dbs chemicals final feasibility report...

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Feasibility Report on the Proposed Expansion in Manufacturing Capacity of Synthetic Organic Chemicals Manufacturing

at M/s DBS Chemicals

Sanghvi-Shirwal [PIN- 412801] Taluka: Khandala, Dist. Satara

August, 2016

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Contents

1. Purpose ........................................................................................................................ 5

2. Background ................................................................................................................. 5

3. Industry Details .......................................................................................................... 6

4. Environmental Policy of DBS Chemicals ................................................................. 7

5. Site Location................................................................................................................ 8

6. Plant Layout ................................................................................................................ 9

7. Processes carried out in the plant ......................................................................... 12

8. Water consumption .................................................................................................. 12

9. Manufacturing process and flow diagram for Para Amino Azo Benzene (PAAB) 13

Product Name: Para Amino Azo Benzene (PAAB) / Solvent Yellow – 1 .......... 13

Raw Materials ............................................................................................................ 13

Manufacturing Process: ........................................................................................... 13

Process Flow details for 1000 kg PAAB ................................................................ 14

Material Balance for 1000 kg PAAB ....................................................................... 15

Treatment and disposal of by-products ................................................................ 16

Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow – 1, Effluent and other outputs in kg from PAAB production.................................... 16

10. Analysis Report of treated effluent........................................................................ 21

11. Proposed scale-up and Additional Products ......................................................... 21

Material Balance of Proposed PAAB 1500 kg batch ............................................ 21

Material Balance in kg for Proposed Scale up of PAAB ...................................... 22

Manufacturing process and flow diagram for Fast Garnet GB base /Ortho Amino Azo Toluene (OAAT) .................................................................................... 23

Manufacturing process ............................................................................................ 23

Chemical Reaction of OAAT .................................................................................... 23

Process flow chart of OAAT ..................................................................................... 25

12. Waste Management for Scale-up........................................................................... 30

Effluent Treatment ................................................................................................... 30

Proposed Effluent Treatment: ................................................................................ 32

Air Pollution Control ................................................................................................. 34

Hazardous Waste Management ............................................................................. 34

13. Justification for Environmental Clearance ............................................................ 34

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Figures

Figure 1: Schematic Details of Village Sanghvi ........................................................... 8

Figure 2: Schematic Layout Plan of DBS Chemicals ................................................... 9

Figure 3: Schematic Layout showing plant equipment ............................................. 10

Figure 4: Water Supply Diagram .................................................................................. 13

Figure 5: PAAB Chemical Reaction ............................................................................... 14

Figure 6: Process flow chart – PAAB ............................................................................ 15

Figure 7: OAAT Chemical reaction ............................................................................... 24

Figure 8: Process flow diagram of OAAT ..................................................................... 25

Figure 9: Process Flow Chart of Yellow Dye ............................................................... 29

Figure 10: Proposed Zero Liquid Discharge Scheme ................................................ 33

Tables

Table 1: Industry Details ................................................................................................. 6

Table 2: Room wise measurements (dimensions in feet) ........................................ 10

Table 3: List of Plant & Machinery ................................................................................ 11

Table 4: Material Balance – (for 1000 kg PAAB) ....................................................... 15

Table 5: Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow – 1 16

Table 6: Effluent and other outputs in kg from PAAB production ........................... 16

Table 7: Other Water Consumption/effluent generation in kg per month ............ 17

Table 8: Treated Effluent Analysis ............................................................................... 21

Table 9: Material Balance of Proposed for PAAB 1500 kg ........................................ 21

Table 10: Material Balance in kg for Proposed Scale up of PAAB ........................... 22

Table 11: Material Balance for 1000 kg OAAT batch ................................................ 25

Table 12: Scale up - Ortho Amino Azo Toluene (OAAT) ........................................... 26

Table 13: Material Balance for 800 kg OAAT batch................................................... 26

Table 14: Material Balance for 1600 kg OAAT batch ................................................ 27

Table 15: Input Raw Material Quantity Details – OAAT / Garnet ........................... 27

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Table 16: Other Water Consumption ........................................................................... 28

Table 17: Material Balance – Yellow Dye .................................................................... 30

Table 18: Monthly production – Yellow Dye ............................................................... 30

Table 19: Proposed Effluent generation from PAAB .................................................. 31

Table 20: Proposed Effluent generation from OAAT / Garnet ................................. 31

Table 21: Proposed Effluent generation from Yellow Dye ........................................ 31

Table 22: Other water consumption ............................................................................ 31

Pictures

Picture 1: Google image of Village Sanghvi in Shirwal area ...................................... 8

Picture 2: Google image showing DBS Chemicals ....................................................... 9

Picture 3: Coiled Jacketed Reactor ............................................................................... 17

Picture 4: Distillation Vessel and Tray ......................................................................... 18

Picture 5: Centrifuges ..................................................................................................... 18

Picture 6: Tray Dryer and Finished Product ................................................................ 18

Picture 7: Solvent Storage Tanks ................................................................................. 19

Picture 8: Finished Product Storage ............................................................................. 19

Picture 9: Neutralisation Tank....................................................................................... 19

Picture 10: Tertiary Treatment ..................................................................................... 20

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1. Purpose

DBS Chemicals is engaged in the manufacture of Synthetic Organic

Chemicals and has been in operation since 1982. DBS Chemicals are

operating their Manufacturing facility at Plot. No. 285, 286/4, 287

notified Shirwal Industrial Area, Sanghvi, Taluka: Khandala, Shirwal-

412801, Dist. Satara in Maharashtra and operate with a valid Consent

to Operate No.BO/AST/RO-Pune/EIC NO.PN-19588-13/10436 dated

20/12/2013 for production of 8MT/Month Para Amino Azo Benzene

(PAAB). (Copy of Consent to Operate is given under Sr.No.14).

This facility has an installed capacity to manufacture 80MT/Month PAAB

and within the same capacity can manufacture 120MT/Month Garnet

(GB Base)/Solvent yellow 3/ or Ortho Amino Azo Toluidine (OAAT) or

5MT/Month Yellow Dye either singly or in combination with minor

modification to existing manufacturing installation. The present activity

at site is only in one shift of 6 hrs during the day which is proposed to

be extended to three shifts of 8hrs a day with scaling up of the batch

to the max possible batch size per shift, and hence it is proposed to

amend the existing 8MT/Month production capacity of PAAB in the

Consent to Operate to 80MT/Month of PAAB with addition of

120MT/Month Garnet/OAAT and 5MT/Month Yellow Dye. The Consent

to Establish for this same has been obtained from MPCB vide consent

order no. B. O/MPCB/AST/EIC.No-PN-2884-16/E/CC-8523 dated:

29.06.2016 (Copy of Consent to Establish is given under Sr.No.15).

The justification for amendment to Consent is detailed below under

Annexure 1.

2. Background

Late Mr. G.V. Utgi a double graduate with M.Sc. (Tech) by research

from UDCT Mumbai in 1963 was the founder member of the

organization.

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DBS Chemicals is the first Manufacturers of Para Amino Azo Benzene

(PAAB), a synthetic organic chemical, in India since 1982 and have

carried a reputation of manufacturing quality Para Amino Azo Benzene

for last 34 years with installed manufacturing capacity of 80MT/month

at their plant at Sanghvi in Satara District. DBS Chemicals is one of the

largest manufacturers of PAAB in India.

This product being an import substitute big reputed companies like

Sandoz India Ltd., Colorchem Ltd., Atul Ltd, who used to import this

product from Germany & Japan now use the product manufactured by

DBS Chemicals.

DBS Chemicals have setup a well-equipped laboratory to help in

development and testing of online process parameters, Raw materials

and finished products.The laboratory has testing instrument like Gas

Chromatograph, Automatic Titrator, UV Spectrophotometer, Karl Fisher

Moisture Meter for finding purity and strength of dyes Intermediates.

Muffle Furnace, Lab Oven, Vacuum Pump, Small Distillation Unit,

Digital pH Meter, Electronic Weighing Balance, and various other

equipments for finding different characteristics of Dyes & Chemicals.

The effort and emphasis of the DBS Chemicals is to ensure consistent

high quality products with a commitment to regular and scheduled

supplies.

3. Industry Details

Following Table 1 gives the industry details.

Table 1: Industry Details

Sr. No.

Details Description

1. Name & Address of

the Industry:

M/s DBS Chemicals, Plot No. 285, 286/4,

287 notified Shirwal Industrial Area,

Sanghvi Shirwal -412801.Taluka

Khandala, Dist. Satara

2. Contact Details Shri Devdatta Utgi, Managing Director,

Cell No. +91-9822030646/9422304669

E mail: [email protected]

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3. Type & Category Chemical Unit in Red SSI Sector

4. Consent to Operate Validity up to : 31.05.2018

5 Products i. Manufactured: Para Amino Azo benzene [PAAB] – 8MT/ month

ii. Proposed under Amendment:

Combined product manufacturing capacity

shall not exceed 205 MT per month comprising (a) Synthetic Organic

Chemicals such as Methylene Yellow N

(Dye Yellow), (b) Synthetic Organic

Chemicals such as PAAB and (c) Fast Bases such Garnet GB based Garnet

(OAAT).

Note: Depending upon the market

demand, above products will be

manufactured singly or in combination in

batch process.

4. Environmental Policy of DBS Chemicals

Environmental Policy of DBS Chemicals states that

“DBS CHEMICALS uncompromisingly commits itself to conserving the

environment, besides protecting it.

We would first look at each and every business of ours from the

perspective of Environmental friendliness for prevention of pollution.

We assure compliance with all applicable environmental legislations

and other statutory requirements.

We will adopt Environmental friendly technologies and ensure

minimum waste generation and strive simultaneously to develop

effective methods for waste treatment to improve the quality of

wastewater generated from our process.

We will always operate our factory and office in a healthy atmosphere

and ensure a high degree of safety for employees and the general

public.

We are committed to conserving water.”

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5. Site Location

DBS Chemicals plant is located at Plot No. 285, 286/4, 287 notified

Shirwal Industrial Area, Sanghvi Shirwal -412801.Taluka Khandala,

Dist. Satara. Picture 1 below shows Google image of Sanghvi Area and

Figure 1 below shows the schematic details of Sanghvi village. The

plant is surrounded by other SMEs such as Hy-Tech, Paranjape Auto

cast Pvt. Ltd. on the east and north side and there is existing

agricultural land on the west side and some more SMEs on the south

side. The plant surrounding area can be seen from the Google image

Picture 2 below.

Picture 1: Google image of Village Sanghvi in Shirwal area

Figure 1: Schematic Details of Village Sanghvi

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Picture 2: Google image showing DBS Chemicals

6. Plant Layout

Figure 2 below shows the schematic of Plant layout and Figure 3 below

shows the schematic of equipment layout.

Figure 2: Schematic Layout Plan of DBS Chemicals

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Figure 3: Schematic Layout showing plant equipment

Table 2 below gives the sizes of areas allocated in the plant for

different equipment and Table 3 below gives the details of Plant and

Machinery.

Table 2: Room wise measurements (dimensions in feet)

Sr.

No.

Description Length Width Height

1 Old plant – changing room to dispatch

room

150 50 25

2 Boiler room 30 18 25

3 Acid Tank shade 38 14 15

4 Sodium Nitrite & Caustic Shade 22 20 15

5 Old bathroom, office, store, lab 55 10 10

6 Hazardous tanks 30 25 12

7 New plant 55 45 28

8 New office to worker room 35 12 10

9 D. G. set room 22 18 15

10 Canteen 12 10 10

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Table 3: List of Plant & Machinery

Sr. No.

Name of equipment Make Capacity Quantity (Nos)

1 Reaction Kettle/ Reactor (SS316L limpet coil, Thickness – 9 MM, Gear Box, Stirrer) RK-1, RK-2, RK-3.

SS 316 L 7 KL 3

2 Distillation Vessel / DV-1 (MS Make) Thickness-9mm MS 3.5 KL 1

3 Distillation Vessel / DV-2(MS limpet coil, Thickness – 9 MM, Gear Box, Stirrer)

MS 7KL 1

4 Distillation Vessel / DV-3(For Solvent distillation)

Thickness-9mm

MS 1KL 1

5 SS 316L Condenser With MS Jacket /C-1 SS/MS Length- 2 Mtr.

1

6 SS 316L Condenser With MS Jacket /C-2 SS/MS Length- 3 Mtr.

1

7 SS 316L Condenser With MS Jacket /C-3 SS/MS Length-1.5 Mtr.

1

8 SS 316L Condenser With MS Jacket /C-4 (Spare) SS/MS Length-2Mtr. 1

9 Receiver-1 (Thickness – 8 mm) MS 3.5KL 1

10 Receiver-2 (Thickness – 8 mm) MS 6 KL 1

11 Receiver-3 (Thickness – 8 mm) MS 1 KL 1

12 Cooling tank with Coil-1 MS 1.5 KL 1

13 Cooling tank with Coil-2 MS 2 KL 1

14 Vertical receiver -1 MS 1 KL 1

15 Vertical receiver -2 MS 1.5 KL 1

16 Vacuum pumps with Motors (All vacuum pumps are two stage oil cooled high vacuum pumps) JB VAC

made.

MS 24 No. 22 No.

19 No. 18 No.

2 2

1 1

17 Centrifuge / Hydro MS 48” 36”

1 2

18 Steam Dryer with 4 Trolley & 100 Aluminium Trays. MS 800 kg 1

19 Cooling tower- 1 MS/PP -- 1

20 Cooling tower- 2 MS/PP -- 1

21 Cooling tower Water Tank- 1 & 2 Cement 2.5 KL 2

22 Ice Cooling Water Tank - 2 Cement 2.5 KL 1

23 Hot Water Tank - 2 MS 2.5 KL 1

24 Acid Tank -1, Thickness-8 mm FRP 0.6 KL 1

25 Acid Tank -2, Thickness-8 mm FRP 1.5 KL 1

26 O.T. storage tank (Big) MS 30 KL 3

27 Aniline storage tank MS 20 KL 3

28 O.T. storage tank (Small) MS 15 KL 3

29 Hot Water Tank - 2 MS 2.5 KL 1

30 Pulveriser With Air Bags MS 3 KL 2

31 Scrubber Unit PP 1

31 DM Plant PP 7 kL/hr 1

32 Water storage tank (Big) PP 5 KL 3

33 Water storage tank (Small) PP 0.5 KL 3

34 Water storage tank Cement 10 KL 1

35 ETP Plant MS/PP -- 1

36 ETP Ground Storage Tank Cement 2 KL

10 KL 10 KL

1

1 1

37 Batch crude tray (Big) MS 1 KL 1

38 Batch crude tray (Medium) MS 0.8 KL 2

39 Batch crude tray (Small) MS 0.2 KL 4

40 Sewing Machine MS -- 3

41 SS316L Autoclave with Magnetic Stirrer (SS limpet coil,

Thickness – 40 MM, Gear Box, Stirrer)

SS316L 1.5 KL 1

42 Purification reactor/SSR(SS limpet coil,Thickness–9

MM, Gear Box, Stirrer)

SS316L 5 KL 1

43 HDPE Black Tank with coil & Gear Box, Stirrer HDPE 3 KL 1

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44 Filter Press with 26 plates PP 1

45 Centrifuge (36” Rubber lined) MS/Rubber

lined

36” 1

46 Air compressor MS 1

47 Hot Oil System(Thermic Fluid Heater) MS 2LacKcal/hr 1

48 Expansion Tank Unit. MS 1

49 Steam Dryer with 2 Trolley & 100 PP Trays. MS/FRP 1

50 SS Multi-miller SS316 1

51 Diaphragm pump PP 2

52 PP Tray PP 0.2 KL 1

53 LDO Storage tanks MS 0.5 KL 1

54 Cartridge Filter PP -- 3

55 Weighing balance MS -- 2

56 IBR Boiler with Cyclone, ID Fan Unit (No.- MR 15480) MS 1 MT 1

57 MS Water storage Tank for Boiler MS 1 KL 1

58 Chimney with Lightening Arrester- 100’ MS L- 100 Ft. 1

59 Chimney MS L- 45 Ft. 1

60 Chimney MS L- 25 Ft. 1

61 Scrubber Chimney PP L- 25 Ft. 1

62 Hazardous Waste Storage Tank MS 8 KL 1

63 DG Set – 125 KVA MS 125 KVA 1

7. Processes carried out in the plant

Main process reaction is nitration which involves

• Diazotization

• Vacuum distillation

• Coupling

8. Water consumption

Water consumption and supply to various activities on the plant

premises are shown in Figure 4 below.

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Figure 4: Water Supply Diagram

YELLOW SS

REACTOR

PRODUCTION FLOOR

WASHING

JACKETED VACUUM

PUMP

LAB & WASHROOMS

ICE WATER

5kLCOOLING TOWER

WASHROOM TANK

BOILER

1kL

HOT WATER

500L

STORAGE TANK

5kL X 2Nos

NITRITE SOLUTION

PREPARATION

CAUSTIC SODA

SOLUTION

PREPARATION AND

REACTION KETTLE

CLEANING

BOREWELL ON SITE

STORAGE TANK

500L

MAIN WATER

SUPPLY TANK

10kL

SOFTENER PLANT DM PLANT

9. Manufacturing process and flow diagram for Para Amino Azo Benzene (PAAB)

Product Name: Para Amino Azo Benzene (PAAB) / Solvent Yellow – 1

Raw Materials

• Aniline Oil (Pure)

• Sodium Nitrite – NaNO2

• Hydrochloric Acid – HCL 30-35% Pure

• Caustic Soda – NaOH (Flakes) • Toluene (Nitration Grade Pure)

Manufacturing Process:

Aniline is reacted with hydrochloric acid to form aniline hydrochloride.

This reacts with Sodium Nitrite to form phenyldiazonium chloride. This

product reacts with aniline to form di-amino benzene at low

temperature. This di-amino benzene with aniline and aniline

hydrochloride at temperature of 400 – 500 C for specific time forms

Para Amino Azo Benzene (PAAB). Sodium Hydroxide is added in

access to neutralise hydrochloric acid. The final pH is 09 to 14.

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Aniline + crude PAAB is taken to the distillation vessel where aniline is

condensed and it goes to receiver. Water layer + other by products

are separated and are transferred to ETP.

Then crude PAAB is transferred to the centrifuge to remove Tar &

other liquid impurities soluble in aniline. PAAB crystals are separated

and dried in a dryer and then taken to pulveriser to get PAAB powder.

Chemical Reaction of PAAB

Figure 5 below shows the chemical reaction involved in manufacturing

of PAAB.

Figure 5: PAAB Chemical Reaction

Process Flow details for 1000 kg PAAB

Following Figure 6 shows the process flow for 1000kg per batch of PAAB

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Figure 6: Process flow chart – PAAB

HCL - 950 kg

HNO2 fumes Water Scrubber Nitric Acid Plant for neutralisation (400Lit)

Jacketed

reaction kettle Crude PAAB

+

Aniline

ETP

Distillation

Vessel Aniline Receiver

Crude PAAB

Semi liquid

Pulveriser

Final Product

PAAB powder – 1000kg

Dryer

Centrifuge

PAAB Crystal

Liquid TAR impurities

50 kg

Effluent – 1440 Lit

Salts 80 kg

Aniline – 1350 Lit

NaNO2 - 400kg

Water – 1300 Lit

Reaction Vessel

NaOH - 120 kg

Water – 100 Lit

Condensation

Material Balance for 1000 kg PAAB

Following Table 4 shows the Material balance for 1000kg PAAB batch.

Table 4: Material Balance – (for 1000 kg PAAB)

Sr. No.

Input Quantity Unit Output Quantity Unit

1 Aniline 1350 kg PAAB 1000 kg

2 NaNO2 400 kg Effluent Water 1440 kg

3 Water for dissolving NaNO2

400 kg HNO2 300 kg

4 HCl 950 kg Water evaporation 450 kg

5 NaOH 120 kg Tar 50 kg

6 Water for

dissolving NaOH

100 kg Waste salts 80 kg

Total Reactants 3320 kg Total Output 3320 kg

7 Toluene 130 kg Recovered Toluene 130 kg

8 Water 900 kg

9 Ice Blocks 35 kg

10 Cold Water 3350 kg

11 Fire wood for

Boiler 1350 kg

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Treatment and disposal of by-products

1. HNO2 fumes are sent to scrubber, thus HNO3 is scrubbed out and taken to ETP for neutralisation.

2. Tar is taken to storage tank then sent to CHWTSDF at Ranjangaon

near Pune for disposal.

3. 1440 L water containing dissolved salts is transferred to ETP.

Existing Scale - Para Amino Azo Benzene (PAAB) / Solvent Yellow

– 1, Effluent and other outputs in kg from PAAB production

Following Table 5 shows the Material Balance for existing scale of

manufacturing of 750kg per batch and Table 6 below shows the

Effluent and other outputs from PAAB or Garnet manufacture. Other

water consumption and effluent generation is shown in Table 7 below.

Table 5: Existing Scale - Para Amino Azo Benzene (PAAB) /

Solvent Yellow – 1

Sr. No.


1 Aniline 1013 kg PAAB 750 kg


3 Water for

dissolving NaNO2

300 kg HNO2 225 kg



6 Water for

dissolving NaOH


Total Reactants 2490 kg Total Output 2490 kg

7 Toluene 100 kg Recovered Toluene 100 Kg

8 Water 675 kg

9 Ice Blocks 25 kg


11 Fire wood for Boiler 1000

kg

Table 6: Effluent and other outputs in kg from PAAB production

Sr. No. Particulars PAAB

Per batch Daily Monthly

1 Alkaline effluent from reaction 1643 3285 85125

2 Vacuum Pump oil water 10 20 500

3 110oC oil water 50 100 2500

4 Production floor washing 25 50 1250

5 Reactor & equipment wash water 50

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Table 7: Other Water Consumption/effluent generation in kg per

month

Sr.No. Particulars Quantity

1 Road Cleaning 1400

2 Laboratory, Shade Floor Cleaning 1500

3 Gardening 3000

Following are the pictures of plant equipment and installations as

detailed below:

Picture 3 – Coiled Jacketed Reactor in which the main reaction is

carried out,

Picture 4 – Distillation Vessel from where the solvent, water are removed and the tray in which the reaction product is collected,

Picture 5 – Centrifuge to remove excess water,

Picture 6 – Tray Dryer for drying the product,

Picture 7 - Solvent Storage area and Solvent Storage Tanks,

Picture 8 – Finished products storage area,

Picture 9 – Neutralisation Tank at ETP area,

Picture 10 – Tertiary Treatment Plant at ETP.

Picture 3: Coiled Jacketed Reactor

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Picture 4: Distillation Vessel and Tray

Picture 5: Centrifuges

Picture 6: Tray Dryer and Finished Product

19

Picture 7: Solvent Storage Tanks

Picture 8: Finished Product Storage

Picture 9: Neutralisation Tank

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Picture 10: Tertiary Treatment

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10. Analysis Report of treated effluent

Treated effluent analysis report of sample drawn on 22.12.2015 is

given in following Table 8.

Table 8: Treated Effluent Analysis

Sr. No Parameter Unit Results

1 pH 7.8

2 Oil & Grease mg/L 5.5

3 Suspended

Solids

mg/L 40

4 BOD mg/L 18

5 COD mg/L 180

6 TDS mg/L 686

7 Sulphates mg/L 200

8 Chlorides mg/L 356

9 Percent sodium % 46

11. Proposed scale-up and Additional Products

The proposed scale-up of existing manufacturing volumes taking

advantage of installed capacity of the plant is detailed in Table 9 below

showing input and output material balance.

Material Balance of Proposed PAAB 1500 kg batch

Material Balance of proposed 1000kg batch PAAB is given in Table 9

below.

Table 9: Material Balance of Proposed for PAAB 1500 kg

Sr. No.


1 Aniline 2025 Kg PAAB 1500 Kg

2 NaNO2 600 Kg Effluent Water 2160 Kg

3 Water for

dissolving NaNO2

600 Kg HNO2 450 Kg

4 HCl 1425 Kg Water evaporation 675 Kg

5 NaOH 180 Kg Tar 75 Kg

6 Water for

dissolving NaOH

150 Kg Waste salts 120 Kg

Total Reactants

4980 Kg

Total Output 4980 kg

7 Toluene 200 Kg Recovered Toluene 200 kg

22

8 Water 1350 Kg

9 Ice Blocks 50 Kg

10 Cold Water 5000 Kg

11 Fire wood for

Boiler 2000 Kg

Material Balance in kg for Proposed Scale up of PAAB

The total monthly quantity of production after the proposed scale-up

of PAAB with 750 kg PAAB per batch and 2 batches per day in

Reaction Kettle 1 as being carried out and with 1500 kg per batch and

2 batches per day in Reaction Kettle 2 will be carried out utilising plant

installed capacity and in three shifts per day. Following Table 10

shows the proposed monthly material balance for PAAB production.

Table 10: Material Balance in kg for Proposed Scale up of PAAB

Sr. No.

Raw material RK – 1 (750 kg) RK – 2 (1500 kg)

Current production line

Proposed production line

Per batch Daily Monthly Per

batch

Daily Monthly (25days) (25days)

1 Aniline 1013 2025 50625 2025 4050 101250

2 NaNO2 300 600 15000 600 1200 30000

3 Water for

dissolving NaNO2

300 600 15000 600 1200 30000

4 HCl 712 1425 35625 1425 2850 71250

5 NaOH 90 180 4500 180 360 9000

6 Water for

dissolving NaOH

75 150 3750 150 300 7500

Total Reactants 2490 4980 124500 4980 9960 249000

7 Toluene 100 200 5000 200 400 10000

8 Water 675 1350 33750 1350 2700 67500

9 Ice Blocks 25 50 1250 50 100 2500

10 Cold Water 2500 5000 125000 5000 1000

0

250000

11 Fire wood for

Boiler

1000 2000 50000 2000 4000 100000

Total PAAB 750 1500 37500 1500 3000 75000

Salt Water (water

softening)

300 300

23

Manufacturing process and flow diagram for Fast Garnet GB

base /Ortho Amino Azo Toluene (OAAT)

1. Product Name: Ortho Amino Azo Toluene (OAAT) / Fast Garnet GB base – Solvent Yellow 3

2. Required quantity – 120 MT/month

3. Raw Materials

• Ortho Toluidine Liquid

• Sodium Nitrite – NaNO2

• Hydrochloric Acid (30-35%)

• Caustic Soda - NaOH (Flakes)

Manufacturing process

Ortho Toluidine (OT) liquid is reacted with hydrochloric acid to form

orthotoluidine hydrochloride. This reacts with sodium nitrite to form

phenyldiazoniumchloride. This product with Ortho toluidine form di-

aminoazo toluene at low temperature. This di-aminoazo toluene

with Ortho toluidine and ortho toluidine hydrochloride form ortho

amino azo toluene at 40◦C-50oC in specific time. Sodium hydroxide

is added in excess to neutralise hydrochloric acid and final pH is 09-

14.

OT + crude OAAT is taken to the distillation vessel where OT is

condensed and then transferred to a receiver. Water layer + other

by products are separated and transferred to ETP. Then crude OAAT

is transferred to the centrifuge to remove TAR & other liquid

impurities soluble in Ortho Toluidine. OAAT crystals are separated

and dried in a dryer and then pulverised to get OAAT powder.

Chemical Reaction of OAAT

Figure 7 below shows the chemical reaction involved in

manufacturing of OAAT.

24

Figure 7: OAAT Chemical reaction

25

Process flow chart of OAAT

Process schematic flow diagram is shown below in Figure 8.

Figure 8: Process flow diagram of OAAT

Water Scrubber Nitric Acid Plant for neutralisation (400Lit)

Crude OAAT

+O.T.

ETP

Distillation

Vessel Aniline Receiver

Crude OAAT

Semi liquid

Pulveriser

Final Product

OAAT powder – 1000kg

Dryer

Centrifuge

OAAT Crystal

Liquid TAR impurities

– 40 kg

Effluent – 1420 Lit

Salts 100 kg

Reaction Vessel

Condensation Jacketed

reaction kettle

HCL – 900 kg

NaNO2– 400 kg

O.T – 1300 lit

Water – 400 lit

NaOH– 120 kg + Water – 100

HNO2 fumes

Material Balance for 1000 kg batch of OAAT/ Garnet /SY3

Following Table 11 gives the Material Balance of 1000kg batch of

OAAT.

Table 11: Material Balance for 1000 kg OAAT batch

Sr. No.


1 Ortho Toluidine 1300 kg OAAT/Garnet 1000 kg


3 Water for dissolving

NaNO2

400 kg HNO2 300 kg



6 Water for dissolving NaOH


Total Reactants

3220 kg



26

8 Water 900 kg

9 Ice Blocks 35 kg


11 Fire wood for

Boiler 1350 kg

Treatment and disposal of by-products

1.HNO2 fumes are sent to scrubber, thus HNO3 is scrubbed out and

taken to ETP for neutralisation. 2.Tar is transferred to storage tank then sent to TSDF at Ranjangaon.

3.1430Ltrs effluent water with dissolved salts is transferred to ETP.

Scale up - Ortho Amino Azo Toluene (OAAT) / Fast Garnet GB

base – Solvent Yellow 3

Following Table 12 gives the Material Balance of Scale-up 1600kg

batch of OAAT.

Table 12: Scale up - Ortho Amino Azo Toluene (OAAT)

Sr. No.

Raw Material For 800 kg batch

For 1600 kg batch

1 Ortho Toluidine 1040 2080

2 HCl (33%) 720 1440

3 Sodium Nitrite (NaNO2) 320 640

4 Sodium Hydroxide

(NaOH) 96 192

5 Toluene (solvent) 100 200

6 Water 1000 2000

7 Fire wood (boiler) 1000 2000

Material Balance for 800 kg OAAT batch

Material balance for 800kg OAAT batch is shown below in Table 13.


Sr. No.




3 Water for

dissolving NaNO2

320 kg HNO2 240 kg



6 Water for

dissolving NaOH


Total Reactants

2576 Kg Total Output 2576 kg


27

8 Water 720 kg

9 Ice Blocks 25 kg


11 Fire wood for

Boiler 1000 kg

Material Balance for 1600 kg OAAT batch

Material balance for 1600kg batch is shown below in Table 14.


Sr. No.




3 Water for

dissolving

NaNO2

640 kg HNO2 480 kg



6 Water for

dissolving NaOH


Total Reactants

5152 kg



8 Water 1440 kg

9 Ice Blocks 50 kg


11 Fire wood for

Boiler

2000 kg

Input Raw Material Quantity Details for OAAT / Garnet/SY3

Input Raw material quantities for OAAT are given in Table 15 below.

Table 15: Input Raw Material Quantity Details – OAAT / Garnet

Sr. No.

Raw material RK – 1 (800 kg) RK – 2 (1600 kg)

Current production line

Proposed production line

Per batch

Daily Monthly Per batch

Daily Monthly (25days) (25days)

1 Ortho Toluidine 104 2080 5200 2080 4160 104000

2 NaNO2 320 640 16000 640 1280 32000

3 Water for

dissolving NaNO2

320 640 16000 640 1280 32000

28

4 HCl 720 1440 36000 1440 2880 72000

5 NaOH 96 192 4800 192 384 9600

6 Water for

dissolving NaOH

80 160 4000 160 320 8000

Total Reactants 2576 5152 128800 5152 10304 257600

7 Toluene 100 200 5000 200 400 10000

8 Water 720 1440 36000 1440 2880 72000

9 Ice Blocks 25 50 1250 50 100 2500

10 Cold Water 2500 5000 125000 5000 10000 250000

11 Fire wood for

Boiler

1000 2000 50000 2000 4000 100000

Total OAAT 800 1600 40000 1600 3200 80000

Salt Water (water

softening)

300 300

Other Water Consumption/effluent generation in kg per month

Table 16 below shows other water consumption at the plant.

Table 16: Other Water Consumption




3 Gardening 3000

Manufacturing process and flow diagram for Yellow Dye

1. Product Name: Yellow Dye

2. Required quantity – 05 MT/month

3. Raw Materials

• Methanol

• Red – 30

• Dimethyl Sulphate

• Sodium Bromide

• Distilled Water

• Hydrochloric acid

• Sodium Chloride

• Sodium Carbonate (Soda Ash)

• Catalyst

29

Manufacturing process

Red 30, methanol, di-methyl sulphate and sodium bromide are kept in

an autoclave pressure of 35-45kg/inch2 for 20 hours. Then it is

purified by water in reaction kettle. This acidic solution is neutralised

by soda ash and is then filtered in filter press. The filtrate is then

transferred to HDPE tank and precipitated by HCl and sodium chloride.

This precipitate with filtrate is then filtered through a filter press to

separate Dye Yellow. Water is then removed by centrifugation and the

filtered dye is dried in a dryer and then powdered using a multi-mill.

4. End use: Pigments

Process flow chart – Yellow Dye / MYN / TT / CD

Following Figure 9 shows the schematic process diagram for Yellow Dye

Figure 9: Process Flow Chart of Yellow Dye

Residue cake – 700 kg

Purification

Reactor

ETP

17000 lit/batch

Filter

press HDPE tank

Multi-miller

Final Product

Yellow Dye – 1000kg

Dryer

Semi product

Centrifuge

Waste Water

200 lit

Pressure vessel -

Autoclave

Methanol – 4600 lit

DMS – 850 kg

Red 30 - 1450 kg

NaBr – 380 kg

Water 17000 lit

Catalyst – 30 kg

Soda Ash – 450kg

HCl - 1200 lit Nacl – 900kg

30

Material Balance for 100kg/day Yellow Dye

Material balance for 100kg/d Yellow Dye is given in Table 17 below.

Table 17: Material Balance – Yellow Dye

Sr. No.

Input Quantity in kg

Output Quantity in

kg

1 Red – 30 125 Yellow Dye 100

2 Methanol 460 Effluent Water 1900

3 DMS 85 Residue Cake 70

4 Sodium

Bromide 38

Water for

evaporation 400

5 Catalyst 21 Other impurities 214

6 Water 1700

7 Soda Ash 45

8 HCl 120

9 NaCl 90

Total 2684 2684

Monthly production of Yellow Dye

Monthly production of Yellow Dye is shown in Table 18 below.

Table 18: Monthly production – Yellow Dye

Sr. No. Input Quantity in kg

Output Quantity in kg

1 Red – 30 5000 Yellow Dye 4000

2 Methanol 18400 Effluent Water 76000

3 DMS 3400 Residue Cake 2800

4 Sodium

Bromide

1520 Water for

evaporation

16000

5 Catalyst 840 Other impurities 8560

6 Water 68000

7 Soda Ash 1800

8 HCl 4800

9 NaCl 3600

Total 107360 107360

12. Waste Management for Scale-up

Effluent Treatment

Proposed Effluent generation and other outputs in kg from PAAB,

OAAT/Garnet, Yellow Dye production and other Water

31

Consumption/effluent generation in kg per month is given in the

following Table 19, Table 20, Table 21 and Table 22.

Small volume of alkaline effluent generated during PAAB

manufacturing will be transferred to ETP. Any other effluent generated

during washing etc. will also be transferred to ETP where it will be

neutralised with HCL in Neutralisation tank along with the alkaline

effluent and the neutralised effluent will be evaporated to separate the

salt and the salt formed will be sent to CHWTSDF.

Table 19: Proposed Effluent generation from PAAB

Sr. No. Particulars PAAB




3 110oC oil water 100 200 5000



Table 20: Proposed Effluent generation from OAAT / Garnet

Sr. No. Particulars OAAT / Garnet




3 110oC oil water 100 200 5000



Table 21: Proposed Effluent generation from Yellow Dye

Sr. No. Effluent 100 kg batch/day

1 Acidic liquid 1,700 lit

2 Liquid waste from centrifuge 100 lit

3 Liquid waste from filter press 100 lit

Total 1900 lit

Table 22: Other water consumption




Waste solvents generated during the process will be distilled in the plant and the

recovered solvent will be sold to authorised recyclers.

32

Proposed Effluent Treatment:

Total effluent generation will be about 10-10.5 KL per day (maximum)

from existing and proposed amended production.

Characteristics of acidic and alkaline raw effluent shall be as follows:

Parameter Unit Acidic

Effluent Alkaline Effluent

pH - 1.2 09-14

BOD mg/l 22000 2700

COD mg/l 138525 17213

TSS mg/l 118 166

TDS mg/l 168789 205321

O&G mg/l 8 12

Chlorides mg/l 102468 171946

Sulphate SO4 mg/l 3000 820

Phosphates mg/l 30 12.3

Proposed Effluent Treatment Scheme

• Effluent Collection

Effluent will be collected in anEffluent Collection Tankby gravity

from all the sources. Tank is provided with 1 day holding capacity.

Air is introduced for proper mixing of effluent.

• Neutralisation

Effluent is then neutralised with addition of Alkali / Acid as required.

Acid and Alkali dosing system with dosing pumps is provided for

neutralisation.

• Coagulation / Flocculation

After neutralisation, effluent is pumped to flash mixer for

coagulation. Alum / PAC doing system are provided for

enhancement of coagulation. Mixer is provided in coagulation tank

for mixing of coagulant and effluent.

Effluent then flows to flocculation tank. Flocculation tank is provided

with slow speed agitator mixer. Flocks are formed in the tank. Fine

flocks adhere to each other to form bigger flocks.

33

• Sedimentation

Effluent flows to sedimentation tank for settlement of flocks. Sludge

from the bottom is withdrawn periodically.

• Treated Effluent Evaporation

Treated effluent is then collected in a tank and then pumped to

evaporator vessel. Excess steam available in the manufacturing

process is used to evaporate the effluent by passing through jackets

of vessel. Effluent is concentrated to suitable volume. Concentrated

sludge is then collected in the tank and then disposed of at TSDF.

Vapour is condensed and condensate is recycled in process.

• Sludge Disposal

Sludge separated from sedimentation tank and from evaporator

disposed of at TSDF.

Figure 10: Proposed Zero Liquid Discharge Scheme

34

Air Pollution Control

Nitrite gas generated during the reaction will be scrubbed through the

wet scrubber with water recirculation and the scrubbed nitrite will be

transferred to ETP for neutralisation with Caustic.

Hazardous Waste Management

All the Hazardous waste that will be generated from the process, ETP

will be disposed of to CHWTSDF. Recovered solvents will be sold to

authorised recycler. DBS Chemicals are members of CHWTSDF a

Ranjangaon near Pune.

13. Justification for Environmental Clearance

The proposed amendment to the existing 8MT/Month production

capacity of PAAB in the Consent to Operate to Synthetic organic

chemicals 80MT/Month of PAAB with addition of Synthetic Organic

Chemicals 120MT/Month Garnet/OAAT and (SOD) 5MT/Month Yellow

Dye is requested with the following justification.

a. Additional land is not required.

b. Additional plant & machinery is not required.

c. Manufacturing process being "Batch Process", production is

proposed to be increased by operating in three shifts instead of one

shift as of today using fully the installed capacity & different

possible product mix and combinations.

d. Implementation of Zero Liquid Discharge.

e. Water is not used in the manufacturing process anywhere, however

waste water is generated only from washings of the vessels and

same is sent to ETP and treated.

f. Treated effluent being chemical in nature & in small quantity of less

than 10cmd will be concentrated further and sent to CHWTSDF for

incineration.

35

g. A small 1Ton per hour capacity wood fired boiler will be provided

with 100 ft. stack height in compliance of air emission standards.

h. Approximately 600 – 800 kg/day Solid waste in the Hazardous

Waste Category 20.3 and Chemical Sludge from ETP in the

Hazardous Waste Category 34.3 will be sent to CHWTSDF at

Ranjangaon near Pune. Membership obtained.

i. Approximately 10-10.5m3/day Domestic waste water and wastes

from floor washing will be sent to ETP. Sludge from ETP will be

disposed to CHWTSDF as stated above.

j. Existing capital investment as on date is Rs. 2.52 Cr. due to

replacement of old boiler and reaction vessels.

k. Bank Guarantee for Rs.1 lakh valid up to 31.03.2017 towards O & M

and towards compliance of consent conditions shall be submitted to

MPCB along with Consent Fees based on capital investment of Rs.

2.52 Cr.

14. Conclusions & Recommendations:

In view of the scenario explained as above, proposed scheme of up-

gradation of the waste management systems (Zero Discharge) and

technical justification, SEAC/SEIAA may consider the proposed

environmental clearance as under:

• Combined product manufacturing capacity shall not exceed 205

MT per month comprising (a) Synthetic Organic Chemicals such

as Methylene Yellow N, (b) Synthetic Organic Chemical such as

PAAB and (c) Fast Bases such Garnet GB based (OAAT)

• Hazardous Wastes shall be sent to TSDF along with the HW

sludge.

• Solvent recovered shall be sold to authorised recycler.

• Zero Liquid Discharge scheme shall be implemented for the

remaining trade effluent. No land disposal is allowed.

36

• Wood fired boiler of 1 MT capacity shall have minimum stack

height as stipulated by MPCB in its Consent to Operate.

(Devdatta Utgi)

Pune, 16.08.2016

Enclosed: • Copy of Consent to Operate, dated 20.12.2013 valid up to

19.12.2018

• Copy of Consent to Establish, dated 29.06.2016

dbs chemicals final feasibility report...

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