1. Eenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/09_Nov... · Pre-Feasibility Report for Proposed expansion Project of Synthetic Organic Chemicals Page 1 of 96 1. E XECUTIVE

Pre-Feasibility Report for Proposed expansion Project of Synthetic Organic Chemicals

Page 1 of 96

1. EXECUTIVE SUMMARY

1.1 BACKGROUND

M/s. Gokul Agro Resources Ltd. is an existing large scale unit located at Survey No.

76/1, 80, 89 & 91 Near Sharma Resort, Meghpar-Borichi, Tal.: Anjar Dist.: Kutch and

engaged in the manufacturing of Refined Oil. At the time of establishment of the unit

in the year 2004, Environment Clearance was not applicable as per the EIA

notification of 1994 for manufacturing of Refined Oil. As per EIA notification of 2006,

manufacturing of existing products was not covered under categories listed in

notification, hence Environment Clearance was not applicable. Therefore, unit has

obtained Consent to Establish (CTE) and Consent to Operate (CCA) from GPCB for

manufacturing of existing products. As per current CCA of GPCB, maximum

production capacity of the unit is 2,29,690 MT/Month. Gokul Group has filed petition in

High Court of Gujarat and received court order, w.e.f. 1st July 2015, for de-merger of

their existing unit Gokul Refoils and Solvent Ltd. (GRSL) in to Gokul Agro Resources

Limited (GARL).

GRSL has been granted Consolidated Consents and Authorization by Gujarat

Pollution Control Board (GPCB) as follows

Survey

No.

Order

No. Letter No.

Date of

Issue Validity

89 AWH-

63949

PC/CCA-KUTCH-171(4)/GPCB ID

17855/221545 07/08/2014 19/06/2019

80 &

91

AWH-

62132

PC/CCA-KUTCH-468(2)/GPCB ID

33304/213613 17/05/2014 13/02/2019

Unit has filed an application at GPCB for amendment in above listed CCA for change

in name of the company to Gokul Agro Resources Ltd. and consolidation of two CCA

into Single one.

Now, considering the market demand, the unit proposes to manufacture various

synthetic organic chemicals derived from Castor Oil to the tune of 12,000 MT/Month.

The proposed project will be covered under Category 5(f)-B as per new EIA

Notification of Ministry of Environment & Forest (MoEF), dated 14/09/2006. Therefore,

unit requires obtaining Environmental Clearance from State Level Environmental

Impact Assessment Authority (SEIAA), Gujarat.


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1.2 SALIENT FEATURES OF THE PLANT SITE:

The proposed project will be set up in existing premises. Existing plot size is

adequate for the proposed project requirement. Thus, no additional land will be

required.

The project site is located in the light industrial zone declared by Gandhidham

Development Authority (GDA) having all basic facilities like availability of water

and natural gas, electricity, transport, telecommunication systems, etc.

The proposed products will be manufactured within the existing industrial

establishment, which would facilitate existing infrastructure mainly covering utility

services.

There is no protected area notified under the Wild Life (Protection) Act (1972) &

Eco-sensitive area notified under Section 3 of the Environment (Protection) Act-

1986 existing within 10 Km radius areas from the Plant Site.

1.3 DETAILS OF EXISTING AND PROPOSED PRODUCTS:

Existing unit is involved in the manufacturing of Refined Castor oil. Unit proposes to

manufacture synthetic organic chemicals derived from Castor oil. The details of

existing and proposed products and by-products are given in Table 1(a), 1(b) & Table

2(a), 2(b).

Table- 1(a): Details of Existing Products

Sr. No. Name Of The Products Capacity

(MT/Month)

1.

Refined Oil :

A. Crude Palmolein (Physical)

B. Crude Palm Oil (Physical)

30,000.00

2. Refined Oil (Conventional): Degummed Soya Oil 12,000.00

3.

Hydrogenated Vanaspati Oil

Hydrogenated Palm Fatty Acid

Bakery Shortenings

7,000.00

4. Crude Soya Bean Oil 8,500.00

5. Solvent Extracted Meal 36,000.00

6. Crude Rapeseed Oil 8,500.00

7. Lecithin 250.00

8. Soya Bean Gums 250.00

9. Soya Flour 6,750.00

10. Soya Vadi 3,500.00

11. Castor Commercial and its different grades 25,000.00

12. Castor Cake 32,400.00


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Sr. No. Name Of The Products Capacity

(MT/Month)

13. Rapeseed / Mustard Seed / Canola Seed Cake 9,540.00

14. Rapeseed / Mustard Seed / Canola Seed Extraction

Meal 25,000.00

15. Castor Extraction Meal 25,000.00

Total 2,29,690.00

1. Captive Power Plant 1.3 MW

2. Filling Plant for Consumer Packing

2.1 Soft Oil Pouch Filling: 200 ML to 1 Liter (Unit I) 2,500.00

2.2 Soft Oil Pouch Filling: 200 ML to 1 Liter (Unit II) 5,000.00

2.3 Soft Oil PET Bottle Filling: 500 ML, 1 Liter & 5 Liters – 2 Lines

(Unit I) 3,500.00

2.4 Soft Oil HDPE Jar Filling: 2 Liters to 15 Liters (Unit I) 3,500.00

2.5 Soft Oil Tin Filling: 15 Liters & 15 Kg. (Unit II) 10,500.00

2.6 Vanaspati Pouch Filling: 200 ML to 1 Liter (Unit I) 3,000.00

2.7 Vanaspati Jar Filling: 2 Liters to 15 Liters / KG (Unit I) 10,500.00

2.8 Vanaspati Tin Filling: 15 Liter and 15 Kg (Unit I) 10,500.00

2.9 Bakery Shortening Filling: 15 Kg. Poly Bag 500.00

3. Empty Tin Container: 15 Liters 6,00,000.00

4. HDPE Jar: 2 Liters and 5 Liters 90,000.00

5. HDPE Jar: 15 Liters and 15 Kg. 60,000.00

6. PET Bottles: 200 ML to 1 Liter 7,50,000.00

Table- 1(b): Details of Proposed Products

Sr.

No. Name of Product

Batch

Size (Kg)

Total

Capacity

(MT/Month)

1. a. Hydrogenated Castor Oil

b. Hydrogenated Palm Strarine

15,000.00

15,000.00 3,000.00

2.

a. 12 Hydroxy Stearic Acid (HSA)

b. Ricinoleic Acid (RA)

c. Hydrogenated Methyl Ricinoleate

3,500.00

3,500.00

5,000.00

2,000.00

3.

a. Polymerized RA

b. Blown Castor Oil

c. Bisamide

3,500.00

4,000.00

4,000.00

500.00

4. a. De-Hydradted Castor Oil (DCO)

b. DCO Fatty Acid

4,000.00

4,000.00 500.00

5. Undecylenic Acid (UDA) 1,000.00 30.00

6. Zinc UDA 1,000.00 30.00

7. Sebacic Acid 8,000.00 240.00

8. Sebacodiamine (C-10 Diamine) 8,000.00 240.00

9. Polyol 115 8,000.00 240.00


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10. Ethoxylated Castor oil 8,000.00 240.00

11. Glycerol Monosterate 8,000.00 240.00

12. Zinc Ricinoleate 5,000.00 150.00

13. DCO Stand Oil 5,000.00 360.00

14. Sulphonated Castor Oil 8,000.00 240.00

15. Distilled Fatty Acid 25,000.00 2,250.00

16. Dimer Acid 7,500.00 750.00

17. Iso Stearic Acid 5,000.00 300.00

18. Euracic Acid 5,000.00 450.00

19. Glycerine 8,000.00 240.00

Total 12,000.00

Table- 2(a): Details of existing By-Products:

Sr.

No. By-Products

Capacity

(MT/Month)

1 Acid Oil 225.00

2 Deodistilate 1200.00

3 Palm Fatty Acid Distillate

4 Spent Earth 650.00

Table- 2(b): Details of proposed By-Products:

Sr.

No. By-Products

Capacity

(MT/Month) Source

1 C18,C24,C18 270.00 Product 18

2 Distilled Monomer 615.00 Product 16

3 Glycerin 800.00

Product 4(b)

Product 7

Product 15

Product 2(a)

Product 2(b)

Product 2(c)

Product 18

4 Heptaldehyde 24.00 Product 5

5 Light Fatty Acid 25.00 Product 4(b)

6 Mixed Fatty Acid 95.00 Product 5

Product 7

7 2-Octanol (85%) 155.00 Product 7

8 Pitch

(C-10 diamine/sebeconitrile) 28.00 Product 8


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9 Pyroletic Mass of

Methyl Ricinoleate 3.00 Product 5

10 Sodium Sulphate 985.00

Product 2(a)

Product 2(b)

Product 7

11 Ammonium Sulphate 15.00 Product 8

(APCM)

1.4 RESOURCE REQUIREMENT

Land: The total land available with the existing unit is 2,12,362.12 sq. m.

additional land of 1,53,173.88 sq. m. would be required for proposed

expansion.

Water: Presently the water requirement of the unit is met by bore well water

supply and same source will be utilized after proposed expansion. The total

fresh water requirement for the existing unit is 951.0 KL/day which will be

increased up to 1105.0 KL/day.

Power: At present, the total connected load of power is 6500 KVA and Captive

Power of 1.23 MW. The power required is procured from Paschim Gujarat Vij

Company Limited (PGVCL) and the same source will be utilized after proposed

expansion. DG Sets (3 Nos. of 500 KVA and one 125 KVA) are installed as a

power backup in case of power failure from PGVCL. There is no additional

requirement of power for proposed expansion.

Fuel: Presently the unit uses; coal @ 8.5 MT/hour + 150 MT/day, LDO @65 lit/h,

HSD @ 416.5 lit/h, and Furnace Oil 6000 kg/day as a fuel. Additional

requirement of the fuel for proposed expansion will be coal @ 30 MT/day,

FO/LDO @ 48 lit/h.

Manpower: Total 613 personnel are working in the existing plant and for

proposed expansion, the unit has planned to employ about 68 additional

personnel comprising of Management, Supervisory and Workers.

Finance: The unit is a Large Scale Unit and has made capital investment of Rs.

14,479.80 lacs in the existing plant. Capital cost towards Environmental

protection measures for existing project is Rs. 400.00 Lacs. The estimated cost

for the proposed expansion will be about Rs. 3950.00 Lacs. Out of which,

capital cost towards Environmental protection measures will be Rs. 250.00 Lacs.


Page 6 of 96

1.5 POLLUTION POTENTIAL AND MITIGATION MEASURES:

Water Pollution: At Present the total industrial waste water generation from

existing unit is 271 KL/day. Effluent from Process @14 KL/Day is reused for

cooling. Remaining 257 KL/Day, after treatment in ETP, is reused for cooling @

57 KL/day and gardening @ 200 KL/Day purpose.

The industrial effluent generation after the proposed expansion will increase

from 271 KL/day to 382 KL/day. Wastewater generated from proposed

expansion is 111 KL/day. Out of which 103 KL/Day will be treated in Multi Effect

Evaporator (MEE) and reused in process again and 8 KL/Day will be reused for

gardening purpose. Treated effluent will be reused in process again. Thus,

existing ETP along with an additional Evaporator will be adequate to treat and

handle the total pollution load.

Air Pollution: There will be some flue gas emission from proposed Thermo pack

installation. Adequate APCM will be installed for proposed Thermo pack. There

will be process gas emission from the proposed expansion in the form of NH3

Gas. Adequate scrubbing system of water scrubber followed by acidic

scrubber will be installed as an APCM. There will be very negligible chances of

fugitive emissions due to process, material handling and Transportation from

proposed expansion.

Hazardous Waste: The main sources of hazardous waste generation from

proposed manufacturing activity will be Process Waste viz. Spent Catalyst,

Spent Carbon, Spent Acid, Distillation residue and dry ETP sludge. The ancillary

source of hazardous waste generation will be discarded containers, barrels,

bottles from storage and handling of raw materials and used/spent oil

generation from plant machinery. The unit has provided an adequate

designated storage area for the hazardous waste storage and has obtained

membership of TSDF.

Greenbelt Development: The unit has developed green belt area in 8,466.00

sq. m. within the industrial premises. Additional greenbelt area will be

developed in 1,02,213.46 sq. m. At present, unit has planted around 1500 Nos.

of trees of various types within premises, Unit proposed to plant additional 1500

Nos. of tress for the proposed expansion.


Page 7 of 96

2. INTRODUCTION

2.1. BACKGROUND

M/s. Gokul Agro Resources Ltd. is an existing large scale unit located at Survey No.

76/1, 80, 89 & 91 Near Sharma Resort, Meghpar-Borichi, Tal.: Anjar Dist.: Kutch.

Presently, the unit is involved in the manufacturing of Refined Oil. Now, the unit

proposes to expand its manufacturing activity and intend to manufacture various

Castor Oil derivatives. As a part of application for obtaining Environmental

Clearance, the unit requires to submit Form-1 and Pre-Feasibility Report of the

proposed project.

The objectives of the report are,

a) To assess the feasibility of the proposed project.

b) To identify various sources of pollution and anticipate the impact of the

proposed project on the environment.

c) To evaluate Environmental Management Plan, to prevent and mitigate the

adverse impact on environment caused due to proposed project.

d) Propose the Terms of Reference to carry out EIA Study for the proposed project

2.2. NATURE OF THE PROJECT:

The unit is an existing large scale unit involved in the manufacturing of Refined Oil and

now proposes to expand its manufacturing activity. Unit intends to add new products

covered under Category 5 (f)-B as per new EIA notification.

The unit believes in sustainable development and is equally concerned about

environment preservation and pollution control. The unit has provided an adequate

Environmental Management System to meet desired norms of effluent discharge

(Water + Air + Solid) as per the statutory recruitments for their existing unit and also

proposes to expand its continuous endeavor for the pollution prevention and

betterment of environment.


Page 8 of 96

2.3. PROJECT PROPONENT:

Details about the promoters are given below:

Table-3: Details of promoters & Directors of the Company

Sr.

No. Name of Director Designation Address

1 Shri Kanubhai J.

Thakkar Director

12, Ambica Nagar Society,

Opp. PGVCL, Sidhpur – 384 151

2 Shri Balwantsinh

C. Rajput

Additional

Director

29, Ambica Nagar Society,

Opp. PGVCL, Sidhpur – 384 151

3 Shri Piyush

Chanra R. Vyas

Additional

Director

“Hari Om”, 29/B, Vasuki Society,

Vasna, Ahmedabad – 38 007

4 Smt. Dipooba H.

Devada

Additional

Director

35/3, Adyapak Niwas, Gujarat

Vidyapith, Ahmedabad - 14

5 Shri Karansinhji D.

Mahida

Additional

Director

1759/B, Sector 2-D,

Gandhinagar – 382 002

6 Shri Bipinkumar J.

Thakkar

Additional

Director

B-33, Upasana Co-op. Hsg. Soc.,

Survey No. 315, Maninagar,

Ahmedabad – 380 008

2.4. NEED FOR THE PROJECT & PROJECT BENEFITS:

Need for the project and its importance to the country and /or region

Castor is bio de-gradable and sustainable. Now-a-days, trend is to replace petroleum

product by the agricultural product. This is one of the commodities which can replace

one to one uses of petroleum products. Hydrogenated Castor Oil and Castor Oil

Derivatives are Agro based Organic Synthetics Chemicals having wide application in

polishes, pharmaceuticals, cosmetics, lubrication and coating & greases where

resistance to moisture, oils & other petrochemical products are required.

Demand-Supply Gap

Based on our informal survey of the market with our current customers and various

traders, we have found that there is a big potential for the range of the products we

are planning. These products will be an addition to the current range of our products.

Imports vs. Indigenous production

The latest trend exhibits the demand within Nationals and International levels. The raw

material for manufacturing the proposed products is easily available in local Indian

market, especially in the proposed area, at competitive rates, which is ultimately

benefit to finish products to enter in Global market at competitive position.


Page 9 of 96

Export possibility

Depending on the international demand of products, the unit has explored the

possibility of exporting the products.

Domestic/Export Markets

Considering the market volatility of castor seeds and the market demand for the

Hydrogenated Castor Oil and Castor Oil Derivative products and advantage of the

location for the project; M/s. Gokul Agro Recourses Ltd. proposes to venture into

Export Oriented Unit.

Employment Generation (Direct and Indirect) due to project.

M/s. Gokul Agro Resources Ltd. will give direct employment to local people based on

their qualification and requirement. In addition to direct employment, indirect

employment will generate ancillary business to some extent for the local population.


Page 10 of 96

3. PROJECT LOCATION AND SITE ANALYSIS

3.1 LOCATION:

The unit is located at Survey No. 76/1, 80, 89 & 91 Near Sharma Resort, Meghpar-

Borichi, Tal.: Anjar Dist.: Kutch, Gujarat. The location map of project site is shown in

Plate-1 and the area covering 5 km radial distance from the project site is given as

Plate-2.

Plate1: Location Map of the Project Site:

Location of Kutch District in Gujarat

Location of Project Site in Kutch District


Page 11 of 96

Plate-2: Google Image showing the area within 5 Km Radius from the project site:

S1. Meghpar Boriachi S6. IFFCO – Udaynagar

S2. Bhaveshwar Nagar S7. Ward 2B

S3. Varsha Medi S8. Tirupatinagar 2

S4. Galpadar S9. Meghpar

S5. Gandhidham

Project Site

Villages/Places covered within 5 Km radius area from the project site


Page 12 of 96

3.2 SITE ANALYSIS & INFRASTRUCTURE SETUP

The salient features of the project site and study area are given below;

3.3 JUSTIFICATION OF SITE SELECTION

The unit is located at Survey No. 76/1, 80, 89 & 91Near Sharma Resorts, Meghpar-

Borichi, Tal.: Anjar Dist.: Kutch, Gujarat and site selection was guided by many

factors like infrastructure, availability of land, water sources, fuel, transportation,

power availability etc. Specific site selection criteria for the proposed project are

given below.

The proposed expansion will be carried out within the existing premises.

Hence, no additional land will be required.

1. Geographical Details : Altitude: 19 m above MSL

Latitude:”(N) 23° 5'53.47"N

Longitude: (E) 70° 5'29.57"E

Topo Sheet No.: F-42/E4

2. Land use of Plant site (% Share)

Industrial Land : 100%Industrial Land

3. Minimum Distances From Plant Site

a) Village : Meghpar Borichi @ 2.5 km, West

b) City : Gandhidham @ 4.0 km, SE

c) Town : Bhaweswer Nagar @ 4.5 km, West

d) Railway Station : Gandhidham @ 7.0 km, SE

e) Highway : N.H. No. 8A @ 4.5 km, North

State Highway @ 0.3 km, South

f) River : Sang River @ 0.75 km, North

g) DomesticAirport : Kandla Airport @ 2.0 km, NE

h) International Airport : Ahmedabad @ 300 km, East

4. Displacement of population : None

5.

Places of interest and importance within 5 Km radius areas from the Plant Site (if,

any): Bhaweswer Jain Temple @ 4.5 West

There is no protected area notified under the Wild Life (Protection) Act (1972) &

Eco - sensitive area notified under Section 3 of the Environment (Protection) Act –

1986 falls within 10 Km radius areas from the Plant Site.

mailto:[email protected]


Page 13 of 96

The project site is highly developed with all basic infrastructure facilities such

as proximity to man power, power, water supply, transport,

telecommunication systems, etc.

Plant site is only 7 km away from city Gandhidham which is well connected by

road and rail to rest of India and having linkage with Bombay and Delhi by

Broad Gauge railway and National Highway No. 8-A.

The water will be sourced from existing bore wells.

The project site is intended for the industrial purpose and thus no

displacement of population will take place.

There is no historical place, Archaeological place, Wildlife sanctuary and

National park within 10 km of the project site.


Page 14 of 96

4. PROJECT DESCRIPTION

4.1 DETAILS OF PRODUCT AND PRODUCTION CAPACITY:

At present, the unit is engaged in the manufacturing Refined Oil. As per current CC&A

of GPCB, maximum production capacity of the unit is 2,29,690.0 MT/Month. Now,

considering need of the project, the unit intends to do expansion in production

capacity with addition of various castor oil derivatives @ 12,000.0 MT/Month in the

same premises.

The list of proposed products and production capacity are given hereunder in Table -

4(A) and details of proposed products are given in Table – 4(B). The list of proposed

by-products and its production capacity are also given in Table - 4(C).

Table – 4(A): List of Proposed Products and Production Capacity

Sr.

No. Name of Product

Batch

Size (Kg)

Total

Capacity

(MT/Month)

1. a. Hydrogenated Castor Oil

b. Hydrogenated Palm Strarine

15,000.00

15,000.00 3,000.00

2.

a. 12 Hydroxy Stearic Acid (HSA)

b. Ricinoleic Acid (RA)

c. Hydrogenated Methyl Ricinoleate

3,500.00

3,500.00

5,000.00

2,000.00

3.

a. Polymerized RA

b. Blown Castor Oil

c. Bisamide

3,500.00

4,000.00

4,000.00

500.00

4. a. De-Hydradted Castor Oil (DCO)

b. DCO Fatty Acid

4,000.00

4,000.00 500.00

5. Undecylenic Acid (UDA) 1,000.00 30.00

6. Zinc UDA 1,000.00 30.00

7. Sebacic Acid 8,000.00 240.00

8. Sebacodiamine (C-10 Diamine) 8,000.00 240.00

9. Polyol 115 8,000.00 240.00

10. Ethoxylated Castor oil 8,000.00 240.00

11. Glycerol Monosterate 8,000.00 240.00

12. Zinc Ricinoleate 5,000.00 150.00

13. DCO Stand Oil 5,000.00 360.00

14. Sulphonated Castor Oil 8,000.00 240.00

15. Distilled Fatty Acid 25,000.00 2,250.00

16. Dimer Acid 7,500.00 750.00

17. Iso Stearic Acid 5,000.00 300.00

18. Euracic Acid 5,000.00 450.00

19. Glycerine 8,000.00 240.00

Total 12,000.00


Page 15 of 96

Table – 4 (B): Details of Proposed Product

Sr.

No. Products CAS No. IUPAC Name Synonyms Use of Product

1. Hydrogenated

Castor Oil 61788-85-0

1,2,3-

Propanetriyl Tris(12-

Hydroxyoctadecano-

ate)

Castor Wax Standard

Commodity.

2. 12 Hydroxy Stearic

Acid (HAS) 106-14-9

12-

Hydroxyoctadecanoi

c Acid

12-HSA

Lubricating

Greases

Manufacture

3. Ricinoleic Acid (Ra) 141-22-0 12-Hydroxyoctadec-

9-Enoic Acid

9-

Octadecenoicacid

Derivatives

Manufacturing

4. Polymerized Ra -- -- -- --

5. Blown Castor Oil 68187-84-8 -- Oxidized Castor Oil Plasticizer

6. Bisamide 123-26-2 --

Ethylene Bis

(12-

Hydroxystearamide)

Plastics

Processing,

Coatings, Inks

7. Hydrogena-ted

Methyl Ricinoleate 141-23-1 -- 12-HSA Methyle Ester Dispersant

8. De-Hydradted

Castor Oil (Dco)

61789-45-5 -- Drying Oil Drying Oil

9. Dco Fatty Acid 61789-45-5 -- Dehydrated Castor

Oil Fatty Acid

Manufactur Of

Resin

10. Undecylenic Acid 112-38-9 10-Undecenoic Acid 10-Hendecenoic Antifungal Drug.

11. Zinc Uda 557-08-4 Zinc Di(10-

Undecenoate)

Undecylenic Acid

Zinc Salt Fungus Treatment

12. Sebacic Acid 111-20-6 Decanedioic Acid Dicarboxylic Acid

C10 Various Product

13. Sebacodia-mine

(C-10 Diamine) -- --

1,10 –

Decanediamine

Bio-Degradable

Plastic Product

14. Polyol 115 -- -- -- --

15. Glycerol

Monosterate 31566-31-1

2,3-Dihydroxypropyl

Octadecanoate

Octadecanoate

Acid,

Baking

Preparations

16. Zinc Ricinoleate 13040-19-2 Zinc Bis-12-Hydroxy-9-

Octadecenoate

Zinc Salt Of Ricioleic

Acid

Odor-Adsorbing

Agent.

17. Dco Stand Oil 68038-02-8 -- DCO Polymer Paints And

Varnish Product

18. Sulphonated

Castor Oil 8002-33-3 -- Turkey Red Oil

Synthetic

Detergent

19. Ethoxylated Castor

Oil 61791-12-6 -- -- Surfactant

20. Hydrogena-ted

Palm Stearine 68514-74-9 -- Palm Oil

Food

Applications.

21. Distilled Fatty Acid 67254-79-9 -- Fatty Acids Industrial Products

22. Dimer Acid 61788-89-4 -- C36 Dimer Acid

Dicarboxylic Acids Surface Coating

23. Iso Stearic Acid 30399-84-9 -- Monocarboxylic

Acid In Personal Care

24. Euracic Acid 112-86-7 (Z)-Docos-13-Enoic

Acid

Cis-13-Docosenoic

Acid Mineral Oils,

25. Glycerin 56-81-5 1,2,3-Propanetriol Glycerol Lubrica Explosives

Plasticizer

http://www.sigmaaldrich.com/catalog/search?term=141-23-1&interface=CAS%20No.&lang=en&region=US&focus=product

https://en.wikipedia.org/wiki/Dicarboxylic_acid

https://en.wikipedia.org/wiki/Dicarboxylic_acid

http://www.commonchemistry.org/ChemicalDetail.aspx?ref=112-86-7


Page 16 of 96

Table – 4 (C): List of proposed By-products

Sr.

No. By-Products

Capacity

(MT/Month) Source

1 C18,C24,C18 270.00 Product 18

2 Distilled Monomer 615.00 Product 16

3 Glycerin 800.00

Product 4(b)

Product 7

Product 15

Product 2(a)

Product 2(b)

Product 2(c)

Product 18

4 Heptaldehyde 24.00 Product 5

5 Light Fatty Acid 25.00 Product 4(b)

6 Mixed Fatty Acid 95.00 Product 5

Product 7

7 2-Octanol (85%) 155.00 Product 7

8 Pitch (C-10

diamine/sebeconitrile) 28.00 Product 8

9 Pyroletic Mass of MR 3.00 Product 5

10 Sodium Sulphate 985.00

Product 2(a)

Product 2(b)

Product 7

11 Ammonium Sulphate 15.00 Product 8 (APCM)

4.2 LAND AND PROJECT LAYOUT:

The existing land area available at the project site is 2,12,362.12 sq. m. Additional land

area of 1,53,173.88 sq. m. will be required for the proposed expansion. Out of the

additional land area, total built up area of 9,641.97 sq. m. will used for industrial

establishment. Hence, total undeveloped area after proposed expansion will be

1,03,096.41 sq. m.

The unit has already provided green belt in 8,466.00 sq. m. within the existing premises

and the green belt will be expanded up to 1,10,679.46 sq, m. (30.17 %) during the

proposed expansion. The detailed breakup of land is given in Table-5. Key plan and

Plant Layout is shown in Drawing 1.


Page 17 of 96

Table – 5: BREAK-UP OF AREA

Sr.

No. Particular

Area (sq. m.) % of

Total

Land Existing Proposed Total After

Expansion

1 Process Plant 11,814.43 2,273.76 14,088.19 3.85

2 Raw Material & Product

Storage 59,722.59 5,904.65 65,627.24 17.95

3 Utility 4,188.78 200.00 4,388.78 1.20

4 Storage (Hazardous

Chemicals) 382.50 0.00 382.50 0.10

5 Storage (Fuel) 2,162.00 200.00 2,362.00 0.65

6 Hazardous Waste Storage

Area 98.24 0.00 98.24 0.03

8 Green Belt 8,466.00 1,02,213.46 1,10,679.46 30.17

9 Roads 38,679.00 17,737.00 56,416.00 15.43

7 Effluent Treatment Plant 1,526.60 529.00 2,055.60 0.56

10 Parking Area 3,554.60 0.00 3,554.60 0.97

11 Administrative Building 1,896.98 534.56 2,431.54 0.67

12 Captive Power Plant 470.40 0.00 470.40 0.13

13 Undeveloped Area 79,400.00 23,696.41 1,03,096.41 28.28

Total 2,12,362.12 1,53,288.88 3,65,651.00 100.00


Page 18 of 96

Drawing 1: Keyplan & Plant Layout


Page 19 of 96

4.3 RESOURCE REQUIREMENT:

Water

The entire water requirement of existing project is met through bore well water supply

and the same source will be utilized after proposed expansion. The total fresh water

requirement will be increased from 951 KL/day to 1105 KL/day after proposed

expansion which comprises domestic, green belt development and industrial

purpose.

Power

At present the total connected load of power is about 6500 KVA, which is procured

from Pashchim Gujarat Vij Company Ltd. (PGVCL). There is no additional requirement

of power for proposed expansion.

The unit has installed D.G. Sets (3 Nos. 500 KVA & 1 No. 125 KVA) as a stand-by, which

are used as an alternate power source in case of main power failure from PGVCL. No

additional DG Set will be required for proposed expansion.

Fuel

The unit uses Coal as a fuel in Boilers & Thermo packs. FO will used in proposed Thermo

pack. The unit uses HSD as a fuel in D.G. Sets.

The details of fuel requirement are given in Table-6.

Table - 6: Details of Fuel Consumption

Fuel Used In Fuel Consumption*

E P T

Coal Boilers15 T/12 T/27T/27T

Thermo pack

8.5 MT/h +

150 MT/Day 30 MT/Day

8.5 MT/Hr +

180 MT/Day

FO/LDO Thermopack400 U 2NOS

1000 U 1NOS 65 lit/h 48 lit/h 113 lit/h

HSD

DG Sets

(3 Nos. 500 KVA & 1 No.

125 KVA)

2000 Lit/day Nil 2000 Lit/day

*E - Existing / P - Proposed / T - Total After Expansion

Manpower

The manpower is one of the main resource requirements for the operation and

maintenance of the plant in a better and efficient way. At present total 613 personnel


Page 20 of 96

are working which will increase up to 681 after proposed expansion. The details of

existing and proposed Manpower are given in Table – 7.

Table –7: Details of Manpower Requirement

Description M

an

ag

em

e

nt Sta

ff (

M/F

)

Su

pe

rvis

ory

Sta

ff, (M

/F)

Cle

rks,

(M

/F)

Co

mp

an

y

Wo

rke

rs,

(M/F

)

Co

ntr

ac

tor

wo

rke

rs,

(M/F

)

Tota

l

E P E P E P E P E P E P

Administration 36 0 06 0 41 0 0 0 0 0 83 0

Production & allied

services 06 3 116 15 02 0 242 12 136 30 502 60

Stores & Dispatch 02 0 10 0 4 8 0 0 0 0 16 8

Others 3 0 09 0 0 0 0 0 0 0 12 0

Total 47 3 141 15 47 8 242 12 136 30 613 68

M- Male, F- Female, E-Existing, P-for Proposed Expansion

*E - Existing / P - Proposed

4.4 DETAILS OF MANUFACTURING PROCESS

Manufacturing of proposed products involve various physical unit operations and

chemical reaction, which are briefly described in this chapter.

1. (a) Hydrogenated Castor Oil (HCO)

(a) Process Description

Refined Castor oil is charged in autoclave under vacuum and heated upto 110°C. Ni

is added to the autoclave as catalyst. The vacuum valve is closed and hydrogen

valve is opened to charge of Hydrogen gas at 8kg/cm2 in the autoclave. The

hydrogenation reaction being an exothermic reaction, the temperature in autoclave

is maintained between 140 - 150°C. The hydrogenation process takes approximately

4hrs. to complete. Sample is drawn and analyzed for Iodine valve, on achieving

Iodine value below 3 units, the reaction mass is cooled to 100°C. The batch is filtered

through pressure leaf filter to recover the Ni catalyst and transferred to storage tanks.

The material from the storage tanks is transferred for manufacturing derivatives or to

flakers. The flaked material is then packed bags and stored in Godown.


Page 21 of 96

(b) Chemical Reaction

Reaction Chemistry C3H5(C18H33O3)3 + 6H

C3H5(C18H35O3)3

Gram/Mole 932 6

938

Chemical name Castor Oil Hydrogen

Hydrogenated

Caster Oil

(c) Material Balance

Capacity TPM : 3000.00

Batch size Kg : 15000

Working Days : 26

Sr. No. Name of Raw Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Refined Castor Oil 14904.0 0.9936 2980.800 Reactant

2 Hydrogen 124.5 0.0083 24.900 Reactant

3 Nickel 1.1 0.00007 0.210 Catalyst

4. Nickel (Recovered) 1.1 0.00007 0.210 Recovered

Catalyst

Total 15030.6 1.0020 3006.120

Output

1 Hydrogenated Castor

Oil 15000.0 1.0000 3000.000 Final Product

2 Nickel (Recovered) 1.1 0.00007 0.210 Recovered

Catalyst

3 Nickel (Spent) 1.1 0.00007 0.210 Solid Waste

4 Losses 28.5 0.0019 5.700 Losses

Total 15030.6 1.0020 3006.120


Page 22 of 96

(d) Flow Diagram

Castor Oil: 14904

Ni Catalyst: 2.1

Autoclave

(Hydrogenation,

140 – 150 °C

Godown

15000

Autoclave

(Cooled upto 100 °C)

Pressure Leaf Filter

Storage Tanks

Flakers

Packaging (Bags)

Hydrogen Gas:

930 Nm3 at 12 kg/cm2

124.5

For Derivatives

Spent Ni: 1.1


Page 23 of 96

1. (b) Hydrogenated Palm Stearine


Palm Stearine is charged in autoclave under vacuum and heated upto 110°C. Ni is

added to the autoclave as catalyst. The vacuum valve is closed and hydrogen valve

is opened to charge of Hydrogen gas at 3-5 kg/cm2 in the autoclave. The

hydrogenation reaction being an exothermic reaction, the temperature in autoclave

is maintained. The hydrogenation process takes approximately 4hrs. to complete.

Sample is drawn and analysed for Iodine valve, on achieving Iodine value, the

reaction mass is cooled to 100°C. The batch is filtered through pressure leaf filter to

recover the Ni catalyst and transferred to storage tanks. The material from the storage

tanks is transferred for manufacturing derivatives or to flakers. The flaked material is

then packed bags and stored in godown.


Reaction

Chemistry C3H5(C54H104O6) + 3H2

C3H5(C54H110O6)

Gram/Mole 889 6

895

Chemical Name Palm Stearine Hydrogen Hydrogenated

Palm Stearine


Capacity TPM 3000.00

Batch size Kg 15000

Working Days 26

Sr.

No.

Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Palm Stearine 14899.4 0.993 2979.888 Reactant

2 Hydrogen 100.6 0.007 20.112 Reactant

3 Nickel 11.7 0.001 2.346 Catalyst

Total 15011.7 1.001 3002.346

Output

1 Hydrogenated Palm

Stearine 15000.0 1.000 3000.00 Finished Product

2 Ni Catalyst (Spent) 11.7 0.001 2.346 Spent Catalyst

Total 15011.7 1.001 3002.346


Page 24 of 96

(d) Process Flow Diagram

Palm Stearine: 9933.0

Ni Catalyst: 7.8

Autoclave

(110 °C)

Filtration

Hydrogenation

Hydrogenated Palm

Stearine: 10000

Ni Catalyst

(Spent): 7.8

Hydrogen: 67.0

Storage


Page 25 of 96

2. (a) 12 Hydroxy Stearic Acid (HSA):


Hydrogenated castor oil (HCO) is charged to the Saponification - Acidulation reactor

followed by hot water addition. Reactor temperature is maintained at 100°C. Caustic

lye is added gradually to saponify HCO. HCO soap sample is drawn and analysed for

acid value, on achieving acid value of 180 KOH/mg, the saponification is complete.

The reaction mass is settled and heated. Then sulphuric acid is added to acidify the

material.

On completion of acidification, the reaction mass is settled. The settled mass is

drained and collected as sweet water and sent to evaporation plant for Glycerine

and Sodium Sulphate. The 12 Hydroxy Stearic Acid mass in the reactor is subjected to

hot water wash of equivalent volume and allowed to settle. The settled mass is

drained and sent to evaporation plant for Glycerineand Sodium Sulphate recovery.

The mass in the reactor is analysed for neutral pH and further subjected to hot water

wash for a volume upto the neutral pH is obtained. The mass is allowed to settle. The

settled mass is drained and sent to Evaporation Plant.

The mass in the reactor is then sent to vacuum dryer and flaker. The flaked 12 Hydroxy

Stearic Acid packed in bags and stored in godown.

(b) Reaction Chemistry

Reaction

Chemistry C3H5(C18H35O3)3 + 3NaOH + 3/2(H2SO4)

3(C18H36O3) + C3H8O3 + 3/2(Na2SO4)

Gram/

Mole 938 120 147

900 92 213

Chemical

Name

Hydrogenated

Caster Oil

Caustic

Soda

Sulfuric

Acid

12 Hydroxy

Stearic

Acid

Glycerin Sodium

Sulfate


Page 26 of 96



Batch size Kg 3500

Working Days 26


Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Hydrogenated Castor

Oil (HCO) 3647.77 1.0422 2084.440 Reactant

2 Caustic Lye (48%) 972.23 0.2778 555.560 For Saponification

3 Sulfuric Acid (33%) 1732.33 0.4950 989.900 For Acidification

4 Water (Fresh) 10.78 0.0031 6.160 Wash Water

(Fresh)

5 Water (Recovered) 5589.22 1.5969 3193.840 Water

(Recovered)

Total 11952.3 3.415 6829.900

Output

1 12 Hydroxy Stearic

Acid (HSA) 3500.0 1.0000 2000.000 Finished Product

2 Glycerine (Crude) 511.1 0.1460 292.060 By-product

3 Sodium Sulphate 854.0 0.2440 488.000 Salt

4 Water (Recovered) 5589.2 1.5969 3193.840 Water Recovered

5 Effluent 1400.0 0.4000 800.000 Effluent

6 Losses 98.0 0.0280 56.000 Losses

Total 11952.3 3.415 6829.900


Page 27 of 96

(d) Process Flow diagram:

Hydrogenated

Castor Oil: 3648.0

Hot Water: 700.0

Saponification –

Acidulation

Reactor at 100 °C

Vacuum Dryer

Saponification

HCO Soap mass

Settled & Heated

Acidification

12 Hydro Stearic

Acid Settling

Wash 1

Wash 2

Caustic Lye (48%): 972

Sulfuric Acid (33%): 1732

Flaker

Packaging (Bags)

Godown

Hot Water: 3500

Hot Water: 1400

Bottom Drain: 3542

Bottom Drain: 3500

Evaporation

Plant

Water 5589

Loss

88

Glycerin

(Crude)

511

4.0 T

Sodium

Sulfate

854

Loss: 10

Effluent

1400


Page 28 of 96

2. (b) Ricinoleic Acid (RA):


Castor oil (CO) is charged to the Saponification - Acidulation reactor followed by hot

water addition. Reactor temperature is maintained at 100°C. Caustic lye is added

gradually to saponify CO. CO soap sample is drawn and analysed for acid value, on

achieving acid value of 180 KOH/mg, the saponification is complete. The reaction

mass is settled and heated. Then sulphuric acid is added to acidify the material.

On completion of acidification, the reaction mass is settled. The settled mass is

drained and collected as sweet water and sent to evaporation plant for Glycerine

and Sodium Sulphate. The Ricinoleic Acid mass in the reactor is subjected to hot

water wash of equivalent volume and allowed to settle. The settled mass is drained

and sent to evaporation plant for Glycerine and Sodium Sulphate recovery. The mass

in the reactor is analysed for neutral pH and further subjected to hot water wash for a

volume upto the neutral pH is obtained. The mass is allowed to settle. The settled mass

is drained and sent to Evaporation Plant.

The mass in the reactor is then sent to vacuum dryer and flaker. The flaked Recinoleic

Acid packed in bags and stored in godown.


Reaction

Chemistry C3H5(C18H33O3)3 3NaOH 3/2 H2SO4

3(C18H34O3) C3H8O3 3/2 Na2SO4

Gram/Mo

le 932 + 120 + 147

894 + 92 + 213

Chemical

Name Castor Oil

Caustic

Soda

Sulfuric

Acid

Ricinoleic

Acid Glycerin

Sodium

Sulfate


Page 29 of 96


Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Castor Oil 3648.8 1.043 2085.020 Reactant

2 Caustic Lye (48%) 978.7 0.280 559.280 For Saponification

3 Sulfuric Acid (33%) 1743.9 0.498 996.540 For Acidification

4 Water (Fresh) 11.2 0.003 6.420 Wash Water (Fresh)

5 Water (Recovered) 5588.8 1.597 3193.580 Water (Recovered)

Total 11971.5 3.420 6840.840

Output

1 Ricinoleic Acid 3500.0 1.000 2000.00 Finished Product

2 Glycerine (Crude) 514.5 0.147 294.020 By-Product

3 Sodium Sulphate 859.7 0.246 491.240 By-Product

4 Water (Recovered) 5588.8 1.597 3193.580 Water (Recovered)


6 Losses 108.5 0.031 62.000 Losses

Total 11971.5 3.420 6840.840


Batch size Kg 3500

Working Days 26


Page 30 of 96

(d) Process flow diagram:

Loss

Castor Oil: 3648.8

Hot Water: 5600.0

Saponification – Acidulation

Reactor at 100 °C

Vaccum Dryer

Saponification

HCO Soap mass

Settled & Heated

Acidification

Ricinoleic Acid

Settling

Wash 1

Wash 2

Caustic Lye (48%): 979

Sulfuric Acid (33%): 1744

Flaker

Packaging

(Bags)

Godown 3500

Hot Water: 3500

Hot Water: 1400

Bottom Drain: 3570

Bottom Drain: 3500

Evaporation

Plant

Water

5589

Loss

106

Glycerin

(Crude)

515

4.0 T

Sodium

Sulfate

860

Effluent

1400


Page 31 of 96

2. (c) Hydrogenated Methyl Ricinoleate:


Hydrogenated Castor Oil is charged in the Methylation reactor followed by catalyst

Sodium Methoxide. Reactor temperature is maintained at 60°C. Methanol is added

gradually in the reactor. The reaction mass is subjected to stirring for 2 hours. On

completion of the reaction the reaction mass is transferred to Separator and allowed

to settle. The settled mass is drained and collected as crude Glycerine.

The excess Methanol is then recovered by heating the reaction mass. The

Hydrogenated Methyl Ricinoleate mass in the reactor is analysed for neutral pH and

subjected to hot water wash for a volume upto the neutral pH is obtained. The mass is

allowed to settle. The settled mass is drained and sent to Evaporation Plant.

The Hydrogenated Methyl Ricinoleate mass in the reactor is then sent to vacuum

dryer and flaker. The flaked Hydrogenated Methyl Ricinoleate is packed in bags and

stored in the godown

(b) Reaction Chemistry:

Reaction

Chemistry C3H5(C18H35O3)3 + 3CH3OH

3(C19H38O3) + C3H8O3

Gram/Mole 938 96

942 92

Chemical

Name

Hydrogenated

Caster Oil Methanol

Hydrogenated

Methyl

Ricinoleate

Glycerine


Page 32 of 96

(c) Material Balance:


Batch size Kg 5000

Working Days 26


Quantity

Remarks

Kg/Batch Kg/Kg of

Product TPM

Input

1 Hydrogenated Castor Oil

(HCO) 5205.5 1.041 2082.20 Reactant

2 Methanol 535.1 0.107 214.020 Reactant

3 Sodium Methoxide 0.03 0.000 0.012 Catalyst

4 Water 7500.0 1.500 3000.00

Total 13240.6 2.648 5296.24

Output

1 Hydrogenated Methyl

Ricinoleate 5000.0 1.000 2000.000

Finished

Product

2 Glycerine (Crude) 697.6 0.140 279.040 By Product

3 Methanol (Recovered) 25.5 0.005 10.200 Solvent

Recovered


5 Losses 17.5 0.004 7.000 Losses

Total 13240.6 2.648 5296.24


Page 33 of 96

(d) Process Flow diagram:

Loss: 17.5

Hydrogenated

Castor Oil: 5205.5

Sodium Methoxide: 0.03

Methylation

Reactor at 60 °C

Packing (Barrels)

Methylation

Reactor at 60 °C

Separator

Separator

Separator

Vacuum Dryer

Methanol: 535.1

Gowdown 5000

Hot Water:

7500

Crude Glycerin 697.6

Effluent: 7500.0

Evaporation

Plant Methanol

(Recovered)

25.5


Page 34 of 96

3. (a) POLYMERISE RA:


Charge RA into clean and dry reactor, start vacuum and stirrer, raise temperature

upto 240 °C and check required parameters. Continue heating to reach required

specific viscosity. When attained the same stop heating and cool for final discharge.


Reaction

Chemistry C18H34O3

C18H32O2 + H2O

Gram/Mole 298

280 18

Chemical Name Ricinoleic

Acid Polymerized RA Water


Capacity TPM 500.00

Batch size Kg 3500

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Ricinoleic Acid 3725.0 1.064 532.143 Reactant

Total 3725.0 1.064 532.143

Output

1 Polymerized RA 3500.0 1.000 500.000 Finished Product


Total 3725.0 1.064 532.143

(d) Process Flow Diagram:

Discharge

Vacuum

Ricinoleic Acid

Cool

Polymerized RA


Page 35 of 96

3. (b) BLOWN CASTOR OIL:


Charge castor oil in Reactor. Raise temperature gradually to required temp. 150 °C.

Start blowing air through Sparger. Continue reaction and draw sample at regular time

interval up to required viscosity. Stop heating and air blowing, cool and pack material

as per requirement in barrel or other alternate.


Reaction

Chemistry C3H5(C18H33O3)3 + 3O2

[C3H5(C18H33O4)3]N

Gram/Mole 932 48

980

Chemical Name Castor Oil Oxygen Blown Castor Oil


Capacity TPM 500.00

Batch size Kg 4000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Castor 4004.0 1.001 500.501 Reactant

Total 4004.0 1.001 500.501

Output

1 Blown Castor Oil 4000.0 1.000 500.000 Finished Product

2 Losses 4.0 0.001 0.501 Losses

Total 4004.0 1.001 500.501


Reactor (100 °C)

Oxidation (150 °C)

Blown Castor Oil

4000.0

Non Condensable

Castor Oil: 4004.0

AIR Air (1%)


Page 36 of 96

3. (c) BISAMIDE:


12 Hydro Stearic Acid is charged to Thermic Fluid Heating Reactor. Maintain

Temperature and add Ethylene Diamide into Reactor gradually. Give time for

digestion and increase reaction temperature such that it can reach upto melting

point at 140 °C. Stop Heating and cool down material to 150 °C and add HCO

maintaining 145 °C temperature. After Flaking, material is packed in 25 & 50 kg Bags &

stored in Godown.


Reaction Chemistry C18H36O3 + C2H8N

C20H42O2N + H2O

Gram/Mole 300 46

328 18

Chemical Name 12 Hydrosteric

Acid

Ethylene

Diamine Bisamide Water


Capacity TPM 500.00

Batch size Kg 4000

Working Days 26


Quantity

Remarks Kg/Batch

Kg/Kg

of

Product

TPM

Input

1 12 Hydroxy Stearic Acid 3846.2 0.962 480.769 Reactant

2 Ethylene Diamine 384.6 0.096 48.077 Reactant

Total 4230.8 1.058 528.846

Output

1 Bisamide 4000.0 1.000 500.000 Finished Product

2 Water (Vapor) 230.8 0.058 28.846 Atmospheric Loss

Total 4230.8 1.058 528.846


Page 37 of 96

(d) Process Flow Diagram:

12-Hydroxy Stearic Acid: 3846.2

Ethylene Diamine: 384.6

REACTOR

Flaking

Heating At 1450C

N-N Bis Amide

4000

Storage

Dispatch

Water (vapor): 230.8


Page 38 of 96

4. (a) DE-HYDRATED CASTOR OIL (DCO)


Charged Castor Oil in Thermic Fluid Heater Reactor, apply vacuum and raise

temperature until it reaches to required temperature. Add required quantity of

catalyst (Sulphuric Acid) gradually. After completion of reaction, cool the material

under vacuum below 70 °C and transfer it to settling tank and finally to Storage tank.


Reaction

Chemistry C3H5(C18H33O3)3

C3H5(C18H31O2)3 + 3H2O

Gram/Mole 932

878 54

Chemical

Name Castor Oil DCO

Water


Capacity TPM 500.00

Batch size Kg 4000.00

Working Days 26


Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input


2 Sulfuric Acid (Catalyst) 27.3 0.007 3.417 Catalyst

Total 4273.3 1.068 534.169

Output

1 DCO 4000.0 1.000 500.000 Finished

Product


3 Sulfuric Acid (Spent) 27.3 0.007 3.417 Spent Acid

Total 4273.3 1.068 534.169


Page 39 of 96


Castor Oil: 4246

H2SO4 (Catalyst): 27

REACTOR

DCO Monomer

Settling Tank

DCO Monomer

Cooler

DCO Monomer

4000

Effluent: 246

Storage Tank

H2SO4 (Spent): 27


Page 40 of 96

4. (b) DCO FATTY ACID


Charge Castor Oil in Autoclave and add Catalyst. Raise temperature and pressure in

Autoclave by passing open Steam. After attaining desired pressure and temperature,

draw sample for required test parameter. Stop heating and discharge batch into

conical separator to settle the mass after achieving desired test parameters. Allow

mass to settle for 30-40 minutes. Drain Ed. Glycerine and send to Evaporation Plant.

Remaining Part Crude Fatty acid is sent to Distillation. Distillation starts in vessel under

vacuum by heating Thermic fluid. Raise Temperature gradually and remove moisture.

After completion of heating, distill out Fatty Acid. At One Point, Fatty Acid distillation

rate reaches to approximately zero. Stop heating and transfer black Oil Fatty Acid to

Cooler Tank and finally to storage tank.

(b) Chemical Reaction:

Reaction

Chemistry C3H5(C18H31O2)3 + 3H2O 3(C18H32O2) + C3H8O3

Gram/Mole 878 54 840 92

Chemical

Name Castor Oil water

Crude fatty

acid Glycerine

Reaction

Chemistry 3(C18H32O2)

Distillation C18H32O2 + CH3(CH2)nCOOH

Gram/Mole 840 280 560

Chemical

Name

Crude fatty

acid

DCO

fatty

acid

Light Fatty Acid


Page 41 of 96


Capacity TPM 500.00


Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Dehydrated Castor

Oil 5888.8 1.472 736.1 Reactant

2 Water 362.0 0.091 45.250

Total 6250.8 1.563 781.350

Output

1 DCO Fatty Acid 4000.0 1.000 500.000 Finished Product

2 Glycerine 616.8 0.154 77.100 By-Product

3 Light Fatty Acid 197.2 0.049 24.650 By-Product

4 Solid Waste 1239.6 0.310 154.950 Solid Waste

5 Loss 197.2 0.049 24.650

Total 6250.8 1.563 781.350


Dehydrated Castor

Oil: 5888

AUTOCLAVE

High Pressure FAT

Splitting

DCO Monomer

Distillation

Crude Fatty Acid

Vapor Loss: 197

DCO FA

4000

Black Oil FA

LEF

197


Page 42 of 96

5. UNDECYLENIC ACID


Methyl Ricinoleate is subjected to cracking by passing it through a heating zone with

temperature of around 590 – 640 °C. After cracking, the pyrolytic product (C7 to C11)

is collected and subjected to distillation in 20 size column. The Heptaldehyde (C7)

distillation product obtained is collected and continuously analysed. As the distillation

product changes, the mass is subjected distillation in 300 size column. The Mixed Fatty

Acid (C8 to C10) is collected and continuously analysed. The remaining pyrolytic

mass of MR is collected and sold to soap manufacture.


Reaction Chemistry C19H36O3

C11H20O2 + C7H15CHO

Gram/Mole 312

184 128

Chemical Name Methyl

Ricinoleate

Undecylenic

Acid Heptaldehyde


Capacity TPM 30.00

Batch size Kg 1000

Working Days 26


Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Methyl Ricinoleate 2500.0 2.500 75.000 Reactant

Total 2500.0 2.500 75.000

Output

1 Undecylenic Acid 1000.0 1.000 30.000 Finished

Product

2 Heptaldehyde (Crude) 800.0 0.800 24.000 By Product

3 Mixed Fatty Acid 600.0 0.600 18.000 By Product

4 Pyroletic Mass of MR 100.0 0.100 3.000

By Proeuct

(Sold to soap

manufacturers)

Total 2500.0 1.000 75.000


Page 43 of 96


Methyl Ricinoleate: 2500

Cracking

590 – 640 °C

Heptaldehyde

Crude

800.0

Distillation

Mixed

Fatty Acid

600.0

Pyrolytic

Mass of MR

100.0

Methyl

Undecylenic

Acid

1000.0


Page 44 of 96

6. Zinc UDA


Charge batch size Undecylenic acid into clean and dry reactor. Start agitation and

raise temperature to 60 °C and start addition Zinc Oxide with care. After addition is

completed, raise temperature upto 150 °C. Check A.V and melting temperature of

product and by attaining Product required specification; the same batch is

discharged into tray and cool to pulverize for required mesh size.


Reaction

Chemistry 2CH2=CH-(CH2)8-COOH + ZnO

(CH2=CH-(CH2)8-COO)2Zn + H2O

Gram/Mole 368 81

431 18

Chemical

Name Undecylein Acid

Zinc

Oxide Zinc Undecylenate Water


Capacity TPM 30.00

Batch size Kg 1000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Undecylenic Acid 860.0 0.860 25.800 Reactant

2 Zinc Oxide 200.0 0.200 6.000 Reactant

Total 1060.0 1.060 31.800

Output

1 Zinc Undecylenite 1000.0 1.000 30.000 Finished Product


Total 1060.0 1.060 31.800


Page 45 of 96


Undecylenic Acid: 860.0

REACTOR 60 °C

Zinc UDA

1000.0

UDA + ZNO

Discharge in Tray

At Room Temp.

Storage Tank

Zinc Oxide: 200.0

150 °C


Page 46 of 96

7. Sebacic Acid


Sebacic Acid is manufactured by Hydrolysis of commercial Castor Oil using Steam in

presence of Zinc Oxide and water. During hydrolysis process light yellow colour fatty

acid (Ricinoleic acid) and glycerin are separated. The fatty acid is then mixed and

sent to cracking unit with controlled flow where simultaneously caustic lye of 45%

strength is charged. During cracking Disodium Sebacate is obtained which is then

neutralized and settled. The product is then subjected to bleaching/discolouring

followed by acidification, crystallization, dewatering, centrifuging, granulating and

packing. The 2-Octanol, Glycerin and fatty acid are generated as byproducts during

the manufacturing of Sebacic Acid.


Reaction Chemistry C57H104O9 + 3H2O

3C18H34O3 + C3H8O3

Gram/Mole 932 54

894 92

Chemical name Castor Oil Water

Ricinolic

Acid Glycerol

Reaction

Chemistry C18H34O3 + 2NaOH

C10H16Na2O4 + C8H18O + H2

Gram/

Mole 298

80

246

130

2

Chemical

name

Ricinolic

Acid

Sodium

Hydroxide

Sodium

Sebacate

2-Octanol

Hydrogen

Reaction Chemistry C10H16Na2O4 + H2SO4

C10H18O4 + Na2SO4

Gram/Mole 246 98

202 142

Chemical name Sodium

Sebacate

Sulfuric

Acid

Sebacic

Acid

Sodium

Sulfate


Page 47 of 96


Capacity TPM 240.00

Batch size Kg 8000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input


2 Caustic soda 9200.0 1.150 276.000 Reactant

3 Sulfuric Acid 11360.0 1.420 340.800 Reactant

4 ZnO 44.0 0.006 1.320 Catalyst

5 Activated Carbon 160.0 0.020 4.800 Purification

6 Water for hydrolysis 928.0 0.116 27.840

7 Water for process 52000.0 6.500 1560.000

Total 89692.0 11.212 2690.760

Output

1 Sebacic Acid 8000.0 1.000 240.000 Finished Product

2 2- Octanol (85%) 5080.0 0.635 152.400 By Product

3 Mixed Fatty Acid 2560.0 0.320 76.800 By Product

4 Glycerine 1368.0 0.171 41.040 By Product

5 ZnO (Spent) 44.0 0.006 1.320 Spent Catalyst

6 Spent Carbon 160.0 0.020 4.800 Spent Carbon

7 Sodium Sulfate 16336.0 2.042 490.080 By Product

8 Water from Process 56144.0 7.018 1684.320 Effluent

Total 89692.0 11.212 2690.760


Page 48 of 96


Loss

Castor Oil: 16000.0

ZnO: 44.0

Water: 928 Hydrogenation

Centrifuge / Filtration

Cracking

Neutralization

Decolorization

Acidification

Crystallizer

NaOH: 9200

H2SO4 for pH

adjustment

Dryer

H2SO4 for pH

adjustment

2-Octanol: 5080

Glycerin:

1368.0

Fatty Acid

Sebacic Acid: 8000.0

Water washing

6500

Effluent: 56144

Na2SO4: 16336

Evaporation loss


Page 49 of 96

8. Sebacodiamine (C-10 Diamine)


Charge Sabacic acid in rector. It is heated to temp. About 200º C. then start the flow

of ammonia gas to the reactor. Maintain the ammonia sparging through the reaction

system in order to remove the water formed during the reaction. Maintain the temp.

between 240-250 °C. Take the sample after about 6 hrs. and check the acid value.

Once the acid value of the sample is below 3 indicates the amide formation is

completed.


Reaction

Chemistry C10H18O4 + 2NH3

H2N-OC-(CH2)8-CO-NH2 + 2H20

Gram/Mole 202 52

218 36

Chemical

name

Sebacic

Acid

Ammonia

Gas Sebacodiamine

Water

Reaction

Chemistry H2N-OC-(CH2)8-CO-NH2

NC-(CH2)8-CN + 2H20

Gram/Mole 218

182 36

Chemical

name Sebacodiamine Sebacodinitrile

Water

Reaction

Chemistry NC-(CH2)8-CN + 2H2

H2N-(CH2)10-NH2

Gram/Mole 182 4

186

Chemical

name Sebacodinitrile

Hydrogen Sebacodiamine


Page 50 of 96


Capacity TPM 240.00

Batch size Kg 8000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks

Kg/Batch Kg/Kg of

Product TPM

Input

1 Sebacic Acid 9,632.00 1.204 288.96 Reactant

2 Ammonia Gas 1,936.00 0.242 58.08 Reactant

3 Hydrogen Gas 390.40 0.049 11.712 Reactant

5 Ni Catalyst 126.72 0.016 3.802 Catalyst

Total 12,085.12 1.511 362.554

Output

1 c-10 diamine

(distilled) 8,000.000 1.000 240.000 Finished Product

2 Purged Ammonia

Gas 161.60 0.020 4.848 To Scrubber

3 Pitch (c-10 diamine

/ sebeco nitrile) 908.80 0.114 27.264 Byproduct

5 Ni Catalyst (Spent) 126.72 0.016 3.802 Spent Catalyst

7 Effluent 2,811.20 0.351 84.336 Effluent

8 Material Loss 76.80 0.010 2.304

Total 12,085.12 1.511 362.554


Page 51 of 96


Sebacic Acid: 9632

Ammonia Gas: 1936 Reactor

Dehydration

Distillation

Hydrogenation

Filtration

Distillation

Ni Catalyst: 126

Hydrogen Gas: 390

Effluent to

ETP

NH3 Gas: 162

Effluent to ETP

Spent Ni: 126

Material Loss: 77

Pitch (byproduct)

Distilled C-10

Diamine: 8000.0

Pitch (byproduct)


Page 52 of 96

9. Polyol 115


Charge Castor oil as batch size into clean reactor. Raise temperature of castor oil up

to 120 °C. Start addition of ketonic resin. After completion of addition, continuously

raise temperature up to 150 °C. After attaining 150 °C cool and discharge Polyol 115.


Reaction

Chemistry C3H5(C18H33O3)3 + C8H8O

C3H5(C18H33O3)3OH8C8

Gram/Mole 932 120

1052

Chemical

Name Castor Oil

Ketonic

Resin Polyol-115


Capacity TPM 240.00

Batch size Kg 8000

Working Days 26


Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input


2 Ketonic Resin 381.0 0.048 11.429 Reactant

Total 8000.0 1.000 240.000

Output

1 Polyol 115 8000.0 1.000 240.000 Finished Product

Total 8000.0 1.000 240.000


Page 53 of 96


Castor Oil: 7619.0

Ketonic Resin: 381.0

REACTOR

120 °C

Polyol: 8000.0

Reactor

150 °C

Cool &

Discharge


Page 54 of 96

10. Ethoxylated Castor Oil


Charge castor oil to required quantity into clean and dry reactor. Start stirrer and add

Ethylene Oxide as per required quantity. Allow to digest for 1 hr and final product is

ready for discharge.


Reaction

Chemistry C3H5(C18H33O3)3 + CH2OCH2

C57H104O9(CH2OCH2)

Gram/Mole 932 44

976

Chemical Name Castor Oil Ethylene

Oxide Ethoxylated Castor Oil


Capacity TPM 240.00

Batch size Kg 8000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input


2 Ethylene Oxide 360.7 0.045 10.820 Reactant

Total 8000.0 1.000 240.000

Output

1 Ethoxilated Castor Oil 8000.0 1.000 240.000 Finished Product

Total 8000.0 1.000 240.000


Castor Oil: 7639.3

Ethylene Oxide: 360.7

Reactor

Ethoxylated Castor

Oil: 8000.0


Page 55 of 96

11. Glycerol Monosterate


Charge all the raw materials in reactor, start heating and stirring. Apply vacuum slowly

and raise temperature up to 150 °C. Maintain the condition for 1 hr after that raise

temperature upto 250-270 °C. Maintain the condition for 3 hrs. Test sample. If found

satisfactory, start cooling & flaking.


Reaction

Chemistry C17H35COOH + C3H8O3

C17H35CO(C4H7O3) + 1/3 H2O

Gram/Mole 284 92

370 6

Chemical

Name Stearic Acid Glycerin

Polyol-115


Capacity TPM 240.00

Batch size Kg 8000

Working Days 26

Sr.

No. Name of Raw Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Stearic Acid 6346.4 0.793 190.391 Reactant

2 Caustic Soda Lye 14.9 0.002 0.447 Reactant

3 Glycerin 2055.9 0.257 61.676 Reactant

4 Phosphoric Acid 3.7 0.000 0.112 Catalyst

Total 8420.9 1.053 252.626

Outpu

t

1 Glycerol Monosterate 8000.0 1.000 240.000 Finished

Product

2 Waste water 402.2 0.050 12.067 Effluent

3 Vapor loss 18.6 0.002 0.559 Vapor

Loss

Total 8420.9 1.053 252.626


Page 56 of 96


Stearic Acid: 6346.4

Glycerin: 2055.9

Caustic Soda Lye: 14.9

Phosphoric Acid: 3.7

REACTOR

150 °C

Glycerol Monosterate:

8000.0

Reactor

250 - 270 °C

Cooling & Flaking

Effluent: 282.0

Vapor Loss: 2.5


Page 57 of 96

12. Zinc Ricinoleate


Charge batch size Recinolic Acid into clean and dry reactor. Start agitation and raise

temperature to 60 °C and start addition of zinc oxide with care. After completion,

raise temperature upto 120 °C. Check A.V. and melting temperature of product. By

attaining Product required specification, the mass is discharged into tray, cool and

pulverized to required mesh size.


Reaction Chemistry 2(C18H34O3) + ZnO

(C36H64O5)Zn

+ 2H2O

Gram/Mole 596 81

641 36

Chemical Name Ricinolic

Acid

Zinc

Oxide

Zinc

Ricinoleate

Water


Capacity TPM 150.00


Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Ricinolic Acid 4670 0.934 140.100 Reactant

2 Zinc Oxide 680 0.136 20.400 Reactant

Total 5350.0 1.070 160.500

Output

1 Zinc Ricinoleate 5000.0 1.000 150.000 Finished

Product

2 Vapor Loss 350.0 0.070 10.500 Vapor Loss

Total 5350.0 1.070 160.500


Page 58 of 96


Ricinoleic Acid: 4670

Zinc Oxide: 680

REACTOR

60 °C

Zinc Ricinoleate: 5000

Reactor

120 °C

Cool & Discharge in Tray

at Room Temp.

Vapor Losses:

350


Page 59 of 96

13. DCO Stand Oil


Charged Castor Oil in Thermic Fluid Heater Reactor, apply vacuum and raise

temperature until it reaches to required temperature. Add required quantity of

catalyst (Sulphuric Acid) gradually. After completion of reaction, cool the material

under vacuum below 70 °C and transfer it to settling tank and finally to Storage tank.


Reaction

Chemistry C3H5(C18H33O3)3

C3H5(C18H31O2)3 + 3H2O

Gram/Mole 932

878 54

Chemical name Castor Oil

DCO Stand Oil Water


Capacity TPM 360.00

Batch size Kg 5000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input


2 Sulfuric Acid 34.2 0.007 2.460 Catalyst

Total 5341.7 1.068 384.601

Output

1 DCO Stand Oil 5000.0 1.000 360.000 Finished Product


3 H2SO4 (Spent) 34.2 0.007 2.460 Spent Acid

Total 5341.7 1.068 384.601


Page 60 of 96


Effluent: 307.5

Castor Oil: 5307.5

H2SO4: 34.2

Thermic Fluid

Heater

DCO Stand Oil:

5000.0

De-hydrated Castor

Oil (DCO)

Storage Tank

Spent Acid

(250 °C)

(260 °C)


Page 61 of 96

14. Sulfonated Castor Oil


Charge castor oil in clean and dry reactor, start cooling and maintain temperature of

oil to 70-80 °C. Start addition of H2SO4 gradually with care as reaction is exothermic.

Maintain temperature to 70-80 °C until H2SO4 addition is completed. Allow stirring for

2 hrs. After two hours, stop stirring and allow the mass to settle for 4-5 hrs. Finally

neutralize the batch with caustic soda.


Reaction

Chemistry C3H5(C18H33O3)3 + 3NaOH + 3(H2SO4)

C57H101Na3O18S3 + 6H2O

Gram/Mole 932 120 294

1238 108

Chemical

Name Castor Oil

Caustic

Soda

Sulfuric

Acid

Sulfonated

Castor Oil Water


Capacity TPM 240.00

Batch size Kg 8000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input


2 Sulfuric Acid 1899.8 0.237 56.995 Reactant

3 Caustic Soda 775.4 0.097 23.263 Reactant

Total 8697.9 1.087 260.937

Output

1 Sulfonated Castor Oil 8000.0 1.000 240.000 Finished Product

2 Waste water 697.9 0.087 20.937 Effluent

Total 8697.9 1.087 260.937


Page 62 of 96


Castor Oil: 6022.6 H2SO4: 1899.8

Reactor

Sulfonated Castor

Oil: 8000.0

Neutralization

Storage

Effluent: 698

(70-80 °C)

NaOH: 775.4


Page 63 of 96

15. Distilled Fatty Acid


Charge Acid Oil in autoclave, raise temperature and pressure by passing open

steam. Attaining pressure and temperature draw sample and test required parameter

test attained stop heating and discharge batch into conical separator to settle the

mass. Allow the mass to settle for 30-40 min. Drain Ed. Glycerin and send to

evaporation plant. Remaining part crude fatty acid for Distillation. Distillation to start in

vessel under vacuum by heating thermic fluid. Raise temp. gradually and removed

moisture. After completion, continued heating and distill out Fatty acid. At one point

fatty acid distillation rate is approx zero. Then stop heating & transfer black oil fatty

acid to cooler tank & final product to storage tank.

(b) Material Balance


Batch size Kg 25000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Acid Oil 35714.3 1.429 3214.286 Reactant

Total 35714.3 1.429 3214.286

Output

1 Distilled Fatty Acid 25000.0 1.000 2250.000 Finished Product

2 Glycerine 3214.3 0.129 289.286 By-Product

3 Distillation Reside 7500.0 0.300 675.000 Solid Waste

Total 35714.3 1.429 3214.286


Page 64 of 96

(c) Process Flow Diagram

Acid Oil: 35714

Steam

Autoclave

Splitting

Purification

Glycerin: 3214 Crude Fatty Acid

Distillation

Distilled Fatty Acid

25000

Hydrogenation

Stearic Acid

Distillation

Different Grade

Stearic Acid


Page 65 of 96

16. Dimer Acid


Take distilled fatty acid in clean and dry reactor. Start stirrer and heating. Add Gallian

Earth as catalyst. Raise temperature upto 240 °C and continue it for 6 hrs. Then add

Phosphoric Acid into reactor & allow it to mix for 1 hr. Cool to 100 °C and filter it. After

filtration, start distillation and collect Dimer acid and monomer.


Reaction Chemistry 2C18H34O3

C36H66O5 + H2O

Gram/Mole 596

578 18

Chemical name Distilled Fatty

Acid

Dimer Acid

+ Monomer Water


Capacity TPM 750.00

Batch size Kg 7500

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Distilled Fatty Acid 13636.4 1.818 1363.636 Reactant

2 Gallian Earth 54.5 0.007 5.455 Catalyst

3 Phosphoric Acid 40.9 0.005 4.091 Catalyst

Total 13731.8 1.831 1373.182

Output

1 Dimer Acid 7500.0 1.000 750.000 Finished Product

2 Distilled Monomer 6136.4 0.818 613.636 By Product

3 Losses 95.5 0.013 9.545 Spent Catalyst

Total 13731.8 1.831 1373.182


Page 66 of 96


Distilled Fatty Acid: 13636

Gallian Earth: 54.5

Reactor

Filtration

Intermediate

Product

Dimer Acid

7500

Distilled Monomer

6136

(240 °C)

Phosphoric Acid: 41

Distillation


Page 67 of 96

17. Iso Stearic Acid


Charge distilled monomer (product from dimer distillation) and start stirring and raise

Temperature by adding Gallian Earth up to 280 °C and maintain for 3 hrs then cool

Hydrogenation product by adding Nickel as catalyst and then distilled out product.


Reaction Chemistry C18H34O3 2H2

C18H36O2 + H2O

Gram/Mole 298

284 18

Chemical name Distilled

Monomer

Iso Stearic

Acid Water


Capacity TPM 300.00

Batch size Kg 5000

Working Days 26


Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Distilled Monomer 8333.3 1.667 500.000 Reactant

2 Gallian Earth 25.0 0.005 1.500 Catalyst

3 Ni 0.8 0.000 0.050 Catalyst

Total 8359.1 1.672 501.550

Output

1 Iso stearic acid 5000.0 1.000 300.000 Finished Product

2 Ni Catalyst (Recovered) 0.8 0.000 0.050 Spent Catalyst

3 Distillation Residue 3358.3 0.672 201.500 Solid Waste

Total 8359.1 1.672 501.548


Page 68 of 96


Distilled monomer: 8333

Gallian Earth: 25

Reactor

Hydrogenation

Intermediate

Product

ISO-Stearic

Acid: 5000

Residue: 3358

280 °C

Distillation

H2 Gas

Ni (Catalyst): 0.8


Page 69 of 96

18. Euracic Acid


Charge Rapeseed Oil in autoclave, raise temperature and pressure by passing open

steam. Attaining pressure and temperature draw sample and test required parameter

test attained stop heating and discharge batch into conical separator to settle the

mass. Allow the mass to settle for 30-40 min. Drain Ed. glycerine and send to

evaporation plant. Remaining part crude fatty acid for Distillation. Distillation to start in

vessel under vacuum by heating thermic fluid. Raise temp. gradually and removed

moisture. After completion, continued heating and distill out Fatty acid. At one point

fatty acid distillation rate is approx zero. Then stop heating & transfer black oil fatty

acid to cooler tank & final product to storage tank.


Reaction

Chemistry C57H100O6 + 3H2O

C54H98O6 + C3H8O3

Gram/Mole 880 54

842 92

Chemical

name Rapeseed oil Water

Crude

Fatty Acid Glycerin

Reaction

Chemistry C54H98O6

C22H42O2 + C16, C24, C18

Gram/Mole 842

338 504

Chemical

name

Crude Fatty

Acid Eurecic Acid Mixed Fatty Acid


Page 70 of 96


Capacity TPM 450.00

Batch size Kg 5000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Rapeseed oil 10451.3 2.090 940.618 Reactant

2 Water 641.3 0.128 57.720 Reactant

Total 11092.6 2.219 998.337

Output

1 Eurecic Acid 5000.0 1.000 450.000 Finished Product

2 C18,C24,C18 2992.9 0.599 269.359 Mixed Fatty Acid

3 Glycerine (Crude) 1092.6 0.219 98.337 By Product


Total 11092.6 2.219 998.337


Rapeseed Oil: 10451

Ni (Catalyst)

Autoclave

Distillation

Crude Fatty Acid

Residue: 2007

Glycerin: 1093

Eurecic Acid

5000

C16, C18, C24

2993


Page 71 of 96

19. Glycerin


A process for the purification of crude glycerin derived from the hydrolysis,

saponification and etherification of natural occur oil or fats. Take this crude glycerol

for pretreatment and neutralized to required pH. Evaporate excess Sweet water to

required purity of glycerin and then finally distillated product & de-colour to required

specification of different grades.

(b) Material Balance

Capacity TPM 240.00

Batch size Kg 8000

Working Days 26

Sr. No. Name of Raw

Material

Quantity

Remarks Kg/Batch

Kg/Kg of

Product TPM

Input

1 Sweet Water 94117.6 11.765 2823.529 Reactant

Total 94117.6 11.765 2823.529

Output

1 Glycerine 8000.0 1.000 240.000 Finished

Product

2 Sodium Sulphate 22588.2 2.824 677.647 By Product


4 Vapor Loss 61647.1 7.706 1849.412 Vapor Loss

Total 94117.6 11.765 2823.529


Page 72 of 96

(c) Process Flow Diagram

AR CP IW

Distillation

12 HSA

+ RA Hydrolysis Esterification

Sweet Water +

Salt (7-8%)

Sweet Water

(9-10%)

Water + Glycerin

(80%)

Evaporation Plant

Vapor

Loss

Sodium Salt

Crude Glycerin

Refined

TECH DYN


Page 73 of 96

4.5 RAW MATERIAL REQUIREMENT

Various types of raw materials will be required for manufacturing of proposed

product. Details of raw material requirement for existing unit and proposed expansion

are given in Table-8. Details of product and raw material regarding storage and

Mode of transportation are given in Table - 9.

Table-8: Details of Proposed Raw Material Requirement

Raw materials Product

No.

Quantity (MT/Month)

kg/kg TPM Group

Max Total

12 Hydroxy Stearic Acid 3(c) 0.962 480.77 480.77 480.77

Acid Oil 15 1.429 3,214.29 3,214.29 3,214.29

Activated Carbon 7 0.020 4.80 4.80 4.80

Ammonia Gas 8 0.242 58.08 58.08 58.08

Castor 3(b) 1.001 500.50 500.50 500.50

Castor Oil

2(b) 1.043 2,085.02 2,085.02

4,116.34

4(a) 1.062 530.75 530.75

7 2.000 480.00 480.00

9 0.952 228.57 228.57

10 0.955 229.18 229.18

13 1.062 382.14 382.14

14 0.753 180.68 180.68

Caustic Lye (48%) 2(a) 0.278 555.56

559.28 559.28

2(b) 0.280 559.28

Caustic soda

7 1.150 276.00 276.00

299.71 14 0.097 23.26 23.26

11 0.002 0.45 0.45

Dehydrated Castor Oil 4(b) 1.472 736.10 736.10 736.10

Distilled Fatty Acid 16 1.818 1,363.64 1,363.64 1,363.64

Distilled Monomer 17 1.667 500.00 500.00 500.00

Ethylene Diamine 3(c) 0.096 48.08 48.08 48.08

Ethylene Oxide 10 0.045 10.82 10.82 10.82

Gallian Earth 16 0.007 5.45 5.45

6.95 17 0.005 1.50 1.50

Glycerin 11 0.257 61.68 61.68 61.68

Hydrogen

1(a) 0.008 24.90 24.90

36.61 1(b) 0.007 20.11

8 0.049 11.71 11.71

Hydrogenated Castor Oil

(HCO)

2(a) 1.042 2,084.44 2,084.44 2,084.44

2(c) 1.041 2,082.20

Ketonic Resin 9 0.048 11.43 11.43 11.43

Methanol 2(c) 0.107 214.02 214.02 214.02

Methyl Ricinoleate 5 2.500 75.00 75.00 75.00

Nickel 17 0.000 0.05 0.05 6.20


Page 74 of 96

8 0.016 3.80 3.80

1(a) 0.000 0.21 2.35

1(b) 0.001 2.35

Palm Stearine 1(b) 0.993 2,979.89 2,979.89 2,979.89

Phosphoric Acid 11 0.000 0.11 0.11

4.20 16 0.005 4.09 4.09

Rapeseed oil 18 2.090 940.50 940.50 940.50

Refined Castor Oil 1(a) 0.994 2,980.80 2,980.80 2,980.80

Ricinoleic Acid 3(a) 1.064 532.14 532.14

672.24 12 0.934 140.10 140.10

Sebacic Acid 8 1.204 288.96 288.96 288.96

Sodium Methoxide 2(c) 0.000 0.01 0.01 0.01

Stearic Acid 11 0.793 190.39 190.39 190.39

Sulfuric Acid

7 1.420 340.80 340.80

1,401.54

8 0.006 1.33 1.33

13 0.007 2.46 2.46

14 0.237 57.00 57.00

2(a) 0.495 989.90 996.54

2(b) 0.498 996.54

4(a) 0.007 3.42 3.42

Sweet Water 19 11.765 2,823.53 2,823.53 2,823.53

Undecylenic Acid 6 0.860 25.80 25.80 25.80

Zinc Oxide

6 0.200 6.00 6.00

27.72 12 0.136 20.40 20.40

7 0.006 1.32 1.32


Page 75 of 96

Table-9: Details of Proposed Products and Raw Material Storage:

Sr.

No. Name of Chemicals Physical form

Type of

packing Packing Size

Maximum

storage

capacity, MT

Characteristic Storage

Pressure

Storage

Temp.

Market/

Source

Products

1. Hydrogenated Castor Oil Solid PP Bag 25/50

Kg 300 T Flake Atm. Amb.

Local/

Export

2. 12 Hydroxy Stearic Acid

(HSA) Solid PP Bag 25Kg 300 T Flake Atm. Amb.

Local/

Export

3. Ricinoleic Acid (RA) Liquid

Lacquer

Coated

Drum

200 Lit 2-Tank

25MT Yellow - Reddish Atm. Amb.

Local/

Export

4. Polymerized Ra Liquid Drum 200 Kg 20 T Viscous Atm. Amb. Local/

Export

5. Blown Castor Oil Liquid Carboy

Drum

50 Kg

200 Kg 20 T Viscous Atm. Amb.

Local/

Export

6. Bisamide Solid PP Bag 25 Kg 20 T Flake/powder Atm. Amb. Local/

Export

7. Hydrogenated Methyl

Ricinoleate Solid PP Bag 25 Kg 100 T Flake Atm. Amb.

Local/

Export

8. De-Hydradted Castor Oil

(DCO) Liquid Drum 190 Kg 30 T Yellow - Reddish Atm. Amb.

Local/

Export

9. DCO Fatty Acid Liquid

Lacquer

Coated

Drum

190 Kg 20 T Water white Atm. Amb. Local/

Export

10. Undecylenic Acid Liquid Carboy 50 Kg 8 T Colorless to pale Yellow Atm. Amb. Local/

Export

11. Zinc UDA Solid

Open

Mouth

Carboy

As Required 2 T White Powder Atm. Amb. Local/

Export

12. Sebacic Acid Solid Paper

Bag

20 Kg

25 Kg 30 T White Powder Atm. Amb.

Local/

Export


Page 76 of 96

13. Sebacodiamine (C-10

Diamine) Solid PP Bag

25/50

Kg 20 T Powder Atm. Amb.

Local/

Export

14. Polyol 115 Liquid Drum 200 Kg 15 T yellowish Atm. Amb. Local/

Export

15. Glycerol Monosterate Solid PP Bag 25 Kg 10 T White Powder/ Flakes

Atm. Amb.

Local/

Export

16. Zinc Ricinoleate Solid PP Bag 25 Kg 2 T Off White powder Atm. Amb. Local/

Export

17. DCO Stand Oil Liquid Drum 200 Kg 10 T Yellow - Reddish Atm. Amb. Local/

Export

18. Sulphonated Castor Oil Liquid Drum 200 Kg 5 T Amber Yellow to Dark Brown Atm. Amb. Local/

Export

19. Ethoxylated Castor Oil Liquid Carboy

Drum

50 Kg

200 Kg 10 T Pasty Atm. Amb.

Local/

Export

20. Hydrogenated Palm

Stearine Solid PP Bag 25 Kg 300 T Flake Atm. Amb.

Local/

Export

21. Distilled Fatty Acid Liquid Plastic

Carboy 190 Kg 300KL Reddish Atm. Amb.

Local/

Export

22. Dimer Acid Liquid

Lacquer

Coated

Drum

200 Kg 10 T Yellow - Light Red Atm. Amb. Local/

Export

23. Iso Stearic Acid Liquid Drum 190 Kg 20 T Colourless - Pale Yellow Atm. Amb. Local/

Export

24. Euracic Acid

Liquid > 35 C

Plastic

Carboy 30 Kg 20 T White Atm. Amb.

Local/

Export

25. Glycerine Liquid Drum 250 Kg 80 T Colourless Atm. Amb. Local

Raw Materials

1. 12 Hydroxy Stearic Acid Liquid Captive consumption Atm. Amb. Local

2. Acid Oil Liquid Captive consumption Yellow - Red Atm. Amb. Local

3. Activated Carbon Solid PPBag 25Kg 10 T Powder Atm. Amb. In Process


Page 77 of 96

4. Ammonia Gas Gas Cylinder 50 Kg 6 T Gas Atm. Amb. Local

5. Castor Liquid Captive Consumption Yellow - Reddish Atm. Amb. Local

6. Castor Oil Liquid Tank -- 150 T*4 Tank Yellow - Reddish Atm. Amb. Local

7. Caustic Lye (48%) Liquid Tank -- 250 T Water white Atm. Amb. Local

8. Caustic soda Solid PP Bag 50 Kg 10 T Flake Atm. Amb. Local

9. Distilled Fatty Acid Liquid Tank - 100 KL Yellowish - Red Atm. Amb. Local

10. Distilled Monomer Liquid Tank - 100 KL Water white Atm. Amb. Local

11. Ethylene Diamine Liquid Drum 200 Kg 2 KL Water white Atm. Amb. Local

12. Ethylene Oxide Gas Cylinder 50 Ltr Colourless flammable Atm. Amb. Local

13. Gallian Earth Solid PP Bag 25 Kg 2 T Powder Atm. Amb. Local

14. Glycerin crude Liquid Tank - 100 KL Water white Atm. Amb. Local

15. Hydrogen Gas Cylinder Truck/Trolly 6000 Nm3 Colourless Atm. Amb. Local

16. Hydrogenated Castor Oil Liquid Captive Consumption Flake Atm. Amb. Local

17. Ketonic Resin Solid PP Bag 25 Kg 3 T Light colour / Clear lumps Atm. Amb. Local

18. Methanol Liquid Tank 20 KL 60 KL Water white Atm. Amb. Local

19. Methyl Ricinoleate Liquid Captive Consumption Yellowish Atm. Amb. Local

20. Nickel Solid Drum 200 Kg 6 T Palate Atm. Amb. Local

21. Palm Stearine Solid/semi

solid Captive Consumption White Atm. Amb. Local

22. Phosphoric acid Liquid Carboy 35 Lit 38 KL Water white Atm. Amb. Local


Page 78 of 96

23. Refined Castor Oil (As per-

6) Liquid Tank - 150 T Pale Yellow- Yellowish Atm. Amb. Local

24. Ricinoleic Acid Liquid Tank - 25 KL Colourless / Yellow Viscous

Liquid Atm. Amb. Local

25. Sebacic Acid Solid Paper Bag 25 Kg 30 T White Powder Atm. Amb. Local

26. Sodium Methoxide Solid PP

Carboy

200 Lit

Capacity 2 T Crystal Atm. Amb. Local

27. Stearic Acid Solid HDPE Bags 25 Kg 20 T White Powder Atm. Amb. Local

28. Sulfuric Acid (Catalyst) Liquid Carboy 35 Lit

125 KL

Thick and Colourless Atm. Amb. Local

29. Sulfuric Acid (33%) Liquid Storage

tank - Colourless Atm. Amb. Local

30. Sweet Water Liquid Storage

tank - 100 KL Colourless Atm. Amb. Local

31. Undecylenic Acid Liquid/solid PP Carboy 200Lit 5 T Pale yellow

Rose like fruity oddour Atm. Amb. Local

32. Zinc Oxide Solid PP Bag 25 Kg 2 T White powder Atm. Amb. Local


Page 79 of 96

The convenient transportation medium will be used for the transportation of products

as well as raw materials. The raw material will be purchased from nearby industries

and the products will be sold in local market or export and transported by road.

4.6 DETAILS OF PROPOSED MACHINERIES & UTILITIES

As unit is proposed to expand its existing capacity, existing equipments and

machineries will be used with some new installation. The details of proposed

equipments and machineries are enlisted hereunder in Table-10.

Table – 10: Details of Proposed Equipments

Sr.

No. Equipments Qty.

Size/

Capacity

(Liter)

Sr.

No. Equipments

Qty

.

Size/

Capacity

(Liter)

1. Reactor -1 1 15T 16. Castor oil storage

tank 2 2 150 KL

2. Reactor-2 1 15T 17. Castor oil storage

tank 3 1 150 KL

3. Reactor-3 1 15T 18. Filtered HCO

Storage Tank 2 20 T

4. Reactor-4 1 15T 19. Flacking Feed Tank 2 6 MT

5. Oil Heater 1 Accessories 20. Drum Flaker 1 1 9 M2

6. Tempered water

cooler 1 Accessories 21. Drum Flaker 2 1 9 M2

7. Heat exchanger 1 0.4 T 22. Drum Flaker 3 1 9 M2

8. Catalyst filter 1 1.2 T

23. Drum Flaker 4 1 9 M2

9. Catalyst filter 1 1.2 T 24. Initial Flake Hopper 2 8 MT

Accessories 10. Oil drying tank 1 25 T 25. Flackes Breaker 2

11. Catalyst mixer

with agitator 1 0.5 T 26.

SS317L Amidation

Reactor(Top Dish

end & Bottom

Conical)

1 10 KL

12. T.W tank 1 0.5 T 27.

SS316 Dryer with

Mechanical Seal

(Top & Bottom Dish

end)

1 10 KL

13. Fat tank with

agitator-A 1 20 T 28.

SS316 Dryer

(Top & Bottom

Dishend)

2 10 KL

14. Fat tank with

agitator -B 1 20 T 29. SS316L Reactor (Top

& Bottom Dish end) 3 10 KL

15. Castor oil storage

tank 1 1 150 KL


Page 80 of 96

5. POLLUTION POTENTIAL AND MANAGEMENT SYSTEM

5.1 WATER POLLUTION

5.1.1 Water Consumption and Waste water Generation

Presently, the fresh Industrial water consumption for manufacturing of existing product

is 923 KL/day, which is used for process, cooling, boiler and washing purpose. The

Industrial wastewater generation from existing production activity is 271 KL/day, which

is reused for cooling @ 71 KL/day and Gardening @ 200 KL/day. The existing water

requirement for domestic activity is 28 KL/day. Wastewater generation from existing

project is 23.9 KL/day which is disposed in soak pit through septic tank.

After the proposed expansion, the fresh industrial water consumption will increase up

to 1060 KL/day. The water requirement for domestic use will also increase up to 31

KL/day. There will be increase in the water consumption and wastewater generation

from domestic activity due to increase in manpower. The total industrial wastewater

generation after proposed expansion will be 382 KL/day. Wastewater generation from

domestic activity will increase up to 24.8 KL/day after proposed expansion.

The water consumption and wastewater generation product wise and category wise

is given in Table-11(a) and Table-11(b). Water balance diagram for proposed

products are given in Drawing –2


Page 81 of 96

Table- 11 (a): Product Wise Water Consumption and Wastewater Generation

Name of Product Product

Code Stream

Water Consumption Wastewater Generation

Liter / Kg

of

Product

KLD Group

Max

Liter / Kg

of

Product

KLD Group

Max

12 Hydroxy Stearic Acid (HSA) 2(a) Process 0.0031 0.24

115.38

0.40 30.77

30.77 Ricinoleic Acid (RA) 2(b) Process 0.0032 6.42 0.40 30.77

Hydrogenated Methyl Ricinoleate 2(c) Process 1.50 115.38 0.00 0.00

Polymerized RA 3(a) Process 0.00 0.00 0.00 0.06 1.24 1.24

De-Hydradted Castor Oil (DCO) 4(a) Process 0.00 0.00 1.74

0.06 1.18 1.18

Dco Fatty Acid 4(b) Process 0.09 1.74 0.00 0.00

Zinc UDA 6 Process 0.00 0.00 0.00 0.06 0.07 0.07

Sebacic Acid 7 Process 6.62 61.07 61.07 7.02 64.78 64.78

Sebacodiamine (C-10 Diamine) 8 Process 0.00 0.00 0.00 0.35 3.24 3.24

APCE 0.16 1.46 1.46 0.00 0.00 0.00

Glycerol Monosterate 11 Process 0.00 0.00 0.00 0.05 0.46 0.46

DCO Stand Oil 13 Process 0.00 0.00 0.00 0.06 0.85 0.85

Sulphonated Castor Oil 14 Process 0.00 0.00 0.00 0.09 0.81 0.81

Euracic Acid 18 Process 0.13 2.22 2.22 0.00 0.00 0.00

Total Process 180.4 103.40

Total APCE 1.46 0.00

Total (Process + APCE) 181.87 103.40


Page 82 of 96

Table –11(b): Category wise Water Consumption and Wastewater Generation

Sr. No. Particulars

Water Consumption,

KL/day

Wastewater Generation,

KL/day

E P T E P T

I Domestic 28 3 31 23.9 0.9 24.8

II Gardening

Fresh Nil 14 14 Nil Nil Nil

Reuse 200 8 208* Nil Nil Nil

III Industrial

a Process &

APCE

Fresh 30 79 109 10 Nil 10

Reuse Nil 103 103 14** 103# 117

b Boiler Fresh 543 30 573 55 3 58

c Cooling

Fresh 198 25 223 40 2 42

Reuse-

Process

Condensate

14** Nil 71 Nil Nil Nil

Reuse-ETP 57

d Washing Fresh 7 3 10 7 3 10

e Others

(WTP) Fresh 145 0 145 145 0 145

Industrial

Consumption /

Generation

Total 994 240 1234 271 111 382

Reuse 71 103 174 14 103 117

Fresh 923 137 1060 257 8 265

Grand total - Fresh (I+II+III) 951 154 1105 280.9 8.9 289.8

Notes:

* 265 KLD Treated Waste Water will be utilized for Greenbelt Development @ 208 KLD

and Cooling @ 57 KLD.

** 14 KLD Effluent from Existing Process will be utilized for Cooling purpose along with 57

KLD from treated effluent

# 103 KLD wastewater generated from proposed project will be treated in Multiple

Effect Evaporator. Condensate from MEE will be reused for proposed process.

#E- Existing, P-Proposed, T-Total after Expansion


Page 83 of 96

Drawing – 2: Water Balance Diagram- Proposed

(208) (57)

(10.0)

(109.0)

(24.8)

(58.0)

(10) (573.0)

(1060.00)

Fresh Industrial

Washing Boiler

(31) To Soak pit

through Septic tank

Fresh Water

(1105)

(103)

Process & APCE

Domestic

Gardening

All units are expressed in KL/day.

(222.0)

ETP

(265)

Evaporator

(265)

(42.0)

(223.0)

Cooling

(145)

Others

(145.0)

(103.0)

Reused for Process

(18.0)

Reused for Cooling

(57)

Reused for Gardening

(14.0)


Page 84 of 96

5.1.2 Waste water Management System

At present, the total industrial waste water generated from the existing unit is 271

KL/day, which is generated from process, boiler, cooling blow down and washing. After

treatment in ETP, treated water @ 271 KL/day is recycled for Process @14 KL/Day,

Cooling @ 57 KL/Day and Gardening @ 200 KL/Day purposes.

After proposed expansion, there will be increase in wastewater generation from 271

KL/day to 382 KL/day from Industrial activities. Wastewater generated from proposed

expansion is 111 KL/day which will be treated in Multi Effect Evaporator (MEE). After

treatment in MEE, it will be reused for process @103 KLD and Gardening @ 8 KL/Day.

Hence, existing ETP along with an additional MEE will be adequate to treat and handle

the total pollution load.

The detail of existing effluent treatment plant and details of Multiple Effect Evaporators

are given hereunder in Table-12 & Table-13 respectively. The schematic flow diagram is

given in Drawing – 3.

The domestic sewage is discharged into soak pit through septic tank and same

practice will be continued after the proposed expansion.


Page 85 of 96

Table-12: Detail of Existing Effluent Treatment Plant

Sr.

No

Name of the

Treatment Unit

No.

of

Units

Length

(m)

Width

(m)

Liquid

Depth

(m)

Hydraulic

Volume

m3

Remark*

1 Screen Chamber 1 1.2 1.5 0.6 1.08

2 Collection

Sump(Sttem-1) 1 2.0 3.45 2.5 17.25

3 Oil & Grease Trap

(OGT 1) 1 5.3 1.8 1.5 14.31

4 Oil & Grease

Trap(OGT-2) 1 9.0 1.5 1.5 20.25

5 Collection Tank CT-1 1 5.3 3.15 3.0 50.08

6 Collection Tank-2 CT-2 2 5.3 5.3 3.0 84.27

7 Acid Solution Tank 1 - - - - 500 lit

LDPE/HDPE

8 Flash Mixer 1 1.0 1.0 1.0 1.0

9 Polyelectrolyte

Solution Tank 1 - - - -

1000 lit

LDPE/HDPE

10 Alkali (Lime) Solution

Tank 1 1.0 1.0 1.0 1.0

11 Alum Solution Tank 1 1.0 1.0 1.0 1.0

12 Floatation Tank with

Oil Trap 1 3.65 3.65 2.1 27.97

13 Scum Sump 1 2.15 2.15 3.0 13.87

14 Neutralization Tank 2 4.1 4.1 3.0 50.43

15 Flocculating Channel 1 3.8 1.0 0.9 3.42

16 Primary Settling Tank 1 3.8 3.8 2.0+2.9

Slant 36.17

17 Aeration Tank (AT 1) 1 15.0 0.5 2.75 20.625

18 Secondary Clarifier

(SC 1) 1 5.0 Dia

3.0

SWD 58.88

19 Aeration Tank 2 (AT 2) 1 8.6 8.6 2.75 203.39

20 Secondary Clarifier

(SC 2) 1 5.0 Dia

3.0

SWD -- 58.88

21 Pri Treated Sump 1 5.3 2.65 3.0 42.135

22 Treated effluent sump

( TES 1 & 2) 2 5.3 5.2 3.0 82.68

23 Sludge Drying Beds 5 5.3 4.7 1.5 37.365 Each

24 Collection Tank 2 - - - 25 Undergro-

und RCC

25 Dosing Tank 2 - - - 0.2 HDPE

26 Sand Filter 1 - - - -- 20 cu.m.

/Hr, MS

27 Activated Carbon

Filter 1 - - - --

20 cu.m.

/Hr, MS


Page 86 of 96

Table-13: Detail of Multiple Effect Evaporator (MEE)

Material of Construction (MOC) SS 304

PARAMETERS Unit PROPOSED

UNIT

Type --

Water Evaporation Capacity Ltr/hr 4770

Feed temperature OC 32 deg.

Total suspended solids PPM NA

Specific gravity of feed Kg/m3 1.0 -1.1

Solids in concentrate (%) 15 to 20%

Concentrate output (kg/hr)

5% Glycerine, 15%

sodium sulphate, &

0.5% fatty acid

SERVICES/UTILITIES REQUIRED

Steam Requirement at 2.5 kg/cm2 (kg/hr) 1950

Cooling water circulation Rate at 30°C (m3/hr) 161

Power installed (excluding cooling

tower and cooling water pump) (KW) 135

Power consumed (KWH) 80

Compressed air requirement at 6

kg/cm2 (nm3/hr) NA

Cooling water inlet temp. (°C) 32

Cooling water outlet temp. (°C) 38

Tolerance:

All performance figure within +5%

All consumption figure within +10%


Page 87 of 96

Drawing – 3: Schematic Diagram of Effluent Treatment Plant

5.2 AIR POLLUTION AND CONTROL MEASURE

The main source of air pollution is flue gas emission from existing as well as proposed

manufacturing activity. There are chances of fugitive emission due to manufacturing

activities and storage & handing of raw materials & products.

5.2.1 Flue Gas Emissions

Presently, the unit has installed Boilers (15 TPH, 1200 U, and 27.5 TPH) and Thermo

Syphone (1000 U), where coal is used as a fuel. The unit has installed Thermo Pack (400

U, 1000 U) where FO is used as fuel. The unit has also installed D.G. Sets (500 KVA & 125

KVA) as an alternate power source in which HSD is used as a fuel.

For proposed expansion, unit will install additional Thermo pack 4 Lac KCal/Hr where

Furnace oil will be used as a fuel.

The details of flue gas stacks along with air pollution control Measure is given hereunder

in Table-14.


Page 88 of 96

Table – 14: Details of Flue Gas Stack along with APC measure

Sr.

No.

Stack

Attach to Status

Stack

Height

(m)

Type of

Fuel

Concentration

of Pollutants

APC

Measure

1

GLV Boiler

(2 Nos.) –

15 TPH each

Existing 40.00 &

2.5 Coal

PM < 150

mg/Nm3

SO2 < 100 ppm

NOX < 50 ppm

Multi Cyclone

Separator

with Bag Filter

2

Geeka

Boiler

(2 Nos.) –

1200 U Each

Existing 23.80 Coal Adequate

Stack height

3

FBC Type

Boiler

(2 Nos.) -

27.5 TPH

Existing 55.00 Coal

Multi Cyclone

Separator

followed by

Bag Filter

4

Thremo

Pack

(2 Nos.) -

400 U Each

Existing 18.00 FO Adequate

Stack height

5

Thermo

Pack -1000

U

Existing 30.00 FO Adequate

Stack height

6

DG SET

(3 Nos.)-

500 KVA

Existing 7.00 HSD Adequate

Stack Height

is Provided 7

DG SET -125

KVA Existing 7.00 HSD

8

Thermo

Syphone (2

Nos.)-1000 U

Each

Existing 30.50 Coal

Teema

Cyclone with

Bag filter

9

Thermo

Pack

4 Lac

Kcal/Hr

Propose

d 18 FO

Adequate

Stack height

is provided

5.2.2 Process Gas Generation

There is no process gas generation from existing manufacturing activities. However, for

proposed expansion there will be process gas generation in the form of NH3 gas.

Adequate scrubbing system will be provided to control the generation of process gas

from proposed expansion.

The details of proposed Air pollution control system for the process emission are given

hereunder in Table-15.


Page 89 of 96

Table - 15: Details of Proposed Process Gas Stack

Sr.

No.

Stack attached

to Air Pollutant

Pollutant

Concentration APCM

1. Reactor NH3 Gas

NH3 ≤ 175

Water Scrubber

followed by

Acidic Scrubber

5.2.3 Fugitive Emission

There is a chance of fugitive emission due to storage, handling and loading unloading

of Raw materials and product from proposed expansion. The unit will take following

precaution for the control of fugitive emission.

The entire manufacturing activities will be carried out in the closed system.

All the reactors will be closed and its manhole will also tightly close.

All the reactors will be properly connect to scrubbing system to avoid leakage of

possible air pollutants.

All the motors of pumps for the handling of hazardous chemicals will be flame proof

and provided with suitable mechanical seal with standby arrangement.

All the raw materials will be stored in isolated storage area and containers are

tightly closed.

Precautionary measures will also be taken while handling various organic/

hazardous chemicals.

There will also be provision of adequate ventilation system in process plant and

hazardous chemical storage area.

The unit has also developed green belt within the factory premises to control the

fugitive emission from spreading in to surrounding environment.

5.3 HAZARDOUS WASTE GENERATION AND MANAGEMENT SYSTEM

Hazardous waste will be generated from proposed expansion as Dried ETP sludge

during treatment of effluent, Spent Acid, Spent Catalyst, Spent Carbon, Distillation

residue will increase due to proposed expansion.

Other ancillary source of hazardous waste generation from proposed activity will be

discarded containers/Barrels from storage and handling of raw materials and

spent/used oil generation from plant machinery.

The details of hazardous waste generation and management after proposed

expansion are given in Table-16.


Page 90 of 96

The unit has already provided designated storage area 382.5 sq. m. for the hazardous

waste storage within premises having impervious floor and roof cover system.

Additional storage will not be required for proposed expansion.

The unit has obtained membership from Saurashtra Enviro Projects Pvt. Ltd. (SEPPL) for

proper disposal of hazardous waste.

Table-16: Detail of Hazardous Waste Generation and Management

Source Type of

waste

Categ-

ory as

per

HW

Rules

Quantity Generation

(MT per Annum) Method of

Storage

/Disposal

Physical

&

Chemical

Form E P T

ETP

Dry ETP

Sludge

(ETP)

I-34.3 120.20

MT

10

MT

130.20

MT

Collection

Storage &

Transportation

Disposal By

TSDS Side

Dry/Semi

Solid

Sludge

Process

Spent

Catalyst I-35.2

18.00

MT

120.00

MT

138.00

MT

Collection

Storage,

Transportation,

Disposal by

Selling out to

registered

recyclers

Solid /

Inorganic

Hexane I-35.2 3000

MT --

3000

MT NA NA

Spent

Carbon I-35.3 --

60

MT

60

MT

Collection,

Storage,

Transportation,

Disposal at

TSDF site

Solid /

Inorganic

Waste

Resin

(RO Plant)

I-34.2 1300

Kgs. --

1300

Kgs.

Collection

Storage,

Transportation,

Disposal by

Selling out to

registered

recyclers

Solid

Distillated

Residue I-36.4

36000

MT

13400

MT

49400

MT

Collection

Storage,

Transportation,

Disposal by

Selling out to

registered

recyclers

Liquid/

Semi

Solid


Page 91 of 96

Raw

Material

Storage

Discarded

containers/

barrels/

Bottles

(Pump

House /

Tank Farm,

Packing

Section)

I-33.3 221.04

MT

(250.

NOS)

5.5

MT

226.54

MT

Collection

Storage,

Transportation,

Disposal by

Selling out to

registered

recyclers

Solid

Scrap

Discarded

Asbestos

Sheet

(Plant

Roofing)

I-15.2 1400

Kgs. --

1400

Kgs.

Collection

Storage,

Transportation,

Disposal by

Selling out to

registered

recyclers

Solid

Scrap

Plants &

Machineries

Used/Spent

Oil

(DG Room)

I-5.1 0.672

KL

0.300

KL

0.972

KL

Collection

Storage,

Transportation,

Disposal by

Selling out to

registered

recyclers

Liquid

Sludge

E= Existing, P= for Proposed expansion, T= Total after proposed expansion

5.4 NOISE POLLUTION CONTROL MEASURES

Noise is an unwanted sound and excessive noise is harmful to health and diminishes the

quality of life. Thus, noise is considered as one of the potential pollutant. Management

of noise includes the monitoring and controlling of noise levels at source, the

transmission paths and the surrounding environment. The main source of noise

generation from the proposed project will be from the DG set. One of the auxiliary

sources of Noise generation sources would be manufacturing activity within the

premises and transportation within and outside the premises.

Low noise D.G. set with acoustic control measures is already provided.

Proper and timely oiling, lubrication and preventive maintenance is carried out for

the machineries and equipments to reduce noise generation.

All the vibrating parts are checked periodically and serviced to reduce the noise

generation. The equipment, which generates excessive noise is provided with

enclosures.

To minimize the adverse effect on the health, Ear muffs/ earplugs are provided to

the people working under high noise area.

To reduce the noise generation during the transportation activities; the vehicles are

kept periodically serviced and maintained as per the requirement of latest trend in


Page 92 of 96

automobile industry. Only those vehicles having PUCs are allowed for the

transportation.

The transport contractor shall be informed to avoid unnecessary speeding of

vehicles inside the premises.

Noise monitoring is done regularly at different parts of the plant.

Green belt area is developed to prevent the noise pollution within the factory

premises, which will be expanded after proposed expansion.

5.5 GREEN BELT DEVELOPMENT

In order to mitigate the air pollutants and to attenuate the noise generated by the

plant and also improving the ecology and aesthetics of the area, the unit has already

developed green belt area in 8,466 m2 (2.31 % of total available area) within the

industrial premises for the abetment of gaseous and noise pollution. Additional

Greenbelt will be developed in 1,10,679.46 m2 (30.17%) for proposed expansion.

Green belt is developed to avoid any kind of fugitive emission in to surrounding

environment in any case. Special care will be taken while planting trees, as regards

their type and density. At present the unit has planted 1500 numbers of plantation

species. Unit intends to plan additional 1500 trees for the proposed expansion.


Page 93 of 96

5.6 ENVIRONMENTAL MANAGEMENT CELL

Apart from having an environmental management plan, it is also necessary to have a

permanent organizational set up for effective implementation of various activities. In

this effect, the company has already assigned responsibilities to officers from various

disciplines to co-ordinate the activities concerned with management and

implementation of environmental control measures. The environmental management

cell set up by the unit is given in Drawing - 4.

Drawing –4: Environmental Management Cell

CEO

Plant-In charge

Chemist

Operator

Helper


Page 94 of 96

6.PROJECT SCHEDULE & COST ESTIMATE

6.1 Schedule of Approval and Implementation

The proposed project has been planned for the manufacturing of Synthetic Organic

Chemical within the existing premises. The entire development will take about 6 months

for the completion of proposed project.

6.2 Capital Investment

The proposed expansion will be carried out within existing industrial premises. The

existing and additional manufacturing facilities as well as infrastructure facilities will be

utilized after proposed expansion. The capital cost of the existing as well as proposed

expansion is given in Table- 17.

Table – 17: Capital Cost of the Project

Sr. No. Description Cost (Rs. In Lac)

Existing Proposed Total

1 Land & Site Development 586.26 500.00 1086.26

2 Building 3,273.66 700.00 3,973.66

3 Plant and Machinery 10,219.87 2,500.00 12,719.87

4 EMP 400.00 250.00 650.00

Total 14,479.80 3,950.00 18,429.80


Page 95 of 96

7. Rehabilitation and Resettlement (R&R) Plan

M/s. Gokul Agro Resources Ltd. is an existing large scale unit located in Gandhidham

Development Authority Industrial Estate in Taluka: Anjar of District: Kachchh in Gujarat.

Since, the proposed project for the manufacturing of various Synthetic Organic

Chemicals will be carried out within the existing industrial premises and no additional

land will be required, there will not be any displacement of population due to

proposed project.


Page 96 of 96

8. Final Recommendation

The unit has proposed adequate measures for the prevention and control of pollution.

With the execution and operation of such control measures along with proper

Environmental Management System, there will not be any major potential for negative

impact on the environment due to proposed expansion project.

On the contrary, there will be positive impact on the socio-economic environment

since proposed project will generate some permanent and secondary employment.

The unit will also establish cordial relations with the nearby villagers and will carry out

social welfare activities according to their needs.

The proposed project will also boosts up ancillary industrial and commercial activities.

Thus, it will improve the economic condition of the area.

Documents

1. Eenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/09_Nov... · Pre-Feasibility Report for Proposed expansion Project of Synthetic Organic Chemicals Page 1 of 96 1. E XECUTIVE