ADDITIONAL DOCUMENTS - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/FormB/TOR/Additional... · 9.5 - 10.0% sulfur dioxide gas. Air required for combustion

ADDITIONAL DOCUMENTS

Annexure 1: Production Details

S. No.

Name of Products Production capacity in MT/M

Existing Proposed Total

1 98% Sulfuric Acid, 25%-65% Oleum, Liquid

SO3 & Liquid SO2 3900 6000 9900

2 Di Methyl Sulphate (DMS) 0 2000 2000

3 70% sulfuric Acid (Co-product) 0 100 100

Total 3900 8100 12000

Annexure 2: Existing consolidated consent and authorization (CC & A)

Annexure 3: Amended consolidated consent and authorization (CC & A)

M/S. AMAL LTD. ADDITION OF NEW PRODUCTS AND EXPANSION OF EXISTING

PRODUCTS IN SULFURIC ACID PLANT AT GIDC ANKLESHWAR FORM I

KADAM ENVIRONMENTAL CONSULTANTS |MAY 2017 10

Annexure 4: Site Location Map




Annexure 5: Project Boundary Map




Annexure 6: Site Layout Map

M/S. AMAL LTD.

ADDITION OF NEW PRODUCTS AND

EXPANSION OF EXISTING PRODUCTS

IN SULFURIC ACID PLANT AT GIDC

ANKLESHWAR FORM I


Table 1: Area Break up at Site

S. No.

Title Area, m2 % of total Area

1 Processing Area (Sulphur Melter, MCC & Control Room 159.29 0.31

2 Storage Area( Sulphar storage, Liq. SO2 cylinder filling storage area, SO2, Engineering Store)

1649.34 3.16

3 Utility Building, GEB Substation, Toilet Block, Compressor Room, Mechenical Work shop, Electrical Room, Blower, D.M Water Plant

733.71 1.41

4 Solid Hazardous Waste Area 12.25 0.02

5 Water Reservoir 111.72 0.21

6 Effluent Treatment Plant 500.00 0.96

7 Cooling tower RCC basin 42.82 0.08

8 Cooler Catch Basin 148.49 0.28

9 DG Sets (D.G.Room, D.G.shed) 327.17 0.63

10 U.G Condensate Tank, Tank Farm 703.14 1.35

11 Lorry Filling Tank 39.14 0.08

12 SO2 Tonner Loading Facility 110.00 0.21

13 Roads 5592.37 10.73

14 Administrative Building 209.48 0.40

15 Greenbelt Area 5214.06 10.00

16 Area for proposed Expansion 36587.65 70.17

Total 52140.623 100.00

M/S. AMAL LTD.




ANKLESHWAR FORM I


Annexure 7: Manufacturing Processes

1(i): 98% Sulfuric Acid

Raw Material: Sulfur, compressed Air, Water

Process Description: The Sulfuric Acid Plant is based on the Double Contact and Double Absorption process. The three main steps of this process are:

Combustion of Sulfur to produce Sulfur Dioxide gas (S + O2 SO2)

Conversion of Sulfur Dioxide gas to Sulfur Trioxide gas in the presence of vanadium pentoxide catalyst (S O2 + 1/2 O2 SO3)

Absorption of Sulfur Trioxide in Sulfuric Acid solution and reaction of water with Sulfur Trioxide to form Sulfuric Acid (SO3 + H2O H2S O4)

The four main sections of the plant are the Sulfur section, Gas section, Acid section and Heat Recovery section.

Sulfur section: This section consists of melting pit, filter pump chamber and pumping pit. Solid sulfur is

fed into the melting pit. The melting pit is provided with steam coils and an agitator. Here sulfur is melted

under agitation by steam at 5 kg/cm2g pressure. Molten sulfur overflows to the filter pump chamber. Filter

pump chamber contains steam coils and sulfur filter pump. This pump delivers dirty sulfur through sulfur

filter. Clean and filtered sulfur is sent to pumping pit. The pumping pit is provided with three metering

pumps which pump molten sulfur into the furnace.

Gas section: Combustion of molten sulfur is carried out in furnace in the presence of dry air to produce

9.5 - 10.0% sulfur dioxide gas. Air required for combustion is supplied by main air blower and then passed

through drying tower (DT) to remove moisture content in the air. Hot combustion gases from the furnace

are cooled down by waste heat boiler # 1 (WHB1) to auto ignition temperature of catalyst before feeding it

to the first pass of the converter.

The conversion of SO2 to SO3 is an exothermic oxidation reaction and is carried out in the presence of

vanadium pentaoxide catalyst in a four/five pass converter. The extent of the reaction is limited by gas

temperature rise and by the formation of SO3. The extent of efficiency of conversion is increased by

carrying out the reaction in successive passes with partial cooling between passes. The SO2 to SO3

conversion is further optimized by providing intermediate absorption stage for the removal of SO3 formed

in the first three passes of the converter and thus making conditions more favorable for the final

conversion in the fourth/fifth pass.

Heat generated due to conversion of SO2 to SO3 in first and second pass is removed in 3 in the circulating

stream of 98% sulfuric acid. Gas from IPAT is heated to the reaction temperature in HE3 followed by HE2

before feeding to fourth pass. Heat generated in the fourth pass is recovered in economizer # 2 (Eco2).

Now, the gas is passed through final absorption tower (FAT) to absorb SO3 generated in fourth pass.

Residual gases from FAT are scrubbed in scrubber and then vented to atmosphere through the stack.

Acid section: Acid section consists of a common acid circulation tank (Acid CT), a common acid circulation

pump (Acid CT pump) and an acid plate heat exchanger (Acid PHE). Hot acid from the acid CT is pumped

by acid CT pump through acid PHE, where water is used as the cooling media. Cooled acid is then

circulated through IPAT and FAT for absorption of SO3from the converter gas and through DT for the

removal of moisture from atmospheric air. Outlet acid from IPAT and FAT becomes concentrated due to

formation of sulfuric acid by the reaction of SO3and H2O while, outlet of DT becomes diluted due to

addition of moisture from the air.

M/S. AMAL LTD.




ANKLESHWAR FORM I


Acid concentration in acid CT is automatically controlled by addition of soft water to acid CT. Level in acid

CT is maintained by tapping out the acid into acid storage tanks (acid ST) at regular intervals.

Heat recovery section: Heat of combustion produced in furnace and heat of reaction produced in

converter is utilized to generate steam at 20-30 kg/cm2g pressure. DM water from boiler feed water tank is

pumped to Eco1 where it is preheated and then send to Eco2 where it is further heated. This preheated

water from Eco2 is fed to WHB1 and WHB2 where steam is produced which is again heated in super-

heater. Part of the steam is passed through pressure regulating valves to reduce steam pressure for

utilization in sulfur melting and the excess steam is supplied to various sections.

Process Flow Diagram:

Table 2: Material Balance of 98% Sulfuric Acid

S.

No.

INPUT/MT of Product

Raw Materials Quantity (kg)

1 Sulfur 0.34

2 Water (Process) 0.185

3 Air (oxygen) 0.475

4 Steam 0.415

Total 1.415

S.

No.

OUTPUT/kg of Product

Remark Components

Liquid

Effluent

Air

Emission

Recovery/

Product

Solid

Waste

1 Eq. Sulfuric acid 1 Product

2 effluent 0.015

3 evaporation loss 1.0

4 steam 0.4

Total 0.015 1.4 1

1.415

H2So4

H2O

Solid SulfurO2

Sulfur Dioxide (So2)

Sulfur Trioxide (So3)

1/2 O2

Vanadium Pentoxide

Cristal

M/S. AMAL LTD.




ANKLESHWAR FORM I


1(ii): 25%-65% Oleum

1(iii): Liquid SO3

Process Description:

Sulphur trioxide gas from the steam heated Oleum Boiler is fed to a vertical shell and tube falling type

Condenser. The sulphur trioxide gas is on the shell side and the water from the cooling tower is falling

over the walls of tubes. This is specially designed from the safety point of view. Here the gas is cooled by

cooling water with the temperature not exceeding 280 C to 320 C. The outlet temp should not exceed 350

C to 400 C. The excess pressure with non-condensable of gases will be released by a scrubber irrigated

with sul acid from the plant. This will prevent any air pollution from the system.

The liquid sulphur trioxide from the condenser is taken to the any of the storage tanks. Storage tanks are

providing with hot water in jacket to maintain the temp. Steam tracing is provided to the liquid sulphur

trioxide line.

From the storage tanks lorry filling is carried out by tanker filling line with flexible hose made from S S wire

braided Teflon hose.

Vents from storage tanks as well as Tanker is connected to scrubber irrigated with Sulphuric Acid. A

flexible corrugated PTFE braided by stainless steel hose is connected from the tank lorry to the scrubber

for preventing any pollution during lorry filling operation.


M/S. AMAL LTD.




ANKLESHWAR FORM I


Liquid SO2

Process Description:

The main Reaction for production of liquid SO2 is S+ 2SO3 3 SO2

Sulphur trioxide gas from the SO3 generator is led to a vertical shell & tube ‘falling film’ type SO3

condenser. The liquid SO3 from the condenser will go to the jacketed storage tank.

Bright yellow solid sulphur is charges into day tank and liquefied. This liquid sulphur and liquid SO3 are

pumped in the reactor by using metering pumps. Reactor is to be initially charged with Oleum from the

storage tank.

The reaction of liquid SO3 and molten sulphur is carried out under a pressure of 6-8 kg/cm2 in a special

reactor. The exothermic heat of reaction during production of sulphur dioxide is removed by circulating

cold water through the jacket of the reactor. The SO2 gases are then passed through polishing towers in

which lumps of solid sulphur react with unreacted sulphur trioxide. The gases then subsequently passed

through spargers for removal the acid mist if any.

Pure sulphur dioxide is then condensed in water cooled condenser and then stored in SO2 Receivers. The

liquid SO2 from the Receivers is then filled up in cylinders (of 900 kg.capacity) for sale.

Main reaction is very fast hence the volume of the reactor is very small. However safety valve and rupture

disc are provided for releasing any excess pressure vent line of safety valves & rupture disk is connected

with existing intermediate absorption tower of existing sulphuric acid plant.

The reactor agitator shaft is provided with proper gland seal to ensure leak free operation.


H2O

Solid SulfurO2

Sulfur Dioxide (So2)

Sulfur Trioxide (So3)

1/2 O2

Vanadium Pentoxide

Cristal

M/S. AMAL LTD.




ANKLESHWAR FORM I


2. Dimethyl Sulfate with Co- Product 70% Sulfuric acid

Raw Material: Methanol, Sulfur Trioxide & Alumina Catalyst

Process Description: Methanol is vaporized in a vaporizer and these vapors of Methanol is passed

through a converter containing Alumina catalyst at elevated temp and this methanol gets converted to Di

Methyl Ether and it is sulphonated with SO3 to get technical Di Methyl Sulphate ( 95%) which is purified by

vacuum distillation to get pure DMS. Bottom product is Sulphuric acid having 25-30% dimethyl sulphate.

Chemical Reaction:

2CH3OH CH3-O-CH3 + H2O

Methanol

Mol wt-32*2

DME

Mol wt-46

Water

Mol wt-18

CH3-O-CH3 +

SO3

H2SO4

CH3-SO4-CH3 + H2SO4

DME

Mol wt-46

Sulpur Trioxide

Mol wt-80

DMS

Mol wt-126


Sulfur Dioxide (So2)1/2 O2

O2 Solid Sulfur

Vanadium Pentoxide

Cristal

1/2 O2 Sulfur Dioxide (So2)

H2O Sulfur Trioxide (So3)

M/S. AMAL LTD.




ANKLESHWAR FORM I


Table 3: Material Balance of Dimethyl Sulphate

S.

No.

INPUT/MT of Product

Raw Materials Quantity (kg)

1 Methanol 0.525

2 Sulphur trioxide 0.68

3 Alumina catalyst 0.00006

8 Water 2

Total 3.2

S.

No.

OUTPUT/kg of Product

Remark Components

Liquid

Effluent

Air

Emission

Recovery/

Product

Solid

Waste

1 Product 1 Product

2 70% Sulfuric Acid 0.05 Co-Product

3 Waste Catalyst 0.00006

4 Evaporation loss-CT 2

2 Liquid Effluent 0.115

Total 0.115 2 1.05 0.00006

3.2

Methanol

Rec. Methanol-Recycle

Sulfur Trioxide

70% Sulfuric Acid

Distillation

Sulphonation

Dimethyl Sulphate

Distillation

Catalytic Reactor




Annexure 8: Raw Material & Product Storage Details

S.

No. Chemical State

Consumption

(KL/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel

Storage

capacity of

Tank (KL)

Maximum

Storage

Capacity

(KL) Press

(Kg/cm2) Temp. (°C)

1 Sulfur Solid 40392 Godown atmospheric ambient 1 1000 1000

2 Methanol Liquid 12600 Tank atmospheric ambient 1 100 100

3 Sulfur Trioxide Liquid 16320 Tank atmospheric ambient 6 10 10

Alumina Catalyst Solid 1.44 Mt|Annum Drums atmospheric ambient - 500 kgs 500 kgs

Storage Details of Products

S.

No. Product State

Production, MTPA Mode of Storage Nos. of vessel

Capacity of Storage

Means, KL Total Storage Capacity

Existing Proposed

1

98% Sulfuric Acid Liquid

3900 6000

Tank 3 300 900

25%-65% Oleum Liquid Tank 3 50 150

Liquid SO3 Liquid Tank 3 50 150

Liquid SO2 Liquid Tank 6 8 48

2 Di Methyl Sulphate (DMS) 0 2000 Tank 3 200 600

3 70% sulfuric Acid (CO

product of DMS) Liquid 0 100

Tank 2 20 40

M/S. AMAL LTD.




ANKLESHWAR FORM I


Annexure 9: Water Consumption and Waste Water Generation Details

Water is sourced from GIDC Water Supply. Existing water demand is 260 Kld and proposed water

demand will be 642 Kld. So after expansion total water consumption will be 902 Kld.

Table 4: Water Consumption Details

S. No.

Area of Consumption

Water Consumption Quantity, KLD

Total after Expansion

Existing Proposed

1 Waste Heat Recovery Boiler 54 83 137

2 Cooling Tower 162 340 502

3 Process 24 172 196

Washing 0 2 2

4 Domestic 15 15 30

5 Gardening 0 25 25

6 Fire Fighting 5 5 10

Total 260 642 902

Existing wastewater generation is 55 KLD. Proposed wastewater generation will be 106. So after

proposed expansion total wastewater generation will be 161.0 KLD. In which 91 KLD will be

discharged in to CETP and 30 KLD domestic wastewater is disposed through Septic tank/soak pit

system.

Table 5: Effluent Generation Details

S. No.

Area of Consumption

Waste water generation Quantity,

KLD Total After Expansion

Disposal / Treatment

Facility Existing Proposed

1 Waste Heat Recovery Boiler 3 5 8

To ETP 2 Cooling Tower 35 73 108

3 Process 2 11 13

4 Washing 0 2 2

5 Domestic 15 15 30 To Septic Tank

Total 55 106 161

132.0 KLD will be discharged in

CETP and Domestic 30 KLD

is disposed through Septic tank/soak pit

system




Existing Water Balance Diagram:

260

54 162 24 15 0 5

127.0

128.6 15

35

3 35 2.0

40

Note: All values are in KLD

Raw Water from GIDC

Waste Heat Recovery

Boiler

Cooling Tower

Domestic Gardening

Septic Tank/ Soak Pit System

Evap + Drift Losses

ETP

Fire Fighting

Process

Fresh Water

Effluent

Losses

Recycled Water

RecoveredSteam to

other plants




Proposed Water Balance Diagram:

642

83 340 172 2 15 25 5

267

1 15

By Product

Sulphuric Acid

73

5 73 11 2

91


Raw Water from Borewell

ETP

Fire Fighting

Fresh Water

Effluent

Losses

Recycled Water


ETP

Fire Fighting

Fresh Water

Effluent

Losses

Recycled Water


ETP

Fire Fighting

Fresh Water

Effluent

Losses

Recycled Water

Raw Water from GIDC

Waste Heat Recovery

Boiler

Cooling Tower

Domestic Gardening

Evap + Drift Losses

ETP

Fire Fighting

Process

Fresh Water

Effluent

Losses

Recycled Water

RecoveredSteam to

other plants

Washings





Water Balance Diagram after Expansion:

902

137 502 196 2 30 25 10

394.0

1 30

By Product

Sulphuric Acid

108

8 109 13 2

131



Boiler Cooling Tower

Washings Domestic Gardening

Evap + Drift Losses

ETP

Fire Fighting

Process

Fresh Water

Effluent

Losses

Recycled Water


Boiler Cooling Tower


Evap + Drift Losses

ETP

Fire Fighting

Process

Fresh Water

Effluent

Losses

Recycled Water


Waste Heat Recovery

Boiler

Cooling Tower



Evap + Drift Losses

ETP

Fire Fighting

Process

Fresh Water

Effluent

Losses

Recycled Water

RecoveredSteam to

other plants

Raw Water from GIDC

Waste Heat Recovery

Boiler

Cooling Tower


Evap + Drift Losses

ETP

Fire Fighting

Process

Fresh Water

Effluent

Losses

Recycled Water

RecoveredSteam to

other plants

M/S. AMAL LTD.




ANKLESHWAR FORM I


Figure 1: Existing Membership Certificate of NCTL for water supply and Waste water Discharge

M/S. AMAL LTD.




ANKLESHWAR FORM I


Annexure 10: Details of Effluent Treatment Plant

Description of Effluent Treatment:

Primary treatment is available at ETP, Amal.

Raw effluent is collected in tank. Neutralization is done by means of Caustic. The neutralized

effluent is then transferred to collection tank and then sent to NTCL.

Figure 2: Process Block Diagram of ETP

M/S. AMAL LTD.




ANKLESHWAR FORM I


Annexure 11: Fuel Consumption

Table 6: Fuel Consumption

S. No.

Stack Attached to

Capacity Stack Nos.

Type of Fuel used

Fuel consumption

Remark

Existing

1

Waste heat boiler

6 ton/hr -

Waste heat boiler

-

This is waste heat boiler. Sulfuric Acid

production is exothermic reaction and hence heat is being generated.

The same is used for steam generation. Hence there is no

fuel or stack involved in it.

Proposed

1 Waste heat

boiler 2 Nos.

6 Ton/hr - Waste heat

boiler -

This is waste heat boiler. Sulfuric Acid

production is exothermic reaction and hence heat is being generated.

The same is used for steam generation. Hence there is no

fuel or stack involved in it.

2 DG Set 600 KVA 1 Diesel 6-8 kl/year

*Note: DG Set will be used only during power failure




Annexure 12: Hazardous Waste Generation

Table 7: Hazardous Waste Generation and Disposal

S. No.

Type of Waste Hazardous Waste Category as per

2016

Quantity kg per Year Source

Method of Collection

Treatment / Disposal Existing Additional Total

1 Catalyst 17.2 60 92 152 Process Drums TSDF-BEIL

2 Used oil 5.1 50 77 127 DG set, Gear

boxes Drums re-refiners

3 ETP Sludge 35.3 3000 4615 7615 Wastewater Treatment

Bags TSDF-BEIL

4 Sulfur sediment 17.1 20000 30769 50769 Process Bags TSDF-BEIL 5 Waste catalyst 17.2 0 1440 1440 Process Drums TSDF-BEIL

6 Waste

Drums/Liners/Carboys| 33.1 0 3000 3000 Packaging - Sell to authorized party/TSDF-BEIL

M/S. AMAL LTD.




ANKLESHWAR FORM I


Figure 3: Existing Provisional Membership Certificate of M/s. BEIL for Hazardous Waste

M/S. AMAL LTD.




ANKLESHWAR FORM I


Annexure 13: Stack Details

Table 8: Details of Flue Gas Stacks

Stack Attached

to Sources Capacity

Nos. of

Stacks

Stack Height,

m

Air pollution

Control measures

Attached

Remark

Existing

Boiler 6 Ton/hr 1 30 Adequate Stack Height

Already dismantled.

Proposed

DG Set 600 KVA 1 - Adequate Stack

Height -

*Note: DG Set will be used only during Power failure.

Table 9: Details of Process Vents

Stack Attached to Nos. of Stacks

Stack Height in m

Pollutants Emitted

Air Pollution Control Measures Attached

Existing

Sulphuric Acid Plant 1 50 SO2, Acid Mist Alkali Scrubber

Proposed

Sulphuric Acid Plant 1 50 SO2, Acid Mist Alkali Scrubber

Documents

ADDITIONAL DOCUMENTS - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/FormB/TOR/Additional... · 9.5 - 10.0% sulfur dioxide gas. Air required for combustion