LIST OF ANNEXURES No. Annexure Title Page.no No. 1 2 3 4 …environmentclearance.nic.in/writereaddata/FormB/TOR/Additional... · 3 Textile Auxiliaries 120 - 60 80 - 40 200 - 100 4

LIST OF ANNEXURES No. Annexure

No. Title Page.no

1 1 Layout Plan 2

2 2 Production and Manufacturing data 5

3 3 Manufacturing Process 6

4 4 Raw Material Consumption Details 21

5 5 Water Consumption 23

6 6 Waste water Generation 24

7 7 Air Emission from Process and APCE 25

8 8 List of Hazardous Waste 26

9 9 Power requirement and its Source 27

10 10 List of Hazardous Chemical 28

11 11 Proposed Terms of Reference 30

Kemit Chemicals Pvt. Ltd., Plot no.78/12 & 78/13, Phase I, GIDC-Vatva, Ahmedabad-382445

Pre-Feasibility Report Prepared by Ahmedabad 2

Annexure 1 Lay Out Plan

LAYOUT Plan @78/12 – Ground Floor

Approach Road

Plant Entrance

Solid Waste storage Area Liquid Storage Tanks

IBR Boiler Laboratory

Raw Material Storage Area

Filter Press



LAYOUT @78/12 – First Floor

SS vessel 8KL

Rubber lined storage 30KL

Rubber lined Storage 16 KL

Glass Lined 16KL Glass Lined 16KL Glass Lined 12.5 KL Glass lined 6.3KL

Cooling Tower

Office



LAYOUT @78/12 – Second Floor

MS Vessle 6KL

MS Vessel 8KL

Charging tanks for liquid raw materials



Annexure 2 Production and Manufacturing Data

No. Product name

Existing Capacity, MT/month Proposed Expansion, MT/month Total Plant Capacity, MT/month

Liquid

Solid

Content, %

w/w

Spray

Dried Liquid

Solid

Content, %

w/w

Spray

Dried Liquid

Solid

Content, %

w/w

Spray

Dried

1 Naphthalene based

Dispersing & Wetting Agent - - - 1,600 50 800 1,600 50 800

2 Methyl Naphthalene based

Dispersing & Wetting Agent - - - 200 50 100 200 50 100

3 Textile Auxiliaries 120 - 60 80 - 40 200 - 100

4 Leather Syntans - - - 1,200 50 600 1,200 50 600

5 Fat Liquor - - - 100 - - 100 -

6 Construction Chemicals

(SNF, PCE) - - - 1,200 50 600 1,200 50 600

Total 120 - 60 4,380 @ 50 2,140 4,500 @ 50 2,200



Annexure 3

Manufacturing Process

Naphthalene Based Dispersing & Wetting Agent (NBDWA) liquid:

Capacity: 1600 MT/month (liquid) and 800 MT/month (Powder)

Naphthalene is charged in a Sulphonator. Naphthalene and Sulphuric Acid and or Oleum are

reacted in MS Sulphonator at 160C for 10 hours. The resultant mass is dumped in glass lined

reactor and condensation with 37% formaldehyde is carried out at 90C for 20 hours. The

condensed product is neutralised by caustic to get final pH of 7.0 and water is added. Finally

the liquid is packed in a drum as a final product.

Mass Balance:

No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Oleum (23%) 3,500 Dispersing Agent Based On

Naphthalene (Liquid)

20,000 Product

2. Sulphuric Acid (98%) 4,300 Process loss 40 Alkali Scrubber

3. Naphthalene 4,300

4. Water 3,740

5. Formaldehyde 2,000

6. Caustic Lye 2,200

Total 20,040 Total 20,040



Process Flow Diagram for liquid Naphthalene Based Dispersing & Wetting Agent

Sulphonation

Condensation

Neutralization

Product content 10 MT

Liquid mass: 20 MT (50%)

Dispatch in Drums /

Tankers

Oleum (23%):7000 kg OR

Sulphuric Acid (98%): 8,600 kg

Water: 3740 kg formaldehyde

(37%): 4,000kg

Water: 5000 kg Caustic Lye

(45%): 4,400kg

Process Gas:40 kg

Alkali

Scrubber



Working

Batch Detail Summary for Liquid NBDWA:

Batch size, MT 20

No. of batches per day 3.2

Batch time, hr. 36

Water Consumption per batch 4.5m3

Water Consumption per day 14.4 m3

Effluent Generation Nil m3

Solid waste generation, per day 32 kg

Naphthalene Based Dispersing Agent (Powder):

Naphthalene is charged in a reactor and heated up to 90 °C. 23 % Oleum and or 98 %

Sulphuric Acid is then added. Raise the temperature till Sulphonation reaction is completed.

After check for the reaction completion, add 37 % Formaldehyde and water is added and

the mass is stirred at 110 ºC for 10 hours. Then the mass is neutralized with Caustic Lye and

Hydrated Lime to bring the pH to about 7. The wet cake is collected and stored as a solid

waste. The filter press is washed and wash water generated is sent to Effluent storage tank.

The wash water will be sent to Spray Dryer unit–M/s Kemit Corporations, for

environmentally safe disposal. The filtrate is further reacted with Soda Ash. Again, the wet

cake is collected and stored as solid waste. Finally, the filtrate is taken to the Spray Drier for

drying. The dry powder as a result is packed in HDPE bags for dispatch

Chemical reaction

Sulphonation

Naphthalene Sulphuric Acid Naphthalene Water Sulphuric Acid

/ Oleum 2 Sulphonic Acid (If Oleum used)

128 98 OR 178 208 18 80

+ H2SO4 / H2S2O7 + H2O + HSO3



Condensation

Naphthalene Formaldehyde 1methylene, Di Naphthalene Water

2 Sulphonic Acid Sulphonic Acid

416 30 428 18

Neutralization

1methylene, Di Naphthalene Caustic Sodium Salt of B-Naphthalene

Water

Sulphonic Acid Sulphuric Acid Condensate

428 80 472 36

+ 2NaOH + 2H2O

CH 2 HO 3 S SO 3 H CH 2 NaO3S SO3Na



Process Flow Diagram for Spray Dried Naphthalene Based Dispersing & Wetting Agent

(Powder)

Sulphonation

Condensation

Neutralization

Product Filtration

Powder Product

Dispatch 10 MT

Spray Drying of Liquid

mass


Liquid mass: 20 MT (50% w/w)

Process Gas

16 kg

Alkali

Scrubber

0.16 kg/d

Wash Water

750 kg

Effluent

Tank 6 KL

Moisture loss

10 MT

Cyclone +

Scrubber

0.33 kg/d



Water: 4000 kg Formaldehyde

(37%): 4,000kg


(45%): 4,400kg

Water: 750 kg



Methyl Naphthalene Based Dispersing Agent:

Capacity: 200 MT/month (liquid) and 100 MT/month (Liquid)

Methyl Naphthalene is charged in a Sulphonator. Methyl Naphthalene and Sulphuric Acid

and or Oleum are reacted in MS Sulphonator at 160C for 10 hours. The resultant mass is

dumped in glass lined reactor and condensation with 37% formaldehyde is carried out at

90C for 20 hours. The condensed product is neutralized by caustic to get final pH of 7.0 and

water is added. Finally, the liquid is packed in a drum as a final product.

Mass Balance:

No. INPUT QTY (Kgs) OUTPUT QTY (Kg) REMARK

1. Oleum (23%) 3,500 Dispersing Agent Based On

Naphthalene (Liquid)

20,000 Product

2. Sulphuric Acid (98%) 4,300 Process loss & emission 40 Alkali Scrubber

3. Methyl Naphthalene 4,300

4. Water 3,740

5. Formaldehyde 2,000

6. Caustic Lye 2,200

Total 20,040 Total 20,040



Process Flow Diagram for liquid Naphthalene Based Dispersing & Wetting Agent

0.16 kg/d

Sulphonation

Condensation

Neutralization


Liquid mass: 20 MT (50%)

Dispatch in Drums /

Tankers




(37%): 4,000kg


(45%): 4,400kg

Process Gas:16 kg

Alkali

Scrubber

0.16 kg/d



Batch Detail Summary for Liquid MNBDWA:

Batch size, MT 20


Batch time, hr. 36

Water Consumption per batch 4.5 m3


Effluent Generation Nil m3

Solid waste generation, per day 32 kg

Methyl Naphthalene Based Dispersing Agent (Powder):

Naphthalene is charged in a reactor and heated up to 90 °C. 23 % Oleum and or 98 %

Sulphuric Acid is then added. Raise the temperature till Sulphonation reaction is completed.

After check for the reaction completion, add 37 % Formaldehyde and water is added and

the mass is stirred at 110 ºC for 10 hours. Then the mass is neutralized with Caustic Lye and

Hydrated Lime to bring the pH to about 7. The wet cake is collected and stored as a solid

waste. The filter press is washed and wash water generated is sent to Effluent storage tank.

The wash water will be sent to Spray Dryer unit–M/s Kemit Corporations, for

environmentally safe disposal. The filtrate is further reacted with Soda Ash. Again, the wet

cake is collected and stored as solid waste. Finally, the filtrate is taken to the Spray Drier for

drying. The dry powder as a result is packed in HDPE bags for dispatch

Chemical reaction

Sulphonation

Methyl Sulphuric Acid 2 Methyl Nathphalene Water Sulphuric Acid

Naphthalene / Oleum 1 Sulphonic Acid (If Oleum used)

142 98 OR 178 222 18 80

+ H2SO4 / H2S2O7 + H2O + HSO3



Condensation

Methyl Naphthalene Formaldehyde 1methylene, Di Naphthalene Water

2 Sulphonic Acid Sulphonic Acid

416 30 428 18

Neutralization

1methylene, Di Naphthalene Caustic Sodium Salt of B-Naphthalene

Water

Sulphonic Acid Sulphuric Acid Condensate

428 80 472 36

+ 2NaOH + 2H2O

CH 2 HO 3 S SO 3 H CH 2 NaO3S SO3Na

+ HCOH + H2O



Process Flow Diagram for Spray Dried Methyl Naphthalene Based Dispersing & Wetting

Agent (Powder)

Sulphonation

Condensation

Neutralization

Product Filtration

Powder Product

Dispatch 10 MT

Spray Drying of Liquid

mass


Liquid mass: 20 MT (50% w/w)

Process Gas

16 kg

Alkali

Scrubber

0.16 kg/d

Wash Water

750 kg

Effluent

Tank 6 KL

Moisture loss

10 MT

Cyclone +

Scrubber

0.33 kg/d




(37%): 4,000 kg

Water: 4,500 kg Caustic Lye (45

%): 4,400kg

Water: 750 kg



TEXTILE AUXILIARIES


Manufacturing process

The physical blending is carried out of raw materials to get the final product. No reaction is

involved. The raw materials are Nonyl Phenol Ethoxylates, Olyl Cetyl Alcohol Ethoxylates,

Turkey Red Oil, O.T Paste etc. The combination of raw materials used largely depends on

properties of end products required.

LEATHER CHEMICALS SYNTAN



For Phenolic Syntans: - Sulphonation of Phenol is carried out in glass lined reactor at 130C for 2 hours - Urea is added in required quantity - Addition of formaldehyde now starts and the condensation reaction is carried out

over a period of 18 hours - The resultant product is neutralised with Caustic flakes - Required quantity of adipic acid, phthalic anhydride and sodium sulphate are added

to get the final product For Resin Syntans

- Sodium Bisulphite is dissolved in water and then condensed with Formaldehyde at 65oC

- Melamine is added to this mixture to form melamine formaldehyde resin - After the reaction with melamine is over, small quantity of urea is added to form

combination of MF and UF resin For Neutralising and Bleaching Syntans

- These are a combination of organic and inorganic salts which are physically blended. No reaction is involved. Salts used in this process depend on property of finished product required.

Batch Detail

Batch size, MT 20.00

No. of batches per day 2.4 No.

Batch time, hr. 24

Water Consumption per batch 5 m3

Water Consumption per day 12 m3



Effluent Generation NIL

Solid waste generation per batch NIL

Solid waste generation per month NIL

Fat Liquors

Capacity: 100 MT/month (liquid)


- Oil is added into a glass lined reactor and heated to desired temperature

- Water and emulsifiers are added and the mixture is stirred for 3-4 hours until

stable

- Softeners are added at final stage to give desired softness to leather.

Batch Details

Batch size, MT 6.00

Batch Time, hr. 6.00

No. of batches per day 4

Water Consumption per batch 1 m3

Water Consumption per day 4 m3




9. Construction Chemicals


(1) PEG Based Polycarboxylate Ether (Liquid & Powder)




After charge raw materials, heat the reactor to 70oC & start addition of emulsion &

potassium per sulphate solution. Charge both solutions simultaneously in 3 hours at 90oC to

95oC. After complete addition, maintain further 1 hour at 90oC to 95oC. Cool to 50oC &

charge Caustic Soda Lye 41 kg. Further mix for 20 minutes & send sample to QC lab for

quality evaluation, then pack in drums.

Batch size, MT 8.00

Batch Time, hr. 8.00

No. of batches per day 3






Mass Balance:

No. Input Qty (Kg) Output Qty (Kg) Remark

1. Acrylic acid 192.0 Poly carboxylate ether 4000.0 Product

2. PEG 3600.0 Vapour Loss 4000.0

3. Meth acrylic acid 88.0

4. Caustic Lye 65.6

5. Soda ash 3.2

6. Potassium per sulphate 19.2

7. Sulphuric acid 32.0

8. DM water 4000.0

Total 8000.0 Total 8000.0



2. Sulphonated alkyl naphthalene formaldehyde condensate sodium salt (Liquid & Powder)

Manufacturing process:

After charge raw materials, slowly heat to 120o temperature. After that maintain 4 hours temperature at 120-125oC to get complete Sulphonation. First charge water in lead bonding reactor, than slowly charge sulphonated mass under cooling. Temperature should be below 80o during drowning of acidic mass. After that charge formaldehyde in 3 hours at 70-80o. After addition of formaldehyde, slowly heat to 100-105o& maintain 8 hours at same temperature to get complete condensation. After condensation charge water & slowly add caustic lye under fast cooling. Temperature should not go above 80o during neutralization. After complete neutralization (PH 7.0 – 7.5), mix further 1 hour to get homogeneous solution. Samples send to QC lab for quality evaluation. If sample okay, then material hand over to spray dryer unit. Run SANFC liquid 50% into spray dryer through feed pump & keep inlet/outlet temperature. Power sample send to QC lab for quality evaluation. If sample okay, then pack in 25 kg bags.

Batch size, MT 20


Batch time, hr. 24






Mass Balance

No. Input Qty (Kg) Output Qty (Kg) Remark

1. Naphthalene 4300

Sulphonated alkyl

naphthalene formaldehyde

condensate sodium salt

10396.00 Product



2. Sulphuric

Acid/Oleum 4300 Vapour loss 9604.00

Due to Spray

drying

3. Formaldehyde

(37%) 2000

4. Caustic Lye (48%) 2200

5. DM Water 7200

Total 20000 Total 20000.00



Annexure 4 Raw Materials Consumption Details

no. Product Raw Material Quantity MT/Month

Existing Proposed Total

1 Naphthalene Based

Dispersing Agent

Naphthalene - 344 344

Oleum (23%) - 280 280

Sulphuric Acid (98%) - 344 344

Formaldehyde - 160 160

Caustic Lye - 176 176

2 Methyl Naphthalene

Based Dispersing

Agent (Liquid)

Methyl Naphthalene - 43 43

Sulphuric Acid - 43 43


Caustic Flakes - 22 22

3 Textile Auxiliaries

Nonyl Phenol Ethoxylates - 10-80 10-80

Olyl Cetyl Alcohol Ethoxylates - 20 20

Turkey Red Oil - 80 80

O.T Paste - 10 10

Acid Slurry - -- --

4 Leather Syntans

Phenol - 258 258


Urea - 300 300


Caustic Flakes - 84 84

Adipic acid - 6 6

Phthalic Anhydride - 6 6

Sodium Sulphate - 120 120

Sodium Bi-Sulphite - 210 210

Melamine - 60 60

Organic salts - 30 30

Inorganic salt - 30 30

5 Fat Liquor

Sulphochlorinated

paraffin oil

OR

Ground nut oil

OR

Cotton seed oil

OR

Chlorinated paraffin oil

-- 60 60

Nonyl Phenol -- 10 10



no. Product Raw Material Quantity MT/Month


Ethoxylates

OR

Olyl Cetyl Alcohol

Ethoxylates

(Emulsifier)

Non-ionic softeners -- 5 5

6 Construction Chemicals

PCF Acrylic Acid - 14 14

PEG - 270 270

Methyl acrylic Acid - 7 7

Caustic Lye - 5 5

Soda Ash - 0.24 0.24

Potassium per sulphate - 1 1


SNF

Naphthalene - 129 129


Caustic Lye - 66 66

Sulphuric Acid/Oleum - 129 129



Annexure 5 Water Consumption

No. Particulars Quantity KL /day


1 Domestic 0.5 1.00 1.50

2 Industrial

Process 1.50 37.50 39.00

Floor / container / Equipment

Washing

1.25 2.75 4.00

Scrubbing 0.00 3.00 3.00

Boiler & Cooling 1.25 3.75 5.00

Sub-Total Industrial Use 4.00 47.00 51.00

3 Gardening& Misc. 0.00 3.00 3.00

Total Requirement 4.50 51.00 55.50



Annexure 6 Waste Water Generation

No. Particulars Quantity KL /day


1 Domestic 0.45 0.90 1.35

2 Industrial

Process 0.50 0.00 0.50

Floor / container / Equipment

Washing

1.25 2.75 4.00

Scrubbing 0.00 3.00 3.00

Boiler & Cooling 0.25 0.75 1.00

Sub-Total Industrial Use 2.00 6.50 8.50

Total Generation 2.45 7.40 9.85



Annexure 7 Air Emission from Process and APCE

No Boiler/ Furnace/ heater

Fuel Existing

SCM/Day

Proposed Increase / Decrease SCM/Day

Total After

Expansion SCM/Day

Stack attached

to

Stack Height

in m

APCM

Existing Proposed

1

IBR Boiler IBR

Boiler PNG 1531 - 1531

IBR Boiler 11 --

2 Hot Air Generator

- Hot Air

Generator

11 --

Process Stack:

No Detail

Source Existing Proposed

1. Sulphonation Process - Two Stage Alkali Scrubbers



Annexure 8 List of Hazardous Waste

No. Category Code

Description Quantity /Annum Existing

Quantity /Annum Proposed Increase

Quantity /Annum Total After Expansion

Mode of Disposal

1. 34.3 ETP Sludge As & when Generated

5.00 5.00 Neutralized Acid residue from Storage

tanks To TSDF site

2 5.1 Spent Oil As & when Generated

0.10 0.10 To MOEF approved vendors

3 33.3 Discarded Containers / Liners/ Barrels

6000 Nos. - 6000 Nos. To GPCB approved vendors



Annexure 9 Power Requirements and its source:

No. Particulars Existing Proposed Total Source

1. Power

requirement

Electricity 100 hp 200 hp 300 hp TPL



Annexure 10 List of Hazardous Chemical with Storage quantity & Category, threshold quantity as per MSIHCR

No. Hazardous

Chemical name Falling under category of MSIHC Rules

Threshold Quantity in MT

Storage details Remark Existing and

MOC Proposed and MOC

Total and MOC

1 Caustic lye; Caustic Flakes

(1) Sr. no. 571 of schedule 1 part II

- - 50 MT MOC- MS Tank

50 MT MOC- MS Tank

-

2 Formaldehyde (1) As per Schedule 1 Part I(b) (v) as flammable liquid under rule 2e (i), 4 (1)(a), 4(2), 17 and 18

(2) As per Schedule 1 Part I (a) sr. no. 3 as Toxic chemical as LD50 as 100 mg/kg falling between 50 to 200 mg/kg

(3) Sr. no. 285 of schedule 1 part II (4) Sr. No. 112 of Group-2 Toxic

Substance in Schedule 3 Part I

5 T for rule 5,7-9,13-15 50 T for 10-12

- 30 MT MOC- MS Tank

30 MT MOC- MS Tank

-

3 Oleum (1) Sr. No. 121 of Schedule 3 Part I Group 2 Toxic substance

(2) Sr. no. 444 of schedule 1 part I as Oleum

(3) Sr. No. 590 of schedule 1 part I as Sulfur Trioxide

(4) Sr. no. 11 of Schedule 2 Sulfur Trioxide storage as Isolated storage

15 t (as Sulfur Trioxide-SO3) for rule 5, 7-9 and 75 t for 10 to 12

- 30 MT (6.9 MT equivalent of Sulphur Trioxide) MOC- MS Tank

30 MT (6.9 MT equivalent of Sulphur Trioxide) MOC- MS Tank

-



4 Phenol (1) As per Schedule 1 Part I(b) (v) as flammable liquid under rule 2e (i), 4 (1)(a), 4(2), 17 and 18

(2) Sr. no. 481 of schedule 1 part II

- - 20 MT MOC- MS Tank

20 MT MOC- MS Tank

Based on FP 85°C

5 Naphthalene Sr. no. 417 of schedule 1 part I - - 200 MT MOC-Room

200 MT MOC- Room

-

6 Sulphuric Acid Sr. no. 591 of schedule 1 part I - - 30 MT MOC- MS Tank

30 MT MOC- MS Tank

-



Annexure 11 Proposed Terms of Reference

The scope of work is including the following activities

1. Product capacity, RM requirement & quality, sources, means of transportation (existing and proposed capacity)

2. RM, Product and intermediate product storage facilities details with Fire & safety aspects (existing and proposed capacity)

3. Justification for expansion, including existing & proposed land, other resources, investment

4. TOR will cover a. Co-ordinates (lat-long) of all four corners of the site. b. The water source, water balance diagram, wastewater generation and re-use

practices (existing and proposed capacity). c. Complete scheme of effluent treatment. Characteristics of untreated and

treated effluent to meet the prescribed standards of discharge under E(P) Rules.

d. Effluent disposal management e. Air Emission Sources, Details of stack emission and action plan for control of

emissions to meet standards. (existing and proposed capacity) f. Measures for fugitive emission control (existing and proposed capacity) g. Details of hazardous waste generation and their storage, utilization and

management. h. Action plan for the green belt development plan in plot and road side

planting. Details of species, width of plantation, planning schedule etc. shall be included.

i. Total capital cost and recurring cost/annum for environmental & pollution control measures shall be included.

j. Action plan for post-project environmental monitoring shall be submitted. k. Plan and fund allocation to ensure the occupational health & safety of all

contract and casual workers l. Details of existing Occupational & Safety Hazards. What are the exposure

levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved,

m. Annual report of health status of workers with special reference to Occupational Health and Safety.

n. The hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

o. Details regarding infrastructure facilities including utilities (existing and proposed capacity)

p. A tabular chart with index for point wise compliance of Previous granted EC, Consent to Establish and Consent to Operate approvals.

q. To Prepare the EMP 5. Specific terms of reference for EIA studies



a. Details on solvents to be used, measures for solvent recovery and for emissions control.

b. Details of process emissions from the proposed unit and its arrangement to control.

c. Work zone monitoring arrangements for hazardous chemicals. d. Detailed effluent treatment scheme including segregation of effluent streams

for units adopting 'Zero' liquid discharge & Effluent disposal plan. e. Action plan for odour control to be submitted. f. Authorization/Membership for the disposal of solid/hazardous waste in TSDF,

if any. g. Action plan for utilization of MEE/dryers salts. h. Material Safety Data Sheet for all the Chemicals are being used/will be used. i. Risk assessment for storage and handling of hazardous chemicals/solvents.

Action plan for handling & safety system to be incorporated. j. Arrangements for ensuring health and safety of workers engaged in handling

of toxic materials

Documents

LIST OF ANNEXURES No. Annexure Title Page.no No. 1 2 3 4 …environmentclearance.nic.in/writereaddata/FormB/TOR/Additional... · 3 Textile Auxiliaries 120 - 60 80 - 40 200 - 100 4