ANNEXURE 1 TERMS OF REFERENCES - · PDF fileTERMS OF REFERENCES • TOR prescribed by MoEF & CC for this sector will be taken in to account. ANNEXURE 2 ... 4 Sodium sulfate 120 -120

ANNEXURE 1

M/S. SUBHASRI PIGMENTS PVT. LTD., ANKLESHWAR

TERMS OF REFERENCES

• TOR prescribed by MoEF & CC for this sector will be taken in to account.

ANNEXURE 2

M/S.SUBHASRI PIGMENTS PVT. LTD., ANKLESHWAR

LIST OF EXISTING & PROPOSED PRODUCTS

Sr.

No

Name of Products and Co-Products

Quantity Total

Quantity

after

Expansion

MT/Month

As per

Existing CCA

AWH – 81502

MT/Month

Proposed

MT/Month

Products

1 CPC Green-7 80.00 170.00 250.00

2 Copper Phthalocyanine Blue Crude 80.00 370.00 450.00

3

Pigment Violet Tonner IC-77 (Lake

Violet) 3.5 0 3.5

4 Pigment Violet Tonner IC-72 0.5 0 0.5

5 Pigment Persian Blue 3.6 0 3.6

6 Beta Blue 30.30 169.70 200.00

7 Pigment Rubine Tonner 1 0 1

8 Pigment Lake Red 0.5 0 0.5

9 Pigment Maroon Tonner 0.5 0 0.5

10 Alpha Blue 0.00 100.00 100.00

Total 199.9 809.70 1009.60

Inorganic Products

1 Ammonium Sulphate 350.00 515.00 865

2 Poly Aluminium Chloride solution 1150 2500 3650

3 Copper Sulphate 30.00 40.00 70.00

4 Sodium sulfate 120 -120 0

Total 4585.00

Co-Products/ By – Products

1 Hydrochloric Acid* 200.00 425.00 625.00

2 Sodium Hypo Chlorite (100 %) 200.00 505.00 705.00

3. Aluminium Chloride Solution** 850 -850 0

Total 1250.00 1330.00

*Also Listed Under Hazardous Waste Category.

** Unit will use aluminium chloride solution for the manufacturing of Poly aluminium chloride.

ANNEXURE 3


LIST OF DIRECTORS

Sr.

No.

Name Present Residential

Address

Designation Contact No.

1. Mr. Krish Srivatsan

Asf – 10, Jalkamal Co –

Op. Hsg. Soc. No.2,

Gattu Vidyalaya Road,

GIDC Ind. Estate,

Ankleshwar – 393002

Dist.: Bharuch

Director (02646)

221780,226164

2. Mrs. Geeta Srivatsan Asf – 10, Jalkamal Co –

Op. Hsg. Soc. No.2,


GIDCInd. Estate,


Dist.: Bharuch

Director (02646)

221780,226164

3. Mr.Dhananjay

Srivatsan

Asf – 10, Jalkamal Co –

Op. Hsg. Soc. No.2,


GIDC Ind. Estate,


Dist.: Bharuch

Director (02646)

221780,226164

ANNEXURE 5


EXISTING & PROPOSED PRODUCT RAW MATERIAL LIST

NAME OF THE

PRODUCT

NAME OF RAW MATERIALS QUANTITY

MT/MT OF

PRODUCT

QUANTITY

MT/MONTH

CPC GREEN - 7 Aluminium Chloride 1.85 463.00

Copper phthalocyanine Blue (CPC) 0.53 133.00

Sodium Chloride (Salt) 0.39 97.00

Chlorine 1.29 324.00

Cuprous Chloride 0.08 21.00

Hydrochloric acid (30%)(Fresh) 0.271 68.00

Dispersing Agent 0.04 9.50

Chloro Benzene 0.05 12.5

Caustic Soda (F) 0.09 23.00

Acetic acid 0.006 1.5

TOTAL 4.597 1152.5

COPPER

PHTHALOCYANINE

BLUE CRUDE

Phthalic Anhydride 1.08 484.00

T.G.Urea 1.51 678.00

Cuprous Chloride 0.18 83.00

Ammonium Molybdate 0.003 1.40

Ortho Nitro Toluene 0.05 21.00

Spent Sulphuric Acid(18% to 20%) 6.14 2765.00

Caustic Soda lye (48%) 0.3 138.00

TOTAL 9.263 4170.4

BETA BLUE CPC Blue Crude 1.05 210.00

Caustic Soda (F) 0.20 40

Hydrochloric acid 0.1 20.00

Xylene/IBA 0.05 10.00

Dispersing Agent 0.15 30

Rosin 0.01 2.4

TOTAL 1.56 312.4

ANNEXURE 5


ALPHA BLUE

CPC Blue Crude 1.00 100.00

Sulphuric Acid(98%) 7.00 700.00

Solvent (Octanoic acid) 0.20 20.00

Emulsifier 0.03 2.60

TOTAL 8.23 823

HCl (30%) Gaseous Hydrochloric acid From

process

0.53 134

TOTAL 0.53 134

SODIUM HYPO

CHLORIDE

Chlorine 0.25 63.00

Caustic Soda Lye (100%) 0.21 53.00

ML of CPC Green crude 2.35 588.00

TOTAL 2.81 704

AMMONIUM

SULFATE

Spent sulfuric acid (15% to 17%) 3.52 3041.00

Spent sulfuric acid (18% to 20%) 1.38 1188.00

Gaseous Ammonium Carbonate & other

impurities from process

0.74 637.00

TOTAL 5.64 4866

POLY ALUMINIUM

CHLORIDE

Aluminium Chloride Solution 0.80 2918.00

Alumina 0.11 385.00

Lime Stone 0.10 350.00

TOTAL 1.01 3653

COPPER SULFATE Solvent* 3.58 251.00

Sulfuric Acid (70%) 0.40 28.00

TOTAL 3.98 279

PIGMENT VIOLET

TONNER IC-77

Sodium ferro Cyanide 1.20 4.20

Sodium sulfate 0.3 1.05

Soda ash 0.6 2.10

Methyl violet dyes 1.00 3.50

Copper sulfate 1.40 4.90

Dispersing agent 0.05 0.18

TOTAL 4.55 15.93

ANNEXURE 5


PIGMENT VIOLET

TONNER IC-72

Sodium molybdate 1.20 0.60

Disodium Phosphate 0.3 0.15

Sulfuric acid 0.6 0.30

Soda ash 0.2 0.10

Methyl Violet Dyes 1.0 0.50

Dispersing agent 0.05 0.03

TOTAL 3.35 1.68

PIGMENT PERSIAN

BLUE

Ferous Sulfate 1.00 3.60

Sulfuric acid 0.34 1.22

Ammonium sulfate 0.59 2.12

Sodium ferro cyanide 1.18 4.24

Dichromate solution 0.18 0.64

Sulfuric acid (10%) 1.67 6.01

TOTAL 4.96 17.83

PIGMENT RUBING

TONNER

4B acid 0.5 0.5

Hydro Chloro acid 0.8 0.8

Sodium nitrite 0.18 0.18

Ice 4.00 4.00

BON acid 0.5 0.50

Caustic lye 0.5 0.50

Calcium chloride 0.5 0.50

TOTAL 6.98 6.98

PIGMENT LAKE

RED C

C acid 0.50 0.25

Hydro Chloro acid 1.00 0.50

Sodium nitrite 0.16 0.08

Ice 4.00 2.00

B Nepthol 0.4 0.20

Barium Chloride 0.5 0.25

TOTAL 6.56 3.28

PIGMENT MAROON Tobias acid 0.50 0.25

ANNEXURE 5


TONNER Hydro Chloride acid 1.00 0.50

Sodium nitrate 0.15 0.08

Ice 4.00 2.00

BON Acid 0.50 0.25

Caustic lye 0.25 0.13

Calcium chloride 0.70 0.35

TOTAL 7.1 3.56

*Solvent layer is generated during the extraction of Aluminium chloride solution. Copper

sulphate crystal is recovered from it.

ANNEXURE 6


EXISTING & PROPOSED PRODUCTS MANUFACTURING

1. Copper Phthalocyanine Green -7

Stage I :- Chlorination

In this stage copper phthalocyanine blue is converted to copper phthalocyanine green by

chlorination reaction.

Chlorination of copper phthalocyanine blue is carried out in a Glass Lined Vessel (GLV).

The raw materials anhydrous aluminium chloride, sodium chloride, CPC Blue, cupric

chloride is charged lot wise into GLV with continuous stirring. Aluminium chloride and sodium

chloride are used as solvent while cupric chloride is used as catalyst. Heating is provided

simultaneously to melt the mixture till temperature is attained.

Chlorine gas is then bubbled through the mixture. Temperature is maintained. Batch is tested at

definite intervals for reaction completion. At the end of reaction chlorination is stopped.

During the reaction, un-reacted Chlorine & liberated HCL are removed from the top of the GLV

and are taken to the two stage water scrubber and alkali Scrubbing system. Conc. hydrochloric

acid is generated from water scrubber and sodium hypo chloride is generated from alkali

scrubber.

Stage II: - Drowning

In this stage chilled water is used to bring down the temperature of the reaction mass so that it

can be taken for filtration.

Required quantity of chilled water and HCL are taken into the drowning vessel, which is

Rubber lined & Brick lined. The reaction melt from GLV is then dumped into the water.

Continuous stirring is provided till temperature reduces.

Some amount of Hydrogen Chloride gas is evolved in this stage, which is taken to the drowning

scrubber.

Stage III: - Filtration I

The cooled reaction mixture from drowning vessel is taken to a filter press (FP1).

Water washing is given to the filter cake. The acidic filtrate is separated as by-product then use

to sale or use in manufacturing of poly aluminium chloride and washing water is taken to ETP

for treatment.

The crude wet cake of copper phthalocyanine green is unloaded into twin screw conveyor and

transferred to distillation vessel by screw pump.

ANNEXURE 6


Stage IV :- Purification/Distillation

Water is taken into distillation vessel and crude wet cake is transferred through screw pump.

Caustic soda flakes is added to adjust the pH. chloro benzene and Dispersing Agent are also

charged. Maintained temperature and pressure. Then distilled out whole chlorobenzen.

Stage V: - Filtration II

Slurry from distillation vessel is taken to the Filter Press (FP2). Filtrate is collected. Washing

is provided to the filter cake till the pH of wash water is neutral. Filtrate and wash water

which are both alkaline are taken to the ETP. At the end of filtration the wet cake of pure

product is loaded on the belt conveyors.

Stage VI: - Spin flash drier

Through the belt conveyor wet cake is discharged in to the Spin Flash Dryer hopper. The

material is dried and the dry powder is collected in different silos and then blended in pneumatic

blender and packed.

ANNEXURE 6


CHEMICAL REACTION

ANNEXURE 6


PROCESS FLOW DIAGRAM

Aluminium Chloride

Sodium Chloride

Cuprous Chloride

Chlorine Gas

Copper Pthalocyanine Blue

Chlorination Phthalocyanine Green

(Crude)

Copper Pthalocyanine Green

(Crude)

Water

Drowning

Crude Slurry

Filtrate

Washing

Crude Cake

Crude Slurry

Water

Washing &

Filtration

Crude Cake

Water

Chloro Benzene

Dispersing Agent

Steam

NaOH

Chloro Benzene

Water Vapour

Slurry

Distillation

Slurry

Wash Water

Filtration II

Filtrate

Washing

Pure cake Copper

Phthalocyanine Green 7

Water Vapor

CPC Green 7

SFD

Copper Phthalocyanine

Green 7 Pure Cake

Chlorine gas

HCl gas

ANNEXURE 6


Material Balance

Stage I: Chlorination

++++++

Stage II : Drowning

Stage III : Filtration

Drowning

Chlorinator

Aluminum Chloride 1575 kg

Sodium Chloride 330 kg

Cupric Chloride 69 kg

Chlorine Gas 1100 kg

Copper Pthalocyanine Blue 450 kg

Total 3524 kg

CPC Green

(Crude) 2856 kg

Total 3524 kg

CPC Green(Crude) 2856 kg

Water 9000kg

Total 11856 kg

Crude Slurry 11356kg

Total 11856kg

HCl Gas 456 kg

Excess Chlorine 212 kg

Filtrate 10000 kg

Washing 11456 kg

Crude Cake 2400 kg

Total 23856 kg

Crude Slurry-11856 kg

Wash Water- 12000 kg

Total 23856 kg

Filtration I ETP

ANNEXURE 6


Stage IV: Distillation

Stage V : Filtration

.

Stage VI : Drying

Distillation

Filtration II

SFD

ETP

Crude Cake 2400 kg

Water 2518 kg

Chloro Benzene 3000 kg

Dispersing Agent 32.50 kg

Steam 4500 kg

NaOH 78 kg

Total 12528.50 kg

Chloro Benzene 2957.50 kg

Water Vapour 3907.50 kg

Slurry 5621 kg

Solvent loss 42.50 kg

Total: 12528.50 kg

Slurry 5621 kg

Wash Water 10000 kg

Total 15621 kg

Filtrate 4161 kg

Washing 9915 kg

CPC Green -7 cake-1545 kg

Total 15621 kg

Water Vapor- 695 kg

CPC Green -7 - 850 kg

Total 1545 kg

CPC Green- 7 Cake 1545 kg

Total 1545 kg

ANNEXURE 6


2. Manufacturing Process of Copper Phthalocyanine Blue Crude

Copper Phthalocyanine Blue Crude:

- Phthalic Anhydride, Urea and solvent (ONT) 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 phtahlamide at 135 °C. Formation of

copper phthalocyanine takes place at a 185°C with release of ammonia gas and CO2 gas.

- The ammonia gas and CO2 gas are scrubbed through scrubbers.

- 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 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 either the

effluent generated during CPC manufacture and finally with fresh water till the soluble

salt are removed.

- Filtrate is transferred to ETP for treatment, while the wet press cake of CPC blue is dried

in spin flash dryer and packed into HDPE bags.

ANNEXURE 6


PROCESS FLOW DIAGRAM FOR CPC BLUE CRUDE:

*Phthalic Anhydried

*T.G.Urea

* Cuprous Chloride

* Ammonium Molybdate

* Solvent Ortho Nitro Toluene

Glass Lined Vessel Ammonia and

CO2 Gas Scrubber

ML (Filtrate)

Ammonium Sulphate solution

Rotary Vacuum

Dryer ONT Recovered

MSRL H2SO4 (18%)

Filter Press

Filtrate (ML) to AS plant

&

Washing to Recycle

SFD

Packing

Evaporator

MSRL

Filter Press

C.Lye-48%

Filtrate (ML) ETP

&

Washing to Recycle

Condensate

reuse in

process

Ammonium

Sulphate

M/S. SUBHASRI PIGMENTS PVT. LTD.,

Mass balance

Input Kg.

Phthalic Anhydride 3500

T.G.Urea 4900

Cuprous Chloride

Ammonium Molybdate

Solvent 6500

Total 15509.50

Input Kg.

Mass 10900

Total 10900

Input Kg.

Mass 4400

H2SO4 (18%) 20000

Water 2

Steam 1800

Total 28200

Input Kg.

Mass 28200

Washing for water 13000

Total 41200

Mass 62

Caustic Lye (48%)

Water 12000

Steam 1500

Total 20300


Kg.

Output

3500 Mass

4900 NH3 ,CO2 & other (Gas)

600

In Scrubber

9.5 Total

6500

15509.50

Kg.

Output

10900 Mass

10900

Recover Solvent

Atmosphere Solvent loss

Total

Kg.

Output

4400 Mass

20000 Total

2000

1800 8200

Kg.

Output

8200 Mass

13000 ML(Filtrate) to Scrubber

1200

Washing to reuse

Total

6200

Output

600

Mass

12000

Total

1500

20300

ANNEXURE 6

Kg.

10900

CO2 & other (Gas) 4609.5

15509.50

Kg.

4400

6350

Atmosphere Solvent loss 150

10900

Kg.

18200

28200

Kg.

6200

ML(Filtrate) to Scrubber 22000

13000

41200

Kg.

20300

20300

M/S. SUBHASRI PIGMENTS PVT. LTD.,

Input Kg.

Mass 20300

Washing for water 13000

Total 33300

Input Kg.

Mass 6500

Total 6500


Output

20300

Mass

13000

ML(Filtrate) to green plant

33300

Washing to reuse

Total

Output

00 CPC Blue

00

Evaporation loss

Total

ANNEXURE 6

Kg.

6500

green plant 13800

13000

33300

Kg.

3255

3245

6500

ANNEXURE 6


3. Manufacturing Process of Pigment Violet Tonner IC-77 (Lake Violet)

PIGMENT VIOLET TONNER IC-77:

Brief Manufacturing Process

First take Methyl Violet dyes liquid with water in big MSRL. Heat it upto 45°C. Stir for 45

minutes and maintain the temp. Then take water in barrel and dissolve copper sulphate. Add this

solution into dyes solution. Then take water in small MSRL and dissolve Sodium Ferro Cyanide,

Sodium Sulphate and Soda ash. Heat it upto 45°C. Add this solution into Dyes Solution and Heat

it upto 65°C. Final Adjacent pH upto neutral. Filter it. Dry it and pulverize it.

Process Flow Diagram:

Methyl Violet Dyes

Water

Solution of copper Sulphate

MSRL-1 MSRL-2

Water

Sodium Ferro cyanide

Sodium Sulphate

Soda ash

Filteration E.T.P Waste water to ETP

Drying

Pulverizing

Evaporation Loss

Finish Product

Violet Tonner IC-77

ANNEXURE 6


Input Kg. Output Kg.

Sodium ferro Cyanide 1.2 Reaction mass 6.1

Sodium sulfate 0.3

Soda ash 0.6

Water 4

TOTAL 6.1 TOTAL 6.1

Input Kg Output Kg.

Mass 6.1 Mass 12.85

Methyl Violet Dyes 1

Copper sulfate 1.4

Dispersing agent 0.05

TOTAL 12.85 TOTAL 12.85


Reaction mass 12.85 Mass 2.5

Effluent to ETP 10.35



Reaction mass 2.5 Dry cake 1

Evaporation loss 1.5

TOTAL 2.5 TOTAL 2.5


Dry cake 1 Product 1

TOTAL 1 TOTAL 1

DRYING

PULVERISING

MATERIAL BALANCE OF PIGMENT VIOLET TONNER IC-77

MSRL-1

MSRL-2

Water 4.3

FILTERATION

ANNEXURE 6


4. Manufacturing Process of Pigment Violet Tonner IC-72

Pigment Violet Tonner IC-72

First take Methyl Violet dyes liquid with water in big MSRL. Heat it up to 45°C. Stir for

30 minutes and maintain the temp. Then take water in small MSRL and dissolve sodium

Molybdate with Disodium Phosphate. Heat it and add this acid complex solution into

Dyes solution and slowly heat it up to 65°C. Filter it. Dry it and pulverize it.


Methyl Violet Dyes

Water

MSRL-1 MSRL-2

Filtration E.T.P Waste water to ETP

Drying

Pulverizing

Evaporation Loss

Finish Product

Violet Tonner IC-72

Water

Sodium Molybdate

Disodium phosphate

10% sulfuric acid

ANNEXURE 6



Sodium molybdate 1.2 Reaction mass 9.7

Disodium phosphate 0.3

Sulfuric acid 0.6

Water 7.4

Soda ash 0.2

TOTAL 9.7 TOTAL 9.7

Input Kg Output Kg.

Mass 9.7 Mass 11.85

Methyl Violet Dyes 1

Water 1.1










TOTAL 2.6 TOTAL 2.6



TOTAL 1 TOTAL 1

DRYING

PULVERISING

MATERIAL BALANCE OF TONNER

MSRL-1

MSRL-2

FILTERATION

ANNEXURE 6


5. Manufacturing Process of Pigment Persian Blue

Pigment Persian Blue:

First take water in big MSRL and dissolve Ammonium sulphate and Sodium ferro

cyanide. Stir it properly and heat it up to 45°C. Then take water in small MSRL and

dissolve Ferrous Sulphate and Sulphuric Acid in it and heat it up to 45°C. Add this

solution in big MSRL. Then make 10% Sulphuric acid solution and add it in big MSRL.

Then make solution of sodium bichromate in water and add it in big MSRL. Stir it

properly and heat this total reaction mass up to 120°C. Filter it. Dry it and pulverize it.


Water

Ammonium sulphate

Sodium Ferro Cynaide

MSRL-1 MSRL-2

Reaction

mass

E.T.P Waste water to ETP

Drying

Pulverizing

Evaporation Loss

Finish Product

Persian Blue

10% Sulphuric acid

Sodium bichromate

solution in water

Filtration

Water

Ferrous sulfate

Sulphuric acid

ANNEXURE 6



Ferous sulfate 1 Reaction mass 5.3387

Sulfuric acid 0.3387

Water 4


Input Kg Output Kg.


Ammonium Sulphate 0.588

Sodium Ferro Cyanide 1.1765

Water 3

TOTAL 10.1032 TOTAL 10.1032


Reaction mass 10.1032 Reaction mass 11.9497

Dichromate solution in

water 0.1765

10% sulfuric acid 1.67

TOTAL 11.9497 TOTAL 11.9497




TOTAL 11.9497 TOTAL 11.9497




TOTAL 2.7 TOTAL 2.7



TOTAL 1 TOTAL 1

FILTERATION

DRYING

PULVERIZING

MATERIAL BALANCE OF TONNER

MSRL-1

MSRL-2

REACTION MASS

ANNEXURE 6


6. Manufacturing Process of Beta Blue

Beta Blue:

Take CPC Blue into Ball Mill for grinding. /then take into reactor with

Xylene/IBA/DA/NaOH. Reflux it. After completion of reflux, add water and start

distillation for removing xylene/IBA. After distillation of xylene/ IBA, whole mass dump

into vessel. Here mass is neutralized with Hydrochloric acid. Filter whole mass through

filter press and wash it. Wet Cake from Filter Press is dried in Dryer then and packed for

dispatch.


Ball Mill

Vessel

Distillation

pH Adjust

CPC Blue

Xylene/IBA

DA

NaOH

Water

HCl

Recovery of

Xylene/IBA

Filtration&

Washing

E.T.P Waste water to ETP

Drying Evaporation Loss

Finish Product

Beta Blue

ANNEXURE 6


Input Kg Output Kg

copper phthalocyanine

Blue 1.050 Reaction mass 1.050

Total 1.050 Total 1.050

Input Kg Output Kg

Mass 1.050 Reaction mass 5.075

Recovered water 0.5

Water of previous batch 2.613

Fresh IBA/Xylene 0.05

Recovered IBA/Xylene 0.5

Caustic flakes 0.2


Rosin 0.012


Input Kg Output Kg

Mass 5.075 Product mass 4.025

Water 0.5

Recovered IBA/Xylene 0.500

Atmosphere solvent loss 0.050


Input Kg Output Kg


Hydrochloride acid 0.100

Fresh water 5.400


Input Kg Output Kg

Product mass 9.525 Wet cake 1.725

Effluent 7.8


MATERIAL BALANCE OF CPC BETA BLUE

NEUTRALIZATION

DISTILLATION

FILTERATION

BALL MILL

VESSEL

ANNEXURE 6


7. Manufacturing Process of Pigment Rubine Tonner

Pigment Rubing Tonner

Manufacture Process:

Preparation of Diazotization:

Initially take water and charge 4B acid in it, stirring it for 30 to 45 minutes, after stirring this

solution it is become clear solution then charge ice in this solution to maintain temperature to

0°C. After maintaining temperature charge sodium nitrite and hydrochloric acid slowly in the

solution.

Preparation of Coupler:

Initial take water and charge caustic lye and BON acid in alkali media, stirring it for 30 minutes

after srirring this solution, it is become clear solution the charge ice in it to maintain

temperetaure up to 10°C to 15°C.

Coupling:

Start mixing diazo solution in to Coupler solution the set pH 8 and Stirring this solution for 1

hour.

Input Kg Output Kg

Product mass 9.525 Wet cake 1.725

Effluent 7.8


Input Kg Output Kg

Wet cake 1.725 Wet cake 2.1

Fresh water 2.988 Water 2.613


Input Kg Output Kg

Mass 2.1 Beta Blue 1


Total 2.1 Total 2.1

SFD

PACKING

WASHING

FILTERATION

ANNEXURE 6


Now, add Calcium Chloride to prepared Calcium Salt formation in it, and stirring it for 30

minutes the add steam from boiler and heat it up to 75°C temperature then filter it, add water for

washing and maintain pH up to 7 then dry it, packing it and dispatch it.


DIAZOTIZATION

COUPLING

Calcium Salt

Formation

Water

4B Acid

HCl

Sodium Nitrite

Ice

Water

BON Acid

Calcium Chloride

Ice

Caustic Lye

Filtration Effluents send to

Drying

Pulverizing

Water Evaporation Loss

Packing and Dispatch

Pigment Rubbing Tonner

Diazotizes Mass

Coupled Mass

Washing Water

ANNEXURE 6



Water 200 Diazolize mass 548

4B acid 50

Hydro Chloro acid 80

Sodium nitrite 18

Ice 200

TOTAL 548 TOTAL 548

Input Kg Output Kg.

Diazolize mass 548 Coupled mass 1048

BON Acid 50

Water 200

Caustic lye 50

TOTAL 1048 TOTAL 1048


Coupled mass 1048 Reaction mass 1098

Calcium Chloride 50



Reaction mass 1098 Reaction mass 200

Effluent to ETP 2198

Washing water 1300



Wet cake 200 Dry cake 100

Evaporation loss 100

TOTAL 200 TOTAL 200



TOTAL 100 TOTAL 100

FILTERATION

DRYING

PULVERIZING

MATERIAL BALANCE OF RUBINE TONNER

DIAZOLIZATION

COUPLING

Ice 200

CALCIUM SALT

FORMATION

ANNEXURE 6


8. Manufacturing Process of Pigment Lake Red C

Pigment Lake Red C

Manufacture process:


Initial take water and charge C acid in it, stirring it for 30 to 45 minutes after stirring this

solution it is become clear solution then charge ice in this solution to maintain

temperature to 0 °C after maintaining temperature charge Sodium nitrite and hydrochloric

acid slowly in the solution.


Initial take water and charge caustic lye and � Napthol in alkali media, stirring it for 30

minutes sfter stirring this solution it is ome clear solution then charge ice in it to maintain

temperature to 20°C.

Coupling:

Start mixing diazo solution in to coupler solution then set pH 8.5 and stirring this solution

for 1 hour.

Now, add barium chloride to prepared salt formation in it, then stirring it for 30 minutes

then as steam from boiler and heat it up to 80°C then filter it, add water for washing and

maintain pH up to 7 then dry it, packing it and dispatch it.

ANNEXURE 6


ANNEXURE 6



DIAZOTIZATION

COUPLING

Water

C Acid

HCl

Sodium Nitrite

Ice

Water

B Nepthol

Caustic Lye

Barium Chloride

Ice


Drying

Pulverizing



Pigment Lake Red C

Diazotizes Mass

Coupled Mass

Washing Water

ANNEXURE 6




C acid 50


Sodium nitrite 16

Ice 200

TOTAL 566 TOTAL 566

Input Kg Output Kg.


B Nepthol 40

Water 200




Barium Chloride 50





Washing water 1300





TOTAL 200 TOTAL 200



TOTAL 100 TOTAL 100

FILTERATION

DRYING

PULVERIZING

MATERIAL BALANCE OF PIGMENT LAKE RED

DIAZOLIZATION

COUPLING

Ice 200

BARIUM SALT

FORMATION

ANNEXURE 6


9. Manufacturing Process of Pigment Maroon Tonner

Pigment Marron Tonner

Manufacture process:


Initial take hot water and maintain temperature to 80°C then charge Tobias acid it,

stirring it for 30 minutes, after stirring this solution. It is become clear solution then

charge ice in this solution to maintain temperature to 0°C after maintaining temperature

charge sodium nitrite and hydrochloric acid slowly in the solution.


Inintial take hot water and maintain temperature to 55°C then charge caustic lye and

BON acid in alkali media, stirring it for 30 minutes after stirring this solution it is become

clear solution then charge ice in it to maintain temperature to 10°C to 15°C.

Coupling:

Start mixing diazo solution to coupler solution then set pH 7.5 and stirring it for 1 hour.

Now, add calcium chloride in it to prepared calcium salt formation, and stirring it for 30

minutes then add steam from boiler and heat it up to temperature 90°C then filter it, add

water for washing and maintain pH up to 7 then dry it, packing it and dispatch it.

ANNEXURE 6


ANNEXURE 6



DIAZOTIZATION

COUPLING

Water

Tobias Acid

HCl

Sodium Nitrite

Ice

Water

BON Acid

Caustic Lye

Barium Chloride

Ice


Drying

Pulverizing



Pigment Maroon Tonner

Diazotizes Mass

Coupled Mass

Washing Water

ANNEXURE 6




Tobias acid 50


Sodium nitrite 15

Ice 200

TOTAL 565 TOTAL 565

Input Kg Output Kg.


BON Acid 50

Water 200

Caustic lye 25




Calcium Chloride 70





Washing water 1300





TOTAL 200 TOTAL 200



TOTAL 100 TOTAL 100

FILTERATION

DRYING

PULVERIZING

MATERIAL BALANCE OF MARRON TONNER

DIAZOLIZATION

COUPLING

Ice 200

CALCIUM SALT

FORMATION

ANNEXURE 6


10. Manufacturing Process of Alpha Blue:-

Take CPC Blue into Ball Mill for grinding. This grinded CPC use for further processing. Take

sulphuric acid (98 %) Glass line vessel. Then slowly charge grinded CPC Blue or crude CPC.

Maintaining required temperature. Maintain the temperature of mass by jacket cooling. The mass

is stirred further for 2-3 hrs and then cooled to room temperature by circulation of water in

jacket. Before drawing of the mass in to MSRL, charge Solvent/DA-111 in to GLV and maintain

for 1 hrs. Then take recycle water in MSRL and drown the mass in MSRL. During drowning

temperature should be around 60 Deg C after drowning filter it and wash it. After filtration

process whatever mother liquor generated that contain approximately 18 to 20 %of sulphuric

acid. This can be use for CPC manufacturing process.

Pigmentation:-

The filter Cake charge in another Vessel which contain recycle water and then charge caustic

flakes or caustic lye for neutralize the mass up to 8 to 8.5 pH and stirrer for 1 hrs after that

charge DA/emulsifier and solvent mixture and stirrer for 1 hrs heat up to 60 to 90 Deg C

temperature and maintain for 2 hrs. The above slurry is filtered and the cake is washed with

recycle and raw water. The wet cake is dried into SFD.

ANNEXURE 6


Material Balance with Process Flow Diagram

Sulphuric Acid (98%)

Solvent -

CPC

Water

Steam

Sulphuric acid (18-20%)

Water

Waste Water (Reused)

Waste Water (Reused)

Glass Line Vessel

Filter- 1

Pigmentation

Filter-2

SFD

MSRL

Ball Mill CPC Blue -

Water

Emulsifier

Wash water

Steam

Product

Evaporation loss

Final Product

Water

ANNEXURE 6


Input Kg Output Kg

CPC Blue 500 CPC Crude 500

Total 500 Total 500

Input Kg Output Kg

CPC Crude 500

Sulfuric acid(98%) 3500

Solvent 100

Total 4100 Total 4100

Input Kg Output Kg

Reaction Mass 4100 Reaction mass 20800

Steam 2200

Recycled water from Filter

press-I 4583

Recycled water from Filter

Press-II 9917


Input Kg Output Kg

Reaction mass 20800 Wet cake 1417

Waste water 4583

Recycle water from Filter Press-II 5000 Spent sulphuric acid(18 to 20%) 19800


Input Kg Output Kg

Water from ammonium sulfate plant 5000

Emulsifier 13

Steam 1500

Wet cake 1417

TOTAL 7930 Total 7930

Input Kg Output Kg

Reaction mass 7930 Wet cake 1430

Water from ammonium slufate plant 12800 Filterate+ washing 21500

Fresh water 2200


Input Kg Output Kg

Wet cake 1430 Final Product 500



MATERIAL BALANCE OF CPC ALPHA BLUE

BALL MILL

PIGMENTATION Reaction mass 7930

FILTER PRESS-2

SFD

GLASS LINE VESSEL Reaction mass 4100

MSRL

FILTER PRESS-I

ANNEXURE 6


INORGANIC PRODUCTS

1. AMMONIUM SULFATE

Manufacturing Process

During the manufacturing process of CPC Blue Ammonia and carbon dioxide gases are

liberated which is absorbed by using of acid scrubber. Ammonium sulfate is recovered by

using of filter.

INPUT KG OUTPUT KG

AMMONIA+CARBON DIOXIDE 4609.5 CARBON DIOXIDE 3080

ACIDIC ML FROM CPC 22000

ALUMINIUM SULFATE

LIQUOUR 32129.5

ACIDIC ML FROM ALPHA 8600

TOTAL 35209.5 TOTAL 35209.5

INPUT KG OUTPUT KG

ALUMINIUM SULFATE LIQUOUR 32129.5

AMMONIUM SULFATE

SOLUTION 32079

IMPURITY+COPPER 50.5

TOTAL 32129.5 TOTAL 32129.5

INPUT KG OUTPUT KG

AMMONIUM SULFATE

SOLUTION 32079 WATER 25829

AMMONIUM SULPHATE 6250


MANUFACTURING PROCESS OF AMMONIUM SULFATE

ACID SCRUBBER

FILTER

EVAPORATOR

ANNEXURE 6


2. POLY ALUMINIUM CHLORIDE SOLUTION

The Aluminium chloride solution is first react with aluminium hydroxide/alumina

hydrate in reaction vessel to increase the alumina (Al2O3) content up to 10 % after

reaction with alumina/aluminium hydroxide neutralized upto pH 1.5 lime stone (CaCO3).

Then filter the solution The resulting solution is Poly aluminium chloride solution.

FLOW DIAGRAM WITH MATERIAL BALANCE

3.

4.

5.

INPUT Kg OUTPUT Kg

AlCl3 solution 5000 PAC solution 6260

Alumina 660

Lime stone 600

total 6260 total 6260

INPUT Kg OUTPUT Kg

PAC solution 6260 PAC solution 6255

Solid waste 5


REACTOR

FILTERATE

MATERIAL BALANCE OF PAC

Reactor

AlCl3 solution (16-18 %)

Aluminium hydroxide/Alumina

Lime Stone

Poly Aluminium Chloride solution

Filtration

Poly Aluminium Chloride solution Poly Aluminium Chloride solution

Solid waste

ANNEXURE 6


3. COPPER SULPHATE

The mother liquor containing CuCl2 is reacted with copper extracting solvent system.

After the reaction is over, copper gets extracted in the solvent system and the same is

separated out by layer separation from the refinate. Add sulphuric acid (20 %) to the

copper rich solvent system to form copper sulphate solution and the immiscible upper

layer of solvent (recycled in the next batch). Copper Sulphate then take for crystallization

by cooling.

PORCESS FLOW DIAGRAM

Stage I: EXTRACTION

Stage II: ACIDIFICATION

Stage III: Crystallization

Copper sulphate solution

(Lower layer)

Extraction

Filtrate from Filtration-I

Copper extracting solvent

Copper rich solvent

(Upper layer)

Aluminium chloride solution

(Lower layer - Collect separately as product)

Reactor

Copper rich solvent

(Upper layer)

Sulphuric acid (20 %)

Upper solvent Layer

(Recycled in next batch)

Copper sulphate solution

(Lower layer)

Crystallizer

Copper Sulphate Crystal

Mother liquor of copper Sulphate

recycle to previous stage

ANNEXURE 6


MATERIAL BALANCE OF COPPER SULFATE

INPUT Kg OUTPUT Kg

Copper rich solvent layer 860 Uppper Solvent layer 799

ML from previous stage 135 Reaction mass 375

H2SO4(70%) 96 Evaporation loss 1

Water 84


INPUT Kg OUTPUT Kg

Reaction mass 375 Copper sulfate crystal 240

Recycle to next batch 135

total 375 total 375

REACTOR

CRYSTALLIZATION

ANNEXURE 6


CO- PRODUCTS/ BY- PRODUCTS

1. Hydrochloric Acid

Excess Unreacted chlorine gas and formed hydrogen chloride gas is emitted during

the chlorination of CPC Blue by using chlorine gas. The process emission (containing

Chlorine gas & hydrogen chloride gas) from the chlorinator is first scrubbed in water

scrubbing system where almost all HCl gas gets scrubbed and results into

Hydrochloric acid solution (22 - 26 %). The gaseous emission after the water

scrubbing system is passed through alkali scrubbing system before discharged into

the atmosphere.


Stage I: SCRUBBING

MATERIAL BALANCE

Input Kg Input Kg

Chlorine 212 Chlorine 212

HCL gas 456 HCL Solution(22 to 26%) 2076

Water 1620


SCRUBBER 1

Cl2 gas to alkali scrubber

Water

Scrubber

Process emission from chlorinator

(Containing CL2 gas & HCl gas)

Water

HCL solution (22 - 26%)

ANNEXURE 6


2. Sodium Hypochlorite (100%)

The un reacted CL2 gas from the chlorinator after passing through water scrubbing system

gets scrubbed in alkali scrubbing system (NaoH) resulting in sodium hypochlorite solution.

(8 -10 %).


Stage I: SCRUBBING

MATERIAL OF SODIUM HYPOCHLORITE SOLUTION

Input Kg Input Kg

Chlorine 212

ML from green plant 2000

Fresh caustic 180


SCRUBBER 2 Sodium Hypo Solution 2392

Alkali Scrubber

Chlorine gas (From water

scrubber)

Caustic soda

Water

Sodium hypochlorite solution (8 – 10 %)

ANNEXURE 7


PROCESS DESCRIPTION OF EFFLUENT TREATMENT PLANT.

Equalization tanks are provided to equalize all the streams coming from filtrate, washing and

other plant except filtrate from purification of crude green which contain high COD. Then by

pump effluent is taken to the reaction tank.

Separate treatment for alkaline filtrate coming from Purification during Crude Green 7.

In this treatment, we take this alkaline filtrate in a separate tank. Here it is neutralize by

Aluminium Chloride sol. /PAC. It is filtered by filter press for removing solid waste. Here we get

60 to 70% COD reduction. Clear filtrate taken for H2O2+FeSO4 treatment and solid waste send to

sludge bed. After H2O2+FeSO4 treatments filter it and filtered liquid mix with our low COD

stream final treatment. Here further we reduce 50-60% of COD and solid waste send to sludge

bed.

In reaction tank, lime solutions are added to neutralize the effluent. After reaction tank, effluent

goes to flocculation tank, where Polyelectrolyte is added to form the flocs for better settling.

Then effluent is passed through clarifier. The supernatant from clarifier goes to supernatant

sump. From bottom of clarifier settled liquid sludge is collected in liquid sludge collection tank

and it is filtered through filter press. After that sludge is stored in sludge drying bed. Filtrate is

collected in supernatant sump.

From supernatant sump effluents passes through sand filter (when ever required) then discharge

to FETP (NCT) pipe line for ultimate disposal to deep Sea.

FLOW DIAGRAM

Influent

GIDC U/G Drainage system

1.

5

8

4

7 6

9

11 13 10

Alkali

Influent

14 Filter

15 Filter

ANNEXURE 7


NAME AND SIZE OF ETP UNIT

Sr.

No. DESCRIPTION

Existing Proposed Dimensions

(m) No. of

units

Capacity

(m3)

No. of

units

Capacity

(m3)

1 Equalization Tank 2 75

2 75 10.75 x 2.88 x

2.4

2 Lime Slurry Tank 2 6.9 - - 2 x 2.2

3 Polyelectrolyte Tank 2 1 - - ----

4 Reaction Tank 2 5 1 5 1.5 x 1.4 x 2.3

5 Flocculation Tank 2 5 1 5 1.5 x 1.4 x 2.3

6 Clarifier (Conical Bottom) 2 40 1 50 4 x 3 x 3.5

7 Supernatant Sump 1 80 - - ----

8 Sand Filter 1 20 kL/hr. - - 1.2 x 3

9 Sampling Point 1 - - - ----

10 Sludge Slurry Tank 1 18.75 2.5 x 2.5 x 3.00

11 Filter Press-1 2 4500 kgs. - - 48” x 48” x 58”

12 Filter Press-2 2 2500 kg 36” x 36” x 51”

13 Sludge Bed 1 5400 - - 54 x 20 x 5

14 Alkali Effluent treatment

Tank 1 18.75 - - 2.5 x 2.5 x 3.00

15 FeSO4+H2O2 Treatment

tank-1 2 18.75 - - 2.5 x 2.5 x 3.00

ANNEXURE 7


CHARACTERISTIC OF EFFLUENT

Sr.

No.

Parameters Before

Treatment

(at the ETP

inlet) mg/l

After Treatment

(at the ETP outlet

& CETP inlet) mg/l

Standard Norms

prescribed

(CETP Inlet norms)

mg/l

1. pH 0-2 6.5-7.5 6.5-8.5

2. T.S.S in mg/L 200-250 100 100

4. C.O.D. in mg/L 1300-1500 < 300 1000

5. Ammonical Nitrogen

in ppm <75 < 25 75

ANNEXURE 8

DETAILS OF WATER CONSUMPTION

Sr.

No

Particulars Existing Water

Consumption

KL/Day

(As per CCA-

AWH 81502)

Proposed Water Consumption

KL/Day

(As per proposed expansion)

Total

Water Consumption

KL/Day

Fresh Recycle Total Fresh Recycle Total

1. Domestic 48 0 0 0 48 0 48

2. Gardening /

Other use

37 0 0 0 37 0 37

INDUSTRIAL WATER CONSUMPTION

3. Process 176.50 -74.5 854* 779.5 102 854* 956

4. Boiler 15 154 100** 254 169 100** 269

5. Cooling 27 170 0 170 197 0 197

6. Washing 25 30 0 30 55 0 55

Total

(Industrial)

243.5 279.5 954 1233.5 523 954 1477

TOTAL

(Domestic +

Industrial

+Gardening)

328.5 279.5 954 1233.5 608 954 1562

*Breakup of 854 KL/Day: -Recycle from RO: - 209 KL/day

Recycle from MEE : - 207 KL/Day

Internal Recycle : - 354 KL/Day

From Boiler Steam : - 84 KL/Day

**MEE Condensate water steam which will be reused in Boiler.

ANNEXURE 8

DETAILS OF WASTE WATER GENERATION

Sr.

No.

Particulars Existing Waste Water

Generation KL/Day (As

per CCA AWH -81502)

Proposed Waste

water

Generation

KL/Day

Total Waste

Water

Generation

after expansion

KL/Day

1. Domestic 47.50 0 47.50

2. Industrial

Process 154.90 333.1 488

Boiler 2.8 42.2 45

Cooling 0 37 37

Washing 25 30 55

Total Industrial 182.7 442.3 625

TOTAL (Domestic +

Industrial)

230.20* 442.3** 672.5

*Existing discharge permission of industrial and domestic waste of unit is

230.20 KL/Day which is continuous after proposed expansion.

**Due to the proposed expansion waste water generation will be 442.3 KL/Day.

Unit will reuse it after treatment so no extra waste water will be generated due to

the proposed expansion.

ANNEXURE 8

WATER BALANCE DIAGRAM

TOTAL WATER REQUIREMENT (608 GIDC FRESH WATER)

TOTAL WATER (956 KL/Day)

(102FRESH+416 FROM RO&MEE+

354 INTERNAL RECYCLE+84 BOILER

STEAM)

WASHING

(55KL/Day)

COOLING TOWER

(197 KL/Day)

GARDENING

(37KL/Day)

BOILER

(169KL/Day FRESH+

100 KL MEE CONDENSATE)

EFFLUENT

GENERATION

(842KL/DAY)

Reused

(354KL/Day)

403 KL/Day ETP (587.5KL/Day)

STEAM

IN PROCESS

(84 KL/DAY)

LOSS

(40 KL/Day)

BLOW DOWN

(45 KL/DAY)

BLOW DOWN

(37 KL/DAY)

LOSS

(160 KL/Day)

WASHING

(55 KL/DAY)

RO (348.3 KL/Day)

MEE (217.3KL/Day)

209 KL/Day-RO permeate

MEE Salt

(10.3 KL/Day)

139.3 KL/Day

Ro Rejected

207 KL/Day

35.74KL/Day

Evaporation loss

78KL/Day

DOMESTIC

(48KL/Day)

SOAK PIT

(47.5 KL/DAY)

230.2 KL/Day to NCTL

Sludge (9 KL/day)

Neutralization

(85 KL/Day)

Sludge (7 KL/day)

STEAM

FOR MEE

(100 KL/DAY)

ANNEXURE 9


DETAILS OF ENERGY CONSUMPTION

Sr.

No.

Electricity Quantity as per

current CCA

No. AWH-81502

Quantity as per

proposed

expansion

Total Quantity

after expansion

1. Electricity connected load 71600 KVA 1079000KVA 1150600 KVA

2. Electricity 3000HP 4500 HP 7500 HP

DETAILS OF FUEL CONSUMPTION

Sr.

No.

Fuel Quantity as per

current CCA

No. AWH-81502

Quantity as per

proposed

expansion

Total Quantity

after expansion

1. Natural Gas 11229 SCM/Day 33000 SCM/Day 44229 SCM/Day

2. Diesel 0 280 L/Hr 280 L/Hr

3. Agro waste/Briquettes 300 Kg/Day 0 300 Kg/Day


ANNEXURE 10

LIST OF HAZARDOUS CHEMICALS

Sr.

No.

List of Hazardous Chemicals

1. Liquid Chlorine

2. Cupric Chloride

3. HCL (30 %)

4. Chloro Benzene

5. DA

6. Xylene

7. Caustic Soda Lye/Flakes

8. Solvent + Kerosene

9. Coc.Sulfuric acid

10 IBA

11 Phthalic Anhydride

12 T.G.Urea

13 Ortho Nitro Toluene

14 Cuprous Chloride

ANNEXURE 11


DETAILS OF HAZARDOUS WASTE GENERATION

Sr.

No.

Type of Waste Category Existing

Quality As

per CCA

No. AWH-

81502

Proposed

Quality

Quantity

after

Expansion

Mode of Disposal

1. ETP sludge/ Gypsum

sludge

35.3 275.16

MT/M

205 MT/M 480.16

MT/M

Collection,

Storage,

Transportation,

Disposal at by

Cement factory or

TSDF site

authorized by the

GPCB.

2. Used Oil 5.1 0.937

MT/Year

1 MT/Year 1.937

MT/Year

Collection,

Storage,

Transportation,

Disposal at by

Selling registered

refiners.

3. Discarded containers/

Empty barrels

33.1 1.5

MT/Month

6

MT/Month

7

MT/Month

Collection,

Storage,

Transportation,

Disposal at by

Selling to

authorize

recycler.

4. Empty bags / Liner 33.1 3.25

MT/Month

4

MT/Month

7.25

MT/Month

Collection,

Storage,

Transportation,

Disposal at by

Selling to

authorize

recycler.

5. MEE Salt 35.3 0 309 MT/M 309 MT/M Collection,

Storage,

Transportation,

Disposal at

available TSDF

site authorized by

ANNEXURE 11


the GPCB.

6. Dust from air filtration

system

26.2 0.010

0 0.010

MT/Year

Collection,

storage, reuse in

the process within

factory premises.

7. Solid Waste* 26.1 0 3 MT/M 3 MT/M Collection,

Storage,

Transportation,

Disposal at

available TSDF

site.

8. IMPURITY+COPPER 26.1 0 7 MT/M 7 MT/M Sell to GPCB

approved

Recycler.

9. Hydrochloric Acid 26.3 200 MT/M 425 MT/M 625 MT/M Sale to actual user

having

permission under

rule-9.

*After lime treatment unit will dispose it at available TSDF site.

ANNEXURE 12


DETAILS OF FLUE GAS EMISSION

EXISTING FLUE GAS EMISSION AS PER CCA 81502

Sr.

No.

Stack attached to Stack

Height

(m)

Type of

fuel

Type of

emission

Permissible

Limit

APCM

01. Steam Boiler

(IBR)-Green Plant

(2.0TPH)

11 Natural

Gas

Particulate

matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

02. Thermic Fluid

Heater –Green-

7(4.0Lac Kcal)

03. Power Plant

boiler/DG-

125KVA

11 Natural

Gas

Particulate

matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

04. Thermic Fluid

Heater-CPC Blue

(10.0Lac Kcal)

11 Natural

Gas

Particulate

matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

05. Steam Boiler

(IBR)

(6.30 TPH)

06. Steam Boiler

(1 TPH)

11 Natural

Gas

Particulate

matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

07. Steam Boiler

(0.6 TPH)

11 Natural

Gas

Particulate

matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

08. Hot Air Generator

(45000 Kcal/Hr)

11 Agro

Waste/

Briquettes

Particulate

matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

Bag Filter

PROPOSED FLUE GAS EMISSION

Sr.

No.

Stack attached

to

Stack

Height

(m)

Type of

fuel

Type of

emission

Permissible

Limit

APCM

ANNEXURE 12


09. Steam Boiler (IBR)

(10.50 TPH)

11 Natural Gas Particulate matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

10. DG-1000KVA 11 Diesel Particulate matter

SO2

Nox

150 mg/NM3

100 PPM

50 PPM

---

11. Thermic Fluid

Heater-CPC &

CPC Green -7 Blue

(10.0Lac Kcal)

11 Natural Gas Particulate matter

SO2

NOx

150 mg/NM3

100 PPM

50 PPM

---

ANNEXURE 13


DETAILS OF PROCESS GAS EMISSION

EXISTING PROCESS GAS EMISSION AS PER CCA-81502

Sr.

No.

Stack

Attached To

Stack

Height

(m)

Air Pollution

Control System

Fuel Parameter Permissible

Limit

1. Chlorination

Reactor

15 Water Scrubber

followed by Alkali

Scrubber

---- HCl

Cl2

20 mg/NM3

09 mg/NM3

2. Reactor

(CPC Blue

Plant)

15 Acid Scrubber ---- NH3 175

mg/NM3

3. Hot Air

Generator for

SFD-Green-7.

(1.8Lac Kcal)

11 Bag Filter Natural

Gas

PM

SOX

NOX

150 mg/NM3

100 PPM

50 PPM

4. Hot Air

Generator for

SFD-CPC Blue

(7.0Lac Kcal)


Gas

PM

SOX

NOX

150 mg/NM3

100 PPM

50 PPM

5. Hot Air

Generator for

SFD(130000

Kcal/Hr)(BETA

Blue)


Gas

PM

SOX

NOX

150 mg/NM3

100 PPM

50 PPM

PROPOSED PROCESS GAS EMISSION

6

Reaction

Vessel

15 Alkali Scrubber ---- Acid

Vapor

7

Hot Air

Generator for

SFD(130000

Kcal/Hr)(Alpha

Blue)


Gas

PM

SOX

NOX

150 mg/NM3

100 PPM

50 PPM

ANNEXURE 13


Documents

ANNEXURE 1 TERMS OF REFERENCES - · PDF fileTERMS OF REFERENCES • TOR prescribed by MoEF & CC for this sector will be taken in to account. ANNEXURE 2 ... 4 Sodium sulfate 120 -120