terms of reference due to the proposed project, -...

ANNEXURE-1

TERMS OF REFERENCE

Due to the proposed project,

1) There will be no additional requirement of fresh water. 2) There will be no extra waste water generation. 3) There will be no extra flue gas emission. 4) There will be no extra hazardous waste generation. 5) There will be no additional requirement of any utility.

Due to the debottlenecking, there will be only 10% increased in production capacity and no increase in pollution load, so please consider our project as a “B-2” category project.

ANNEXURE-2

LIST OF PRODUCTS

Sr. No

Name of product Existing capacity in MT/Year as per CCA NO:AWH-

49945

Proposed capacity in MT/Year

Total capacity in MT/Year

1. Acrylic fiber & Tow

20,000 2,000 22,000

2. Captive Power Plant (Coal Based)

5.5MW 0 5.5MW

ANNEXURE-3

LIST OF DIRECTORS

Sr. No

Name Present Residential Address

Designation Contact No.

1. Shri Paul. Oswal

Auro Mira Bhawan, H. No. 2722, Gurdev Nagar. Pakhowal Road, Ludhiana.-141001, Punjab.

Chairman & Director

Office : (0161) – 2228945

2. Shri Darshan Lal Sharma

B-xx-770/2, Gurdev Nagar, Ludhiana,141001, Punjab, India

Director Office : (0161) – 2228945

3. Shri Sachit Jain Auro Mirra Bhawan, 2722, Gurdev Nagar, Pakhowal Road, Ludhiana-141001, Punjab, India

Director Office : (0161) – 2228945

4. Shri Bal.Krishan Choudhary

1099, Sector 14, Faridabad-121007, Haryana, India

Managing Director

Office : (0124) – 4981610

5. Shri Surinder Kumar Bansal

D-7,Maharani Bagh, New Delhi- 110065, Delhi, India

Director --

6. Shri Sanjit.Paul. Singh

House No.202B, Court Greens, Lalburnum, Sector-28,Gurgaon-122001, Haryana, India

Director --

7. Shri Munish.Chandra.

Gupta

House.No 771, sector-15,Part-11,Gurgaon-122001, Haryana, India.

Director --

8. Geeta Mathur B-1/8,Vasant Vihar, New Delhi-110057, Delhi, India

Director --

ANNEXURE-5

DETAILS OF RAW-MATERIALS

Sr. no

Name of product

Production capacity

MT/Year

Sr. No.

Name of Raw Material

Consumption quantity kg/kg of product

1. Acrylics fibers & TOW

22,000 1. Acrylonitrile 0.909

2. VAM 0.090

3. Sodium thiocyanate 0.002

4. Sodium Metabisulphite 0.024

5. Sodium Chlorate 0.009

6. Thioglycol 0.002

Total 1.036

2. Captive Power Plant (Coal

Based)

5.5MW 1. Coal 8.0 MT/Hr

ANNEXURE-6

MANUFACTURING PROCESS (PROCESS DESCRIPTION + MATERIAL BALANCE)

Japan Exlan’s acrylic fiber process is divided into 2 areas, namely CHEMICAL AREA &

FIBER AREA.

A. Chemical Area:

Chemical Area consists of Polymerisation, dope making & solvent recovery.

1. Polymerisation:

Polymerisation is prepared by the continuous aqueous suspension polymerisation of the

reactive ingredients (Acrylonitrile + VAM) in a precisely controlled reactor system to

provide a raw polymer characterized by constant composition and close control of

molecular weight. The unique catalyst system (Sodium chlorate & Sodium metabisulphite)

results in close control of molecular weight and high percent conversion.

Untreated monomer is stripped under vacuum then condensed and reused. Polymer in

slurry form is continuously overflowed from reactor and it is washed in polymer washing

machine to remove contaminated materials. Washed polymer now stored in polymer

holding tank.

2. Dope Making:

Polymer in slurry form dissolved with highly concentrated solvent (Sodium Thiocyanate)

by continuous dissolver. The dissolved spinning solution (dope) with good uniformity is

fed to a flash deaerator, then to a dope heater and then transferred to spinning.

3. Solvent Recovery:

As the solvent (Sodium thiocyanate) in the coagulation bath of spinning machine is diluted,

the diluted coagulant is transferred to a solvent recovery. The grain form active carbon is

used for purification of the recovered solvent. Highly efficient 5-effect evaporator is

applied for concentration of solvent. The recovered condensed water which is vaporised in

the evaporator is used in tow washing as wash water. Concentrated solvent is adjusted for

pH and to the concentration required and send to dope making.

B. Fiber Area:

Fiber Area is divided in two process, namely spinning and After Treatment.

ANNEXURE-6

1. Spinning:

Spinning dope is extruded in the diluted coagulant through the spinnerets and gel fiber is

fed to a tow washing process. Uniformly coagulated gel tow is completely washed out from

solvent and then processed in hot stretching machine. For purpose of getting dense and

solid fiber without void structure tow from Hot stretching machine is fed to apron dryer (Ist

heat treatment).

2. After Treatment:

Conditioned tow from dryer is immersed in finishing bath and fed to Crimper. The crimped

tow is fed to 2nd heat treatment at steamer for permanent setting of fiber properties. In these

way physical properties such as stress-strain, toughness, uniformity in fiber structure,

durability of crimp is attained.

Finally tow is transferred to a final dryer for being dried to certain moisture content and

then to a tow baler or to staple baler after cutting.

ANNEXURE-6

NOTE *CAN=ACRYLONITRILE, VAM=VENYL ACETATE MONOMER, SC=SODIUM CHLORATE, SMBS=SODIUM METABI SULPHITE

TG=2-MERCAPTO ETHANOL

**TIO2=TITANIUM DIOXIDE, PRS=SODIUM THIOCYANATE, TDDM=TITANEUM DIOXIDE DISPERSING MACHINE

Solvent Filtration

Evaporator (Concentrate or of solvent)

Solvent Recovery

TDR (TOW DRIER)

(Drying)

FAT (FINISH APPLICATION TROUGH)

CRIMPER

ADR (APPRON DRIER) (Drying)

Tow Washing

Polymerization Reactor

Polymer Washing Machine

Polymer Storage

Dope (Polymer Solution

Making)

Deafration & Filtration

**TDDM

SPM (SPINNING MACHINE)

Monomer Recovery

RECYCLED TO REACTOR

**TIO2

(For Dull Fiber production only)

Finish Oil

Baling (Finished Product) Staple & Tow

**PRS

CAN, VAM, SC, SMBS, TG

ANNEXURE-6

Basis: (Poly prod.)2.471 MT/hr

RM & Additives 2.711 MT/hr

DM water 19.328 MT/hrRO water 10.000 MT/hr

Soft water 3.1 MT/hr To RO: 15.500 MT/hr

Raw water 0.05 MT/hrTo ETP: 14.218 MT/hr

Steam: 1.65 MT/hr

36.839 MT/hr 29.718 MT/ hr7.121 MT/hr

Basis: (Fibre prod.)2.5 MT/hr

To Textile: 20.833 MT/hr

DM water 0.025 MT/hr To CT: 0.229 MT/hr

Steam: 0.275 MT/hr Losses: 0.023 MT/hr

21.09 MT/hr 21.09 MT/hr13.664 MT/hr

Strong PRSFrom Text: 46.62 MT/hrWeak PRS

Sodiumthiocyanate

0.005 MT/hr

To Text (ED): 37.0 MT/hrDM water 6.25 MT/hr To ETP: 3.672 MT/hr

Raw water 0.042 MT/hr To CT: 6.747 MT/hr


62.083 MT/hr 48.419 MT/hr

Basis: (Fibre prod.)Dope 20.83 MT/hr 2.5 MT/hr

ED water 37.000 MT/hr WPRS to Solv 46.62 MT/hr

DM Water 4.815 MT/hrRaw Water 1 MT/hr Evoperation loss 5.31RO Water 4.16 MT/hr

Effluent to ETP 15.700 MT/hrSteam 5.725 MT/hr losses 3.4

73.530 MT/hr 71.030 MT/hr2.500 MT/hr

Raw Water 1.000 MT/hr To ETP: 4.050 MT/hrDM water 3.950 MT/hr Evoperation: 2.570 MT/hr


8.18 MT/hr 8.18 MT/hr

2.5

POLYMERIZATION

SPG

DOPE MAKING

SOLVENT RECOVERY

AFT

Final product MT/hr

Material Balance

ANNEXURE-7

WATER CONSUMPTION DETAILS

Sr. No.

Section

Water Consumption KL/Day (As per

current CCA-No:-AWH-49945)

Water Consumption KL/Day(As per

proposed expansion)

TOTAL Water

Consumption

1. Domestic 95 NIL 95

INDUSTRIAL

2. Process 1420 NIL 1420

3. Soft Water+ CT 910 NIL 910

4. Boiler 450 NIL 450

5. Others 325 NIL 325

TOTAL 3200 NIL 3200

ANNEXURE-7

WASTE WATER GENERATION

Sr. No.

Section

Waste Water Generation

KL/Day (As per current CCA-

No:-AWH-49945)

Waste Water Generation

KL/Day (As per

Proposed Expansion)

Total Waste Water

Generation

1. Domestic 21 NIL 21

INDUSTRIAL

2. Process 970 NIL 970

3. Soft Water+ CT

295 NIL 295

4. Boiler 60 NIL 60

5. Others 0 NIL 0

TOTAL 1346 NIL 1346

ANNEXURE-7

WATER BALANCE DIA-GRAM

DOMESTIC95 M3

WATER CONSUMPTION

(3105M3/day) + (95 M3/Day)

PROCESS 1420 M3

BOILER 450M3

OTHERS 325 M3

COOLING WATER 910 M3

EVAPORATION LOSS 615 M3

COOLING WATER 295 M3

BLOW DOWN 60 M3

EVAPORATION LOSS 840 M3

TOTAL EFFLUENT (1346 M3)

(1325 M3 (Industrial) + 21 M3 (Domestic)

450 M3 390 M3

970 M3

21 M3

SOAK PIT

LOSSES-325

60 M3 295 M3

1325 M3

ANNEXURE-8

FUEL CONSUMPTION

* Furnace oil &High Speed Diesel is used only in case of emergency.

POWER CONSUMPTION

SR.

NO

FUEL QUANTITY

(As per current CCA

No:-AWH-49945)

QUANTITY

(As per Proposed

Expansion)

TOTAL

1. Furnace Oil* 2.25 KL/Hr NIL 2.25KL/Hr

2. Coal 8.0 MT/Hr NIL 8.0Mt/Hr

3. High Speed Diesel* 160 Ltr/Hr NIL 160 Ltr/Hr/DG

SR. NO

POWER QUANTITY (As per current CCA

No:-AWH-49945)

QUANTITY (As per proposed

expansion)

TOTAL QUANTITY

1. Electricity 5.5MW NIL 5.5MW

ANNEXURE-9

HAZARDOUS WASTE GENERATION

Sr. No.

Waste Category Quantity/ Year

(As per current

CCA NO:AWH-

49945)

Quantity/ Year

(As per Proposed

Expansion)

Total Facility

1 ETP 35.3 600 MT 0 MT 600 MT

Collection, storage,

Transportation and Disposal at TSDF at BEIL.

2 Used Oil 5.1 12 MT 0 MT 12 MT Collection, Storage,

Transportation, Disposal by

selling to Registered Re-

refiners. 3 Discarded

Containers/ Bags/Liners

33.1 200 MT 0 MT 200 MT

Collection, Storage,

Decontamination

4. Spent Carbon 35.3 0.5 MT 0 MT 0.5 MT



incineration at CHWIF-BEIL.

5. Polymer Waste

21.1 1.1 MT 0 MT 1.1 MT




6. Filter & Filter

material

36.2 24 MT 0 MT 24 MT Collection, Storage,



ANNEXURE-10

TREATMENT SCHEME FOR EFFLUENT TREATMENT PLANT

The stream from poly section is passed through degasser tower so as to strip off volatile Matter. Effluent

from other streams is collected in Buffer Tank and Equalization Tank. Buffer Tank is provided with one

day retention and equalization tank is provided with a retention time of two hours at peak flows.

Effluent is treated in following steps:

1. Air Stripping : Only the poly stream containing the volatile polymers would be stripped in

Air stripper.

2. Alkaline Chlorination : To reduce level of sodium thiocyanate in the effluent before treating

Biologically.

3. Biological & Chemical: This process is carried out to reduce the organic compounds from the

Oxidation effluent.

4. Physio Chemical Treatment (TT): This process is carried out to reduce the pollutant load (liquid

pollutant converted in to solid pollutant ) by different chemicals doses & separation of solid sludge

done through filter presses.

5.Effluent Recycling & Reuse (RO , MEE& ATFD) : This process is carried out for purification of

effluent through RO & MEE for water recycling & reuse .

AIR STRIPPING

The continuous streams of polymerization are directly taken into air stripper mechanism for the stripping

of the volatile monomers present in the stream. The monomers present like Acrylonitrile are volatile in

nature and so can be stripped off. The effluent after passing through the stripper would be taken into

equalization tank where it would be mixed with other streams.

ALKALINE CHLORINATION

Effluent streams containing cyanide are treated by alkaline chlorination for reducing the cyanide

concentration. The alkaline chlorination process oxidizes cyanide by the addition of chlorine. The initial

reaction forms Cyanogens chloride (CNCl), this reaction is instantaneous at all pH levels. In the presence

of Caustic, Sodium Cyanate is formed from cyanogenchloride, the rate of this reaction is pH dependent

and is low below pH-8.0, so pH is maintained above 8.5. Excess chlorine is used to complete the reaction.

Cyanide waste treatment is accomplished continuously by addition of Caustic (48% NaOH) to raise the

ANNEXURE-10

pH to 8.5. Effluent line is fitted with online static mixer. pH is monitored by the pH indicator and

controller which adjust the dosing rates of NaOH. Effluent is then taken to reaction tank where gaseous

chlorine is added

The ORP indicator cum controller is installed in the reaction tank so as to control the dosages of chlorine

to the effluent. The chemical reactions involved are as follows:-

NaCN + Cl2 → CNCl + NaCl

CNCl + 2NaOH → NaCNO + H2O + NaCl

2NaCNO + 4 NaOH + 3Cl2 → 2CO2 + 6NaCl + N2 + 2H2O

Effluent is then passed to pH adjustment tank under gravity, HCl will be dosed for pH adjustment. pH is

controlled in the range 7 to 8 so as to be suitable for biological process.

BIOLOGICAL AND CHEMICAL OXIDATION

The combined effluent after pH adjustment is pumped to distribution chamberwith the help of 2Nos.

of 110 m3/hr pumps.

Effluent is taken then into aeration tank under gravity. The circular nature of aeration tank provides very

high retention time to liquid particles and ensures complete degradations of substrate. Diffusers are

provided for supply of atmospheric oxygen which is necessary for aspiration of micro-organisms is

responsible for bio-degradation of the organic matter. The diffused aeration generates hydraulic currents,

so that the effluent activated sludge mixtures experiences “Complete mix” regime. The liquid then enters

the clarification step placed centrally, for liquid MLSS separation. The sludge from the clarifier is

recycled back to the aeration compartment.

The clarified effluent is then taken for tertiary treatment , solid pollutant separated out by filter

presses and then treated effluent taken to aerated lagoon for polishingpurpose. Approximately 12 hours

retention is provided in this tank. Two numbers of floating surface aerators are provided in this aerated

lagoon. After this polishing, treated effluent is passed into a blending tank. DM regeneration water, Spg,

effluent and cooling tower & boiler blow down is added in blending tank for dilution purpose.

The excess sludge from the biological system is taken to the sludge sump from where it is pumped to

centrifuge/ Filter press .De-watered sludge is further dried on sludge drying bed. Then dried sludge is

packed in lined HDPE bags and stored in scientifically designed hazardous waste storage area. Tertiary

clarifier sludge is fed to filter press and filter cake is then dried in sludge drying beds which are packed in

HDPE lined bags and stored in designed hazardous waste storage area.

ANNEXURE-10

DOMESTIC WASTE WATER IN TO SEPTIC TANK AND SOAK PIT

Domestic waste water/ Sewage is collected in septic tanks/soak pits system .Excess / overflow of soak

pits, pumped into ETP and then It is treated with industrial effluent.

DETAILS OF PLANT & EQUIPMENT OF ETP Sr.No.

Description Size (m) / Capacity

Nos. Water Holding Capacity m3

Construction

1. Buffer Tank 8 x 8 x 3.5 1 224 RCC with acid proof lining

2. Equalisation Tank 8 x 8 x 3.5 1 224 --Do--

3. Reaction Tank 11 x 3 x 3 1 99 --Do--

4. pH adjustment Tank 3.5 x 3.5 x 3.5 1 45 --Do--

5. Feed Tank 4.5 x 4.5 x 3.5 1 70 RCC

6. Trickling Filter ø14 x 4.5 1 -- RCC

7. Distribution Chamber 1.5 x 2 x 1 1 3 RCC

8. Aeration Tank ø23 x 5 1 1500 RCC

9. Secondary Clarifier ø12 x 3 1 330 RCC

10. Aeration Lagoon 30 x 15.5 x 3 1 1395 RCC

11. Blending Tank 6 x 6 x 3.5 1 125 RCC

12. Sludge Sump 2 x 2 x 2 1 8 RCC

13. Centrifuge Platform 4 x 4 1 -- RCC

14. Gas Chlorination Shed 4 x 3 1 -- RCC

15. Chemical House & MCC 16 x 6 1 -- Brick

16. Degasser Tower ø1.4 x 2.8 1 -- Carbon Steel

17. Effluent Transfer Pumps to Equalisation Tank

10 m3 /hr.

2 -- PP

18. Effluent Transfer Pumps to Reaction Tank

110 m3 /hr

2 -- Cl

ANNEXURE-10

19. Trickling Filter Feed Pumps

115 m3 /hr

3 -- Cl

20. Sludge Recycle Pumps 100 m3 /hr 2 -- Cl

21. Centrifuge Feed Pumps 3 m3 /hr 2 -- Cl

22. Booster Pump 15 m3 /hr 1 -- Cl

23. Drain Sump Pump 2 m3 /hr 1 -- Cl

24. Air Blower 23 m3 /min. 1 -- Cl

25. Air Blower 1100 m3 /hr 2 -- Cl

26. NaOH Dosing Tank 1 Dia x 1.2 2 900 Liters FRP

27. Polymer Dosing Tank 100 liters 2 -- FRP

28. HCl Dosing Tank 1.2 Dia x 1.6 1 1600 Liters FRP

29. Urea/DAP Dosing Tank 250 Liters 1 -- FRP

30. NaOH Dosing Pumps 0-50 Lit/hr 2 -- PP

31. Treated Effluent pump 125 m3 /hr 2 -- CI

32. Fecl3 dosing pump 100 LPH 1 -- PP

33. M. Floc dosing pump 100 LPH 1 -- CI

34. E C T dosing pump 20 LPH 1 -- CI

35. Tertiary sludge pump 20 m3/hrs 3 -- CI

36. Chlorination system 20kg/hr 2 --

37. Filter press 914*914*38 plate

4 -- PP

38. RO-03Stages Cap. 400KDL 1 Unit

-- SS& PP

39. MEE Cap. 20KLD 1Unit -- SS

40. ATFD Feed Rate 180Kg/Hrs , Surface Area

5m2

1 -- SS

ANNEXURE-10

2 to5 m3/hr 24 m3/hr 24 m3/hr

24 m3/hr 00 m3/hr

Sludge 23 m3/hr 24 m3/hr

DISTRIBUTION CHAMBER

1.0 m3/hr

A.T.- OD-23M DIA., ID-12M DIA. & 5M ht., SEC. CL. 12 M DIA * 3 M ht.,

22 m3/hr

22 m3/hr

53 m3/hr2 m3/hr

15 m3/hr

ETP CAPACITY= 110 m3/hrs TERTIARY TREATMENT(TT) CAPACITY= 35m3/hrs

CAP.- 125 M4TREATED WATER DISCHARGE FOR

GARDENING / NCT PIPE LINE WTP regeneration water, C.T.

blowdown, Boiler blowdown, etc.

FILTER PRESS 4 NOS.

1 m3/hr 2.3M DIA.*1.5M 1.75M DIA.*1.5M 1.75M DIA.*1.5M SPG. EFFLUENT16 M3/HR

21 m3/hr

22 m3/hrCAP- 1395 M3

CAP- 50 M3

SIZE- 8M DIA.*2.5M SIZE-2M*2M*2.8M 14 m dia. *4.5 m ht.CAP.- 125 M3

SLUDGE DRYING BED

23 m3/hr

MIXING TANK

ETP FLOW DIAGRAM

24 m3/hr

CAP.-224 M3 CAP.-224 M3 CAP.-99 M3 CAP.- 45 M3

BUFFER TANK 8m*8m*3.5m

EQUALISATION TANK 8m*8m*3.5m

REACTION TANK 11m*3m*3m

PHAT 3.5m*3.5m*3.5m

TRICKLING FILTER FEED TANK

TRICKLING FILTER

AERATION TANK

SEC. CLARIFIER

TERTIARY CLARIFIER

COLLECTION TANK 4m*4m*3.2m MGF ACF-1 ACF-2

BLENDING TANK 6M*6M*3.5M

AERATION LAGOON 30M*15.5M*3M

ANNEXURE-10

EFFLUENT CHARACTERISTIC BEFORE AND AFTER TREATMENT

Sr.

No. Parameters Units

Standards

prescribed

Inlet ETP

Discharge

1 pH -- 6.5 to 8.5 9-10 7-8

2 Total Suspended Solids

mg/l 100 25-35 10-15

3 Total Dissolved Solids

mg/l 2100 1800-2500 1500-1950

4 B.O.D.(3 days at 27°C)

mg/l 30 275-375 20-26

5 C.O.D. mg/l 100 1800-2200 80-90

ANNEXURE-11

FLUE GAS EMISSION Sr. No

Stack Attached To

Stack Height in Meter

Air Pollution Control System

Parameter Permissible Limit

1. Boiler1. (Low Pressure GT-4013)

67 ---

Particulate Matter

SOx

NOx

150mg/NM3

100 ppm

50 ppm

2. Boiler-2 (High pressure GT-4069)

62 ESP

3. D.G.Set* (6 Nos)

16 each (2stack/ D.G.Sets)

----

*Unit is using D.G.Set only in case of emergency.

Note:-There will be no changed in Flue gas emission due to the proposed project.

terms of reference due to the proposed project, -...

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