M/s. A One Chemicals, Ankleshwar ANNEXURE I TERMS OF REFERENCEenvironmentclearance.nic.in/writereaddata/Online/TOR/10_Dec_2016... · M/s. A One Chemicals, Ankleshwar M/s. Jyoti Om

M/s. A One Chemicals, Ankleshwar

M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar 1

ANNEXURE I

TERMS OF REFERENCE

∑ Site description and plant lay out.

∑ List of raw materials and consumption quantity.

∑ List of finished products and production quantity.

∑ Manufacturing process details with mass balance.

∑ Details of flue gas emission, process emissions, waste water discharge & solid waste

generation and disposal.

∑ Complete water balance.

∑ Details of Effluent Treatment plant.

∑ Details of air pollution control systems.

∑ One season base line data of soil, water, air and noise for study area.

∑ Environment impact assessment due to excavation and construction activities,

manufacturing process and its operations etc.

∑ Details of Environmental Management Plan (EMP) and mitigation measures.

∑ Occupational health and safety program for the project.

∑ TOR prescribed by MoEF for this sector will be taken in to account.



ANNEXURE II

LIST OF PARTNERS

Sr. No.

Name AddressTelephone No./Fax No./ E- Mail Address

1. Mr. Ganshyambhai B. Patel 1,2,3 Hanes villa Bungalows,Nr. SuvernavillaBunglows, Hebatur Cross road, ThaltejBopal,Ahmedabad-380054Ph:- (R) 20960898/ (F) 02646-253449Fax:- 02646-224156E-Mail:- [email protected]@aonechemicals.com

2. Mr. Ashwinbhai G. Patel

3. Mr. Vipulbhai N. Patel 19-22, Hanes villa Bungalows,Nr. SuvernavillaBunglowsHebatur cross road, ThaltejBopal,Ahmedabad-380054(R):- 29096009



ANNEXURE III

SITE PLAN



PLANT LAYOUT



ANNEXURE IV

LIST OF PRODUCTS AND THEIR PRODUCTION CAPACITY

Sr. No.

Product Quantity as per CCA-50195 in MT/Month

Quantity as per Proposed for EC MT/Month

Quantity After Expansion in MT/Month

1. CPC Blue 300 350 6502. Beta Blue 25 125 1503. Alfa Blue 25 0 25

By-Product4. Ammonia Liquor (10 to

15 %)300 -300 0

5. Ammonium Carbonate 1500 -1500 06. Ammonium Sulphate 120 120 240

Total 2270 -1205 1065



ANNEXURE- V

DETAILS OF RAW MATERIAL CONSUMPTION

Name of Product

Sr.No Name of Raw Material

Existing Raw

Material qty.

(MT/M)

Proposed Raw

Material qty.

(MT/M)

Quantity After

Expansion in

MT/MonthCPC Blue 1 Phthalic Anhydride 333 388.5 721.5

2 Cuprous Chloride 59.7 69.7 129.43 Ammonium

Molybdate0.93 1.09 2.02

4 T G Urea 442.5 516.25 958.755 ONT 24 28 526 H2SO4 (98%) 33.3 38.85 72.157 Spent Acid (10-

15%)189 220.5 409.5

8 Caustic Soda 22.5 135 257.5Total 1104.93 1289.08 2394.01

ALFA BLUE

1 CPC Blue crude 26.25 0 26.252 Sulphuric Acid

(70%)120.25 0 120.25

3 Emulsifier 0.125 0 0.125146.625 0 146.625

BETA BLUE

1 CPC Blue crude 25.75 128.75 25.752 Dilute HCl 0.325 1.625 0.953 Caustic Flakes 0.375 1.875 2.254 IBA / Xylene

(solvent)12.5 62.5 75

Total 38.75 194.75 233.5Ammonium

Sulphate1 Ammonium

Carbonate1000 1000 2000

2 H2SO4 (20%) 300 300 6003 H2SO4 (98%) 30 30 60

Total 1330 1330 2660Total 2620.305 2813.83 5434.135



ANNEXURE- VI

BREIF MANUFACTURING PROCESS:

Manufacturing Process for CPC Blue

∑ Charge ONT in G.L. Vessel. Then add urea, Cuprous Chloride, Phtahalic Anhydride &

Ammonium molybdate into the vessels.∑ Gradually raise temperature up to 170°C to 175°C, which is maintained for 2-3 hours.∑ On completion of reaction, charge the reaction mass into Rotary vacuum dryer, where

ONT recovery takes place. Recycled the recovered ONT in the next batch.∑ Scrub Ammonia and Caron dioxide gases evolved during process to water scrubber to get

solution of ammonium carbonate.∑ Take Crude CPC from Rotary Vacuum Dryer to MS rubber lining tank for purification.

Where acid is added & stem is charged directly to remove impurities.∑ Filter this purified CPC in filter press.∑ Give wet cake alkali wash and water wash.∑ Carryout the drying of the purification wet cake of CPC in S.F. Dryer.∑ Packing of dried powder from S.F.D for dispatch.

Chemical reaction



Material Balance for CPC Blue



Ammonium Sulphate

Scrubber water ammonium carbonate is taken in glass line reactor and addition into

Sulphuric acid (98%) upto maintain pH 6.5 then CLR Heating up to 1000C.

Under vacuum distillation condensate water receiving to collection tank.

After completion of reaction mass is dump to criticizer and to given to jacket cooling.

Then the mass taken into centrifuge for filteration filter water collected into collection

tank while the product which is remain in crystal form for Ammonium Sulphate is make

final product and filter water is reprocess in GLR.

Flow diagram of Manufacturing Process of Ammonium Sulphate

*H2SO4 (20%) is coming from First wash.

Steam

Ammonium Carbonate Soln.

Condensed water reuse in scrubber system

Mix of Conc. -H2SO4 (98%) + H2SO4 (20%)*

Ammonium Sulphate (semi-solid)

Crystallizer

Product: Ammonium Sulphate

Centrifuge

Liquid Recycle into



Material Balance:

Manufacturing Process for Beta Blue

Crude CPC Blue is taken into Ball mill for grinding. Here the particle size of the material

gets reduced. Then the grinded material is taken into the reactor with Caustic Flakes.

Caustic flakes are used to get alkaline pH. The alkaline pH results in better dispersion of

particles for pigmentation. The mass is refluxed for pigmentation. Here the color of the

material gets enhanced due to fine tuning with Xylene / IBA.

This is only a physical process and does not involve any chemical reaction. After

completion of reflux, the mass is distilled for recovery of Xylene / IBA. After recovery of

Xylene / IBA, the mass is neutralized with hydrochloric acid to increase the particle size

of beta blue. The whole mass is washed and filtered in filter press. Filtrate and washing

are use for manufacturing of CPC Blue Crude. Wet cake from filter press is dried in dryer

/ SFD.

Material Balance for Ammonium Sulphate(for 1kg Batch)Input Kg. Output Kg.

Ammonium Carbonate Solution

(8-10%)

8.330 Reaction Vessel Ammonium Sulphate solution

1.538

H2SO4 (98%) 0.250 Condensate water for scrubber

9.542

H2SO4 (20%) 2.500 Total 11.08Total 11.08

Input Kg. Crystallizer Output Kg.Ammonium Sulphate

Solution1.538 Semisolid

Ammonium Sulphate

1.100

Evaporation loss 0.438Total 1.538 Total 1.538

Input Kg. Centrifuge Output Kg.wet Ammonium

Sulphate1.100 Ammonium

Sulphate -Product1.000

water Reuse for next batch

0.100

Total 1.100 Total 1.100



Chemical Reaction:

Material Balance:



Manufacturing Process for Alpha Blue

1. Charge 98% Sulphuric acid inSS jacketed vessel and add required quantity of CPC blue in 4 hours maintaining the temperature of 50.C.

2. Continue stirring till CPC gets dissolve in acid.

3. Transfer the batch by air pressure in another vessel containing sufficient water to make final concentration of 15% to 20% acid.

4. Filter the mass through filter press and wash with water to bring pH 5.5.

5. Charge wet cake in wooden vat containing water and add dispersing agent.

6. Heat with live steam and bring pH to neutral with the help of caustic lye.

7. Filter the slurry and wash with water.

8. Wet cake is dried through spin flash dryer and packed.

Chemical Reaction:

+Cu

N

NN

N

N

NN

N

Copper Pthalocyanine Blue

H2SO4

(98%) Heat

70 ºCCu

N

NN

N

N

NN

N

Pthalocyanine Blue

+ H2SO4

(25-40 %)



Material Balance:



ANNEXURE- VII

DETAILS OF WATER CONSUMPTION

∑ Source of water: GIDC

Sr. No.

Particular Water Consumption in KL/DayQuantity as per CCA-50195 in KLD

Quantity as per Proposed for EC in KLD

Quantity After Expansion in KLD

1. Domestic 5 0 52. Industrial

a) Process 245 25 270(130fresh+140recycle)

b) Washing 5 0 5 (recycle)c) Boiler 25 25 50d) Cooling 10 10 20 (recycle)e) Other ( Gardening)

10 -1 9 (recycle)

f) Scrubber 00 1 1(recycle)g) Coal Handling

00 1(Scrubber Filter) 1(Scrubber Filter)

Total(Domestic + Industries)

300 61 361(185 fresh + 175 recycle + 1 Scrubber Filter)



DETAILS OF WASTEWATER GENERATION

*Unit will be zero liquid discharge. Out of 302 KL (Process Effluent), 64 KL

effluent is Acidic in nature which will be reused in ammonium sulphate plant and

remaining 238 KL will be sent in ETP.

Sr. No.

Particulate Waste Water Generation in KL/DayQuantity as per CCA-50195 in MT/Month

Quantity as per Proposed for EC in MT/Month

Quantity After Expansion in MT/Month

1. Domestic 4.5 0 4.52. Industrial

a) Process 240 62 302b) Washing 5 0 5c) Boiler 3 2 5d) Cooling 2 0 2e) Other (Gardening)

0 0 0

Total(Domestic + Industries)

254.5 64 318.5



EXISTING WATER BALANCE DIAGRAM

Consumed

0.5

v All quantity are in KL/Day

Water Consumption300

Domestic 5

Process245

Blow down2

From Process

240

Evaporation27

Evaporation8

ETP250

Boiler25

Cooling10

Blow down3

Soak Pit4.5

22

Washing

5

From Washing5

Gardening10



PROPOSED WATER BALANCE DIAGRAM

v All quantity are in KL/Day

Consumed0.5

Water Consumption360

(185 Fresh + 175 recycle)

Domestic 5

Process270

Blow down

2

From Process

302

Evaporation50

Evaporation8

ETP250

Boiler50

Cooling20

Blow down5

Soak Pit4.5

45

Washing5

From Washing5

Gardening& other

9

Ammonium Sulphate Plant

64

Spray Dryer75

Scrubber1

Coal Handling

1

MEE250

MEE residue75

MEE Distillate175

Recycle 175

Effluent generated from chemical 37



ANNEXURE-VIII

EFFLUENT TREATMENT PLANT

There are three streams coming from production activity. First is ammonium carbonate

solution. This is being sent to Bhavanagar under valid consent. During monsoon period

or prevailing market condition, unit has proper facility for converting ammonium

carbonate to ammonium sulfate. The facility comprise of destructing ammonium

carbonate to form ammonia and carbon dioxide. The liberated ammonia is scrubbed in

sulfuric acid to form ammonium sulfate.

The second stream is mother liquor generated from the manufacturing process is acidic

in nature and having higher concentration of ammonical nitrogen. Mother liquor passes

through the filter press and then the entire quantity of Mother Liquor is sent to ETL for

further treatment.

The third stream is washing. The washing of the filter press is sent to the collection tank.

The wash water is being neutral to slight acidic in nature. The wash water goes to the

Neutralization tank, where it is treated with hydrated lime. So that sulphuric acid is

converted to gypsum and copper is precipitated out in to copper hydroxide. Additional

caustic is added for the complete precipitation of copper hydroxide. The pH between 10.5

to 11 is maintained by consisting mixing of polyelectrolytes in to the water and it also

removes turbidity from the water.

Then the water is filtered through a plate and frame type filter press and then it is routed

to an air stripper. In air stripper, ammonia is stripped out from the tank.



Then the stripped water is collected in to another collection tank to bring down the pH to

7 by using HCl and PAC is added to remove the turbidity. After the treatment water is

filtered through plate and frame type filter press. Then it is sent to the primary clarifier.

After that effluent is taken to an aeration tank where the biological treatment is being

provided to reduce the BOD/COD level. After that wastewater is allowed to go to both

the secondary clarifier where sludge and biological mass is removed while the clear

effluent goes to the chemical oxidation tank.

The overflow of chemical oxidation tank is collected to treated water sump. The waste

water from treated water sump is pumped for the tertiary treatment followed by the sand

filtration and charcoal treatment prior to final disposal in drainage system of NCTL.

PARTICULARS OF EFFLUENT TREATMENT PLANT

Sr.

No.

Name of the unit Capacity

1. Acid proof brick lined neutralizer (I) with stirrer 36 KL

2. Acid proof brick lined neutralizer (II) with stirrer 36 KL

3. 2 nos. plate and frame type filter press 1) 48” x 48” x 70”

2) 36” x 36” x 45

4. 1 nos. plate and frame type filter press 48”x 48” x 70”

5. Storage tank for filtrate of neutralized concentrated stream

(with stirrer for agitation)

50 KL

6. Ammonia stripping tower for concentrated stream 10 M3/hr



6A Ammonia stripping tower for general stream 10 M3/hr

7. Underground collection cum recirculation tank for forced

draft ammonia stripping tower for concentrated stream

40 KL

7.A Underground collection cum recirculation tank for forced

draft ammonia stripping tower

40 KL

8. Acid proof brick lined collection cum equalization tank

(with aeration grid for gentle mixing)

60 KL

9. Acid proof brick lined collection cum equalization tank

(with aeration grid for gentle mixing)

65 KL

10. Flash Mixer 1 KL

11. Hopper bottom settling tank 48 KL

12. Aeration tank with surface aerator 216 KL

13. Secondary clarifier (2 in nos.) (with recirculation

arrangement)

27 KL each

14. Chemical Oxidation tank 18.75 KL

15. Treated water sump 21 KL

16. Pressure sand filter 1.2 Ø x 1.2 m

17. Activated charcoal column 1.2 Ø x 1.2 m





PROPOSED

DESCRIPTION OF AMMMONIUM SULPHATE PLANT (STEAM-A):-

TANK NO-3A 3B ACID PROOF BRICK LINED NUTRILAZATION TANK WITH

STIRER:-

In tank no. 1& 2, we take process scrubber solution (Ammonium Carbonate Solution) and add 40% acidic solution (Which is generated by Adding Sulphuric Acid (98%) into our Mother Liquor (25-30 %) and prepare 40% acidic solution). This is then maintained at 6 pH. Then we filter this solution through plate & frame type filter press. After that, we collect the filtrate in to the Acid proof Brick lined collection tank (Tank No.05). This collected solution is sent to Ammonium Sulphate plant for further process.

PROCESS DESCRIPTION OF EFFLUENT TREATMENT PLANT (STEM-B):

TANK NO.01& 02- ACID PROOF BRICK LINE TANK WITH STIRER:-

We take last washing, caustic washing, and neutral washing filtrate (General Stream) into collection tanks 01 & 02. We maintain pH 7.5 with hydrated lime & filter it through plate & frame type filter press.

We take last washing, caustic washing, and neutral washing filtrate (General Stream) into collection tanks 01 & 02. We maintain pH 7.5 with hydrated lime & filter it through plate & frame type filter press.

Filtrate water collected in Collection Tanks (No.4A, 4B & 4C). After that, the filtrate sent to MEE. MEE distillate will be reuse and MEE residue will be sent to Spray Dryer for further process. We also connected stand by for collection of filtrate storage tanks ( i.e. 5A, 5B, 5C1, 5C2, 5C3& 5D) because of break down for the system.



Revised ETP Plant lay out for both strems:

Stream 1(62 KL/Day Mother liquier send to Ammonium Sulphate Plant)



Stream 2(75KL/Day Treated effluent send to spray dryer for ZLD)

Washing

Caustic Wash & General

4A

2

F.P 3A

F.P 3B

1

4B

4C

5A

5B

5C1

5C2

5C3

5D

MEE

SPRAYDRYER



SR.NO.NAME OF THE UNIT AMMO.SULPHATE (STEAM-

A) CAPACITY

3A-3B Acid proof brick lined neutrilizer with stirrer 36KL

( Ammonium Carbonate + 40% ML)

4 1 nos plate and frame type filter press 1)is of 48"x48"x70plate

5 Collection Tank 01 Nos 40 kl

SR.NO. NAME OF THE UNIT ETP PLANT (STEAM-B) CAPACITY

1 & 2 Acid proof brick lined neutrilizer with stirrer ( 02 NOS) 120 KL

3A 1 nos plate and frame type filter press 1)is of 48"x48"x70plate

3B 1 nos plate and frame type filter press 2)is of 36"x36"x70plate

4A Collection Tank 01 Nos 100 KL

4B Collection Tank 01 Nos 100 KL

4C Collection Tank 01 Nos 100 KL

5A Storage Tank 96 KL

5B Storage Tank 432 KL

5C1 Storage Tank 80 KL



5D Storage Tank 80 KL

MEE 207 KL



Detail of Coal Fired Spray Dryer

Process Description:

Air require for drying is initially filtered through an air Pre-filter before being heated in an direct coal fired HAG.

Hot air is sent to drying section for drying purpose.

Feed is send to atomization system for uniform atomization. Feeding is controlled by Adjusting speed of feed pump based on desire outlet dryer outlet temperature.

The effluent and hot air come in the contact with each other and drying take place in a counter current fashion.

The evaporated water is carried out by the exhaust air. The suspended solid is collect below chamber and cyclone.

The exhaust gas is then passes through cyclone separator for fine recovery.

Exhaust air is further passed through a direct contact wet scrubber.

Clean air is then exhaust through to the atmosphere.



Fig. 1Coal Fired Spray Dryer



ANNEXURE-IX

ELECTRICITY AND FUEL CONSUMPTIONS

Sr. No.

Particulars Existing as per Consent Quantity

ProposedQuantity

Total Quantity Source

1. Natural Gas 4000Nm3/Day 2000 Nm3/Day

6000 Nm3/Day Gujarat Gas

2. Coal 800kg/Hr.

1400 kg/Hr.

2200 kg/Hr. Local

3. Energy-Electricity

750KVA 950 KVA 1700 KVA DGVCL



ANNEXURE- X

DETAILS OF FLUE GAS EMISSIONS

*After EC permission existing boiler 1 & 2 will be stand by. Boiler 3 is coal fired boiler.

Stack No.

Source of emission

Type of emission

Permissiblelimit

Stackheight

(m)

Stackdia

meter(mm)

Pollutioncontrol

equipment

Existing Flue Gas Emission: (As per CCA No: AWH-50195)1. Boiler- 1 PM

SO2

NOx

150 mg/Nm3

100 ppm50 ppm

30 600 Multi cyclone

Separator2. Boiler-2

(Stand By)PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

30 600

3. Thermopek 1 & 24 Lac Kcal/Hrs.

PMSO2

NOx

150 mg/Nm3

100 pp50 ppm

20 300 --

4. Thermopek 3,4,5 & 64 Lac Kcal/Hrs.

PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

20 300 --

5. Pre-heating tank

PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

20 300 --

Proposed Flue Gas Emission

1. Hot Air Generator for Spray Dryer

PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

35 600 Scrubber and Cyclone

Separator

2. Boiler 3 PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

30 600 Multi cyclone

Separator



PROCESS EMISSION

DETAILS OF AIR POLLUTION CONTROL SYSTEM

Scrubbing System

Unit has Natural gas fired Boiler for generation of steam. The stack height of the boiler is

30 meter.

Unit has 3 scrubbers vertical cylindrical type packed column of which is having 0.785 M3

packing and 1065 liters volume. The scrubber tank is having 3000 liters capacity. The

blower is having capacity of 1000 M3/Hr. The scrubber pump capacity is 6 M3/Hr. Height

of the vent is 15 Meter. One of the scrubber is for Acidic Fumes, second is for alkaline

fumes and one is stand by.

Stack No.

Source of Emission

Type of Emission

PermissibleLimit

Stack Height(meter)

Stack diameter(mm)

Air pollution control system

EXISTING PROCESS EMISSION

1. Reactor I, II, III & IV

NH3 175 mg/Nm3

25 300 2 stage water scrub with each reactor followed by venturi scrubber.

2. Spin Flash Dryer

PM 150 mg/Nm3

12 600 Bag Filter

PROPOSED PROCESS EMISSION3. Reactor

V, VI & VII

NH3 175 mg/Nm3

25 300 2 stage water scrub with each reactor followed by venturi scrubber.



Flow Diagram of water Scrubber

A1

A2

B1

B2

C1

C1

C2

C2

D1

D2

F

E1

G1 G2 G3

G

H

A- REACTOR

B- RECEIVER (I)

C- SCRUBBER

D- RECEIVER (II)

E- SCRUBBER RECYCLING TANK (I) (WATER MEDIA)

F- SCRUBBER RECYCLING TANK (II) (WATER MEDIA)

G- AMMONIUM CARBONATE STORAGE TANK

H- ACID MEDIA SCRUBBING SYSTEM



ANNEXURE- XI

DETAILS OF HAZARDOUS WASTE

Sr. No.

Hazardous waste

Category

Quantity as per CCA in MT/Month

Quantity as per

Proposed CTE in

MT/Month

Quantity After

Expansion in

MT/Month

Disposal

1. ETP waste 26.1 2400MT/Year

0 2400MT/Year

Finally disposed to approved TSDF.

2. Spent Oil 5.1 0.060 MT/Year

0.060 0.120MT/Year

Disposed by selling to register Re-refiners.

3. Discarded Container

33.1 1,20,000 Nos. / Year

1,25,000 2,45,000 Nos. / Year

Disposed by selling to registered recyclers or reused in waste filling

or disposed to approved TSDF after

decontamination.



ANNEXURE- XII

LIST OF HAZARDOUS CHEMICAL

Sr.No. Name of Chemical

1 Phthalic Anhydride

2 Cuprous Chloride

3 Ammonium Molybdate

4 T G Urea

5 ONT

6 H2SO4 (98%)

7 Spent Acid (10-15%)

8 Caustic Soda

9 Ammonium Carbonate

Documents

M/s. A One Chemicals, Ankleshwar ANNEXURE I TERMS OF REFERENCEenvironmentclearance.nic.in/writereaddata/Online/TOR/10_Dec_2016... · M/s. A One Chemicals, Ankleshwar M/s. Jyoti Om