PROPOSED CHANGE IN PRODUCT MIX IN SYNTHETIC ORGANIC ...environmentclearance.nic.in/writereaddata/... · FORM-I for PROPOSED CHANGE IN PRODUCT MIX IN SYNTHETIC ORGANIC CHEMICALS MANUFACTURING

FORM-I

for

PROPOSED CHANGE IN PRODUCT MIX IN

SYNTHETIC ORGANIC CHEMICALS MANUFACTURING UNIT

(Without Increase in Total Production Tonnage & Total Pollution Load)

of

M/s. BASF India Limited

Plot No. 4B, Dahej Industrial Estate, Village: Dahej,

Taluka: Vagra, Dist: Bharuch-392 130, Gujarat

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

(See paragraph - 6)

FORM 1

Sr.

No.

Item Details

1. Name of the project/s M/s. BASF India Limited

2. S. No. in the schedule 5(f)

3. Proposed

capacity/area/length/tonnage to

be handled/command area/lease

area/number of wells to be drilled

• Existing Production Capacity

= 5,47,000 TPA & 20 million pieces/Annum

• Total Production Capacity after change in Product

Mix


(Total Production Capacity remains same after

change in product mix) – Refer: Annexure-1

• Plot Area: 2,34,400 m2

• No bore well is and will be drilled within the

premises.

4. New/Expansion/Modernization Proposed change in product mix

(Introduction of new product with additional

production plant)

5. Existing Capacity/Area etc. • Existing Production Capacity


• Plot Area: 2,34,400 m2

6. Category of Project i.e. ‘A’ or ‘B’ ‘A’ (MoEFCC's amendment Notification:

Reference: Annexure-16)

7. Does it attract the general

condition? If yes, please specify.

No

8. Does it attract the specific

condition? If yes, please specify.

No

9. Location

Plot/Survey/Khasra No. Plot No. 4B

Village Dahej

Tehsil Dahej Industrial Estate, Taluka: Vagra

District Bharuch – 392 130

State Gujarat

10. Nearest railway station/airport

along with distance in kms.

By road distance: Nearest Railway Station: Bharuch = 40 km (approx.)

Nearest Airport : Vadodara = 120 km (approx.)

11. Nearest Town, city, District

Headquarters along with distance

in kms.

By road distance: Nearest Town: Bharuch = 40 km (approx.)

Nearest District Head Quarter: Bharuch = 40 km

(approx.)

12. Village Panchayats, Zilla Parishad,

Municipal Corporation, local body

(complete postal address with

telephone nos. to be given)

Dahej Ind. Estate

13. Name of the applicant M/s. BASF India Limited

14. Registered Address Plot No. 4B, Dahej Industrial Estate, Village:

Dahej, Taluka: Vagra, Dist: Bharuch – 392 130,

Gujarat

15. Address for correspondence:

Name Mr. Jayant Bahekar

Designation (Owner/Partner/CEO) Site Director

Address M/s. BASF India Ltd.

Plot No. 4B, Dahej Industrial Estate, Village:

Dahej, Taluka: Vagra, Dist: Bharuch – 392 130,

Gujarat

Pin Code 392 130

E-mail [email protected]

Telephone No. Phone : +91 2641 660101

Mob : +91 9920495365

Fax No.

16. Details of Alternative Sites

examined, if any. Location of

these sites should be shown on a

topo sheet.

No

17. Interlinked Projects No

18. Whether separate application of

interlinked project has been

submitted?

No interlinked project has been submitted.

19. If yes, date of submission NA

20. If no, reason NA

21. Whether the proposal involves

approval/clearance under: if yes,

details of the same and their

status to be given.

(a) The Forest (Conservation) Act,

1980?

(b) The Wildlife (Protection) Act,

1972?

(c) The C.R.Z. Notification, 1991?

No

22. Whether there is any Government

Order/Policy relevant/relating to

the site?

No

23. Forest land involved (hectares) No

24. Whether there is any litigation

pending against the project

and/or land in which the project is

propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court,

if any and its relevance with the

proposed project.

No

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which

will cause physical changes in the locality (topography, land use, changes in water

bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes/No Details there of with approximate

quantities frates, wherever possible)

with source of information data

1.1 Permanent or temporary change in

land use, land cover or topography

including increase intensity of land

use (with respect to local land use

plan)

Yes Reference: Annexure – 2

1.2 Clearance of existing land,

vegetation and Buildings?

No --

1.3 Creation of new land uses?

No --

1.4 Pre-construction investigations e.g.

bore Houses, soil testing?

No --

1.5 Construction works? Yes Reference: Annexure – 2

1.6 Demolition works? No --

1.7 Temporary sites used for

construction works or housing of

construction workers?

No --

1.8 Above ground buildings, structures

or earthworks including linear

structures, cut and fill or

excavations

Yes Production plant, tank farm and ware

house

1.9 Underground works mining or

tunneling?

No --

1.10 Reclamation works? No --

1.11 Dredging? No --

1.12 Off shore structures? No --

1.13 Production and manufacturing

processes?

Yes Reference: Annexure - 3

1.14 Facilities for storage of goods or

materials?

Yes Existing storage facilities/area is

available as an existing infrastructure for

storage of existing raw materials,

finished products, hazardous/solid

wastes, etc.

Additional storage facility for raw

material and finished goods will be

created by constructing tank farm and

ware house

1.15 Facilities for treatment or disposal

of solid waste or liquid effluents?

Yes • Water consumption & Waste water

generation details

– Reference: Anneure-4.

• Effluent Treatment Plant details


• Hazardous/Solid wastes generation

and disposal mode details


1.16 Facilities for long term housing of

operational workers?

No --

1.17 New road, rail or sea traffic during

Construction or operation?

No --

1.18 New road, rail, air waterborne or

other transport infrastructure

including new or altered routes and

stations, ports, airports etc?

No --

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in Traffic

movements?

No --

1.20 New or diverted transmission lines

or Pipelines?

No --

1.21 Impoundment, damming, culver

ting, realignment or other changes

to the hydrology of watercourses or

aquifers?

No --

1.22 Stream crossings? No

1.23 Abstraction or transfers of water

form ground Or surface waters?

Yes • No ground water is and shall be used.

• Raw water requirement is met

through GIDC water supply and will be

met through same source after

proposed change in product mix.

• No increase in raw water consumption

after proposed change in products mix

and will remain same as existing.

1.24 Changes in water bodies or the land

surface Affecting drainage or run-

off?

No --

1.25 Transport of personnel or materials

for construction, operation or

decommissioning?

Yes Transportation of personnel or raw

materials/finished products is primarily

by road only.

1.26 Long-term dismantling or

decommissioning or restoration

works?

No --

1.27 Ongoing activity during

decommissioning which could

have an impact on the

environment?

No --

1.28 Influx of people to an area either

temporarily or permanently?

No --

1.29 Introduction of alien species? No --

1.30 Loss of native species or genetic

diversity?

No --

1.31 Any other actions? No --

2. Use of Natural resources for construction or operation of the Project (such as land,

water, materials or energy, especially any resources which are non-renewable or in short

supply):

Sr.

No.

Information/checklist confirmation Yes/No Details thereof (with approximate

quantities /rates, wherever possible)


2.1 Land especially undeveloped or

agricultural land (ha)

No --

2.2 Water (expected source &

competing users) unit: KLD

Yes • Raw water requirement is met through

GIDC water supply and will be met

through same source after proposed

change in product mix.

• No increase in raw water consumption

after proposed change in products mix

and will remain same as existing.

• Water consumption & Waste water

generation details – Reference:

Anneure-4.

2.3 Minerals (MT) No --

2.4 Construction material - stone,

aggregates,

And / soil (expected source - MT)

Yes Construction materials will be procured

from local market.

2.5 Forests and timber (source - MT) No. --

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes • Reference: Anneure-7.

• No increase in power requirement and

fuels consumption after proposed

change in products mix and will remain

same as existing.

2.7 Any other natural resources (use

appropriate standard units)

No --

3. Use, storage, transport, handling or production of substances or materials, which could

be harmful to human health or the environment or raise concerns about actual or

perceived risks to human health.

Sr.

No.

Information/Checklist confirmation Yes/No Details there of (with approximate

quantities/rates, wherever possible)


3.1 Use of substances or materials,

which are hazardous (as per MSIHC

rules) to human health or the

environment (flora, fauna, and

water supplies)

Yes Reference: Annexure -8.

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No --

3.3 Affect the welfare of people e.g. by

changing living conditions?

No --

3.4 Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the

elderly etc.

No --

3.5 Any other causes No --

4. Production of solid wastes during construction or operation or decommissioning

(MT/month)

Sr.

No.




4.1 Spoil, overburden or mine wastes No --

4.2 Municipal waste (domestic and or

commercial wastes)

No --

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Reference: Anneure-6.

4.4 Other industrial process wastes Yes Reference: Anneure-6.

4.5 Surplus product No --

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Reference: Anneure-6.

4.7 Construction or demolition wastes Yes

Structural waste will be sell to authorized

vendor

4.8 Redundant machinery or equipment No --

4.9 Contaminated soils or other

materials No --

4.10 Agricultural wastes No --

4.11 Other solid wastes Yes

Reference: Anneure-6.

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr.

No.




5.1 Emissions from combustion of fossil

fuels from stationary or mobile

sources


5.2 Emissions from production

processes


5.3 Emissions from materials handling

storage or transport

No • Raw materials receive in

drums/carboys/bags/tankers and

handled in closed charging system with

proper ventilation and charged through

close pipeline in to reactors/treatment

units. It will be done through same way

after proposed change in product mix.

• Thus there is no any kind of emission

through storage and transport.

5.4 Emissions from construction

activities including plant and

equipment

Yes Water sprinkling during construction to

avoid dusting and Barication of

construction area.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Water sprinkling during construction to

avoid dusting and Barication of

construction area.

5.6 Emissions from incineration of

waste

No --

5.7 Emissions from burning of waste in

open air e.g. slash materials,

construction debris)

Yes

Structural waste will be sold to

authorized vendor.

5.8 Emissions from any other sources No --

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.



with source of information data with

source of information data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes • There are few activities due to which

noise generates. The equipments

resulting in noise generation are

machineries of plant and diesel

generator. Adequate noise controls

measures are provided.

• Proper and timely oiling, lubrication and

preventive maintenance is carried out for

the machineries & equipments to reduce

noise generation.

• Use of PPE like ear plugs and ear muffs

are made compulsory near the high noise

generating machines.

• Noise monitoring is done regularly in

plant area.

• The D.G. Set is installed in a closed room

and provided with acoustic enclosure.

• The unit has developed plantation within

the premises which helps to prevent the

noise pollution within site as well as

surrounding area.

6.2 From industrial or similar processes Yes • All machinery/equipment is well

maintained, have proper foundation with

anti vibrating pads wherever applicable

and thus noise levels is within

permissible limits.

• An acoustic enclosure is provided for D.G.

set.

6.3 From construction or demolition Yes Barication of construction area.

6.4 From blasting or piling No No Blasting is required for construction.

6.5 From construction or operational

traffic

No --

6.6 From lighting or cooling systems No --

6.7 From any other sources No --

7. Risks of contamination of land or water from releases of pollutants into the ground

or into sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No.

Information/Checklist

confirmation

Yes/No Details there of (with approximate



7.1 From handling, storage, use or

spillage of hazardous materials

Yes • All hazardous materials stored with safely

measures separately in designated

storage area.

• Dyke walls are provided around

raw/hazardous materials storage tanks.

• Materials stored in bags / drums keep on

pallets with concrete flooring and

company takes preventive action for no

spillage likely to occur.

• Reference: Annexure -8.

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes Sewage is treated in existing ETP along

with industrial effluent and treated

effluent sends to GIDC underground drain

for its final disposal into deep sea.

7.3 By deposition of pollutants emitted

to air into the and or into water

No --

7.4 From any other sources No --

7.5 Is there a risk of long term build up

of pollutants in the environment

from these sources?

Yes • Environmental Management System

(EMS) is installed i.e. ETP, Air Pollution

Control systems, Hazardous Waste

Handling and Management system as per

rules, etc. which eliminates the possibility

of building up of pollution.

8. Risk of accidents during construction or operation of the Project, which could affect

human health or the environment

Sr.

No.

Information/Checklist

confirmation

Yes/No Details there of (with approximate



8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous

substances


8.2 From any other causes No --

8.3 Could the project be affected by

natural disasters causing

environmental damage (e.g.

floods, earthquakes, landslides,

cloudburst etc)?

No --

9. Factors which should be considered (such as consequential development) which could

lead to environmental effects or the potential for cumulative impacts with other

existing or planned activities in the locality

Sr.

No.

Information/Checklist confirmation

Yes/No

Details there of (with approximate

quantities/rates, wherever possible) with

source of information data

9.1 Lead to development of

supporting. utilities, ancillary

development or development

stimulated by the project which

could have impact on the

environment e.g.

• Supporting infrastructure

(roads, power supply, waste

or waste water treatment,

etc.)

• housing development

• extractive industry

• supply industry

• other

Yes Please refer Annexure – 10.

9.2 Lead to after-use of the site, which

could have an impact on the

environment

No --

9.3 Set a precedent for later

developments

No --

9.4 Have cumulative effects due to

proximity to other existing or

planned projects with similar effects

No --

(II) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance (within 15km.) Proposed

project location boundary

1 Areas protected under international

conventions, national or local

legislation for their ecological,

landscape, cultural or other related

value

No Plot is located within the Dahej Industrial

Estate.

2 Areas which important for are or

sensitive Ecol logical reasons -

Wetlands, watercourses or other

water bodies, coastal zone,

biospheres, mountains, forests

Yes Narmada River

3 Area used by protected, important

or sensitive Species of flora or fauna

for breeding, nesting, foraging,

resting, over wintering, migration

No --

4 Inland, coastal, marine or

underground waters

Yes Sea cost: < 10 km & Narmada estuary: 4-5

km

5 State, National boundaries No --

6 Routes or facilities used by the

public for access to recreation or

other tourist, pilgrim areas

No --

7 Defense installations No --

8 Densely populated or built-up area Yes Bharuch city = appox. 40 Km away from

project site.

9 Area occupied by sensitive man-

made land uses Hospitals, schools,

places of worship, community

facilities)

No --

10 Areas containing important, high

quality or scarce resources (ground

water resources, surface resources,

forestry, agriculture, fisheries,

tourism, minerals)

No --

11 Areas already subjected to pollution

environmental damage. (those

where existing legal environmental

standards are exceeded)or

No --

12 Areas susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquake s, subsidence

,landslides, flooding erosion, or

extreme or adverse climatic

conditions)

No --

IV). Proposed Terms of Reference for EIA studies: NA

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

1 List of Products with Production Capacity and Raw Materials Consumptions

2 Plot Layout

3 Brief Manufacturing Process Description

4 Water Consumption & Waste Water Generation

5 Description of Effluent Treatment Plant (ETP)

6 Solid/Hazardous Waste Generation and Disposal Mode

7 Power and Fuel Requirements

8 Storage Details of Hazardous Chemicals and Control Measures

9 Details of Sources of Emissions and APCM

10 Socio-economic Impacts

11 Copy of Land Possession/Plot Allotment document

12 Copy of common TSDF & CHWIF Membership Letter

13 Copy of GIDC letter for water supply

14 Copies of current valid CC&A

15 Toposheet

16 Copy of Amended Notification of MoEFCC Dated November 01, 2009

ANNEXURE-1

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY AND RAW MATERIALS

CONSUMPTION

SR.

NO.

PRODUCTS CAS No. PRODUCTION QUANTITY

(TON/ANNUM)

Existing After Change in

Product Mix

A. INTEGRATED POLYURETHANE (KU) COMPLEX

1. Polyether Polyols (PEOLs) 56731-02-3 50,000 T 50,000 T

2. Polyester Polyols (PESOLs) 25214-18-0 50,000 T 50,000 T

3. Methyl Diphenyl Di Isocyanate (MDI) splitter

(Distillation of crude MDI) 32055-14-4

80,000 T 80,000 T Monomeric MDI (MI+ME) 101-68-8

Polymeric MDI (M50 + M20) 9016-87-9

4. Poly Urethane (PU) Systems

a. Poly Ether Polyol (PEOL) / Polyester Polyol

(PESOL) Blends 63641-63-4

90,000 T

90,000 T

b. Isocyanate Blends 9016-87-9

c. Prepolymers 26447-40-5 35,000 T 35,000 T

5. Cellasto -- 20 million

pieces

20 million pieces

6. Thermoplastic Polyurethane (TPU) 25190-06-1 7,000 T 7,000 T

B. SURFACTANTS

7. Sulfation Products --

1,00,000 T 85,000 T

Sodium Lauryl Sulphate (SLS) high active 151-21-3

Sodium Lauryl Sulphate (SLS) low active 151-21-3

Sodium Lauryl Ether Sulphate (SLES) high

active

9004-82-4

Sodium Lauryl Ether Sulphate(SLES) low

active

9004-82-4

Linear Alkyl Benzene Sulphonic Acid (LABSA) 27176-87-0

Sodium Lauryl Sulphate (SLS) dry (needles)*

151-21-3

* one week production volume dry needles packed on pallet

LIST OF BY-PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY

Sr.

No.

PRODUCTS CAS No. Quantity

(T/Annum)

1. Sulfuric Acid (98%) ** 7664-93-9 380

Total 380

** Sulfuric Acid (98%) to be generated as by product is sent to BASF, Thane plant for reuse

or sold to actual end users.

8. Low Temperature Reaction (LTR) Products

20,000 T 20,000 T Gr. B - Liquid Alkano-amides (Comperlans) --

Gr. B – Betaines (Dehytons) 61789-40-0

Gr. C – Sulfosuccinates (Texapon) 577-11-7

9. High Temperature Reaction (HTR) Products

15,000 T 15,000 T

Gr. B - Dehyton intermediates --

Gr. D - Ester waxes (Cutina) --

Gr. E- Trimethyl-propanesters (Synatives) --

Gr. F Solid Alkano-amides (Comperlans) --

C. Polymeric Dispersions

1,00,000 T 1,00,000 T Acronals 55965-84-9

Styronals 55965-84-9

Basoplasts --

D. Coolant Fluids for automotive engines

Super Concentrate (SC) Coolants 107-21-1

-- 15,000 T Concentrate Coolants

107-21-1

Ready to Use (RTU) Coolants 107-21-1

Total 5,47,000

T/Annum

&

20 million

pieces/Ann

um

5,47,000

T/Annum &

20 million

pieces/Annum

RAW MATERIAL CONSUMPTION

SR. NO. RAW MATERIALS QUANTITY

(T/ANNUM)

Existing After Change in Product Mix


1. Polyether Polyols (PEOLs)

PO 29,587 29,587

Sugar 10,000 10,000

Vicinals 1,772 1,772

Glycerine 1,772 1,772

Heel 6,783 6,783

Imidazole 81 81

2. Polyester Polyols (PESOLs)

Adipic Acid 37,000 37,000

Diethylene glycol 17,000 17,000

MEG 10,000 10,000

Butane Diol 11,000 11,000

Additives Cat. 333 333

TMP 130 130

3. MDI Splitter

Crude MDI 80,000 80,000

4. PU Systems

a. & b. PEOL / PESOL & Isocyanate Blends

PEOL/ PESOL 67,500 67,500

TDI (50%) 7,500 7,500

PMDI (50%) 7,500 7,500

c. Prepolymer

PESOL 17,000 17,000

PEOL 17,000 17,000

MDI 18,000 18,000

5. Cellasto

NDI 230 230

PESOL 990 990

Water + Additives 110 110

6. TPU

MDI 3,000 3,000

PESOL 3,400 3,400

1,4 BDO 800 800

Catalyst & Stabilizer 35 35

B. SURFACTANTS

7. Sulfation Products

Sulfur 4739 3682

Fatty alcohol 9418 7318

Fatty Ethoxylate 23515 18271

Ammonia (25%) 216 168

Sodium Hydroxide (50%) 11578 8996

Hydrogen Peroxide 314 244

Sodium Chloride 62 48

Sodium Sulfate 150 117

Sodium Carbonate 1 1

Hydroxyethanediphosphoric Acid 22 17

Sulfuric Acid (30%) 36 28

Acticide MBS (preservatives) 3 2

Kathon CG (preservatives) 3 2

BIOZID (preservatives) 3 2

Trisodium Citrate 2H2O 140 109

Sodium Hypochlorite 10% 1 1

Sodium Dithionite 3 2

Dodecylbenzene sulphonic acid 288 224


Citric Acid 134 134

Potassium Sorbate 161 161

Sodium Sulfite 67 67

Maleic Anhydride 57 57

Sodium Carbonat 2 2

Dehydol 229 229

Coconut Oil 3249 3249

Methylethanolamine 707 707

Sodium methylate 34 34

Sodium Bifulfite 2 2

Sulfuric Acid 6 6

Sodium Monochloroacetate 1,720 1,720

Sodium Hydroxide 67 67

Dehyton 3822 3822

Dimethyl cocoamine 226 226

Diethanolamine 90 90

Acetic acid 6 6

Formaldehyde 2 2

Lorol 369 369

Sodium Dithionite 6 6


Edenor ST 05 3000 3000

Ethylene glycol 500 500

Celite 545 / Tonsil 26 26

Edenor MEPK 12-18 1100 1100

Diethanolamine (DEA) 550 550

Sodium methylate 13 13

NaCl 50 50

Sodium Bisulfite 50 50

Aminoethylethanolmine (AEEA) 1000 1000

Sodium Monochloroacetate 1,500 1,500

NaOH 716 716

Edenor 12-99 1700 1700

Edenor HK 12-18 1800 1800

Dimethylaminopropylamine 850 850

Celite 535 9 9

Trimethylpropane 200 200

Fatty Acid 550 550

C. POLYMERIC DISPERSIONS

Liquor ammonia 95 95

Sodium bicarbonate 35 35

Acrylamide (50 %) 550 550

Disponil 6 6

Formaldehyde 5 5

Styrene 19700 19700

n-Butyl Acrylate 13750 13750

Rongalit 2 2

Sodium Persulphate 320 320

t- BHP 85 85

Acticide 70 70

Trilon 3 3

Sodium Pyrophosphate 40 40

Dowfax 70 70

tDMK 240 240

Butadiene 8400 8400

Sodium lauryl sulphare 30 30

Sodium meta bisulphate 70 70

Acetone 46 46

Caustic Soda lye 331 331

Acrylic Acid 1,100 1,100

Agitan 6 6

Methyl Methacrylate 2,100 2,100

Calcium Acetate Food Grade 0.84 0.84

TERMAMYL 0.15 0.15

Acetic Acid 25 25

Amylex 15 270 270

Emulsifying Agent 0.36 0.36

Ferrous Sulphate 0.5 0.5

Hydrogen Peroxide 57 57

Etingal L 0.25 0.25

2-Ethylhexyl Acrylate 60 60

Trilon B Pwd. 2.77 2.77

Formaldehyde 4.2 4.2

tert-Butyl hydroperoxide 70% 83 83

Acrylonitrile RM 474 474

Caustic Soda 48% 145 145

D Coolant Fluids for automotive engines

Monoethylene glycol, tech. grade -- 9670

Potassium hydroxide solution 48 % -- 577

Sodium hydroxide, 50% -- 61

Sebacic acid -- 313

Dodecanedioic acid -- 6

Adipic acid -- 30

2-Ethylhexanoic acid -- 126

Isononaic Acid -- 33

Phosphoric acid, 75% -- 38

Benzotriazol -- 11

Tolutriazole -- 30

Super Concentrate G96-00 -- 39

Other addeitives -- 325

TOTAL 471762 471762

ANNEXURE-2

PLOT LAYOUT

ANNEXURE-3

BRIEF MANUFACTURING PROCESS DESCRIPTION


1. Polyether Polyols (PEOL)

1.1 Process Description

The synthesis of low molecular weight rigid polyether polyols (or polyols) is a batch process.

Several different raw materials like Sugar, Glycerin, TDA Vicinals and a Heel are used as starters,

depending on the product. The starters and the catalyst Imidazole are dosed in to an inert

reactor.

The correct amount of Propylene oxide, “PO” needed for the syntheses is also dosed. Syntheses

proceeds in the reactor at a temperature between 105 and 140°C, depending on the type of

polyol. The dosing time of the PO is between 4 and 8 hours depending on the type of polyol. The

resulting reaction heat (exothermic reaction) of the PO with the starter and the catalyst is

removed by the internal cooling coils in the reactor. Subsequently, the remaining PO is further

reacted, “post cooking”.

Unreacted PO is then further removed from the polyether by applying vacuum (steam jets or

vacuum pump). The finished polyether is further cooled down to storage temperature and

pumped out to the storage tank.

1.2 Chemical Reaction

(C3H6)O +C2H5OH KOH HO-C3H6-C2H5

1.3 Material balance

Reactor

29588 T

PO

10004 T Sugar

1772 T Vicinals

1772 T Glycerine

6783 T Heel

81 T Imidazole/water

Peol 50000 T

Offgas to Regeneration

Thermal Oxidiser (RTO) 150

T

2. Polyester Polyols (PESOL)


The process involves the polycondensation reaction between Adipic Acid and Glycols (MEG,

DEG, and Butandiol) at temperatures of about 250°C. The Polyester Polyol is the main product

and water is the by-product.

To remove water from the reaction mass on a continuous basis so that reaction is completed to

full conversion, the distillation is carried out under vacuum conditions. A fractionation column

with suitable structured packing is installed to ensure pure water is distilled out of the reaction

mass and raw materials losses are minimized.

Water vapors from column are then condensed in overhead condensers and the same is

collected in a collection tank.

This water is sent to Effluent treatment plant for Primary, secondary treatments etc.

Post completion of reaction, small excess charge of Glycols is recovered in separate tank. This

Glycol mixture can be recycled back in the next batch or sold to Glycol recovery units as side

product. Else it can be sent for incineration to recover calorific value.

There are no gaseous products formed and reaction leads to no gaseous emissions.

The reaction is endothermic and there is no risk of runaway exothermic reaction.


2.3 Material Balance

POLYCONDENSATION

Adipic Acid

MEG

Diethylene glycol

Butane Diol

TMP 220 kg

26,198 kg

5676 kg

10479 kg

6588 kg

Pesol

36000 Kg

Additives Cat.

87 Kg

Effluent Water

5660 Kg

ETP

Excess Recovered Glycols 303 Kg

Recycle 202 Kg

Process waste

(101 Kg)

3. MDI SPLITTER (Distillation of crude MDI)


Crude MDI is a mixture of polymeric MDI (PMDI) and monomeric MDI (MMDI). In a first

purification step, the crude MDI is separated into the PMDI stream, an isomer stream and inerts

(MCB, HCl, N2) by high temperature vacuum distillation. The bottom product is the desired PMDI

that is cooled down and fed into check tanks and subsequently to one of the finished products

tanks. Condensed MDI isomers, with traces of PMDI, are obtained and transferred to a second

distillation column for further purification. In this column the residual PMDI is removed and the

isomers are separated in two monomeric grades MI & ME. After cooling down, the final products

are discharged to the check tank and to the storage tank.


Overall material balance for MDI splitter

Production Capacity 80,000 t/a

Considering working

hours 7,800 hrs/year

10,256 kg/hr

Raw material input Product output

Kg/hr Kg/hr Remarks

CMDI 10,256

PMDI

(M50+M20) 5,641 Products

of CMDI

distillation

ME 4,308

MI 308

Total Input 10,256 Total output 10,256

Waste water

generation 500

From offgas

scrubber

Offgas from

Scrubber 30 Nm3/hr

Blender

Additives

(2,250 T)

PESOL/PEOL (67,500 T)

Amine Cat.

(3,750 T) Water/blowing

agent (1,500 T)

Blends (75,000 T)

Material Balance

4. PU Systems

a. Polyol Blends

Process Description

The process involves physical blending with no chemical reaction of various polyether polyols or

polyester polyols and certain catalysts and additive materials. As there is no chemical reaction

and its pure blending process, there is no risk of any runaway reaction. No gaseous products are

formed. No effluent is generated in the process.

b. Isocyanate Blends

Process Description

Process is simple mixing of different types of Aromatic Isocyanate Grades such as TDI, PMDI, MS

etc in required composition. No gaseous products are formed as no reaction is involved. No

byproducts and liquid effluent is generated in this process.

Material Balance

Blender

MDI 50% (7,5 00 T)

PMDI 50% ( 7,500 T)

Isocyanate ( 15 ,000 T)

To atmosphere through

filter

C. PREPOLYMER

Process Description

Reaction of Polyester/Polyether Polyols is carried out with Methyl Diphenyl Di-isocyanate (MDI)

at a temperature of about 70°C.No gaseous products are formed in the reaction. No byproducts

and liquid effluent is generated in this process. The product is packed in drums.

O=C=N-R -N=C=O + HO-R -OH [-OC -NH-R -NH -CO-O -R -O -]n

( MDI)

Material Balance

Reactor

Pesol/Peol

MDI 18 KT

17 KT

Additives Cat. (<1%)

Prepolymer

35 KT

Chemical Reaction

5. CELLASTO


The cellasto-prepolymer is produced in a discontinuous batch process by the chemical reaction

of polyol and isocyanate components.

The prepolymerization takes place in buckets in which polyol is discharged. The buckets are

placed in to prepolymer double reaction unit which are then heated. After that, NDI is dosed

manually into these buckets within a certain time. Then both ingredients are agitated. This is

followed by an exothermic reaction. Subsequently the prepolymer is cooled down.

After prepolymer process is finished, the buckets with prepolymer are stored in an oven.

To start up mould line the mould are heated up to the required temp. and dosing machine is

charged with prepolymer and crosslinker (various ingredients like additives, catalysts, stabilizer,

emulsifying agents etc.) agent. They are stirred in the mixing head and dosed into the mould

cavities. After the ending of the dosing the conveyor reached the green strength and is ready to

demould.

After the foaming process on the mould line the parts have to be thermal treated in order to

reach the final material properties and performance. The produced parts are collected in

aluminium boxes at the mould line.



Overall material balance for Cellasto Plant

Production Capacity 20,000,000 pieces/a (excluding rejection)

21052632 pieces/a (including rejection)

Average part weight 50 g

1052632 Kg/a

Material loss (assumed) 15%

Raw material consumption 1210526 Kg/a

Raw material input Product output

Kg/a t/a pieces/a Kg/a

PESOL 983368 983 Cellasto pieces 20000000 1000000

NDI 227158 227 Sold waste (rejected

pieces to be disposed) 1052632 52632

Solid waste due to

material loss (15%) 181579

Total Input 1210526 Total Solid Waste 234211

Prepolymer

Reactor

Dosing

machine

Mould Line Curing Oven

NDI

PESOL

Cross Linker

Cellasto

Solid Waste off

Specification rejects

6. TPU


There are two methods of production and both can/will be utilized on the site:

• Band casting

• Reaction extrusion

In the Band Casting production process the basic ingredients are fed into a mixing head and

intensively mixed for very short times before the reaction mass is discharged onto a continuous

steel or plastic conveyor belt on which the mixed components react under heat and the mass

solidifies. This method can be used continuously and discontinuously. The main difference being

that in the discontinuous conveyor belt/separate block system the solid tray of material is

removed at the end of the conveyor belt, thermally treated in an oven, ground to chips in a mill

and, if necessary extruded and pelletized to obtain uniformly shaped pellets. During continuous

production, the reaction mass is transferred directly from the conveyor belt to an extruder for

final reaction, homogenization and processing into pellets.

In the Reactive Extrusion process the raw materials – diisocyanate, polyol, chain extenders – are

metered in one step into a twin screw reactor extruder where they react as they move down the

screw, forming a highly viscous mix and finally an almost completely reacted TPU.

The product is stored in silo(s) and packed in 100 kg/drum or 1000 kg/tie-bag sealed with PP/PE

plastic bag to avoid moisture penetration.



Production Unit

3000 T MDI

3400 T PESOL

800 T 1,4 BDO

35 T Catalyst & Stabilizer

TPU 7000 T

Liquid Waste 40 T

(Treatment - burn)

Waste Slab 44 T

(Treatment – Recycled by

Customer)

Melt 160 T

(Treatment – Recycled by

Customer)

Recycle and waste

granules 160 T

(Treatment – Rework)

B. SURFACTANTS

7. SULFATION


Sulfur combustion

In a first step solid sulfur is melted and injected into the burner. In the burner the liquid sulfur

oxygenates to SO2-gas. The hot gas (600-700°C) is further oxygenated to SO3 in a converter with

a catalyzed bed. The SO3-Gas (98%) is cooled down with cooling air in two coolers before

entering the reactor.

Air drying unit

In the air drying unit 10 ambient air is cooled down, in a first step by cooling tower water in a

second step by chilled solution to 3-5°C. Subsequently the air passes one of two parallel,

regenerative solid desiccant beds. One bed is in operation and in the mean time the other bed is

under regeneration. The treated air has approximately a dew point of -70/-60°C. This dried air is

used for the SO3 generation as well as dilution air before the gas is entering the reactor.

The reactor

The diluted gas (3-6% SO3) and the organic are entering at the top of the two reactors, a smaller

reactor with 48 and a larger reactor with 90 tubes. The organic forms a liquid falling film inside

of the tubes while the gas is flowing in the middle of the tubes. The reaction of organic and SO3

to sulfuric ester takes place in the falling film. In two following cyclones the sulfuric ester is

separated from the gas phase.

Ageing unit

In case of linear alkyl benzene sulfonic acid (LABSA) production the acid leaving the reactor is

hydrolyzed in the ageing unit, before it is stored in the finished product tank farm unit 17.

Neutralization

In case of sodium lauryl sulfate (SLS) and sodium lauryl ether sulfate (SLES) the sulfuric ester

flows continuously from the cyclones through the neutralization loop of neutralization I or II. The

sulfuric ester is routed to the suction of the high shear mixer. The high shear mixer homogenizes

the sulfuric ester, water, alkali, several additives and forms paste. For producing SLS needles the

sulfuric ester enters neutralization III being a loop with internal cooling and no degasser from

where it is pumped directly to the Turbo Tube Dryer.

The neutralized paste of SLS or SLES is fed to a degasser under a vacuum of approx. 100 mbar.

The vacuum of the degasser can reduce dioxane by water stripping. The vapor is condensed by a

condenser and routed via a droplet separator to a water ring pump which contains a close

cooling loop.

Adjustment

From the neutralization and degassing loop I and II the SLS and SLES paste enter continuously

one of the adjustment vessels. In order to obtain final product specifications more chemicals are

added and homogenized in the adjustment vessels. The specified product is pumped to the

finished product tank farm or filled into drums.

As an additional option intermediate product of the tank farm could be diluted in a dilution

vessel. In contrast to the adjustment vessels the dilution vessel has an additional high shear

mixer in the circulation loop and the opportunity to preheat the entering water.


7.3 Material Balance for Sulfation

7.3.1 Material Balance for SLES

Sr.

No.

Raw Material Qty. (g) Product Qty. (g)

1 Sulfur 70 SLES 1000

2 Oxygen from Process Air 100

3 Fatty Ethoxylate 500

4 Water 170

5 Sodium Hydroxide 150

6 Hydrogen Peroxide 10

7.3.2 Material Balance for SLS

Sr.

No.


1 Sulfur 87 SLES 1000

2 Oxygen from Process Air 130

3 Fatty alcohol 511

4 Water 43

5 Sodium Hydroxide 221

6 Ammonia 8



The production can be splitted into three product groups:

Group A: Liquid Alkano-amides (Comperlans)

Group B: Betaines (Dehytons)

Group C: Sulfosuccinates (Texapon)

Raw material:

Group A: Diethanolamine, Edenor

Group B: Dehyton Intermediate, Dimethyl Cocoamine

Group C: Dehydol LS3

E.g. Group A:

Chemicals/ catalysts:

Raw Materials are charged in to vaccum reactor.

The chemicals such as strong acids, sodium methylate and caustic soda in surge container are

routed to reactor by gravity. Some small amount liquid catalyst can be fed into reactor via

catalyst small vessel.

Reaction:

The liquid is discharged to reactor and heated up by steam via heating external coil. Then the

solid in big bag is discharged into reactor. When the reaction temperature is reached, the

catalyst (solid or liquid) is dosed into reactor. E.g. during the reaction of manufacturing

comperlan, the reactor is operated under vacuum, the methanol as by-product released as

vapor can be condensed in the cooling water condenser and finally condensed in the chilled

water condenser. Leakage air is routed to the water ring pump with closed loop cooling and

compressed to atmosphere pressure. Rest of methanol in air can be totally washed out in the

caustic soda scrubber. The waste water is routed to the waste water treatment. The waste

methanol as distillate is accumulated in distillate vessel and the pumped to the finished tank

farm for disposal.

After the reaction step the finished product is cooled by an external plate cooler and transferred

by reactor bottom pump via bag filter to tanks in the finished product tank farm.

Scrubber:

Rest of methanol after chilled condenser and water ring pump can be totally washed out in the

caustic soda scrubber. The SO2 gas released as by-product during dissolving process of sodium

sulfite into water can be also scrubbed by caustic soda solution. The alkalic waste water is

routed to the waste water treatment.


Sr.

No. Raw Materials Qty. (g) Products Qty. (g)

1. Citric Acid 0.4 Texapon 1000

2. Potassium Sorbate 4

3. Sodium Sulfite 102

4. Maleic Anhydride 83

5. Sodium Carbonat 1.65

6. Dehydol 232.7

7. DM Water 575

1. Coconut Oil 215.5 Comperlan 1000

2. Methylethanolamine 781

3. Sodium methylate 8

1. NaCl +Sodium Bifulfite 6 Dehyton 1000

2. Citric Acid 3

3. Potassium Sorbate 5

4. Sulfuric Acid 7

5. Sodium Monochloroacetate 100

6. Sodium Hydroxide 10.08

7. Dehyton 255

8. DM Water 613.65



The production can be splitted into three product groups:

Group A: Comperlan

Group B: Dehyton (Betaines) Intermediates

Group C: Cutina

Raw material:

Group A: Edenor 12/18 methyl ester, Diethanolamine

Group B: Dimethylamonopropylamine (DMAPA)

Group C: Ethylene glycol, Edenor St05, Oleic acid, Edenor C12 99

Chemicals/ catalysts:

Raw Materials are charged in to vaccum reactor.

The chemicals such as strong acids or strong bases such as caustic soda in surge container are

dosed to reactor by gravity. Some small amounts of liquid catalyst can be fed into reactor via

catalyst small dosing vessel.

Reactor and condenser / vacuum unit:

The liquid is discharged to reactor and heated up by thermal oil up to 240°C via external heater.

Then the solid in big bag is discharged into reactor. When the reaction temperature is reached,

the catalyst (solid or liquid) is dosed into reactor. During the reaction, the reactor can be

operated under vacuum in order to remove water as reaction by-product, some volatile

reactants are condensed selectively by the hot water dephlegmator. The water vapour can be

condensed in the cooling water final condenser. Condensate from deplegmator can be

separated in organic phase and water phase in a gravity separator. The organic phase can be fed

back to reactor. The water phase is routed to distillate vessel and then pumped out to waste

water treatment.

In case methanol as by-product the methanol is routed to waste methanol tank in tank farm.

Leakage air is routed to the steam ejectors and water ring pump with closed loop cooling and

compressed to atmosphere pressure. Rest of volatile organics in air can be totally washed out in

the caustic soda scrubber of the LTR unit.

After the reaction step the finished product is cooled by an external cooler and transferred by

reactor bottom pump to tank farm or to refinery vessel for further steps.

Refinery vessel with filter press

The product from HTR reactor is cooled and pumped to the refinery vessel. In this vessel the

product will be neutralized by caustic soda solution, washed by process water, bleached by

bleaching earth and dried by vacuum. When refinery steps are finished, the product is pumped

via filter press and cooler to tank farm as finished product.

Some product can be pumped directly to LTR reactor (Dehyton Intermediates) in order to finalize

the final reaction step.

Some products of Cutina and Comperlan with high melting point will be pelletized or flaked in a

pelletizing or flaking unit.

Finished product tank farm

The tanks are, if required, can be tempered and kept warm against heat loss by tempered water

heating coil or steam in order to avoid product freezing. Especially Comperlan, Cutina must be

kept at 80 C, above its melting temperature.

All finished products can be coupled via coupling header to filling station for tank truck loading

or routed to drum filling unit/ flaking unit.


Sr. No. Raw Materials Qty. (g) Products Qty.(g)

1 Edenor MEPK 677 Comperlan 1000 2 Diethanolamine 320 3 Sodium methylate 8

1 Edenor ST05 887 Cutina AGS/EGMS 1000 2 Ethylene Glycol 113 3 Celite 545 / Tonsil 5

1 NaCl + Sodium Bifulfite 10 Dehyton KE 1000 2 Aminoethyleethanolamine 104 3 Sodium Monochloroacetate 191 4 NaOH 129 5 Edenor 172 6 Water 394

1 NaCl + Sodium Bifulfite 10 Dehyton K 1000 2 Dimethylaminopropylamine 83 3 Sodium Monochloroacetate 100 4 NaOH 3 5 Edenor 182 6 Water 622

1 Celite 535 4 Synative 1000 2 Trimethylpropane 223 3 NaOH 4 4 Fatty Acid 768

C. POLYMERIC DISPERSION

Process Description

The process to manufacture polymer dispersions consists of five steps: pre-mixing,

polymerization, blow-down step (post reaction), deodorization, filtration and conditioning of

the final dispersion.

Step 1: Premix

An aqueous solution consisting mainly of emulsifiers and smaller amounts of monomers and

auxiliary agents are mixed in the premix vessel and kept in preparation for the controlled feed

of the aqueous phase to the reactor.

Step 2: Reaction

The evacuated polymerization reactor (200 mbarabs) is loaded with an initial amount of de-

mineralized water (DM-water) and an initial amount of emulsifiers. The reactor is heated with

jacket and live steam close to the reaction temperature.

At 83°C a pre-charge quantity of premix1 (aqueous solution) and monomers (butadiene,

Butylacrylate and Styrene) from the monomer tanks are added. Then a pre-charge of initiator is

added to start the reaction, which is indicated by a temperature rise. Subsequently, a direct

feed of the aqueous phase, monomers and initiator starts. A homogeneous monomer/water

pre-emulsion is formed by means of an emulsion injector. Initiator solution and butadiene are

added after the mixing into the same feed pipe.

The reaction heat is removed from the reaction mixture via the cooling jacket. Feed and

reaction time will be in the order of 3-4.5 hours, the total batch time will be 5 to 7 hours.

Step 3: Post reaction

After the end of the polymerization, the dispersion is transferred to the evacuated

(300 mbarabs) blow down vessel within 10 - 15 minutes using the residual pressure of and

gravity. The transfer of the batch is assisted by adding low pressure steam into the top of the

reactor. The condensation of steam on the reactor wall washes most of the remaining

dispersion down and completes the transfer of the batch. This steam pressure optimizes

emptying of the reactor and minimizes wall fouling, therefore, reduces the need for high

pressure water jet cleaning and the subsequent large volumes of cleaning water.

Premix vessel has already been made ready for the next batch and after reactor is emptied into

the blow down reactor, the unit is ready for the start of the next batch.

In the post reaction starts with a chemical post treatment using aqueous solutions of tertiary

butyl hydroxoperoxide and sodium acetone bisulfite in order to reduce the residual monomer

content. The pH-value is adjusted with sodium hydroxide before adding the chemical

deodorization component. The pH-adjustment avoids coagulum formation during physical

steam stripping.

Step 4: Deodorization

Further reduction of residual volatiles is done in the deodorization system. The dispersion is

stripped with steam in column. To avoid overheated steam, which may lead to the formation of

coagulum, the steam has to be conditioned with DM-water

The off-gases generated during the deodorization will be condensed, the condensate will be

stripped again with steam and the off-gases of the condensate stripper will be incinerated in

the off gas burner system.

Step 5: Filtration and conditioning

The dispersion leaves the deodorization column with a temperature of about 75 °C and is

cooled down to 35 °C in the vacuum cooling system. The dispersion is collected in a

conditioning vessel (K 6111) where the specified product properties such as solids content, pH-

value, biocides, and defoamer are adjusted. Finally, the dispersion is transferred via filtration

into the storage tanks for filling into drums or containers.

All waste gases are handled in the off gas burner system in the boiler.

The waste waters are collected. Steam condensate is reused for polymer solids adjustment

whilst contaminated polymer dispersed in the waste water (white water) if unable to be reused

is chemically flocculated in a simple agitated vessel. The clarified water (COD < 1000 ppm) is

transferred to the biological waste water treatment plant for further treatment. The effluent

water will have COD < 100 ppm which is according to the local regulation. Solid wastes

(flocculated polymer, post-concentrated in a filter press, filtration residue etc.) are collected

and are incinerated by a Government licensed service provider.

For Basoplasts

For the start of the reaction an initial amount of demineralized water (DM-water) together with

an initial amount of monomers (2-Ethylhexyl acrylate,Acrylonitrile) plus a quantity of intiator

solution and - in some cases - Amylex15 are filled into the poly reactor. The reactor is

evacuated conditions, the initial start quantity of the monomer pre-emulsion is heated up by

direct steam injection up to the desired start temperature (e.g. 95ºC). Now the direct feed of

the aqueous phase, monomer phase, and initiator start. . From these two components, a

homogenous monomer/water pre-emulsion is formed by means of a static mixer. Initiator

solution are added after the mixing into the same feed pipe. The reaction is DCS-controlled and

supervised continuously during the total feed time. The reaction heat is removed from the

reaction mixture via the c0oling jacket. For the cooling jacket, cooling tower water will be used.

Feed and reaction time will be in the order of 3 –4 hours, the total batch time will be 6 hours.

After the end of the reaction the base dispersion will be transferred to the evacuated (300

mbar abs.) blow down reactor

The transfer of the batch is completed by slightly pressurizing with steam from the top of the

reactor. The advantage of this procedure is as follows: Due to condensate formation on the

walls of the reactor the remaining dispersion is washed down and transferred together with the

batch. Thus increasing the yield and minimizing reactor fouling, the need for high pressure

cleaning and the amount of wastewater for cleaning is reduced.

The reactor and the premix vessel are now available for the next batch after the product

transfer.

After the product transfer to the blow down reactor the post reaction starts with the chemical

post treatment using aqueous solutions of Rongalit, TBHP, and Sodium Acetone Bisulphite in

order to decrease the residual monomer content. Optionally the pH-value may be adjusted

with Sodium Hydroxide and/or NH3-solution before adding the chemical deodorization

components.

Chemical Reaction

Styrene-Butadiene Dispersions, the main monomers are

Styrene

Butadiene

Acrylonitrile

In case of Acrylic dispersions the main monomers are Acrylics and Styrene

R stands for different chemical groups, which make up the different Acrylic monomers

In some case vinyl acetate

and a polymer dispersion is the final product of an emulsion polymerization

Material Balance (Acronal)

Sr.

No.


1 Liquor ammonia 1.20 Acronal 1000

2 Sodium bicarbonate 1.66

3 Acrylamide 50 % 21.82

4 Disponil AES 25 13.35

5 Formaldehyde 2.26

6 Styrene 164.67

7 n-Butyl Acrylate 380.94

8 Rongalit C 0.73

9 Vorproduct T 6772 6.53

10 Sodium Persulphate 3.18

11 t- BHP 1.68

12 Emulan OP 25 2.71

13 Acticide MV 1.36

14 Water 347.71

15 Adjusted water 50.20

Material Balance (Styronal)

Sr.

No.


1 Trilon 0.01 Styronal 1000

2 Sodium Pyrophosphate 1.40

3 Dowfax 9.26

4 tDMK 6.99

5 Acrylamide 14.30

6 Styrene 259.75

7 Butadiene 187.97

8 Sodium lauryl sulphare 3.68

9 Vorproduct 12.55

10 Sodium Persulphate 5.05

11 t- BHP 1.64

12 Sodium meta bisulphite 1.15

13 Acetone 0.73

14 Caustic Soda lye 6.62

15 Acrylic Acid 15.88

16 Agitan 0.12

17 Acticide 1.94

18 Water 421.80

19 Adjusted water 49.16

D. Coolant Fluids for automotive engines

1. Blending & Packing Process Description for Super Concentrate Products

Process Description:

The new coolant production line is a blending unit, and mainly made up of reactor, heating and

cooling system, storage tanks and transfer pumps. In the process of a batch reaction, add

a certain amount of MEG and KOH solution first, at the same time heat the reactor with hot

water, when the temperature of solution in reactor reaches ~ 50℃, add a certain amount of

solid or fluid organic acids and KOH solution, then heat solution in reactor to ~ 60℃. The added

materials will blended in this condition in reactor. When the blending proceeds some time

later, cool solution in reactor with cool water, then add other additives like antifoaming agents

and dyestuffs. After a period of time, when all components are dissolved, transfer the product

in reactor to tank farm with pump. The batch size of super concentrate will be ~ 18 MT and

cycle time will be ~ 16-24 hours.

Typical Reaction and block flow diagram is as below,

Material Balance:

Note –

1. This is a batch process

2. No waste generated during the blending process.

Blending

Process in

Reactor

Mono Ethylene Glycol

48% KOH Solution

Organic Acid

Additives

Total Input 18 Tons

Transfer to Storage

Tanks at tank farm

Total Input 18 Tons

2. Blending & Packing Process Description for Concentrate & RTU Products

Process Description:

For production of Ready to Use (RTU) and concentrate coolant, Super concentrate from

storage tank (TK-2501A/B) or from blending reactor transferred to the FG storage tank (TK-

2502A/B) and will be blend with MEG and DM water. The batch size of concentrate and

RTU will be ~ 50 MT and cycle time will be ~ 48 hours.

Material Balance:

Note –

1. This is a batch process

2. No waste generated during the mixing process.

Mixing

Process in

Tanks

Super Concentrate

DM Water

Mono Ethylene Glycol

Total Input 40 Tons

Transfer for Drumming

OR Tanker loading

Total Input 40 Tons

ANNEXURE-4

WATER CONSUMPTION AND WASTE WATER GENERATION

SECTION EXISTING QUANTITY

(KL/DAY)

AFTER CHANGE IN PRODUCT

MIX (KL/Day)

Water

Consumption

Waste water

Generation

Water

Consumption

Waste water

Generation

Industrial Process 250 250 250 250

Washing 623 215 623 215

Boiler 332 265 332 265

Cooling 3550 420 3550 420

Total (Industrial) 4755 1150 4755 1150

Domestic 100 100 100 100

Gardening 100 - 100 -

Total Water Consumption

(KL/DAY)

4955 1250 4955 1250

NOTE: Water consumption and waste water generation won’t increase after change in products

mix and will remain same as existing.

ANNEXURE-5

DESCRIPTION OF EFFLUENT TREATMENT PLANT (ETP)

M/s. BASF India Ltd. has an ETP consists of primary, secondary and tertiary treatment facility.

Detail of the ETP plant with unit dimensions is as below.

The WWT plant is designed to treat polluted process waste water streams including used fire

fighting water, cooling tower blow-down, sanitary waste water and rainwater from potentially

contaminated process areas (first flush) and tank farm areas.

The system contains in essence the treatment stages bar screen, neutralization, equalization,

off-spec-management, 2 stage biological activated sludge process with 2 separated sludge

circles, sludge thickening and dewatering with belt filter press or alternative centrifuge.

Under normal condition biological treatment is operated as one treatment train with 100%

capacity. The biological cascade with 2 stages should be designed in that way, that it is possible

to operate stage one (TK XX07; X XX01) and stage two (TK XX08; X XX02) in parallel in case of

maintenance or break down. In case of maintenance it should be possible to send WW from TK

XX07 to X XX02 and from TK XX08 To X XX01.

Sludge thickener and belt filter press are planned as single line (100% capacity). Each line is able

to operate in single mode.

The configuration and arrangement of the waste water treatment plant has to be arranged in

such a way so as to permit the accommodation of a further treatment line adjacent to the

existing at a future date.

Process WW streams are pumped via header system to the planned treatment plant.

Temperature and flow rate should be monitored. If required the influent should also be

monitored by explosimeter. For cost allocation i might be useful to install flow proportion auto

sampler system (preferential by gravity flow) to the neutralization unit comprising a

homogenization tank and a 2 stage neutralization cascade. All tanks are linked with HDPE. The

waste water will be neutralized with H2SO4 (alternative HCL) and NaOH (concentrations of

agents to be finalized during detailed engineering).

Neutralized WW flows to the equalization tank TK XX04 preferential by gravity flow. An optional

TOC measurement can be used to alarm organic peak loads and to divert the off-spec waste

water to TK XX05/ TK XX06. TK XX06 might not be necessary if high concentrated streams from

EM will be buffered in the process plant directly.

From TK XX04 WW is transported to the biological treatment using pumps with variable

frequency control (VFC). The system should be controlled using TOC monitoring and flow

measurement (if required explosimeter).

Up from the biological unit waste water will flow down up to the end of the treatment system

by gravity.

The biological unit should be established in a compact design. To avoid foaming the system

should be equipped with invent mixer/aerators. A preliminary quotation of the aeration unit is

prepared by invent company and is handed over to the CONTRACTOR. Maximum air supply at

normal condition is estimated with 1665 m3/hr. The feed of plant air is controlled by dissolved

oxygen probes. The dissolved oxygen concentration in the aerobic zone is above 2 mg/l.

The control system has to be worked out by CONTRACTOR using continuous monitoring of O2

Concentration (redundant DO measurement in each tank). The invent mixers are run with fixed

speed. The blowers should be equipped with VFC.

Under normal operation condition TK XX07 serves as high load aeration whereas TK XX08 is

operated as an extended aeration where specialized microorganism is established to degrade

non readily biodegradable compounds. A back up mixer system is installed in TK XX08 cooling

tower blow down sanitary WW should be pumped to TK XX08 directly. For the design a water

level of 5.5 m was selected (free board 0.5m). PH has to be monitored in TK XX07 an TK XX08.

If required nitrogen and phosphate are dosed in both biological stages (e.g. Urea; H3PO4).

Buffer tanks for a two week storage should be provide. Tank capacity and dosage rate have to

be elaborated during detail engineering. Nutrient dosage should be controlled by influent flow

to biological treatment.

As described above NH3-N is removed by decentralized physical/chemical treatment process of

ammonia stripping by degradation of nitrogen compounds. NH3 can be generated within the

activated sludge process which is mainly incorporated in the biomass.

The mixed liquor concentration in all zones are controlled at 4000-5000 mg / l with the return

sludge pumps.

To prevent unintended degassing in the sedimentation, degassing chambers in the effluent of

TK XX08 should be provide.

After each activated sludge treatment process, the mixed liquor is separated from the treated

waste water in the secondary sedimentation using 2 circular clarifiers. Scrapper system surface

skimmer devices and scum collecting system have to be provided. The separated sludge is

recycled back into the activated sludge tank TK XX07, respected.

The cleared waste water flow by gravity into effluent pump pit followed by the effluent control

pit in case that the effluent does not comply with the legal requirements it can be pumped back

to the neutralization and can be diverted to the off-spec basin.

It is recommended to reserve some space near the EPP in case that a sand filtration step is

required in future. In that case the pumps P XX13 A,(B) can be used to feed the sand filter

system.

Excess sludge is routed to circular thickeners. The thickened sludge is dewatered in a belt filter

presses to a solid concentration of about 20%. To improve the dewatering quality cationic

flocculating agent has to be added. For better homogenizing inline mixer or adequate system

should be provide in the feed line to the belt filter press. A polymer system and measuring tank

is required (to be specified during detailed engineering). The maximum amount of excess

sludge is estimated with around 500 kg dry solid/day. Assuming a dry solid content of 20% after

dewatering, maximum sludge amount for disposal is around 2.5 t/d. The dewatered sludge is

collected in bunkers or containers for further transportation by truck.

Supernatant from the thickener, filtrate and flushing water flow to a filtrate sump to be

pumped to the equalization.

PE system,belt filter presses and truck loading are located in a filter press house.

Chemical dosing tank and dosing pumps with belonging station and facilities are located in a

tankfarm area. Doesing pumps should be housed.

A control room and laboratory is required which can be located in the COB building.

List of ETP units & Flow diagram is given below.

ETP UNITS:

Sr.

No.

Name of Unit Size (m X m X m) Tag No. Volume

M3

Detention

Time hrs/min

1 Inline Bar Screen 155 m3/hr. FXX 01 --- ---

2 Buffer neutralization

Tank

10 m x 8m x (3.9 m +1m) TK XX01 310 5.72hrs

3 Neutralization Tanks-1 3.5 m x 3.5m x (3.3 m +1m) TK XX02 40 45 min

4 Neutralization Tanks-2 3.5 m x 3.5m x (3.3 m +1m) TK XX03 40 45 min

5 Equalization-1 12 m x 12 m x (7 m +1m) TK XX04 1000 18.46 hrs

6 Equalization-2(stand by) 12 m x 6 m x (7 m +1m) TK XX05 500 9.23 hrs

7 Equalization-3 (Stand by) 12 m x 6 m x (7 m +1m) TK XX06 500 9.23 hrs

8 Aeration Tank-1 25.1 m x 12m x (5.5 m +0.5m) TK XX07 1670 30.83 hrs

9 Secondary Clarifier-1 10 m dia x (4 m + 0.5 m) X XX01 390 7.2 hrs

10 Aeration Tank-2 20.1 m x 9m x (5.5 m +0.5m) TK XX08 1000 18.46 hrs

11 Secondary Clarifier-2 11.7 m dia x 4 m X XX02 506 9.34 hrs

12 Sludge Thickner 3.6 m dia x 4 m X XX03 47 50 min

13 Effluent Pump Pit 3.2 m x 3.2m x (3 m +0.5m) EEP 30.72 35 min

14 Effluent Control Pit 3.2 m x 3.2m x (3 m +0.5m) ECP 30.72 35 min

15 Acid Dosing Tank

(H2SO4)

2 m3 DXX01 --- ---

16 NaOH Dosing tank 5 m3 DXX02 --- ---

17 Nutrient Dosing tank

(H3PO4)

1 m3 DXX03 --- ---

18 Nutrient Dosing tank

(Urea)

1 m3 DXX04 --- ---

19 Poly electrolyte Dosing

Tank

1 m3 UXX01 --- ---

20 Sand Filtration (Optional) 15-60 m3/hr --- --- ---

21 Filter Press --- FXX02 --- ---

22 Filtrate Sump Pit --- FSP --- ---

EFFLUENT TREATMENT PLANT FLOW DIAGRAM

ANNEXURE-6

SOLID/HAZARDOUS WASTE GENERATION AND DISPOSAL MODE

Sr.

No.

Solid/Hazardous

Waste

Category Quantity Mode of

disposal Existing Total after Change

in Product Mix

1 Used Oil 5.1 10 KLPA 10 KLPA Collection, Storage,

Transportation, Disposal

by Selling to Registered

re-processors/reuse as

lubricant.

2 Process Waste/

Residues

26.1 165 TPA 165 TPA Collection, Storage,

Transportation, disposal

at CHWIF or for co-

processing at approved

facility.

3 ETP Sludge 34.3 4500 TPA

4500 TPA

Collection, Storage,


at approved TSDF site.

4 Spent Carbon 35.3 210 TPA 210 TPA Collection, Storage,



5 Filter Aid/ Filter

Plates




6 Discarded

Containers,

Barrels, Liners,

contaminated

with hazardous

wastes/

Chemicals

33.3 1500 TPA 1500 TPA Collection, storage,

Decontamination and

detoxification,

transportation and

disposal by selling to

authorize -vendors.

7 Distillation

Residue



at approved CHWIF.

8 Spent Organic

Solvent


Transportation and

disposal at approved

CHWIF and/or recovered

though in house solvent

recovery plant for reuse.

9 RO Membrane / 34.2 5 TPA 5 TPA Collection, Storage,

NOTE: Solid/Hazardous waste quantities won’t increase after change in products mix and

will remain same as existing.

Spent icon

exchange resin

Transportation, Disposal at

approved TSDF site.

10 Spent Catalyst

(Vanadium

Pentoxide)


Transportation, Disposal at

approved TSDF site.

ANNEXURE-7

_______________________________________________________________________

POWER AND FUEL REQUIREMENT

TOTAL POWER REQUIREMENT (KW)

Sr.

No.

Requirement Source

Existing Total After

Change in

Products Mix

Existing After Change in Products

Mix

1. 9000 KW 9000 KW • DGVCL (GEB)

• D.G. Set - 1 no.

2500 KVA (emergency

standby)

• DGVCL (GEB)

• D.G. Sets - 3 nos.

- 2500 KVA

- 3000 KVA

- 1800 KVA

(emergency standby)

FUEL REQUIREMENT

Sr. No. Fuel Consumption

Existing Total After Change in

Product Mix

1 Natural Gas 5000 NM3/hr 5000 NM

3/hr

2 Diesel 100 Liter/day 100 Liter/day

NOTE: Power requirement and Fuels Consumption won’t increase after change in products

mix and will remain same as existing.

ANNEXURE-8 ___________________________________________________________________________________________________________________

STORAGE DETAILS OF HAZARDOUS CHEMICALS AND CONTROL MEASURES

Sr.

No

Name of

Hazardous

Quantity

Max. that

Can be

stored

Places of

its

Storage

No. of

Storages

Operating

Pressure &

Temp.

Type of Hazards

Possible (Fire,

explosive, toxic

release, spillage etc.

Control measures

provided

1 Butadiene 19 KT Storage

tank 1 4 bar@20-25

0C Flammable

• Automatic leak detector sensor

• Deluge system for ST

• Overflow devices and cut-off

• Filling only up to 80%

• Level Interlocks with pump

2 Acrylic Acid 1.6 KT Storage

tank 1 Normal Corrosive






3 Styrene 17 KT Storage

tank 1

Normal

Flammable






4 NDI 20 Ton Storage

tank 1

Normal Toxic






5 Toluene

Sulfonic Acid 0.033 Ton

Separate

Flammable

material

warehouse

-

Normal Flammable

• Smoke detector and alarm

• Fire hydrant system

• Sprinkler

6 Fatty alcohol 105 m3

Storage

tank 1

Normal Toxic






7 Dimethylamino-

propylamine 25 m

3

Storage

tank 1

Normal Toxic

and Flammable






8 Liq. Ammonia 0.12 KT

Raw

material

ware house

-

Normal Toxic and Flammable -

9 Formaldehyde 0.23 KT

Flammable

material

warehouse

-

Normal Flammable

• Smoke detector and alarm

• Fire hydrant system

• Sprinkler

10 Propylene

Oxide

100 m3/

day

Storage

tank 1

0.5 bar @ 20-

250C Flammable






ANNEXURE-9

DETAILS OF SOURCES OF EMISSIONS AND APCM

Sr.

No

Source of Emission Stack

Height

(meter)

Stack

Diameter

(meter)

Fuel

name

Type of

Emission

Pollution

Control

Equipment

1 Boiler 40 1.1 NG SPM

SOx

NOx

-

2 Thermic Fuild Heater 35 0.45 NG SPM

SOx

NOx

-

3 Hot Water Generator *

-- -- -- SPM

SOx

NOx

-

4 Process Vent-I (EM Plant) 15 0.15 -- SO2 Alkali Scrubber

5 Process Vent-II

(EM Plant)

15 0.05 -- NH3 Alkali Scrubber

& Water

Scrubber

6 Process Vent-III (EM

Plant)

30 0.8 -- SO2

ESP & Alkali

Scrubber

7 Process Vent-IV

(EM Plant)

30 0.8 -- OFF

GASE

Regenerative

Thermic Oxidiser

8 Process Vent-V

(EM Plant)

15 0.05 -- PM Bag Filter

9 Process Vent-VI

(EM Plant)

30 0.1 -- N2 Alkali Scrubber

10 Process Vent-VII

(EM Plant)

18 0.15 -- PM Bag Filter

11 Formulation Vessels*

21 -- -- SOLVENT

FUMES

Activated

Carbon Filter

12 Dust Collector-I* 23 -- -- SPM Dust Collector

13 Dust Collector-II* 23 -- -- SPM Dust Collector

14 Dust Collector-III* 23 -- -- SPM Dust Collector

15 QC Fume Hood Vent* 15 -- -- SOLVENT

FUMES

Activated

Carbon Filter

16 Tank Farm Vent* 11 -- -- SOLVENT

FUMES

Activated

Carbon Filter

17 Steam Catch* 15 -- -- --- Activated

Carbon Filter

18 Filling Line Fume Hood

Vent*

15 -- -- SOLVENT

FUMES

Activated

Carbon Filter

19 Dust Collector* 23 -- -- SPM Dust Collector

20 Process Vent-III (Rector

System Use)

11 0.15 -- REACTO

R OFF

GASES

Activated

Carbon Filter

21 Process Vent-IX (Rector-

1202 System House)

11 0.15 -- REACTO

R OFF

GASES

Activated

Carbon Filter

22 Process Vent-X (Rector-

1201 Combined System

House)

11 0.1 -- REACTO

R OFF

GASES

Activated

Carbon Filter

23 Process Vent-XI (HCl Tank

Process Vent-Xi Scrubber)

6.5 0.08 -- HCL

FUMES

Caustic Scrubber

24 Process Vent-XII (ED

Plant)

12 0.15 -- FUMES

FOR

DRUM

CHARGIN

G

Waste Scrubber

25 Process Vent-XIII (TPU

Plant)

7 0.50 -- HOT AIR Waste Scrubber

26 Process Vent-XIV (QA Lab) 15 0.25 -- LAB

EXHAUST

Adequate Stack

Height Provided

27 Process Vent-XV (QA Lab) 15 0.25 -- LAB

EXHAUST

Adequate Stack

Height Provided

28 Process Vent-XVI (QA Lab) 10 0.60 -- LAB

EXHAUST

Adequate Stack

Height Provided

29 Process Vent-XVII

(Coolant)*

20 -- -- PM Bag Filter

30 D. G. Set – 2500 KVA ** 25 0.55 Diesel

(100

Liter/day)

SPM

SOx

NOx

Dust Collector,

Silencer

31 D. G. Set – 3000 KVA ** 30 0.55 Diesel

(100

Liter/day)

SPM

SOx

NOx

Dust Collector,

Silencer

32 D. G. Set – 1800 KVA ** 30 0.55 Diesel

(100

Liter/day)

SPM

SOx

NOx

Dust Collector,

Silencer

* Yet not installed & ** use in emergency only

Note: Fuel gas and Process gas emissions won’t increase after change in product mix and

will remain same as existing.

ANNEXURE-10

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement is sufficient.

2) INDUSTRIES

Required raw materials and skilled and unskilled laborers are utilized maximum from the

local area. The increasing industrial activity will boost the commercial and economical status

of the locality, to some extent.

3) PUBLIC HEALTH

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

that the emission is 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 have been taken under the EMP.

4) TRANSPORTATION AND COMMUNICATION

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

development of this project will not cause any additional impact. In brief, as a result of the

expansion there will be no adverse impact on sanitation, communication and community

health, as sufficient measures have been taken under the EMP. There will be no any

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

ANNEXURE – 11

COPY OF LAND POSSESSION / PLOT ALLOTMENT DOCUMENT

ANNEXURE – 12

COMMON TSDF & HWIF MEMBERSHIP LETTER

ANNEXURE – 13

COPY OF GIDC LETTER FOR WATER SUPPLY

ANNEXURE – 14

COPIES OF CURRENT VALID CC&A

Amendment to CC&A

Amendment to CC&A

ANNEXURE – 15

TOPOSHEET

ANNEXURE-16

COPY OF AMENDED NOTIFICATION OF MOEFCC DATED NOVEMBER 01, 2009

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