 2 NOx PM SO 2 NOx PM SO 2 NOx PM SO 2 NOx PM SO 2 NOx Permissible Limit 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 150mg/NM 3 100 PPM 50 PPM 6. Thermic Fluid Heater (2 Nos) (10 Lac Kcal/Hr) 11 for each Natural gas ---- PM SO 2 NOx 150mg/NM 3 100 PPM 50 PPM
ANNEXURE-13 As per Existing CCA No.: AWH-73496 PROCESS GAS EMISSION Sr. No. APCM attached to 1 Spin Flash Dryer (2 Nos) (2 stack) 2. Stack attached with Reactors (1 common stack) For Proposed Expansion 3 Stack attached with Reactors (1 common stack) 4. Spin Flash Dryer (2 Nos) (2 stack) Stack Height APCM Pollutant Remarks 11 for each Bag Filter for each PM 150 mg/nm 3 16 Water scrubber NH 3 175 mg/nm 3 16 Water scrubber 11 for each Bag Filter for each NH3 175 mg/nm 3 PM 150 mg/nm 3
ANNEXURE-13 PROCESS GAS EMISSION AFTER PROPOSED EXPANSION Sr. No. APCM attached to 1 Spin Flash Dryer (2 Nos) (2 stack) 2. Stack attached with Reactor (1 common stack) 3 Stack attached with Reactor (1 common stack) 4. Spin Flash Dryer (2 Nos) (2 stack) Stack Height APCM Pollutant Remarks 11 for each Bag Filter for PM 150 mg/nm 3 each 16 Water scrubber NH 3 175 mg/nm 3 16 Water scrubber NH3 175 mg/nm 3 11 for each Bag Filter for PM 150 mg/nm 3 each