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ANNEXURE – 1
DETAILS OF EXISTING PRODUCTS AND PROPOSED PRODUCTS
LIST OF EXISTING PRODUCTS AND PROPOSED PRODUCTS:
Sr.
No.
Product As Per Consent Quantity
(MT/Month)
Total Proposed Quantity
(MT / Month) 1. Monochloro Acetic Acid (MCAA) 500 2000
2. Sulfur Mono Chloride 40 80
3. Trichloro Acetic Acid (TCAA) 25 250
By-Products
1 Mixed Chloro Acetic Acid or ML
of MCAA
175.5 702
2 HCl 1010 3764
3 Sodium Hypochlorite 40 200
LIST OF RAW MATERIAL REQUIRED:
Sr.
No.
List of raw materials
required
Existing (MT / Month)
Proposed (MT /
Month)
1. Acetic Acid 403 1612
2. Liquid Chlorine 600 2242
3. Sulfur Monochloride 15.25 65.5
4. Mixed Chloro Acetic Acid 17.5 175
5. Sulfur 20 38.4
ANNEXURE – 2
MANUFACTURING PROCESS
CHEMICAL EQUATION
MATERIAL BALANCE DIAGRAM
DETAILS OF EACH PRODUCT :
NAME OF PRODUCT : MONOCHLORO ACETIC ACID (MCAA) QUANTITY TO BE PRODUCED : 2000 MT / Month
Raw material consumption per month: Manufacturing Process: The Chlorinators (Reaction Vessels) are MS Glass Lined, steam jacketed vessels. These vessels are charged with 99% pure Acetic Acid. Then, sulfur Mono chloride, as a catalyst, is charged equivalent to 1% of the Acetic Acid quantity. The vessel is then heated up to 90 oC and Chlorine is fed through pipeline from Chlorine tonner. While the chlorination is carried out, SMC (Catalyst) is again fed periodically (3-4%) of total quantity of Acetic Acid. The reaction temperature is maintained between 90 oC to 95 oC by cooling water in the jacket. During the above chlorination process, one Hydrogen (H) element of Acetic Acid is replaced by Chlorine (Cl) and generates Hydrochloric Acid in gaseous form. The Hydrochloric Acid Gas generated from the reaction is drawn through a 4 inch HDPE/Lead pipe and two Glass (Shell & Tube) Reflux Condensers of Cooling water and Chilled water respectively to the Aqueous Scrubbing system. The end point of reaction is determined by measuring the specific gravity. When the specific gravity of reaction mass reaches to 1375 gm/lt. at 62 oC, the reaction is complete. The above completed reaction mass known as Chlorinated Acetic Acid Mass (CAAM) contains following composition. Mono Chloro Acetic Acid: 90 to 92 % Di Chloro Acetic Acid : 7 to 8 % Unreacted Acetic Acid : 1 to 2 % The Chlorinated Acetic Acid mass (CAAM) produced is also sold as a separate product. CAAM of about 730MT/month is produced as per the market demand by using the same conventional method as that for mono chloro acetic acid preparation. The CAAM is then taken in to the Glass lined crystallizing vessel (Crystallizer) provided with the stirrer and the temperature is brought down to 35 oC. Then the mass is sent to the centrifuge from the bottom outlet and the mixture of Dichloro Acetic Acid and Acetic Acid with dissolved
Raw materials Requirement (MT/Month)
Acetic Acid 1612MT
Liquid Chlorine 2020MT
Sulfur Monochloride 58MT
Monochloro Acetic Acid is taken out as Mother Liquor OR Mixed Chloro Acetic Acid. The crystals of Monochloro Acetic Acid from centrifuge are packed in the bags as a final product. Thus, from the above reaction, Monochloro Acetic Acid, Mother Liquor or Mixed Chloro Acetic Acid (MCAA), and Hydrochloric Acid of 30% Concentration are produced. Chemical Reaction: CH3COOH + Cl2 --------------> ClCH2COOH + HCl Material Balance Basis: 10,000 Kgs of MCAA in each reactor Input Output
Material
Quantity Kgs/ batch
Material
Quantity Kgs / batch
Acetic Acid 8065 Monochloro Acetic Acid – crude 11431
Chlorine 10114 Dichloro Acetic Acid 1387
Sulfur Monochloride 291 Unreacted Acetic Acid 162
Hydrochloric Acid 5200
Sulfur Chloride 290
TOTAL 18470 18470
MCAA in Crude Mass 11431
Kgs
MCAA dissolved in DCA and Unreacted Acetic Acid 1431 Kgs
Net quantity of MCAA per Batch as output 10,000 Kgs. OR Quantity of chlorinated acetic acid mass (CAAM) 12862 Kgs.
Hydrochloric Acid is scrubbed in Scrubbing tower as 30% solution in water.
FLOW CHART:
NAME OF PRODUCT : TRI CHLORO ACETIC ACID (TCAA)
QUANTITY TO BE PRODUCED : 250 MT / Month
Raw material consumption per month:
Raw materials Requirement
(MT/Month)
Mixed Chloro Acetic Acid 175 MT
Liquid Chlorine 180 MT
Sulfur Monochloride 7.5 MT
Manufacturing Process:
The mixed Chloro acetic acid, generated from the Monochloro Acetic Acid reaction is a mixture of
unreacted Acetic Acid, Monochloro Acetic Acid and Di Chloro Acetic Acid. This mixture is further
chlorinated to Trichloro Acetic Acid. In case of Monochloro Acetic Acid, the Chlorination process
carried out is a partial chlorination.
The quantity of Liquor Generation is very less, and this liquor of Trichloro acetic acid is recycled.
Hence, there is only Hydrochloric Acid produced. The Trichloro Acetic Acid process is carried out
in the same reaction vessel in which Monochloro Acetic Acid is being produced. Thus, from the
above Reaction, Trichloro Acetic Acid is produced, Mother Liquor is recycled and Hydrochloric
Acid of 30% Concentration is produced.
Chemical Reaction:
CH3COOH + 3Cl2 --------------> Cl3CCOOH + 3HCl
Material Balance – TCAA
Basis: 10,000 Kgs of TCAA in each reactor
Input Output
Material
Quantity Kgs / Batch
Material
Quantity Kgs / Batch
Mixed Chloro Acetic Acid 6938 Trichloro Acetic Acid (crude mass) 10632
Chlorine 6941 Hydrochloric Acid 3547
SMC 300
Total 14179 Total 14179
TCAA in Crude Mass 10632Kgs
Unreacted mix chloroacetic acid + dissolved TCA + catalyst 632 Kgs
Net quantity of TCAA per Batch as output 10,000 Kgs
Hydrochloric Acid is scrubbed in Scrubbing tower as 30% solution in water.
FLOW CHART:
NAME OF PRODUCT : SULFUR MONO CHLORIDE
QUANTITY TO BE PRODUCED : 80 MT / Month
Raw material consumption per month:
Manufacturing Process:
Chlorinators are charged with 99.9% pure Sulfur Granules, with some quantity of Sulfur Mono
Chloride inside reactor as a reaction media. Chlorine is then sparged through the sparger from a
chlorine cylinder. The sulfur charged, will react with this Sulfur Mono Chloride and make Crude
form of Sulfur Mono Chloride. Crude mass is first converted into Mono Chloride and if any excess
chlorine is available, this mono chloride will be converted into Di Chloride and Tri Chloride
respectively. Hence, there is practically no chance of liberation of unreacted chlorine gas, since the
reaction is suspended at a Mono stage.
The vent of the second reactor is connected to the Caustic Scrubber. The unreacted Chlorine, if any,
is scrubbed here to make Sodium Hypochlorite which is then sold.
Chemical reaction:
2S + Cl2 --------------> S2Cl2
Material Balance: Basis : 8000 Kgs./batch
Input Output
Material Qty in Kgs. /
batch
Material Qty in Kgs. / batch
SMC 2000 SMC 8000
Sulfur 3840 SMC (Recycle) 2000
Chlorine gas 4160
Total 10,000 Total 10,000
FLOW CHART:
Raw materials Requirement (MT/Month)
Sulfur 38.4 MT Liquid Chlorine 41.6 MT
ANNEXURE – 3
WATER CONSUMPTION
WASTE WATER GENERATION
DETAILS OF EFFLUENT TREATMENT PLANT
MEMBERSHIP COPY OF THE CETP
Details of Water Consumption:
Source of Water : Existing Borewell in the Plant premises
Breakup Existing Consumption
m3/day
Proposed consumption
m3/day Domestic 0.5 2.0
Process 21.425 85.7 Utilities 3.3 13.2 Washings 1.0 1.0 Total 26.225 104.9
The source of water supply is from the borewell located inside the factory premises. Most of the
water consumption is utilized for scrubbing activities and manufacturing byproducts.
Details of waste water generation :
Breakup Existing Proposed New
Products
Domestic 0.5 1.8
Process Nil Nil
Utilities Nil Nil
Washings 1.0 1.0
Total 1.5 2.8
The domestic waste water will be disposed off in soak pit.
Process water through the scrubbing activity is used for the production of 30% HCl and sodium
hypochlorite, which will be sold. Water from the boiler condensate is recycled.
The only waste water generated from the unit is from plant washings, which will be neutralized in
the effluent treatment plant using caustic soda. The neutralized waste water will then be collected in
10 KL storage tanks (2 in Nos.) and sent to the CETP of Enviro Infrastructure Co. Ltd. (EICL) for
further treatment.(Membership of the CETP is already available)
DETAILS OF EFFLUENT TREATMENT PLANT :
ANNEXURE 4
DETAILS OF AIR EMISSION SOURCES
AND
AIR POLLUTION CONTROL DEVICES (SCRUBBERS)
Details of Air Emission:
Existing scenario:
Stack attached to Non-IBR steam boiler
Fuel used Wood waste / LDO Quantity of fuel Wood - 2000 Kgs/ day or
LDO – 1200 Lit/ day Type of emissions SO2, NOX & PM Stack height 40 feet. Stack diameter at the top 8 inches
For the existing plant, only Non-IBR steam boiler is used for heating purposes. For recovery of HCl
one FRP graphite scrubber is installed. The tail gases containing chlorine is then scrubbed in the
caustic scrubber (2 in No.) to produce sodium hypochlorite. HCl and Sodium hypochlorite are sold
as by-products.
Stack attached to Water Scrubber for HCl
Type of emission HCl
Stack height 20 mts.
Capacity of Scrubber 50 kg/hr
Scrubber medium Water
Stack attached to Caustic Scrubber
Type of emission Cl2
Stack height 20 mts.
Capacity of scrubber 10 kgs/hr
Scrubbing medium Caustic Soda
Proposed Expansion Activity:
For the Proposed Expansion (2 Nos.) IBR 3Mt/hr steam boiler and a Thermic fluid boiler will be
installed for heating activities.
Utility Stacks :
Stack attached to IBR steam boiler No. 1
Capacity 3 MT/hr
Fuel used White coal/ Agrowaste/ Wood waste
Quantity of fuel 3.8 MT / day
Type of emissions SO2, NOX & PM
Stack height 40 feet
Stack diameter at the top 8 inches
Stack attached to IBR steam boiler No. 2
Capacity 3 MT/hr
Fuel used White coal/ Agrowaste/ Wood waste
Quantity of fuel 3.8 MT / day
Type of emissions SO2, NOX & PM
Stack height 40 feet
Stack diameter at the top 8 inches
Stack attached to Thermic fluid boiler
Fuel used LDO
Quantity of fuel 200 ltrs/ day
Type of emissions SO2, NOX & PM
Stack height 40 feet
Stack diameter at the top 8 inches
To reduce the emissions of particulate matter from the burning of wood, a cyclone followed by bag
filter will be installed. A schematic of the cyclone is given below :
Process Stacks :
HCl which will be scrubbed off from the tail gases will be recovered in 2 stage water scrubbers
and sold as a product. The unreacted chlorine will be passed through two stage caustic scrubber
and converted to sodium hypochlorite which will be also sold off
Stack attached to Water Scrubber
Gas scrubbed HCl
Stack height 20 mts
Type of scrubber - primary FRP/Graphite (shell & tube)
Capacity of the primary scrubber 500 kgs/hr
No. of Scrubbers 2 Nos.
Type of scrubber - secondary SCC
Capacity of the secondary scrubber 50 Kgs/hr.
No. of Scrubbers 2
Scrubbing medium Water
By product recovered HCl
Sources of Gaseous Emission Caustic Scrubber
Gas scrubbed Cl2
Stack height 20 mts.
Stages of Scrubbing primary
Type of Scrubber - primary FRP/HDPE
Capacity of the primary scrubber 100 kgs/hr
No. of Scrubbers 2
Type of scrubber - secondary PP/HDPE
Capacity of the secondary scrubber 100 kgs/hr
Scrubbing medium Caustic
By-product recovered Sodium Hypochlorite
ANNEXURE – 5
DETAILS OF HAZARDOUS WASTE GENERATION AND DISPOSAL
Details of solid waste generated after the expansion:
For the proposed expansion activitites, the effluent is generated from the plant washings. The
effluent will be slightly acidic in nature which will be neutralized with caustic soda and does not
generate any sludge.
Raw materials like, acetic acid is received in tanker load, Cl2 in returnable tonners and sulphur in
loose. Hence no empty bags / liner / empty barrel generation.
The only hazardous waste generated from the plant is the used oil,which will be sold to the
authorized recyclers.
Sr
no
Waste
detail
Waste
category
Chemical
form
Physical
form
Existing
Quantity to
be
disposed
Proposed
Quantity to
be disposed
Mode of
disposal
1 Used
oil
5.1 Gear box,
transformer,
lubrication oil,
thermic fluid
heater oil
Viscous
liquid
0.2 KL/Yr 1.0 KL/Yr Applied on
MS
Structures
to prevent
corrosion or
sold to
authorized
oil
recyclers.