annexure-i list of products and raw materials...

M/s. Meghmani Organics Ltd., Panoli

- 1 -

Annexure-I

List of products and raw materials

List of Products

Sr.

No.

Name of product Quantity (MT/month)

Existing Proposed Total

1. Copper Pthalocyanine Blue 125 1000 1125

2. Pigment Alpha Blue 25 75 100

3. Pigment Beta Blue 25 400 425

4. CPP 3 Nos. x

1.048 MW

-- 3 Nos. x

1.048 MW

By product

1. Amm. Sulphate 10 643 653

List of Raw Materials

Sr. No.

Raw Materials Quantity (MT/month)

Existing Proposed Total

CPC Blue – 1125 MT/month

1 Phthalic Anhydride 134.41 1075.30 1209.71

2 Cuprous Chloride 24.44 195.50 219.94

3 T G Urea 197.95 1583.60 1781.55

4 ONT/DCT 226.79 1814.30 2041.09

5 Ammonium Molybdate 0.44 3.50 3.94

6 Caustic 2.45 19.60 22.05

Alpha Blue – 100 MT/month

1 CPC Crude 26.32 78.95 105.26

2 Sulphuric Acid (70%) 157.89 473.67 631.56

3 Lime 37.50 112.50 150.00

4 Caustic Soda 0.55 1.64 2.19

5 Oleic Acid 0.40 1.19 1.58

6 TLS 1.32 3.95 5.26

Beta Blue – 425 MT/month

1 CPC Crude 25.00 400.000 425.000

2 MEK 2.50 40.000 42.500

3 Xylene 0.50 8.000 8.500

4 Caustic Flakes 1.00 16.000 17.000

5 Rosine 2.25 36.000 38.250

6 IBA 2.50 40.000 42.500

7 HCl 3.75 60.000 63.750


- 2 -

Annexure-II

Manufacturing Process

1. CPC Blue

Manufacturing Process:

Charge Ortho Nitro Toluene in glass lined vessel. Then add Urea, Phthalic

anhydride and Ammonium Molybdate to it.

Raise the temp. to 1900C and maintain it for about 4 hours.

Scrub ammonia and carbon dioxide gases evolved during process to water

scrubber to get solution of ammonia carbonate.

Dump the crude mass of CPC into venulett and distill out unreacted ONT under

vacuum.

Charge crude CPC in open MSRL vessel containing water and raise the

temperature to 850C.

Add Mother liquor of alpha blue containing 15 to 20% Sulphuric Acid so as to

have desired quantity of Sulphuric Acid to dissolve isomers of CPC Blue.

Filter the material through air pressure in PP filter press.

Wash the wet cake hot water.

Dry the material through spin flash dryers and pack.

Mass balance:

Input Kg Kg. Output

Water 857 943Ammonium carbonate (Use

for Amm. Sulphate

recovery)

NH3

Phthalic Anhydride 1075

Cuprous Chloride 196

T G Urea 1584

ONT/DCT 1814

Ammonium Molybdate 4

Water 857 1715 ONT Recovery

100 Loss

Steam 1715

Caustic 20

Co. Water 2143

ML of Alpha Blue 1072

Hot Water 1286 5144 CPC ML (use for A.S.)

2863 Drying Loss

1000 CPC Blue

Total 11765 11765

Drying

Mass Balance of CPC Blue

G L Vessel

S S Venulettor

CPC Purification

Filtration

Scrubber


- 3 -

2. Alpha Blue


Charge 98% Sulphuric acid in SS jacketed vessel and add required

quantity of CPC blue in 4 hours maintaining the temperature of 500C.

Continue stirring till CPC gets dissolved in acid.

Test on microscope for dissolution.

Transfer the batch by air pressure in another vessel containing sufficient

water to make final concentration of 15% to 20% acid. The acid solution

is to be sprayed in water maintaining the temperature of drowned mass

around 950C.

Filter the mass in filter press and wash with water.

Charge wet cake in vessel containing water and add dispersing agent

Heat with live steam and bring pH to neutral with help of caustic soda and

then maintain temperature of 950C for four hours.

Filter the slurry and wash with water.

Wet cake is dried through spin flash dryer and packed.


- 4 -

Mass balance:

Input Kg Kg Output

CPC Crude 1052

70% Sulphuric Acid 6315

Water 380

Water 8305

15000 25% Sulphuric Acid

Lime 1500 91298 waste water

Water 96945 5000 Gypsum w/c

Caustic Soda 22

Oleic Acid 16

Water 10000

TLS 53

Steam 5000

Water 10000 25790 Waste Water

1500 Drying Loss

1000 Alpha Blue

Total 139588 139588

P P Filter Press

Spin Flash Dryer

Mass Balance of Alpha Blue

M S Jacketed Vessel

Drowing in MSRL

Brick Linked Vessel

Flitration

Washing

S S Vessel

Pigmentation


- 5 -

3. Beta Blue


Charge CPC blue in the ball mill and carry out grinding.

Charge CPC blue in to the MS vessel and add, Rosin, Xylene, Caustic and

Beta adhesive and reflux the mass. (Xylene is recovered through

distillation)

Transfer the mass in a vessel containing the water and treat the slurry

using HCl and live steam, Filter the Slurry through filter press and give

wash to wet cake using water.

Filter the mass through the filter press and give a wash of water to wet

cake

Dry the wet cake through spin flash drying.

Pack the product.

Mass balance:

Input Kg Kg. Output

CPC Crude 1000

MEK 100

Xylene 20

Caustic Flakes 40

Water 10000

Rosine 90

IBA 100

Steam 2000

HCL 150

Water 10000

32300 waste water

Water 11300

1500 Drying Loss

1000 Beta Blue

Total 34800 34800

Spin Flash Dryer

Purification

Mass Balance of Beta Blue

Grinding Equipment

Ball Mill

Dpigmentation &

Purification

Filtration/Washing


- 6 -

Mass Balance of Copper Sulphate/Ammonium Sulphate

Input Kg Kg Output

Ammo.Carbonate 943

CPC ML 5144

386 Copper earth

Sulphuric Acid 11.2 10.71 CuSO4

4800 Condensate Water

258 Vapour Loss

643 Ammonium Sulphate

Total 6098 6098

MEE

Copper Sulphate and Ammonium Sulphate recovery

Ammonium Sulphate

Repparation

Filter Press

Copper Sulphate

Recovery


- 7 -

Annexure-III

Water balance diagram- Total after expansion

Total water consumption= 1726 KLD [621(Fresh water) + 1105 (recycle)]

Process 1228

Utility 300

Greenbelt 70

Domestic 30

Washing 60

25 to soak

pit

Scrubber

38

Boiler 200

Cooling 100

77

109 + 60 + 20 + 25 = 214

20 25

60

to GIDC Drainage

Condensate 192* 4.0

Beta plant 532

CPC blue 193 + 77

+ 50

549

42

By product recovery 191 + 38

MEE 229

By product 26

Loss 11

Drying loss

129

Water

retained

with RM

50

Spent acid 50 D. loss

25

Water

retained with

RM 10

Alpha

plant

498

RO

109

440* Permeate

Reuse

20

D. loss 5

478

RO

385* Permeate

Reuse

503

Loss 2.5

Condensate 88* 4.0

Salt 2.5

MEE 93


- 8 -

Water consumption

Sr.

No.

Break up Existing Water

Consumption

(KL/day)

Total Water

Consumption after

consumption

(KL/day)

1. Domestic 20.0 30.0

2. Green Belt 70.0 70.0

3. Industrial

a Process 220 1228

b Boiler 250 200

c Cooling 100 100

d Washing 12.5 60

e Scrubber 10 38

f Water treatment 10 00

Total Industrial 602.5 1626

Total (1 +2 + 3) 692.5 1726

Recycle water 0 1105

Fresh water requirement 692.5 621

Wastewater generation

Sr.

No.

Break up Existing w/w

Generation

(KL/day)

Total w/w generation

after expansion

(KL/day)

I Domestic 10 25.0

II Industrial

a Process 187 109

b Boiler 3 20

c Cooling 12 25

d Washing 5 60

e Water treatment 10 0

Total Industrial 217 214*

Total 227 239

* Process waste water from CPC blue, beta blue which have higher organic and

inorganic load hence we have decided to achieve zero discharge of above both the

products. Only w/w from beta blue which have low organic load and washing, utilities

are going to ETP and finally discharge to CETP resulted to reduce qty of wastewater

discharge to CETP.


- 9 -

Annexure-III (a)

ETP details

Treatment Scheme:

As the manufacturing activities generate different streams of effluent containing

high Concentration of certain pollutants like Ammonical nitrogen, copper, highly

acidic etc. each of the major polluting stream has been segregated for removal

of specific pollutants and then allowed either to sell them as by products or to

mix it with general stream for further treatment at Central/General effluent

treatment plant.

1) CPC BLUE

The effluents from CPC blue plant are -

1. Ammonium Carbonate solution

2. Mother liquor/Washing as a dilute sulfuric acid

Above both the effluents are mixed In Ammonium Sulfate slurry preparation

tank which is a feed for MEE plant. The A.S. slurry is then filtered and the slurry

is taken to MEE feed tank. From this tank feed is taken to MEE plant (100 m3

/day capacity quadruple effect) to mfg. Ammonium Sulfate.

In MEE plant 4 nos. of callandria and thermo - compression method is used to

mfg. Ammonium Sulfate as a by-product. Condensate is also generated in MEE

plant and it is recycled in CPC plant for washing.

2) Alpha Blue

The effluent stream containing 20 to 25% of Sulphuric Acid is generated during

the manufacturing process of Alpha Blue. All the acid generated is taken to CPC

plant for purification purpose.

Balance qty. of effluent from manufacturing of the Alpha Blue process is taken

to effluent treatment plant as it is having fairly less pollution potential and is

having high pH. Neutralize the effluent, pass through filter press and RO.

Permeate of RO will be reused and reject of RO will be evaporate in MEE.

Condensate of MEE further reuse.

3) Beta Blue

The total qty. of effluent from manufacturing of the Beta Blue process is taken

to effluent treatment plant as it is having fairly less pollution potential and is


- 10 -

having pH in neutral range. The effluent is received in collection tanks so that

both the tanks can be used in alternate day in a cyclic manner.

The effluent is then taken to the primary clarifier where addition of alum and

poly electrolyte is used for floc generation. Floc is settled and the clear water is

overflowed to the aeration tank. The sludge from the bottom of the primary

clarifier is taken to be sludge drying beds.

In the aeration tank, air is supplied through the aerators to keep the entire

mass in the homogenous conditions as well as to supply the air for the healthy

growth of the bacteria. The regular addition of the nutrients like phosphoric acid

and cow dung is added in aeration tank. From the aeration tank effluent is

taken to the secondary clarifier for the settlement and from the bottom, sludge

is taken to sludge drying beds. Effluent from the secondary clarifier is taken to

pre final tank for further settlement. Most of the suspended particles are settled

in pre final sump. As an extra preparation we have added nos. of 48 X 48 PP

make filter press to remove any Suspended particles. The filtered treated water

is then passed to Sand filter and carbon filters. Then effluent is passed through

RO before final discharge to GIDC pumping station Panoli.

Name of ETP unit with size

Sr.

No.

Name of Unit Size in Meters

1 Neutralization Tank/Stripper 1,2,3,4 5.0 x 5.0 x 5.0

2 Primary Clarifier 6.0 dia x 3.0

3 Aeration Tank 24.0 x 12.0 x 3.0

4 Secondary Clarifier 9.0 dia x 3.0

5 Secondary Treated Effluent Sump/

Pre Final Tank

8.0 x 8.0 x 2.5

6 Pressure Sand Filter (M.S.) 2.5 dia x 1.5

7 Activated Charcoal Treatment (M.S) 2.5 x 1.5

8 Final Treated Water Sump/Final

Discharge Sump

8.0 x 8.0 x 2.5

9 Sludge Drying beds 4 Nos. 4.0 x 8.0

10 Collection tank for spent Acid from

Alpha Plant (1 No)

2 Nos. HDPE Tank 20 KL

11 Collection tank for scrubbed liquor of

Ammonia (1 No)

2 Nos. HDPE Tank 30 KL

12 Copper Recovery Plant 40 MT/Month


- 11 -

Schematic Flow Diagram of ETP - Alpha blue and Beta Blue plant


- 12 -

Schematic Flow Diagram of ETP - CPC Plant


- 13 -

Annexure-IV

Hazardous waste details

Sr.

No.

Type of Waste Category

as per

HWM

rules,

2016

Quantity Method of Disposal

Existing Total

after

expansion

1. Gypsum Waste 26.1 6000

MT/year

10000

T/Year

Collection, Storage,

Transportation and Disposal at

TSDF-BEIL

2. ETP sludge 35.3 720

MT/year

800 MT/M Collection, storage,

transportation & disposal at

TSDF-BEIL

3. Used Oil 5.1 1200

lit/year

1500

lit/Year

Collection, storage &

transportation and selling to

recyclers authorized by GPCB.

4. Discarded

containers/

drums/ liners

33.1 3000

nos./year

5000

Nos./Year

Collection, storage,

transportation and disposal at

TSDF-BEIL.

6. Spent Sulphuric

Acid (20-22%)

D-II 6000

MT/year

18250

MT/Year

Spent sulphuric acid from Alpha

blue plant will be sold out to the

potential users authorized by

GPCB under Hazardous Waste

Management Rules.

7. Dust Iron Air

Filtration

26.2 2400

Kg/year

3000

Kgs/Year

Collection, Storage

Transportation and Disposal at

TSDF-BEIL.

8. Copper

Sulphate &

Copper Earth

B-III 480

MT/year

3000

MT/year

144

MT/year

8000

MT/Year

Collection, Storage,

Transportation and Sale to

actual authorized end users.


- 14 -

Annexure-V

Details of Air Pollution

Sr.

No.

Stack attached to Stack

Height

in meter

Fuel Type &

Fuel

Consumption

Rate

APC

measure

Pollutant

Flue Gas Stack – Existing

1. Boiler-2 nos.

(5 TPH each)

30 Coal – 36

MT/day

ESP SPM<150 mg/Nm3

SO2<100 ppm

NOX<50 ppm

2. Thermic Fluid

Heater-1 & 2

(20 lakhs Kcal/hr.)

30 Coal – 20

MT/day ESP SPM<150 mg/Nm3

SO2<100 ppm

NOX<50 ppm

3. Thermic Fluid

Heater-3 & 4

(20 Lakhs Kcal/hr.)

30 Coal – 20


SO2<100 ppm

NOX<50 ppm

4. CPP-2 nos. 30 Natural Gas –

200 NM3/hr.

-- SPM<150 mg/Nm3

SO2<100 ppm

NOX<50 ppm

Flue Gas Stack – Proposed addition

1. Boiler-1 no.

(8 TPH)

30 Coal – 50

MT/day

ESP SPM<150 mg/Nm3

SO2<100 ppm

NOX<50 ppm

2. Thermic Fluid

Heater-(2 Nos.)

(20 lakhs Kcal/hr.

each)

30 Coal –20


SO2<100 ppm

NOX<50 ppm

3. D G Set (500 KVA) 11 HSD-70 Lit/Hr - SPM<150 mg/Nm3

SO2<100 ppm

NOX<50 ppm

Process Gas Stack – Existing

1. Reactor of CPC Blue

Plant (4 Nos.)

20

(Common

stack)

-- 3 stage

water

scrubber

Ammonia<175

mg/Nm3

2. Spin Flash Dryer

(4 Nos.)

15 (Each) -- Bag filter

followed

by Cyclone

SPM<100 mg/Nm3

Process gas stacks - Proposed addition


Plant (4 Nos.)

20

(Common

stack)

-- 3 stage

water

scrubber

Ammonia<175

mg/Nm3


Plant (4 Nos.)

20

(Common

stack)

-- 3 stage

water

scrubber

Ammonia<175

mg/Nm3

3. Spin Flash Dryer

(2 Nos.)

15 (Each) -- Bag filter

followed

by Cyclone

SPM<100 mg/Nm3

annexure-i list of products and raw materials...

Documents