Annexure-1 Location of the project site Annexure-2 …environmentclearance.nic.in/writereaddata/FormB/TOR/...Maruti Chemicals Annexure of Form-1 ANNEXURE -2 Layout Plan 2 1 No Area

Maruti Chemicals

Annexure of Form-1

LIST OF ANNEXURE

Annexure-1 Location of the project site

Annexure-2 Layout plan

Annexure-3 Break up of land area requirement

Annexure-4 Details of products and raw materials and storage facility for the same

Annexure-5 Details of manufacturing processes

Annexure-6 Details of water consumption and wastewater generation

Annexure-6 A Water balance diagram

Annexure-7 Details of effluent treatment

Annexure-8 Details of solid/hazardous waste and mode of disposal

Annexure-9 Details of electricity and fuel

Annexure-10 Details of stacks

Annexure-11 NOC from Principal Chief Conservator of Forest

Maruti Chemicals

Annexure of Form-1

ANNEXURE -1

Location Map

Gujarat map showing Gandhinagar district:

District:

Gandhinagar

Maruti Chemicals

Annexure of Form-1

District map showing talukas:

Taluka: Kalol

Maruti Chemicals

Annexure of Form-1

Kalol taluka map showing village Rakanpur

Village: Rakanpur

Maruti Chemicals

Annexure of Form-1

Google Earth Image:

Latitude: 23°06’06.82” N

Longitude: 72°28’39.99” E

Maruti Chemicals

Annexure of Form-1

ANNEXURE -2

Layout Plan

No Area No Area No Area 1 Reaction area 10 Solvent room 19 Rejected FP store 2 Drying Area 11 Solvent room 20 Rejected RM & PM store 3 Drying Area 12 Solvent room 21 Drying Area 4 Steam boiler area 13 Office 22 Security room 5 Hot air generator 14 Finished product room 23 Pulverization & sifting 6 ETP evaporator 15 Electric room 24 Pulverization & sifting 7 ETP filtration tank 16 Maintenance room 25 Liquid store 8 Pre-Filtration tank 17 R & D room 26 Liquid store 9 Chemist room 18 R & D room

1 2

3

4 5

7

6

8

19 1 1

1 1

1

2

1

1

1

17

2

2

Gound Floor Lay out

26

2 2

2

Maruti Chemicals

Annexure of Form-1

No Area No Area F1 RM store room F5 RM retain room F2 PM store room F6 Instrument room F3 Microbial testing Lab F7 Quality control room F4 Media Preparation room F8 Production Area

F1 F4 F3 F2

F7 F6 F5

First Floor Lay out plan

Production Area

Terrace

F8

Maruti Chemicals

Annexure of Form-1

ANNEXURE-3

Details of Land Area

Sr. No. Description Area (in Square Meters)

1. Manufacturing process area 1000

2. Storage (raw materials) 400

3. Storage (products) 100

4. Storage (fuel) 100

5. Storage (water) 50

6. Storage (hazardous/solid waste) 50

7. Storage (hazardous chemicals) 80

8. ETP area 50

9. Road 300

10. Green belt 1047 (33%)

Total Area of the Project 3177

Maruti Chemicals

Annexure of Form-1

ANNEXURE-4

List of Products, Raw Materials and Storage Details

Products:

Sr. No Product MT/Month

Existing Proposed Total after Expansion

1 Methacrylic Acid Copolymers

i Methacrylic Acid Copolymers Type-A

0.5 19.5

5.0

ii Methacrylic Acid Copolymers Type-B 2.5

iii Methacrylic Acid Copolymers Type-C 2.5

iv Methacrylic Acid Copolymers Aqueous Dispersion

10.0

2 Acrylic Acid Polymers

i Acrylic Acid Homopolymers 0.5 30.0 30.5

ii Acrylic Acid Copolymers Nil 5.3 5.3

iii Acrylic Acid Interpolymers Nil 3.0 3.0

3 Sodium Starch Glycolate

i Sodium Starch Glycolate (Maize) 5.0 53.7

47.1

ii Sodium Starch Glycolate (Potato) 11.6

4 Croscarmellose Sodium 1.0 45.6 46.6

5 Methyl Paraben

1.0 21.8

4.4

6 Propyl Paraben 1.3

7 Sodium Methyl Paraben 11.5

8 Sodium Propyl Paraben 5.6

9 Sodium Stearyl Fumarate Nil 3.9 3.9

10 Polacrillin Potassium Nil 8.9 8.9

11 Polyoxyl Hydrogenated Castor Oil Nil 5.8 5.8

Total 8.0 197.5 205.5

Maruti Chemicals

Annexure of Form-1

Raw Materials:

S. No. Name Consumption per month (MT)

1 Starch Maize 40.7 2 Caustic Soda* 16.2 3 Monochloro Acetic Acid* 9.5 4 Methanol* 7.8 5 Starch Potato 10.0 6 Sodium Carboxy Methyl Cellulose 48.4 7 Hydrochloric Acid* (30% w/v) 3.6 8 Acrylic Acid 37.8 9 Allyl Ether of Polyalcohol 0.4 10 Ethylene Dihloride 19.6 11 Alkyl Methacrylate* 0.4 12 Methacrylic Acid 9.6 13 Methyl Methacrylate* 4.3 14 Ethyl Acrylate 1.3 15 Methacrylic Acid Copolymer Type-C 6.0 16 Polysorbate 80 0.5 17 Sodium Lauryl Sulphate 0.1 18 Stearyl Alcohol 2.7 19 Maleic Anhydride* 1.0 20 Acetone* 1.4 21 p-Hydroxy Benzoic Acid 5.0 22 1-Propanol* 0.8 23 Methyl Paraben 10.0 24 Propyl Paraben 5.0 25 Divinyl Benzene 2.6 26 Caustic Potash 1.7 27 Hydrogenated Castor Oil 4.0 28 Ethylene Oxide* 2.2

*Hazardous chemicals as per Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and Amendment Rules.

Maruti Chemicals

Annexure of Form-1

Storage Facility for Raw Materials:

Sr. No

Raw material Physical

state Type of

container No. of containers

Total storage at

a time (MT)

1 Starch Maize Solid HDPE 400 bags x 25 kg 10.0

2 Caustic Soda Solid HDPE 100 bags x 50 kg 5.0

3 Mono Chloroacetic

Acid Solid HDPE 40 bags x 50 kg 2.0

4 Methanol Liquid HDPE 500 drums x 200 kg 10.0

5 Starch Potato Solid Paper 80 bags x 25 kg 2.0

6 Sodium Carboxy Methyl Cellulose

Solid Paper 200 bags x 25 kg 5.0

7 Hydrochloric Acid

Solution Liquid HDPE 5 drums x 200 kg 1.0

8 Acrylic Acid Liquid HDPE 25 drums x 200 kg 5.0

9 Allyl Ether of Polyalcohol

Liquid HDPE 1 drum x 200 kg 0.2

10 Ethylene Dichloride Liquid HDPE 75 drums x 200 kg 15.0

11 Alkyl Methcrylate Liquid HDPE 5 drums x 200 kg 1.0

12 Methacrylic Acid Liquid HDPE 20 drums x 200 kg 4.0

13 Methyl

Methacrylate Liquid HDPE 10 drums x 200 kg 2.0

14 Ethyl Acrylate Liquid HDPE 10 drums x 200 kg 2.0

15 Methacrylic Acid

Copolymer Type C Solid HDPE 80 drums x 25 kg 2.0

16 Polysorbate 80 Liquid HDPE 2 drums x 200 kg 0.4

17 Sodium Lauryl

Sulphate Solid HDPE 5 bags x 50 kg 0.25

18 Stearyl Alcohol Solid HDPE 10 bags x 50 kg 0.5

19 Maleic Anhydride Solid Paper 4 bags x 25 kg 1.0

Maruti Chemicals

Annexure of Form-1

20 Acetone Liquid HDPE 10 drums x 160 kg 1.6

21 P-Hydroxy Benzoic

Acid Solid Paper 80 bags x 25 kg 2.0

22 1-Propanol Liquid HDPE 10 drums x 160 kg 1.6

23 Methyl Paraben Solid HDPE 40 bags x 25 kg 1.0

24 Propyl Paraben Solid HDPE 20 bags x 25 kg 0.5

25 Divinyl Benzene Liquid HDPE 2 drums x 250 kg 0.5

26 Caustic Potash Solid HDPE 2 bags x 50 kg 0.1

27 Hydrogenated

Castor Oil Liquid HDPE 5 drums x 200 kg 1.0

28 Ethylene Oxide Gas MS 5 cylinder x 100 kg 0.5

Maruti Chemicals

Annexure of Form-1

ANNEXURE-5 Details of Manufacturing Processes

1. Methacrylic Acid Copolymers i. Manufacturing Process of Methacrylic Acid Copolymer, Type-A Methacrylic Acid along with Methyl Methacrylate are dissolved in Ethylene Dichloride and cooked in presence of a catalyst at a temperature between 45o C to 200o C for a period of 2 to 12 hrs. After the reaction over, the whole mass is allowed to cool at room temperature. The solid product is separated by filtration. The organic solvent is recovered by distillation. The solid product obtained is dried and pulverized to a desired particle size. The product is analyzed and packed. Material Balance:- Sr.

No. Input

Physical State

Unit Quantity / Batch

1 Methacrylic Acid Liquid kg 250.00 2 Methyl Methacrylate Liquid kg 250.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid litre 3500.00 Sr.

No. Output

Physical State

Unit Quantity/Batch

1 METHACRYLIC ACID COPOLYMERS TYPE-A Solid kg 500.00 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00

Flow Diagram:-

Methyl Methacrylate Ethylene Dichloride Distillation

Methacrylic Acid Reaction Filtration

Pulverization Drying Analysis & Packing

Solid Product

Maruti Chemicals

Annexure of Form-1

ii. Manufacturing Process of Methacrylic Acid Copolymer, Type-B Methacrylic Acid along with Methyl Methacrylate are dissolved in Ethylene Dichloride

and cooked in presence of a catalyst at a temperature between 45o C to 200o C for a period of 2 to 12 hrs. After the reaction over, the whole mass is allowed to cool at room temperature. The solid product is separated by filtration. The organic solvent is recovered by distillation. The solid product obtained is dried and pulverized to a desired particle size. The product is analyzed and packed. Material Balance:-

Sr. No.

Input Physical

State Unit

Quantity / Batch

1 Methacrylic Acid Liquid kg 150.00 2 Methyl Methacrylate Liquid kg 350.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid litre 3500.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 METHACRYLIC ACID COPOLYMERS TYPE-B Solid kg 500.00 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00

Flow Diagram:-

Methyl Methacrylate Ethylene Dichloride Distillation



Solid Product

Maruti Chemicals

Annexure of Form-1

iii. Manufacturing Process of Methacrylic Acid Copolymer, Type-C Methacrylic Acid along with Ethyl Acrylate are dissolved in Ethylene Dichloride and

cooked in presence of a catalyst at a temperature between 45o C to 200o C for a period of 2 to 12 hrs. After the reaction over, the whole mass is allowed to cool at room temperature. The solid product is separated by filtration. The organic solvent is recovered by distillation. The solid product obtained is dried and pulverized to a desired particle size. The product is analyzed and packed. Material Balance:- Sr.

No. Input

Physical State

Unit Quantity /

Batch 1 Methacrylic Acid Liquid kg 250.00 2 Ethyl Acrylate Liquid kg 250.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid kg 3500.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 METHACRYLIC ACID COPOLYMERS TYPE-C Solid kg 500.00 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00

Flow Diagram:- iv. Methacrylic Acid Copolymers Aqueous Dispersion Methacrylic Acid Copolymers Type-C, Polysorbate 80, Sodium Lauryl Sulphate and water are mixed to form an aqueous dispersion of Methacrylic Acid Copolymers.

Ethyl Acrylate Ethylene Dichloride Distillation



Solid Product

Maruti Chemicals

Annexure of Form-1

Material Balance:-

Sr. No.

Input Physical

State Unit

Quantity / Batch

1 Methacrylic Acid Copolymers Type-C Solid kg 600.00 2 Polysorbate 80 Liquid kg 46.00 3 Sodium Lauryl Sulphate Solid kg 14.00 4 Water Liquid kg 1400.00 Sr.

No. Output

Physical State

Unit Quantity / Batch

1 METHACRYLIC ACID COPOLYMERS AQUEOUS DISPERSION

Solid kg 2060.00

Flow Diagram:- 2. Acrylic Acid Polymers

i. Manufacturing Process of Acrylic Acid Homopolymers Acrylic acid along with Allyl ether of polyalcohols, are dissolved in ethylene dichloride and in presence of a catalyst, are heated at a temperature between 40o C to 200o C for a period of 2 to 12 hrs. The whole mass cooled at a room temperature, after the reaction over. The solid product is separated by filtration and washed with fresh solvent. The organic solvent is recovered by distillation. The solid product is dried and pulverized to a desired particle size. Finally product is analyzed and packed.

Methacrylic Acid Copolymers Type-C

Polysorbate 80

Water

Sodium Lauryl Sulphate

Mixing Methacrylic Acid

Copolymers Aqueous Dispersion

Maruti Chemicals

Annexure of Form-1

Material Balance:-

Sr. No. Input Physical State Unit Quantity / Batch

1 Acrylic Acid Liquid kg 1008.00 2 Allyl Ether of Polyalcohols Liquid kg 10.00 3 Catalyst Solid kg Q.S. 4 Ethylene Dichloride (Solvent) Liquid kg 6048.00

Sr. No. Output Physical State Unit Quantity / Batch

1 ACRYLIC ACID HOMOPOLYMERS Solid kg 1018.08 2 Ethylene Dichloride (Solvent) Liquid kg 5745.60 3 Solvent Loss Liquid kg 302.40

Flow Diagram: ii. Manufacturing Process of Acrylic Acid Copolymers: Acrylic acid, alkyl methacrylate, along with allyl ether of polyalcohols, are dissolved in ethylene dichloride and in presence of a catalyst, are heated at a temperature between 40o C to 200o C for a period of 2 to 12 hrs. The whole mass is cooled at a room temperature, after the reaction over. The solid product is separated by filtration and washed with fresh solvent. The organic solvent is recovered by distillation. The solid product is dried and pulverized to a desired particle size. Finally product is analyzed and packed.

Solid Product

Allyl Ether of Polyalcohols

Ethylene Dichloride Distillation

Acrylic Acid Reaction Filtration


Maruti Chemicals

Annexure of Form-1

Material Balance:-


1 Acrylic Acid Liquid kg 504.00 2 Alkyl Methacrylate Liquid kg 25.20 3 Allyl Ether of Polyalcohols Liquid kg 5.00 4 Catalyst Solid kg Q.S. 5 Ethylene Dichloride (Solvent) Solid kg 3500.00


1 ACRYLIC ACID COPOLYMERS Solid kg 534.17 2 Ethylene Dichloride (Solvent) Liquid kg 3325.00 3 Solvent Loss Liquid kg 175.00

Flow Diagram: iii. Manufacturing Process of Acrylic Acid Interpolymers: Acrylic Acid, Alkyl methacrylate, along with allyl ether of polyalcohols, are dissolved in ethylene dichloride and in presence of a catalyst, are heated at a temperature between 40o C to 200o C for a period of 2 to 12 hrs. The reaction mass then bubbled with Ethylene Oxide. The whole mass cooled at a room temperature, after the reaction over. The solid product is separated by filtration and washed with fresh solvent. The organic solvent is recovered by distillation. The solid product is dried and pulverized to a desired particle size. Finally product is analyzed and packed.

Solid Product





Alkyl Methacrylate

Maruti Chemicals

Annexure of Form-1

Material Balance:- Sr.

No. Input

Physical State

Unit Quantity /

Batch 1 Acrylic Acid Liquid kg 504.00 2 Alkyl Methacrylate Liquid kg 21.00 3 Ethylene Oxide Gas kg 70.00 4 Allyl Ether of Polyalcohols Liquid kg 5.00 5 Catalyst Solid kg Q.S. 6 Ethylene Dichloride (Solvent) Liquid kg 3500.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 ACRYLIC ACID INTERPOLYMERS Solid kg 600.04 2 Ethylene Dichloride (Solvent) Liquid kg 3150.00 3 Solvent Loss Liquid kg 350.00

Flow Diagram: 3. Manufacturing Process of Sodium Starch Glycolate (Maize & Potato) To the methanolic solution of Caustic Soda, Monochloro Acetic Acid and Maize / Potato starch is added slowly and cautiously. The whole mass, in presence of suitable catalyst, is cooked at reflux temperature for a period of 3 to 5 hrs. After completion of reaction, pH is adjusted & the solid product obtained on filtration is washed with Methanol and dried. The dried product is sifted and oversize particles are pulverized. The sample is sent for

Solid Product





Alkyl Methacrylate Ethylene Oxide

Maruti Chemicals

Annexure of Form-1

analysis. The finished product is packed in drums / boxes. The Methanol is recovered by distillation. Material Balance of Sodium Starch Glycolate (Maize):- Sr.

No. Input

Physical State

Unit Quantity /

Batch 1 Starch Maize Solid kg 1506.00 2 Caustic Soda Solid kg 240.00 3 Mono Chloroacetic Acid Solid kg 283.50 4 Methanol (Solvent) Liquid kg 4518.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 SODIUM STARCH GLYCOLATE (MAIZE) Solid kg 1746.00 2 Sodium Chloride Solid kg 175.50 3 Water Liquid kg 108.00 4 Methanol (Solvent) Liquid kg 4292.10 5 Solvent Loss Liquid kg 225.90

Material Balance of Sodium Starch Glycolate (Potato):-

Sr. No.

Input Physical

State Unit

Quantity / Batch

1 Starch Potato Solid kg 1004.00 2 Caustic Soda Solid kg 160.00 3 Mono Chloroacetic Acid Solid kg 189.00 4 Methanol (Solvent) Liquid kg 3012.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 SODIUM STARCH GLYCOLATE (POTATO) Solid kg 1164.00 2 Sodium Chloride Solid kg 117.00 3 Water Liquid kg 72.00 4 Methanol (Solvent) Liquid kg 2861.40 5 Solvent Loss Liquid kg 150.60

Maruti Chemicals

Annexure of Form-1

Flow Diagram:- 4. Manufacturing Process of Croscarmellose Sodium To the Methanol, Sodium salt of Carboxy Methyl Cellulose is charged in the reactor. The pH is adjusted using inorganic acid and\or alkali. The whole mass, in presence of suitable catalyst, is cooked for a period of 3 to 5 hrs. After complete reaction, pH is adjusted & the solid product obtained on filtration is purified by using Methanol and dried. The sample is analyzed and material is packed. Methanol is recovered by distillation. Material Balance:- Sr.

No. Input

Physical State

Unit Quantity /

Batch 1 Sodium Carboxy Methyl Cellulose Solid kg 968.00 2 Hydrochloric Acid (30.0 % W/V) Liquid kg 73.00 3 Caustic Soda Solid kg 80.00 4 Methanol (Solvent) Liquid kg 2904.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 CROSCARMELLOSE SODIUM Solid kg 932.00 2 Sodium Chloride Solid kg 117.00 3 Water Liquid kg 72.00 4 Methanol (Solvent) Liquid kg 2758.80 5 Solvent Loss Liquid kg 145.20

Caustic Soda

Methanol Distillation Maize / Potato Starch

Reaction Filtration

Drying

Analysis Packing

Mother Liquor

Pulverization

Solid Product Chloro Acetic Acid

Sifting

Catalyst

Maruti Chemicals

Annexure of Form-1

Flow Diagram:- 5. Manufacturing Process of Methyl Paraben Parahydroxyl Benzoic Acid is charged in the reactor and, dissolved in excess Methyl Alcohol. Suitable catalyst is added and the whole mass is heated to a temperature between 50o C to 250o C for about 10 hrs. After the complete reaction, the solution is allowed to cool slowly. The solid product obtained after filtration is re-crystallized in Methanol and dried in dryer. The product is packed after analysis. Material Balance:-


1 p-Hydroxy Benzoic Acid Solid kg 503.70 2 Methanol Liquid kg 116.80 3 Catalyst Solid kg Q.S. 4 Methanol (Solvent) Liquid kg 2500.00


1 METHYL PARABEN Solid kg 554.80 2 Water Liquid kg 65.70 3 Methanol (Solvent) Liquid kg 2375.00 4 Solvent Loss Liquid kg 125.00

Solid Product

Hydrochloric Acid Aqu. solution

Methanol Distillation

Sodium Carboxymethyl Cellulose

Reaction Filtration


Maruti Chemicals

Annexure of Form-1

Flow Diagram :- 6. Manufacturing Process of Propyl Paraben Parahydroxyl Benzoic Acid is charged in the reactor and, dissolved in excess 1-Propanol. Suitable catalyst is added and the whole mass is heated to a temperature between 50 oC to 150 oC for about 4 hrs. After the complete reaction, the solution is allowed to cool slowly. The solid product obtained after filtration is re-crystallized in 1-Propanol and dried in dryer. The product is packed after analysis. Material Balance:- Sr.

No. Input

Physical State

Unit Quantity /

Batch 1 p-Hydroxy Benzoic Acid Solid kg 503.70 2 1-Propanol Liquid kg 219.00 3 Catalyst Solid kg Q.S. 4 1-Propanol (Solvent) Liquid kg 2000.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 PROPYL PARABEN Solid kg 657.00 2 Water Liquid kg 65.70 3 1-Propanol (Solvent) Liquid kg 1800.00 4 Solvent Loss Liquid kg 200.00

p-Hydroxy Benzoic Acid

Methanol Distillation

Catalyst Reaction Filtration

Pulverization Drying Analysis &

Packing

Solid Product

Maruti Chemicals

Annexure of Form-1

Flow Diagram :- 7. Manufacturing Process of Sodium Methyl Paraben Methyl Paraben is charged in the reactor and caustic soda dissolved in Methanol is added slowly and stepwise with cooling till the desired pH is obtained. The excess solvent is recovered by distillation. The product obtained is transferred to the dryer. Once dried, the material is pulverized and analyzed before packing. Material Balance:-

Sr. No. Input Physical

State Unit

Quantity / Batch

1 Methyl Paraben Solid kg 500.08 2 Caustic Soda Solid kg 131.60 3 Catalyst Solid kg Q.S. 4 Methanol (Solvent) Liquid kg 1000.00

Sr. No. Output Physical

State Unit

Quantity / Batch

1 SODIUM METHYL PARABEN Solid kg 572.46 2 Water Liquid kg 59.22 3 Methanol (Solvent) Liquid kg 950.00 4 Solvent Loss Liquid kg 50.00

p-Hydroxy Benzoic Acid

1-Propanol Distillation

Catalyst Reaction Filtration


Packing

Solid Product

Maruti Chemicals

Annexure of Form-1

Flow Diagram :- 8. Manufacturing Process of Sodium Propyl Paraben Propyl Paraben is charged in the reactor and Caustic Soda dissolved in Methanol is added slowly and stepwise with cooling till the desired pH is obtained. The excess solvent is recovered by distillation. The product obtained is transferred to the dryer. Once dried, the material is pulverized and analyzed before packing. Material Balance:- Sr.

No. Input

Physical State

Unit Quantity /

Batch 1 Propyl Paraben Solid kg 500.40 2 Caustic Soda Solid kg 111.20 3 Catalyst Solid kg Q.S. 4 Methanol (Solvent) Liquid kg 1000.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 SODIUM PROPYL PARABEN Solid kg 561.56 2 Water Liquid kg 50.04 3 1-Propanol (Solvent) Liquid kg 950.00 4 Solvent Loss Liquid kg 50.00

Methyl Paraben Methyl Alcohol Distillation

Caustic Soda Semi Solid Mass


Packing

Reaction

Maruti Chemicals

Annexure of Form-1

Flow Diagram :- 9. Manufacturing Process of Sodium Stearyl Fumarate Add Stearyl Alcohol and Maleic Anhydride to the reactor. The whole mass, in presence of suitable catalyst, is cooked at reflux temperature for a period of 3 to 5 hrs. After the reaction, Solvent Acetone is charged in the reactor. Thereafter, the desired pH is adjusted with caustic soda & the solid product obtained on filtration is purified by using Acetone and dried. The sample is analyzed and material is packed. Solvent Acetone is recovered by distillation. Material Balance:- Sr. No.

Input Physical

State Unit

Quantity / Batch

1 Stearyl Alcohol Solid kg 540.00 2 Maleic Anhydride Solid kg 196.00 3 Catalyst Solid kg Q.S. 4 Caustic Soda Solid kg 80.00 5 Acetone (Solvent) Liquid kg 5400.00 Sr.

No. Output

Physical State

Unit Quantity /

Batch 1 SODIUM STEARYL FUMARATE Solid kg 780.00 2 Water Liquid kg 36.00 3 Acetone (Solvent) Liquid kg 5130.00 4 Solvent Loss Liquid kg 270.00

Flow Diagram:-

Propyl Paraben Methanol Distillation

Caustic Soda Semi Solid Mass


Packing

Reaction

Maruti Chemicals

Annexure of Form-1

10. Manufacturing Process of Polacrillin Potassium:- Pump solvent Ethylene Dichloride in reactor. Charge Methacrylic Acid and Divinyl Benzene. Charge catalyst and close the main hole. Slowly heat to reflux temperature.

Continue heating to a reflux temperature 80 oC for 4 hrs. Stop heating and cool the reaction mass to room temperature. Centrifuge the slurry, wash with Ethylene Dichloride.

Dry the cake at temperature below 80 oC. Pulverize & sift the product. Material Balance:-


1 Methacrylic Acid Liquid kg 510.00 2 Divinyl Benzene Liquid kg 260.00 3 Catalyst Solid kg Q.S. 4 Caustic Potash Solid kg 170.00 5 Ethylene Dichloride (Solvent) Liquid kg 3500.00


1 POLACRILLIN POTASSIUM Solid kg 890.00 2 Water Liquid kg 50.00 3 Ethylene Dichloride (Solvent) Liquid kg 3150.00 4 Solvent Loss Liquid kg 350.00

Solid Product

Stearyl Alcohol Acetone Distillation

Maleic Anhydride Reaction Filtration


Packing

Caustic Soda

Maruti Chemicals

Annexure of Form-1

Flow Diagram:- 11. Manufacturing Process of Polyoxyl Hydrogenated Castor Oil:- Hydrogenated Castor Oil is charged into the reactor. Charge catalyst & purge Ethylene

Oxide slowly with stirring taking care that internal temperature does not exceed 40 oC. The whole mass is then cooked at a temperature at 30 oC to 60 oC for a period of about 4 hrs. Discharge viscous liquid into the carboys. Allow to cool to room temperature

when it will become semisolid at temperature below 20 oC. Material Balance:-

Sr. No.

Input Physical

State Unit

Quantity / Batch

1 Hydrogenated Castor Oil Liquid kg 400.00 2 Ethylene Oxide Gas kg 176.00 3 Catalyst Solid kg Q.S. Sr.

No. Output

Physical State

Unit Quantity /

Batch

1 POLYOXYL HYDROGENATED CASTOR OIL

Semi Solid kg 576.00

Solid Product

Methacrylic Acid Ethylene Dichloride Distillation

Divinyl Benzene

Reaction Filtration


Maruti Chemicals

Annexure of Form-1

Flow Diagram:- Hydrogenated

Castor Oil

Catalyst

Ethylene Oxide Reaction Product

Analysis & Packing

Maruti Chemicals

Annexure of Form-1

ANNEXURE-6

Details of water consumption and wastewater generation Water Consumption (2nd day onwards)

Source of water: Borewell

Sr. No.

Description

Water Consumption (kl/day)


A Domestic 0.75 0.5 1.25*

B Gardening Nil 5.4 5.4

C Industrial

1 Process 0.2 0.4 0.6

2 Evaporative water loss during condensation

Nil 0.3 0.3

3 Boiler 2.0 12.0 14.0 (2.2 recycled + 11.8 fresh)

4 Cooling Tower 0.1 0.5 0.6

5 Floor & Equipment

Washing 0.2 0.2 0.4

Total C (1 to 5) 2.5 13.4 15.9

(2.2 recycled + 13.7 fresh)

Total (A+B+C) 3.3 19.3 22.6

(2.2 recycled + 20.4 fresh)

*25 persons x 50 litre/day

Maruti Chemicals

Annexure of Form-1

Wastewater Generation

Sr. No.

Description Wastewater Generation (kl/day)


A Domestic 0.6 0.4 1.0

B Gardening Nil Nil Nil

C Industrial

1 Process 0.16 0.34 0.5

2 Evaporative water loss during condensation

Nil Nil Nil

3 Boiler 0.1 1.3 1.4

4 Cooling Tower Purge Nil 0.1 0.1

5 Floor & Equipment

Washing 0.2 0.2 0.4

Total C (1 to 5) 0.46 1.94 2.4

Total (A+B+C) 1.06 2.34 3.4

Water balance diagram is attached as Annexure-6A

Maruti Chemicals

Annexure of Form-1

ANNEXURE-6 A

Water Balance Diagram after Expansion (2nd day onwards)

Total Water Consumption

20.4 (fresh)

Domestic

1.25

Gardening

5.4

Industrial

13.7

Process

0.6

All figures are in kilo litre/day

Septic tank/Soak pit

1.0

From Process

0.5

Evaporative water loss while condensation of solvents

0.3

Boiler

11.8

Blow down

1.4

Cooling

0.6

Cooling Tower Purge

0.1

Floor and Equipment

Washing 0.4

From Washing

0.4

Effluent Treatment Plant

2.4

Treated Water for Re-Use

2.2

Maruti Chemicals

Annexure of Form-1

ANNEXURE-7

Details of Effluent Treatment

Domestic wastewater: Domestic wastewater will be disposed off by means of septic tank /soak pit system.

Industrial wastewater The industrial wastewater from the unit will be collected in a collection tank. Then it will be pumped to a settling tank where settling of solids will take place. The supernatant effluent will be transferred to a storage tank from where it will be

pumped to a distillation unit. The sludge from the settling tank will be allowed to go to a nutch filter. The sludge

remaining on the filter will be dried and collected in HDPE bags for disposal to TSDF site.

The filtrate from the nutch filter will be taken to the storage tank before distillation. Distilled water will be collected in a recycling water tank from where it will be

recycled to the plant. The residue left in the distillation/evaporation tank will be dried and stored for

disposal.

Flow diagram of the Effluent Treatment Plant is given in the next page.

Maruti Chemicals

Annexure of Form-1

Schematic Flow Diagram of Effluent Treatment Plant

Maruti Chemicals

Annexure of Form-1

ANNEXURE-8

Details of Hazardous Waste and its Disposal

Types of Waste

Category as per

Schedule-1 of HW Rules

Quantity (MT/Year) Disposal Details


ETP Sludge

34.3 3.6 5.4 9 Will be collected, stored and transported to a TSDF site for disposal.

Waste Lubricating Oil

5.1 Nil 0.12 0.12 Will be collected, stored and reused within the premises and excess will be sold to authorized recyclers.

Discarded Drums/ Bags

33.3 6.0 64 70 Will collected, stored and reused within the premises and excess will be sold to authorized recyclers.

Process Waste (consisting of inorganic salts)

28.1 0.3 140.7 141 Will be collected, stored and transported to a TSDF site for disposal.

Maruti Chemicals

Annexure of Form-1

ANNEXURE-9

Details of Electricity and Fuel

Electricity:

Source Competing Users

Connected Load


Uttar Gujarat Vij Co. Ltd. Nearby industries 95 kVA 50 kVA 145 kVA

Fuel:

Description Source

Consumption (MT/day)


Wood Domestic 1.1 Nil Nil

Saw Mill Wooden Chips / White Coal

Domestic Nil 22 22

Maruti Chemicals

Annexure of Form-1

ANNEXURE-10

Details of EXISTING Stacks / Vents

Sr. No.

Stack attached to

Existing Fuel

Pollutant

Height of stack from

ground level (m)

Diameter of

stack (m)

Air pollution control unit

Flue gas stacks attached to

1 Steam Boiler

(1 TPH) Wood (1.1

MT/day)

SPM SO2 NOx

12 0.1 Multi

Cyclone Separator

2 Hot Air

Generator

SPM SO2 NOx

12 0.1 Multi

Cyclone Separator

Note: There is no any existing process vent.

Details of PROPOSED Stacks / Vents

There will be no additional stacks / vents due to the proposed expansion. Saw mill wooden chips / white coal will be used as a fuel to the tune of 22 MT/day in Steam Boiler and Hot Air Generator.

ANNEXURE-11

NOC from Principal Chief Conservator of Forest

Documents

Annexure-1 Location of the project site Annexure-2 …environmentclearance.nic.in/writereaddata/FormB/TOR/...Maruti Chemicals Annexure of Form-1 ANNEXURE -2 Layout Plan 2 1 No Area