This is a new stand-alone unit. Not expansion

This is a new stand-alone unit. Not expansion.

KEM ONE CHEMPLAST PRIVATE LIMITED FORM-1 FOR CPVC AND ITS COMPOUNDS MANUFACTURING PLANT

AT KARAIKAL, PUDUCHERRY UT FORM I

KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 24

3 ANNEXURES

Annexure 1: Site Location Map showing Distance from Interstate Boundary

KEM ONE CHEMPLAST PRIVATE

LIMITED

FORM-1 FOR CPVC AND ITS

COMPOUNDS MANUFACTURING PLANT



Annexure 2: Copy of Notification


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Annexure 3 : Site Location Map on Google Image




Annexure 4: Site Layout Map


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Table 1: Area Break up at Site

S. No. Item Area in m2 %

1 Processing Area 900 3.7

2 Storage Area 520 2.2

3 Effluent Treatment Plant 420 1.7

4 Cooling tower 400 1.7

5 DG Sets 510 2.1

6 Vacant Area and Roads 10037 41.5

7 Administrative Building 172 0.7

8 Greenbelt Area 7900 32.7

9 Compounding Plant 900 3.7

10 Warehouse 1500 6.2

11 Utility and Maintenance Section 600 2.5

12 11 KV Yard and Switchgear 300 1.2

Total 24159 100


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Annexure 5: Manufacturing Processes and Mass Balance

Chemical Reactions

In the manufacturing process of CPVCs, S-PVC is chlorinated by photochlorination.

The reaction is initiated by UV irradiation of chlorine inside a fluid bed reactor:

Cl2 → 2 Cl*

Then the chlorination can take place:

SPVC-H + Cl* → CPVC* + HCl

CPVC* + Cl2 → CPVC + Cl*

Several termination reactions occur,:

2 Cl* → Cl2

CPVC* + Cl* → CPVC

CPVC-H* + Cl* → CPVC + HCl

2 CPVC* → CPVC

The result is a partial substitution of H by Cl.

Chlorine content increases from 56.8% in S-PVC up to 67%.

C-PVC resins plant

The S-PVC powder is stored in big bags. S-PVC is loaded in the oxygen degassing hopper. Before

being chlorinated, Oxygen and moisture contents in the S-PVC powder must be removed. This is

done by several nitrogen flushing followed by degassing under vacuum.

From the Oxygen degassing hopper the S-PVC is sucked to feed the reactor first fluidized with

nitrogen. At that stage the pressure is set at 0.1 MPaG and temperature at 60°C. Then chlorine is

introduced progressively into the process according to a flow ramp meanwhile the reaction

temperature increases under control from 60°C up to 72.5°C in one hour and a half.

The heat of reaction (350 kcal/kgCl2) and the heat from the UV lamps are removed by a demi water

loop around the UV lamps, this loop being itself cooled by means of cooling water. The fluidization

gases also participate to the reaction cooling.

The reaction gases leaving the reactor pass first through two cyclones Sx201A/B for C-PVC dust

removal and then filtered in Sx202A. At that point the reaction gases are split in two streams. The

main one is recycled and the other one is sent to the HCl unit, to recover HCl as a 33%HCl solution.

The recycled reaction gases are enriched with pure gaseous chlorine before being dried, by means

of sulfuric acid supported on pumice grains, and recycled back to the reactor after cooling, by means

of a lobe compressor C5x01 followed by a process loop gas cooler E5x01.

After an average of 8-9h of chlorination, the reactor is flushed with nitrogen.

The C-PVC is then transferred to the degassing vessel D6201A/B where, during 4 hours, the

adsorbed Cl2 and HCl are removed by flushing the C-PVC powder with dry air.

The exhaust mixture of air is sent to a scrubber circulated with Caustic soda and Sodium bi sulphite

solution to remove the Chlorine and HCl.


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Then the C-PVC passes through the screen S6243 and is sent to the C-PVC daily storages

R7403A/B/C.

The C-PVC resins plant has 2 reactors:

Volume 37 m3

Height 14m

12 UV stages for a total of UV Lamps-100Watts: 1532

S-PVC approximate load of 10t

C-PVC approximately produced : 12.84t

The reactor is used continuously during approximately 10 weeks before being cleaned. At that time

some UV lamps are changed if required.

Process Flow Diagram

Figure 1: Process Flow diagram of CPVC Production


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Annexure 6: Storage Details

Table 2: Storage Details of Raw Material

S.

No. Chemical State

Consumption

(MT/Month)

Means of

Storage

Mean

Storage

Capacity, MT

No. of

Storage

Total

Storage,

MT

1 PVC Solid 1800 Bags 1 500 500

2 Sulphuric

Acid Liquid 15

Rubber Lined MS

Tanks 15 1 15

3 Additives Solid

/ Liquid

510 Bags /

Drums

Assorted bagging available

One Month Stock

500

Table 3: Storage Details of Products

S.

No. Chemical State

Production,

MTPA

Means of

Storage

Mean

Storage

Capacity, Kg

No. of

Storage

Total

Storage, MT

1 CPVC Solid 22000 Bags

25 / 500 / 675 /1000 or any

other as required by customer

15 Days 1000

2 HCl (30%) Liquid 42000 PP/FRP/ MS RL tanks

--- 15 Days 1600


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Annexure 7: Water Consumption and Waste Water Generation Details

Table 4: Water Consumption Details

S. No. Area Water

Consumption in KLD

Effluent Generation

in KLD

Treated Effluent Disposal mode

A RO Plant 670 167 To desalination plant of

Existing Chemplast Sanmar Plant

1 Domestic 20.5 15 To be treated in STP and then treated water will be

used for Gardening

2 Cooling Tower 250 70 To desalination plant of


3 Reactor Washing 90 90

To desalination plant of Existing Chemplast Sanmar Plant after filtration and pH

neutralization

4 Scrubber 17.5 17.5 To desalination plant of

Existing Chemplast Sanmar Plant after pH neutralization

5 HCL Synthesis 95 0 To be sold as Byproduct

6 Steam Condensate from Process 0 24 To desalination plant of


7 Gardening 30 0

Total 503 383.5




Figure 2: Water Balance


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Annexure 8: Details of STP

Sewage generation @ 15 KLD and will be treated in proposed STP. After treatment treated water

will be used for on land irrigation.

STP Process Description

The STP plant consisting of the following treatment units:

1. Screen Chamber

2. Oil & Grease tank

3. Equalization Tanks

4. MBBR Tank

5. Secondary Settling Tank

6. Intermediate Collection Tank

7. Dual Media Filter

8. Final Collection Tank

9. Sludge Drying Bed / Sludge Collection Sump & Filter Press

The unit wise process description is given below.

Screen Chamber

The sewage will be conveyed through the Sewage Network pipeline into Screen Chamber. Screen

Chamber is provided to remove the bigger size solid particles from the sewage. Screen is proposed

in the screen chamber. From this Screen Chamber Sewage will be transferred to oil and grease tank

via gravity.

Oil & Grease Tank

Oil & Grease Tank is provided to remove the floating oil & grease from the Sewage and is provided

with the baffle system. In this tank sewage will pass through the Inlet baffle and continuously

overflows to the Equalization Tank. During this process Oil & Grease will be separated and floated

on the surface and then after it will be removed manually. The floating oil content separated from

top of the tank will be collected separately in drums. This waste oil will be disposed off. The treated

sewage will be taken to Equalization Tank for further treatment.

Equalization Tank

The prime purpose of this tank is to collect and store the sewage. Air will be supplied through

aeration grid provided at the bottom of tank. This will reduce foul smelling and will ensure constant

load onto the further treatment units. From this tank the sewage will be further transferred to the

MBBR tank for biological treatment.

MBBR Tank

The sewage water from the equalization tank will be passed to the MBBR tank for biological

treatment. As it is a biological system it has to be operated continuously all 24 hours and there by

constant feed of sewage is required.

The MBBR has been provided with air diffusers of suitable capacity to provide necessary dissolved

oxygen mixed to the sewage and it also helps in fluidization of Media. The MBBR Reactor is also

provided with plastic media for the microbial growth. This helps in efficient BOD removal. Air Blowers


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for oxidation, provides the aeration. If required, Nutrients in the form of Nitrogen & Phosphate are

added for biological growth.

Secondary Settling Tank

The secondary settling tank is provided for settlement of secondary sludge solids. Biologically

treated sewage transferred to the settling tank via gravity. The sludge settled at the bottom shall

be collected in sludge drying beds or sludge collection Sump. Secondary Tube Settler is provided

with the Tube Settler Media for increasing the surface area to increasing the settling time. The clear

effluent from top of media will be transferred to intermediate collection tank.

Intermediate Collection Tank

An intermediate tank is proposed to store secondary treated sewage for tertiary disinfection

treatment. The clear sewage from the settling tank shall be collected in an intermediate collection

tank. In this tank liquid chlorine in form of Sodium Hypochlorite (NaOCl) will be mixed using aeration

grid provided at the bottom of the tank. The aeration will help to achieve effective mixing of chlorine

solution with dosage of NaOCl. The sewage is then pumped to dual media filter for tertiary

treatment.

Dual Media Filter

A Dual Media Filter will be provided for removal of residual suspended solids. Dual Media filter (DMF)

consisting of gravel, a different gradation of sand and activated carbon filter. Backwash and bypass

flow arrangements will be provided for the Dual Media Filter. The backwash water of the system

shall be taken to the Equalization Tanks.

Final Collection Tank

Outlet from Dual Media Filter will be collected in a Final Collection Tanks, where the treated sewage

will be stored. From this tank the treated sewage will be reused in flushing and gardening.

Sludge Drying Bed

The Sludge from the Secondary tube settler is pumped by sludge recirculation pump to the Sludge

Drying Beds. The Beds consist of Gravel, stones, sands to filter the water sludge. The sludge to be

dried under the sun and dried sludge will be suitably disposed & the filtrate will be taken to the

equalization tank.

Flow diagram for proposed sewage treatment plants is given in Figure 3.




Figure 3: Block diagram of STP


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Annexure 9: Fuel Consumption

Table 5: Fuel Consumption Details

S.

No.

Stack

Attached to Capacity

Stack

Nos.

Stack

Height

Type of Fuel

used

Fuel

consumption

1 DG Set 500 kVA 1 11 HSD 125 L/hr

Note: DG Set will be used for emergency purpose.


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Annexure 10: Hazardous Waste Generation

Table 6: Hazardous Waste Generation Details

S. No. Type of Waste Hazardous

Waste Category

Quantity per Year

Source Treatment / Disposal

1 Used Oil & Waste

Oil 5.1 2 KL

Compressors, blowers etc.

To registered recyclers

2 CPVC Crusts 22.5 10 MT Production To be disposed off at TSDF

operated by Ramky at Gummidipondi, TN

3 ETP Sludge 34.3 150 MT Filtration and pH

correction

To be disposed off at TSDF operated by Ramky at

Gummidipondi, TN

4 Fused UV lamps Not

Classified 5000 Nos.

Photochlorination reactor

To be disposed off at TSDF operated by Ramky at

Gummidipondi, TN

Table 7: Solid Wastes

S. No.

Type of Waste Quantity MT

per Year Source

Collection, Treatment / Disposal

1 STP Sludge 2 Sewage

treatment plant Will be used as manure for

gardening

2 Pumice stone 5 Sulphuric acid

tower

Will be used for land filling

within the site after cleaning.


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Annexure 11: Stack Details

Table 8: Stacks Details

Stack Attached to Sources Capacity Nos. of Stacks Stack Height, m

DG Set 500 kVA 1 11

Table 9: Details of Process Vents

Stack Attached to Nos. of Stacks

Stack Height in m

Pollutants Emitted

Air Pollution Control Measures Attached

HCl synthesis 1 30 HCl & Chlorine Absorption tower using water as an absorption

media

CPVC Reactor and De-gassing vessel

1 12 Chlorine Alkaline scrubber

PVC Conveying to Silo 1 25 PM Bag Filter

PVC Conveying to Oxygen Degassing

1 10 PM Bag Filter

Conveying - Degassing Vessel to Hopper

1 25 PM Bag Filter

Evacuation of air 1 10 PM Bag Filter

Conveying CPVC from Reactor

1 25 PM Bag Filter

Conveying CPVC to Compounds

1 25 PM Bag filter

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B-3, Sector 49, Sohna Road, Gurgaon, India – 122 002

E: [email protected]; T/F : 0124-424 2430-436

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

mailto:[email protected]

mailto:[email protected]

http://www.kadamenviro.com/

Documents

This is a new stand-alone unit. Not expansion