ANNEXURES Sr. Content...

ANNEXURES

Sr.

No.

Content

1 List of products with production capacity and raw materials

2 Plot layout

3 Brief manufacturing process, chemical reaction and mass balance

4 Details of water consumption and waste water generation

5 Details of effluent treatment plant

6 Details of hazardous/solid waste generation, management and disposal mode

7 Details of air pollution sources and control measures

8 Details hazardous chemical storage facility

9 Socio - Economic impacts

10 Proposed Terms of References

11 GIDC Plot Allotment Letter

12 GIDC Water Supply Letter

13 Toposheet

ANNEXURE-I

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr.

No.

Name of the

Products CAS no. /CI no.

Quantity

MT/Month End-use of products

1 Acid Green-16 12768-78-4

15

Textile Industries &

Lather Industries, Ink

Industries, etc.

2 Acid Red-52 3520-42-1

3 Acid Blue-1 116-95-0

4 Acid Blue-7 3486-30-4

5 Acid Blue-9 2650-18-2

50 6 Acid Blue-15 5863-46-7

7 Acid Violet-17 4129-84-4

8 Acid Violet-49 1694-09-3

TOTAL 65

RAW MATERIAL CONSUMPTION:

Sr.

no.

Name of the

Products

Name of the Raw

Materials CAS no. /CI no.

Quantity

MT/Month

1 Acid Green-16

Naphthalene 91-20-3 4.17

Sulfuric acid 7664-93-9 10.94

Soda 1310-73-2 10.8

DEA 127-19-5 6.25

Formaldehyde (37%) 50-00-0 2.3

sulphanilic acid 121-57-3 0.1

MnSO2 7785-87-7 4.17

Sodium Dichromate 7789-12-0 1.15

Oxalic Acid 6153-56-6 1.7

Salt 7647-14-5 5.21

2 Acid Red-52

Benzaldehyde

disulfonic acid 88-39-1 0.7

Diethyl meta

aminophenol 91-68-9 0.9

H2SO4 98% 7664-93-9 3.8

Salt 7647-14-5 4.4

Soda 1310-73-2 0.07


HCl 30 % 7647-01-0 1

3 Acid Blue-1

Benzaldehyde

disulfonic acid 1008-72-6 4.8

Diethyl aniline 91-66-7 5.3

H2SO4 98% 7664-93-9 7.15

Soda ash 1310-73-2 1

Sodium Sulfate 7757-82-6 11

Dichromate 7778-50-9 1

4 Acid Blue-7

Benzaldehyde

disulfonic acid 1008-72-6 4

Ethyl benzyl aniline 92-59-1 6.4

H2SO4 98 % 7664-93-9 6.8

C.Lye 1310-73-2 4.44

Sodium Sulfate 7757-82-6 2.12

Acetic Acid 64-19-7 2.84

Lead peroxide 1309-60-0 2.52

MnSO4 10034-96-5

Salt 7647-14-5 12.4

5 Acid Blue-9

Ethyl Benzyl Aniline

Sulfonic Acid 101-11-1 11.10

Ortho Benzaldehyde

sulfonic acid 1008-72-6 3.99

Soda ash 1310-73-2 2.40

H2SO4 98% 7664-93-9 4.79

Oxalic Acid 6153-56-6 2.60


Salt 7647-14-5 21.88

6 Acid Blue-15

Ethyl benzyl aniline

sulfonic acid 101-11-1 55

Di ethyl meta toluene 91-67-8 10.42

C.Lye 1310-73-2 5.6

Copper sulphate 7758-99-8 0.9

Sodium thiosulphate 7772-98-7 6.25

7 Acid Violet-17


sulfonic acid 101-11-1 75

C.Lye 1310-73-2 7.7

Formaldehyde 50-00-0 7


Di ethyl Aniline 91-66-7 12.7

hydrogen peroxide 7722-84-1 8.7

8 Acid Violet 49


sulfonic acid 101-11-1 76.5

C.Lye 1310-73-2 8

Formaldehyde 50-00-0 7


Di methyl Aniline 91-66-7 11.8

hydrogen peroxide 7722-84-1 9

ANNEXURE-II

PLANT LAYOUT

ANNEXURE-III

MANUFACTURING PROCESS DESCRIPTION

1. Acid Green 16:

Manufacturing Process:

In M.S. reactor Naphthalene and Sulphuric Acid is mixed for reaction. Then add soda ash and

filter it. Wet cake formed is Naphthalene Disulfonic Acid will be used for further procedure and

effluent goes to ETP. Now in another M.S lead bonded jacketed vessel take Diethyl aniline,

formaldehyde and sulphanilic acid. Add Soda ash to this mass and filter it. Effluent goes to ETP.

Now mix this wet cake with previously prepared wet cake of Naphthalene Disulfonic Acid, also

add water and sulphuric acid. Once this mass is oxidized using water, Sodium dichromate, oxalic

acid, sulfuric acid and soda ash; it is salted with common salt and filtered. Wet cake obtained

now is dried in dryer, pulverized in ball mill as per required standard and packed for sale.

Chemical Reaction:

Mass Balance:

Stage-1

Input Qty (kg) Output Qty (kg)

Naphthalene 40 Naphthalene di Sulphuric acid 44

Sulfuric acid 50 Effluent 109

Soda 63

Total 153 Total 153

Stage-2


DEA 60 Filtrate 198

Formaldehyde (37%) 22 Effluent 200

sulphanilic acid 1

Water 250

MnSO4 40

Soda 25

Total 398 Total 398

Stage-3


Naphthalene di Sulphuric

acid

44 Stage-3 542

Filtrate 198

Sulfuric Acid 50

Water 250

Total 542 Total 542

Stage-4


Stage-3 542 Product 96

Water 100 Effluent 577

Sodium Dichromate 11 Losses 66

Oxalic Acid 16

Sulfuric Acid 5

Soda 15

Salt 50

Total 739 Total 739

2. Acid Red 52


Benzaldehyde-1, 3-disulfonic acid and diethyl Meta Amino phenol condensation, the products

with sulfuric acid dehydration, and sodium dichromate oxidation, and finally isolated as sodium

salt. Filter it and make slurry and spry dried it.

Chemical Reaction:

Mass Balance:

Stage:1


Water 4000 Stage-1 1500

Benzaldehyde disulfonic

acid

500 Effluent 3830

Diethyl meta aminophenol 650

H2SO4 98% 180

Total : 5330 5330

Stage:2



Stage-1 1500 Effluent 3600

Evaporate 170

Total : 4500 4500

Stage:3




H2SO4 2665

Salt 800

Total : 9195 9195

Stage:4


Water 3200 Acid Red 52 7480


Soda 50

Sodium Dichromate 150

HCl 30 % 730

Salt 2500

Total : 8280 8280

3. ACID BLUE 1


Benzaldehyde-1, 3-disulfonic acid and N,N-diethyl Aniline (2 More) condensation and oxidation

with dichromate, and then turn it into sodium sal. And spray dry it.

Chemical Reaction:

Mass Balance:


Water 6000 Acid Blue 1 1050


acid

500 Effluent 6015

Diethyl aniline 555 Evaporate 2100

H2SO4 98% 750

Soda ash 100

Sodium Sulfate 1155

Dichromate 105

Total : 9165 9165

4. ACID BLUE 7


Benzaldehyde-1, 3-disulfonic acid and N-benzyl-N-Ethyl Aniline (2 more) condensation and

oxidation with lead peroxide in presence of acetic acid, convert into sodium salt and spry dry it.

Chemical Reaction:

Mass Balance:




acid

500 Effluent 5840

Ethyl benzyl aniline 800 Evaporate 2100

H2SO4 98 % 850

C.Lye 555

Sodium Sulfate 265

Acetic Acid 355

Lead peroxide 315

Salt 1550

Total : 9190 9190

5. ACID BLUE 9


Ortho-Benzaldehyde sulfonic acid and ethyl benzyl aniline sulfonic acid (EBASA) condensation,

oxidation with sodium dichromate in presence of oxalic acid, and then the product into the

ammonium salt or sodium salt and spray dry it.

Chemical Reaction:

Mass Balance:


Water+ ICE 2000 Acid Blue 9 6260

Ethyl Benzyl Aniline

Sulfonic Acid

1390 Evaporation loss 1850

Ortho Benzaldehyde

sulfonic acid

500

Soda ash 300

H2SO4 98% 600

Oxalic Acid 325

Sodium Dichromate 255

Salt 2740

Total : 8110 8110

6. ACID BLUE 15


Ethyl benzyl aniline sulfonic acid (EBASA) condensation, and then (a) oxidation as dimer water

molecules (hydrol), again with N-N-diethylmeta toludine condensation, oxidation with

hydrogen peroxide in presence of copper sulphate and translated into sodium salt, spray dry it.

Chemical Reaction:

Mass Balance:




sulfonic acid

3900 Evaporation loss 8360

Di ethyl meta toluene 750

C.Lye 400

Ice 1200

Copper sulphate 60

Sodium thiosulphate 450

Total : 11960 11960

7. ACID VIOLET 17



molecules (hydrol), again with N-N-diethyl Aniline condensation, oxidation with hydrogen

peroxide in presence of copper sulphate and translated into sodium salt, spray dry it.

Chemical Reaction:

Mass Balance:


Water 4950 Acid Violet 17 2600


sulfonic acid

3900 Evaporate 9380

C.Lye 400

Formaldehyde 360

Ice 1200

Copper sulphate 60

Di ethyl Aniline 660

hydrogen peroxide 450

Total : 11980 11980

8. ACID VIOLET 49



molecules (hydrol), again with N-N-dimethyl Aniline condensation, oxidation with hydrogen

peroxide in presence of copper sulphate and translated into sodium salt, spray dry it.

Chemical Reaction:

Mass Balance:


Water 4840 Acid Violet 49 2550


sulfonic acid

3900 Evaporate 9260

C.Lye 400

Formaldehyde 360

Ice 1200

Copper sulphate 60

Di methyl Aniline 600

hydrogen peroxide 450

Total : 11810 11810

ANNEXURE-4

DETAILS OF WATER CONSUMPTION & WASTE WATER GENERATION

SR.

NO.

DESCRIPTION EXISTING

WATER CONSUMPTION

(KL/Day)

WASTE WATER

GENERATION (KL/Day)

1 Process 7.1 4.7

2 Boiler 1 0.1

3 Cooling 1 0.3

4 Washing 0.5 0.5

Total Industrial 9.6 5.6

5 Domestic* 2 1.6

6 Gardening 1 --

Grand Total 12.6 7.2

* Domestic waste water will be disposed through septic tank & soak pit.

Water Balance Diagram:

Source: Water Tanker

Water Requirement: 12.6 KLD

Domestic

2 KLD

Process

7.1 KLD

Cooling

Tower

1 KLD

Gardening

1 KLD

4.7 KLD 0.3 KLD

ETP: 5.6 KLD

Washing

0.5 KLD

0.5 KLD 1.6 KLD

Septic

tank & Soak

Pit

Boiler

1 KLD

0.1 KLD

Spray Dryer: 5.6 KLD

ETP Sludge and Spray

Dryer Sludge to TSDF site

ANNEXURE-5

DETAILS OF ETP, SPRAY DRYER

EFFLUENT TREATMENT PLANT (ETP).

First all wastewater streams of wastewater shall be collected in Collection Cum

Neutralization Tank-01 (CNT-01). where the continuous addition and stirring of Lime

solution is done to maintain neutral pH of wastewater from Lime Dosing Tank (LDT-01) as

per requirement by gravity. Mixer (M-01) is provided at bottom of the CNT-01 to keep all

suspended solids in suspension and to provide proper mixing.

Then after, neutralized wastewater shall be pumped to Filter Press-01 (FP-01) where, Poly

shall be added from Ploy Dosing Tank (PDT-01) with help of Poly Dosing Pump to increase

efficiency of Sludge dewatering. Dewatering of sludge shall be carried out in FP-01 before

storage in HWSA and ultimate disposal to TSDF. Clear effluent from FP-01 shall be collected

in Primary Treated Effluent Sump-01 (PTES-01). Then it will be pumped to Spray Dryer for

further treatment. Solids from SD-01 shall be storage in HWSA and ultimate disposal to

TSDF.

SIZE OF TANKS

S.N

. Name of unit

Size (m x m x

m) No. MOC/ Remark

Flow = 5.6 KLD(Proposed)

1 Collection cum Neutralization Tank-

01 (CNT-01) 10 KL 1 RCC M25

2 Filter Press-01 (FP-01) 5 KL/D 1 MS+PP

3 Treated Effluent Sump-01 (TES-01) 15 KL 1 RCC M25

4 Lime Dosing Tank (LDT-01) 500 lit 1 HDPE

5 Poly dosing Tank (PDT-01) 100 Lit 1 HDPE

6 Spray Dryer (SD-01) 10 KL/D 1 SS316

Process Flow Diagram:

ANNEXURE-6

DETAILS OF HAZARDOUS/SOLID WASTES GENERATION AND DISPOSAL MODE

SR.

NO.

TYPE OF WASTE CATEGOR

Y NO.

QUANTITY

(MT/MONTH)

DISPOSAL MODE

1 ETP Sludge 34.3

15 Collection, Storage, Transportation and sent

to common TSDF site for disposal.

2 Used Oil 5.1 0.1 Collection, Storage, Transportation and sell to

GPCB registered reprocess or/refiner.

3 Discarded

Drums/Container

s /Bags

33.1 10 Collection, Storage, Decontamination,

Transportation & sell to GPCB authorized

Vendor.

4 Spray Dryer Salt 34.3 18 Collection, Storage and sent to common TSDF

site for disposal.

5 Sodium Sulphate

Solution from

Scrubber

26.1 30 Collection, Storage and sell to end users

having Rule 9 Permission.

ANNEXURE-7

DETAILS OF HAZARDOUS CHEMICALS STORAGE AND HANDLING

Power Requirement & Fuel Requirement

Power required from MGVCL will be 60 HP

D. G. Set: 20 HP

Fuel

Imported Coal/PNG Gas/Agro Waste/Bio Coal: 1 MT/Day

HSD: 5 Liter/Hr

Flue Gas Emission:

Sr.

No.

Stack/Vent

attached to

Stack

Height

(meter)

Stack

Diameter

(meter)

Fuel name &

Quantity

Type of

Emission APCE

1. Boiler (0.8 TPH) 12 0.3

Agro waste /

Biofuel

(1 MT/Day) PM

SO2

NOx

Multicyclone

Separator

and Dust

Collector

2

D.G. Set

(Capacity – 20

HP)

11 0.1 Diesel

(5 Liter/hr)

Adequate

Stack Height

Process Gas Emission:

Sr.

No.

Stack/Vent

attached to

Stack

Height

(meter)

Stack

Diameter

(meter)

Type of

Emission APCE

1. Reaction Vessel 11 0.1 SO2

Two Stage

Alkali

Scrubber

ANNEXURE-8

DETAILS OF HAZARDOUS CHEMICALS STORAGE AND HANDLING

Sr.

No.

Name of the material Type of

hazard

Kind of

Storage

Max. Quantity to be

stored (MT)

No. of Tanks drums

or carboys

1 Sulfuric Acid Toxic Drum 5 25

2 Caustic Soda Toxic Drum 3 15

3 Sodium Sulfate Toxic Drum 3 15

4 Caustic Lye Toxic Drum 5 25

5 Di ethyl meta toluene Toxic Drum 4 20

6 Diethyl Aniline Toxic Drum 4 20

7 Hydrogen Peroxide Toxic Drum 3 15

ANNEXURE-10

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement is expected to generate some permanent jobs and secondary jobs

for the operation and maintenance of plant. This will increase direct/indirect employment

opportunities and ancillary business development to some extent for the local population. This

phase is expected to create a beneficial impact on the local socio-economic environment.

2) INDUSTRIES

Require raw materials and skilled & unskilled laborers will be utilized maximum from local area.

The increasing industrial activity will boost the commercial and economical status of the locality,

to some extent.

3) PUBLIC HEALTH

The company will regularly examine, inspects and tests its emission from sources to make sure

that the emission will keep below the permissible limit. Hence, there will not be any significant

change in the status of sanitation and the community health of the area, as sufficient measures

will be taken under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the existing site is having proper linkage for transport and communication, the

development of this project will not cause any additional impact.

In brief, as a result of the proposed expansion project, there will be no adverse impact on

sanitation, communication and community health, as sufficient measures will be proposed to be

taken under the EMP. Hence, proposed expansion project is not expected to make any significant

change in the existing status of the socio - economic environment of this region.

ANNEXURE – 11

PROPOSED DRAFT TERMS OF REFERENCE

1. Project Description

Justification of project.

Promoters and their back ground

Project site location along with site map of 10 km area and site details providing various

industries, surface water bodies, forests etc.

Project cost

Project location and Plant layout.

Infrastructure facilities

Water source and utilization including water balance.

List of Products & their production capacity

Details of manufacturing process of products

List of hazardous chemicals

Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5 km

area.

Other industries in the impact area

Prevailing environment quality standards

Existing environmental status vis a vis air, water, noise, soil in 10 km area from the project site.

Ground water quality at 5-6 locations within 10 km.

Complete water balance

3. Socio Economic Data

Existing socio-economic status, land use pattern and infrastructure facilities available in the study

area were surveyed.

4. Impacts Identification and Mitigatory Measures

• Identification of impacting activities from the proposed expansion project during construction

and operational phase.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Hazardous/Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including

6. Risk Assessment

• Objectives, Philosophy and methodology of risk assessment

• Details on storage facilities

• Process safety, transportation, fire fighting systems, safety features and emergency capabilities to

be adopted.

• Identification of hazards

• Consequence analysis

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Information on Rain Water Harvesting

9. Green Belt Development plan

ANNEXURE – 12

COPY OF LAND POSSESSION / PLOT ALLOTMENT DOCUMENT

CERTIFICATE FOR THE LAND USED FOR INDUSTRIAL PURPOSE.

ANNEXURE – 13

COPY OF COMMON TSDF MEMBERSHIP LETTER

ANNEXURE – 14

GOOGLE MAP

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