As per standard ToR of organic manufacturing sector issued by MoEF&CC.

Transcription

1 ANNEXURE I Terms of Reference As per standard ToR of organic manufacturing sector issued by MoEF&CC. 1

2 ANNEXURE II List of Directors Sr. No. Name of Director Designation Address Telephone no. 1. Shri. Rajendra V. Chairman& 1401,Antriksh Murar Gogri Managing Director Road Mulund (W) Mumbai Shri. Rashesh C. Gogri Vice Chairman & Managing Director 601,Antriksh Murar Road Mulund (W) Mumbai Shri. Parimal H. Desai 4. Shri. Manoj M. Chheda 5. Shri. Kirit R. Mehta 6. Smt. Hetal Gogri Gala 7. Shri. Renil R. Gogri Whole-Time Director Whole-Time Director Whole-Time Director Whole - Time Director Whole - Time Director A/1403, 14 th floor, Runwal Heights, L.S.B. Marg, Mulund (w) Mumbai Dunhill Villa Co. Op. Hsg. Soc. Ltd., Besant Road, Santacruz (W), Mumbai , Pushpendra Mension, Phirojshah Mehta Road, Santacruz (W), Mumbai B, Gopal Sadan, Block No. 801, 8 th Floor, Jamshed Road, Matunga (E), Mumbai , Antriksh. Murar Road Mulund (W) Mumbai

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4 SITE PLAN ANNEXURE III A 1

5 PLANT LAYOUT ANNEXURE III B 2

6 List of Products Sr. No. List of Products Quantity in MT/Annum Chlorination Products maximum quantity MT/Annum where in individual maximum quantity of each product is defined. The production will be controlled based on generation of 30% HCl (45600 MT/Year) 1. Mono Chloro Benzene And/or Para Di Chloro Benzene/ Ortho Di Chloro Benzene/ Mono Di Chloro Benzene And/or Tri Chloro Benzene / Tri Chloro Benzene And/or 4. Ortho Chloro Toluene / Para Chloro Toluene And/or 5. 6 Chloro 2 Nitro Toluene / 4 Chloro 2 Nitro Toluene And/or Chloro 4 Nitro Toluene And/or Any Other Chlorination Products -- And/or 8. 30% HCl ANNEXURE IV 1

7 Raw Material Consumption Quantity Sr. No. Name of Product Quantity in MT/M Name of Raw Material A. Chlorination Products 1. Mono chloro Benzene And/Or 2. Ortho Di chloro Benzene/ Ortho Di Chloro Benzene/ Mono Di Chloro Benzene And/Or 3 1,2,3/1,2,4/ Tri Chloro Benzene And/Or 4 Ortho Chloro Toluene/Para Chloro Toluene And/Or 5 6 Chloro 2 Nitro toluene/4 Chloro 2 Nitro Toluene And/Or 6 2 Chloro 4 Nitro Toluene And/Or Quantity in ton ANNEXURE V Quantity in MT/MT Quantity in MT/M 3545 Fresh benzene Recovered benzene Chlorine Total Fresh benzene Recovered benzene Chlorine Total Fresh Benzene Recovered benzene Chlorine Total Fresh Toluene Recovered Toluene Catalyst Chlorine Total Fresh ONT Chlorine Recovered ONT Total Fresh PNT Chlorine Recovered PNT Total

8 BREIF MANUFACTURING PROCESS: ANNEXURE VI 1.1 PRODUCT: 1, & 2:-MONOCHLORO BENZENE AND ORTHO DICHLORO BENZENE AND PARA DICHLORO BENZENE BRIEF MANUFACTURING PROCESS The chlorine in the gaseous form is reacted with benzene in the chlorinator; Reaction is followed by benzene recovery then separation of crude mono chloro benzene and Di chloro benzene. Crude product is then subjected to Flash Distillation to get pure product. CHEMICAL REACTION 3

9 MATERIAL BALANCE OF MONO CHLORO BENZENE Input Kg Output Kg Fresh benzene 2459 Recovered benzene 2358 Chlorination HCl 1150 Chlorine 2238 Reaction mass 5905 Total 7055 Total 7055 Reaction mass 5905 Distillation Recovered Benzene 2358 MCB 3547 Total 5905 Total 5905 HCl 1150 HCl loss 10 Water 2660 HCl Scrubber HCl solution(30%) 3800 Total 3810 Total

10 MATERIAL BALANCE OF PARA DI CHLORO BENZENE/ORTHO DI CHLORO BENZENE/MONO DI CHLORO BENZENE Input Kg Output Kg Fresh benzene 1229 Recovered benzene 2359 Chlorination HCl 1150 Chlorine 2237 Reaction mass 4675 Total 5825 Total 5825 Reaction mass 4675 Distillation Recovered Benzene 2359 DCB Crude 2316 Total 4675 Total 4675 HCl 1150 HCl loss 16 Water 2660 HCl Scrubber HCl solution(30%) 3794 Total 3810 Total 3810 Crude DCB 2316 Crystalizer P-DCB pure 1150 Crude DCB 1166 Total 2316 Total 2316 Crude DCB 1166 Fractionation O-DCB 1136 Residue 30 Total , 2, 3-TRI CHLORO BENZENE AND 1, 2, 4- TRI CHLORO BENZENE BRIEF MANUFACTURING PROCESS The chlorine in the gaseous form is reacted with either benzene or ortho di chloro benzene in the chlorinator; Reaction is followed by benzene or Ortho di chloro benzene recovery then separation of crude tri chloro benzene. Crude product is then subjected to Flash Distillation to get pure product. 5

11 CHEMICAL REACTION 6

12 MATERIAL BALANCE OF 1, 2, 3, TCB AND 1, 2, 4 TCB Input Kg Output Kg Benzene 820 HCl 1150 Recovered Benzene 1640 Chlorination Reaction mass 3547 Chlorine 2237 Total 4697 Total 4697 Recovered Benzene 1640 Benzene Reaction mass 3547 recovery Mix products 1907 Total 3547 Total TCB Mix products 1907 Distillation Reaction mass 518 Total 1907 Total TCB 488 Reaction mass 518 Distillation Residue 30 Total 518 Total 518 HCL HCl 1150 HCl loss 16 SCRUBBER Water % HCl 3780 TOTAL 3796 TOTAL

13 4. ORTHO CHLORO TOLUENE & PARA CHLORO TOLUENE BRIEF MANUFACTURING PROCESS The chlorine in the gaseous form is reacted with toluene in the chlorinator. Reaction is followed by toluene recovery then separation of crude chloro toluene. Crude product is then subjected to Flash Distillation to get pure product. CHEMICAL REACTION 8

14 MATERIAL BALANCE OF ORTHO CHLORO TOLUENE & PARA CHLORO TOLUENE Input Kg Output Kg Fresh Toluene 2899 HCl 1150 Recovered Toluene 750 Reaction mass 4769 Catalyst fresh 0 Chlorination Catalyst 33 Chlorine 2237 Total 5919 Total 5919 Crude 4769 Filter Catalyst 33 Crude 4736 Total 4769 RecoveredToluene 750 Toluene Reaction mass 4736 recovery Mix products 3986 Total 4736 Total 4736 OCT Mix products 3986 Distillation PCT 996 Residue 31 Total 3986 Total 3986 HCl 1150 HCL HCl loss 10 Water 2660 SCRUBBER 30% HCl 3800 TOTAL 3810 TOTAL

15 5. 6-CHLORO 2 -NITRO TOLUENE AND 4-CHLORO 2-NITRO TOLUENE BRIEF MANUFACTURING PROCESS The chlorine in the gaseous form is reacted with ortho nitro toluene in the chlorinator; Reaction is followed by ortho nitro toluene recovery then separation of crude chloro nitro toluene. Crude product is then subjected to Flash Distillation to get pure products. CHEMICAL REACTION 10

16 MATERIAL BALANCE Input Kg Output Kg Fresh ONT HCl 1150 Recovered ONT Chlorination Reaction mass 7898 Chlorine 415 Total Total 9048 Recovered ONT 4316 Toluene Reaction mass recovery Mix products 3581 Total Total Chlror2Nitro 2000 Mix products Distillation toluene 1550 Residue Total Total 3581 HCl 1150 HCL HCl loss 10 Water 2660 SCRUBBER 30% HCl 3800 TOTAL 3810 TOTAL CHLORO 4-NITRO TOLUENE BRIEF MANUFACTURING PROCESS The chlorine in the gaseous form is reacted with Para nitro toluene in the chlorinator, Reaction is followed by Para nitro toluene recovery then separation of crude chloro nitro toluene. Crude product is then subjected to Flash Distillation to get pure products. 11

17 CHEMICAL REACTION 12

18 MATERIAL BALANCE Input Kg Output Kg Fresh PNT HCl 1150 Recovered PNT Chlorination Reaction mass 9718 Chlorine Total Total PNT 4316 Toluene Reaction mass recovery Reaction Mass 5402 Total Total 9718 Product 5372 Reaction mass 5402 Distillation Residue 30 Total 5402 Total 857 HCl 1150 HCL HCl loss 10 Water 2660 SCRUBBER 30% HCl 3800 TOTAL 3810 TOTAL

19 DETAILS OF WATER CONSUMPTION ANNEXURE VII Sr. Section Water Consumption No. KL/Day 1 Domestic 10 2 Industrial Process 90 Washing 20 DM plant 230 Boiler 210(From DM Plant) Cooling 230 Gardening 15 Total (Industrial) 585 TOTAL (Industrial + Domestic)

20 DETAILS OF WASTE WATER GENERATION Sr. No. Section Waste Water Generation KL/Day 1 Domestic 9 2 Industrial Process 200 Washing 20 Boiler 15 Cooling 40 DM plant 20 (Regeneration Water) Gardening 0 Total (Industrial ) 295 TOTAL(Industrial + Domestic)

21 Water Balance Diagram GIDC Water 595 KLD Domestic 10 KLD Sock Pit 9 KLD Process 90 KLD Effluent 200 KLD Washing 20 KLD Washing 20KLD DM Plant 230 KLD Boiler 210 KLD Regeneration n Water 20 KLD Cooling Tower 230 KLD Blow down 40 KLD Gardening 15 KLD Blow down 15 KLD TO ETP 295 KLD Treated Effluent will be sending to CETP/ Discharged to GIDC Underground Drainage Pipeline 1

22 Effluent Treatment Plant ANNEXURE-VIII EFFLUENT TREATMENT PROCESS DESCRIPTION The effluent generated from the industry is received in Collection Tank. Then it will transfer in to Neutralization & Equalization tank where ph will be adjusted, it will then take to filter press to remove TSS, and filtrate collected in Equalization tank. It will then feed in primary clarifier where the sludge will allowed to settled and will remove and feed to SBD. The overflow from primary clarifier will sent to secondary treatment system. The secondary clarifier the secondary sludge will removed and feed to the SBD where it will mixed with the primary sludge and the overflow will passed through sand filter and carbon column and then taken to collection tank and then the treated effluent will discharged to common effluent treatment plant for further treatment through underground drainage system of G.I.D.C. Details of Effluent Treatment Unit Sr. Name of Unit Quantity Capacity MOC No. 1. Collection tank 2 Nos. 150 KL & 30 KL HDPE 2. Neutralizer 2 Nos. 75 KL HDPE 3. Filter press 2 Nos. 4. Equalizer 1 Nos. 300 KL RCC 5. Oil & Grease 1 Nos. 20 KL RCC Separator 6. Primary Clarifier 1 Nos. 100 KL RCC 7. Secondary Clarifier 1 Nos. 100 KL RCC 8. Carbon filter 1 Nos. 20 m 3 MS 9. Sand filter 1 Nos. 20 m 3 MS Effluent Quality Before Treatment And After Treatment Sr. Parameters Units Inlet Outlet No. 1. ph < COD mg/lit BOD mg/lit Oil & Grease mg/lit Suspended Solid mg/lit

23 EFFLUENT TREATMENT FLOW DIAGRAM DM Water Cooling Tower Boiler Blow Down Washing Collection Tank Lime Dosing Equalization Tank Primary Clarifier Dilute Collection Tank Neutralization Filtration Secondary Treatment Sludge Secondary Clarifier Filtrate Sludge Sand filter Carbon Filter ETP Outlet 2

24 Energy and Fuel Consumption Details Sr. Name Requirement Source No. 1. Diesel 450 LIT/H Local Market Annexure-IX 2. Energy KVA Torrent Power Electricity 3. Natural Gas 28 MT/Day GSPC 4. Steam from adjoining unit 15TPH From Neighboring Industry Flue Gas Emissions Sr. Stack attached No to 1. Boiler ( 15 TPH) 2. DG Set (750 KVA) (2 nos.) Process Emission Sr. Stack No. attached to Stack Height in meter Stack Diame ter 30 m 750 mm 12 m 250 mm Stack Height in meter Stack Diameter APCM Probable Pollutants - SPM SOx - NOx APCM 1 Chlorinator 11 m 100 mm Two Stage Water Scrubber followed by Alkali Scrubber 2 Calcium Chloride Solution Preparation Probable Pollutants Cl 2 HCl Permissible Limit 150 mg/nm ppm 50 ppm 11 m 100 mm --- CO 2 -- Permissible Limit 09 mg/nm 3 20 mg/nm 3 3

25 DETAILS OF AIR POLLUTION CONTROL SYSTEM 4

26 ANNEXURE X Details of Hazardous Waste Sr. Type of Category Quantity in MT/Year Treatment and No. hazardous no. disposal waste 1. ETP Waste Collection, storage, transportation & disposal at TSDF, 2. Distillation Residue 3. Discarded containers/bags Collection, storage, transportation, disposal at CHWIF/co processing facility What so ever Collection, storage, Decontamination,Disposal by sold to authorize Recyclers. 4. Used oil liter Collection, Storage, Transportation, Disposal by selling to registered reprocessors. 5. Spent catalyst Collection, Storage, Transportation, Disposal by Registered regenerators 6. Insulation Waste What so ever Collection, Storage, Transportation 5

27 disposal by at TSDF Site % HCL D Collection, Storage, Transportation disposal by Registered users and sellers Details of Solid Waste Sr. Waste Quantity Mode of Disposal No. 1. Glass Waste ( Z 13) What so ever Incineration Facility 2. Paper waste (Z44) What so ever Incineration Facility 3. Bio-Medical Waste What so ever Will be disposed off as per Bio Medical Waste Rules 4. Cotton waste What so ever Incineration Facility 5. Wooden Waste What so ever Authorized Scrap Vendors 6

28 ANNEXURE XII List of Hazardous Chemical Sr. No. Name of Hazardous chemical 1. Benzene 2. Toluene 3. Chlorine 7