list of products (proposed)
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LIST OF PRODUCTS (PROPOSED)
Sr.No. Name of Product Existing Quantity
(MT/Month)
Total Quantity after expansion
(MT/Month) 1 Benzyl Acetate 20 50 2 Benzyl Benzoate 20 50 3 Benzyl Alcohol 20 50 4 Benzyl Cyanide 20 50 5 Phenyl Acetic Acid 20 50 6 Benzyl Salicylate 20 50
7 Naphthalene Acetic Acid (Tech) and Sodium Salt
5 30
8 Sodium Acetate 6 0 9 Sodium Benzoate 6 0 10 Para Methoxy Phenyl Aceto nitrile 0 50 11 Para Methoxy Phenyl Acetic Acid 0 10 12 Naphthalene Acetamide 0 10
13 Dibenzyl Ether (High boiler of Benzyl Alcohol)
0 30
14 High boiler of Benzyl Benzoate 0 10 15 High boiler of Benzyl Acetate 0 15 16 Trading (Repacking)
0 150 Benzyl Acetone
1 Acetyl Naphthalene
Benzyl Acetate The existing manufacturing capacity of the plant is 137 MT/Month. The Total Manufacturing capacity of the plant after expansion will be 205 MT/Month. The total manufacturing capacity for Benzyl Acetate / Benzyl Benzoate / Benzyl Alcohol / Benzyl cyanide / Phenyl Acetic Acid / Benzyl Salicylate will be 50 MT/Month. Trading activities will be carried out for Benzyl Acetone, 1-Acetyl Naphthalene and Benzyl Acetate. The total quantity for trading will be 150 MT/Month.
Raw Material Requirement :
Raw Materials Existing Qty (MT/Month)
Proposed Qty (MT/Month)
Benzyl Chloride 27.50 68.50
Benzyl Cyanide 21.50 53.50
Beta Napthol 0.00 10.00
Catalyst 0.50 0.85
Caustic Soda Lye 0.00 23.00
Caustic Lye 7.50 19.00
HCl 24.00 60.00
Liq. Ammonia 0.00 19.00
MCA 0.00 14.00
Napthlene Acetic Acid 6.00 36.00
N-Hexane 0.00 14.00
Para Anisyl Alcohol 0.00 54.50
Paraformaldehyde 1.65 10.00
Refined Naphthalene 6.65 40.00
Soda Ash 13.60 34.00
Sodium Acetate 1.30 3.50
Sodium Benzoate 15.50 39.00
Sodium Cyanide 9.50 24.00
Sulfuric Acid 1.75 10.50
Thionyl Chloride 0.00 10.50
Toulene 0.00 46.20
Trimethyl Amine 0.20 0.75
Zinc Chloride 0.30 1.50
Details of each Product: 1) Benzyl Acetate :
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Benzyl Acetate 20 50
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Benzyl Chloride 18.0 45 Sodium Acetate 1.27 3.18
Catalyst 0.22 0.55
Brief process: Benzyl chloride and Sodium Acetate is reacted in presence of catalyst for 8 hours. The temperature is maintained and then the reacted mass is cooled, washed. The crude is separated, distilled under high vaccum Chemical Reaction:
CH2.Cl
+ Na. COO CH3
CH2COOCH3
+ NaCl
C6H5CH2.Cl + Na.COOCH3 C6H5CH2.COOCH3 + NaCl
Benzyl Chloride Sodium Acetate Benzyl Acetate
Flowchart with Mass Balance:
REACTOR
BENZYLACETATE1100 KGS
VACCUMDISTILLATION
WASHING
BENZYL ACETATE
HEAT
BENZYL CHLORIDE 1000 kgs
SODUIM ACETATE 700 kgs
CATALYST 12 kgs
CRUDE BENZYL ACETATE
WATER 3000 KGS WASHING TO ETP 3000 KGS
High Boiler of Benzyl Acetate
2) Benzyl Benzoate :
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Benzyl Benzoate 20 50
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Benzyl Chloride 13.4 33.5 Sodium Benzoate 15.5 38.75
Catalyst 0.34 0.85
Brief process: Benzyl chloride and sodium benzoate is reacted in presence of catalyst at elevated
temperature for 12 hours. After the reaction, the mass is washed and layer separated to get
Benzyl Benzoate crude. The separated crude is washed under high vacuum to get pure Benzyl
Benzoate.
Chemical Reaction :
CH2Cl
+ NaCOOC6H5
CH2COOC6H5
+ NaCl
C6H5CH2Cl + NaCOOC6H5 C6H5CH2.COOC6H5 + NaCl
Benzyl Chloride Sodium Benzoate Benzyl Benzoate
Flowchart with Mass Balance:
REACTOR
BENZYLBENZOATE1000 KGS
VACCUMDISTILLATION
WASHING
BENZYL BENZOATE
HEAT
BENZYL CHLORIDE 670 kgsSODUIM BENZOATE 775kgs
CATALYST 17 kgs
CRUDE BENZYL BENZOATE
WATER 2500 KGS WASHING TO ETP 2500 KGS
HIGH BOILER OF BENZYL
BENZOATE
3) Benzyl Alcohol :
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Benzyl Alcohol 20 50
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Benzyl Chloride 27.3 68.25 Soda Ash 13.6 34.0
Brief process: Benzyl chloride is hydrolysed with dilute soda ash for 12 hours at an elevated temperature. The mass is washed and the layer is separated to get crude Benzyl Alcohol. The crude is distilled under high vacuum at normal temperature to get pure Benzyl Alcohol. Chemical Reaction :
CH2Cl
+ Na2CO3
CH2OH
+ NaCl + CO2
C6H5CH2Cl + Na2CO3 C6H5CH2OH + NaCl + CO2
Benzyl Chloride Sodium Ash Benzyl Alcohol
Flowchart with Mass Balance
REACTOR
BENZYLALCOHOL1000KGS
VACCUMDISTILLATION
WASHING
BENZYL ALCOHOL
HEAT
BENZYL CHLORIDE 1365 kgs
CRUDE BENZYL ALCOHOL
WATER 10000 KGS WASHING TO ETP 10000 KGS
HIGH BOILER OF BENZYL ALCOHOL
SODA ASH 680 KGS
4) Benzyl cyanide :
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Benzyl Cyanide 20 50
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Benzyl Chloride 24.2 60.5 Sodium Cyanide 9.44 23.6
Brief process: Benzyl Chloride and Sodium Cyanide is reacted in presence of catalyst for 10~12 hours. After reaction layer is separated and after proper washing, Benzyl Cyanide crude is separated. The crude is distilled under high vacuum to get the final product. Chemical Reaction :
CH2Cl
+ NaCN
CH2CN
+ NaCl
C6H5CH2Cl + NaCN C6H5CH2CN + NaCl
Benzyl Chloride Sodium Cyanide Benzyl Cyanide
Flowchart with Mass Balance :
REACTOR
BENZYLCYANIDE1000 KGS
VACCUMDISTILLATION
WASHING
BENZYL CYANIDE
HEAT
BENZYL CHLORIDE 1210 kgsSODUIM CYANIDE 472 kgs
CRUDE BENZYL CYANIDE
WATER 2500 KGS WASHING TO ETP2500 KGS
RESIDUE FOR INCINERATOR
5) Phenyl Acetic Acid:
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Phenyl Acetic Acid 20 50
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Benzyl Cyanide 21.3 53.25 Caustic Lye 7.5 18.75
HCl 24.0 60.0
Brief process: Benzyl Cyanide is hydrolised with strong alkali solution and acidified with dilute HCl. The slurry formed is then centrifuged. The centrifuged cake is dried to get Phenyl Acetic Acid powder or flakes. Chemical Reaction :
CH2CN
+ NaOH
CH2COOH
C6H5CH2CN + NaOH C6H5CH2COOH.
Benzyl Cyanide Sodium Hydroxide Phenyl Acetic Acid
Flow Chart with Material Balance:
REACTOR
CENTRIFUGE &DRYING, PACKING
P.A.A.
REACTOR
BENZYL CYANIDE (1065 kgs)
WATER
CAUSTIC LYE(375 kgs)
HCl (1200 kgs)
Phenyl Acetic Acid
CHARCOAL (1200 kgs)
5) Naphthalene Acetic Acid:
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Naphthalene Acetic Acid 5 30
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Refined Naphthalene 6.65 40.0 Paraformaldehyde 1.65 10.0
Zinc Chloride 0.245 1.5
Sodium Cyanide 2.67 16.0
Soda Ash 0.125 0.75
Trimethyl Amine 0.125 0.75
Caustic Lye 5.75 34.5
Sulfuric acid 1.75 10.5
Brief process: Chloromethylation: Refined Naphthalene and paraformaldehyde is reacted with HCl to produce Chloromethyl Naphthalene. Nitrilation: The chloromethyl naphthalene is nitriled and hydrolysed with strong alkali. Distillation: Nitriled crude is distilled to remove any unreacted material. The mass is diluted in large volume for acidification. Acidified material is centrifuged and dried to get Naphthyl Acetic Acid.
Chemical Reactions CH2Cl
CH 2CN
CH 2COOH
Naphthalene Chlorom ethyl
Naphthalene Acetic Acid
CHLORO METHYL
REACTION
NAPHTHALENE ACETIC ACID
1000 KGS
DRYER IN FLUID BED DRYER
CENTRIFUGE
ACIDIFICATION
HYDROLYSIS
NITRILEDISTILLATION
NITRILEREACTION
NAPHTHALENE ACETIC ACID
HCl 4250 KGS WATER 1500 KGS
REFINED NAPHTHOIENE 1330 KGS
PARAFORMALDEHYDE 530 KGS
ZINC CHLORIDE 49 KGS
SODUIM CYANIDE 534 KGS
SODA ASH 25 KGS
TRIMETHYL AMINE 25 KGS
CAUSTIC LYE 1150 KGS
WATER 4000 KGS
WATER 25000 KGS
SULFURIC ACID 350 KGS
WATER 25000 KGSMOTHER LIQUOR
TO ETP
Flow Chart with Material Balance:
Sodium Salt of Naphthalene Acetic Acid:
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Sodium Salt of
Naphthalene Acetic Acid 5 30
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Naphthalene Acetic Acid 6.0 36.0 Caustic Lye 2.0 12.0
Brief process: Naphthalene Acetic Acid, caustic lye and water are added in a reactor and the material is spray dried to get Sodium salt of Naphthalene Acetic Acid Flowchart with Mass Balance:
REACTOR
Na. SALT OFNAPHTHALENE
ACETIC ACID1000 KGS
SPRAY DRIER
SODUIM SALT OF NAPHTHALENE ACETIC ACID
NAPHTHANE ACETIC ACID1200 KGS
CAUSTIC LYE 400 KGS
WATER 3000 KGS
6) Para Methoxy Phenyl Aceto Nitrile: (New Product)
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Para Methoxy Phenyl
Aceto Nitrile --- 50
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Para Anisyl Alcohol --- 54.55 Toulene --- 39.5
Soda Ash --- 1.0
Brief process: Para Anisyl Alcohol and toluene are chlorinated with HCl in a reactor. The reacted mass is cynated by addition of sodium cyanide in presence of soda ash and toluene. The mass is distilled under vacuum to get the product. Flowchart with Mass Balance:
CHLORINATION
4- METHOXYLPHENYL ACETO NITRILE
1650 KGS
DISTILLATION
CYANATION
PARA METHOXYL PHENYL ACETO NITRILE
PARA ANISYL ALCOHOL 1800 KGS
TOLUENE 650 KGSHCl 3500 KGS
PARA ANISYL CHLORIDE
SODIUM CYANIDE 750 KGS
4- METHOXYLPHENYL ACETO NITRILE (CRUDE)
SODA ASH 34 KGS
TOLUENE 650 KGS
RESIDUE FOR INCINERATION
6) Beta Naphthoxy Acetic Acid: (New Product)
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Beta Naphthoxy Acetic
Acid --- 10
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
MCA --- 13.5 Caustic Soda Lye --- 23.1
Beta Napthol --- 10.0
HCl --- 15.4
Toulene --- 46.2
Brief process: MCA, Caustic Soda Lye and water are mixed in a reactor to form salt of MCA. Then Beta Napthol is added in presence of caustic soda lye to form salt of Beta Naphthol. Then HCl is added to form salt of Beta Naphthoxy Acetic acid. The crude is dried and recrystallized in presence of toluene. The pure Beta naphthol acetic acid which is centrifuged, dried and packed. Chemical Reaction :
Flowchart with Mass Balance:
REACTORMCA (440 KGS)
CAUSTIC SODA LYE (400 KGS)
WATER
REACTORBETA NAPHTOL (325 KGS)
CAUSTIC SODA LYE (350 KGS)
WATER
SALT OF MCA
SALT OF BETA NAPHTHOL
REACTOR HCl (500 KGS)
SALT OF BETA NAPHTHOXY ACETIC ACID
CENTRIFUGE,DRYING OF
CRUDE
ML TO ETP
RECRYSTALLISATION OF CRUDE
TOULENE (1500 KGS) DISTILLATION
RECYCLED BACKTO PROCESS
RESIDUE FORINCINERATION
CENTRIFUGE,DRYING OF BETA
NAPHTHOXY ACETIC ACID (325 KGS)
7) Naphthalene Acetamide: (New Product)
Name Existing Production Quantity
(MT/Month)
Proposed Production Quantity
(MT/Month) Product Naphthalene Acetamide --- 10
Raw material consumption per Month
Material Existing Requirement (MT/Month)
Proposed Requirement (MT/Month)
Naphthalene Acetic Acid --- 11.1 Thionyl Chloride --- 10.5
N- Hexane --- 14.0
Liquor Ammonia --- 19.0
Brief process:
Naphthalene acetic acid, N-Hexane and Thionyl Chloride are charged in a reactor. Then liquor ammonia is added to the reactor. After the completion of the reaction, the material is centrifuged, dried and packed.
Chemical Reaction:
CH2COOH CH2COCl
CH2COCl CH2CONH2
+ Cl2OS + HCl + SO2
+ NH3 + HCl
Flowchart with Mass Balance:
REACTOR
NAPHTHALENE ACETIC ACID 1110 KGS
THIONYL CHLORIDE 1050 KGS
N - HEXANE 1400 KGS
REACTORLIQ. AMMONIA 1900 KGS
CENTRIFUGE ML TO
ETP
RECRYSTALLIZATION AND CENTRIFUGE
DRYING, BLENDING & PACKING
NAPHTHALENE ACETAMIDE (1000 KGS)
SITE PLAN
&
LAYOUT PLAN
1. DETAILS OF WATER CONSUMPTION.
2. DETAILS OF WASTE WATER GENERATION.
Details of water consumption:
Source of water: GIDC Water Supply
Waste Water Generation Details : Sr. No.
Breakup Existing Waste Water Generation (M3/Day)
Proposed Waste Water Generation (M3/Day)
1. Domestic 1 8
2.
Industrial
a) Process 17 70
b) Boiler Blowdown 0.5 3
c) Cooling Tower Blow Down 0.5 2
d) R.O. Reject - 30
3. Washing 1 15
Total 20 128 Total waste water generation from the plant will be 128 KL/Day, of which 8 KL/Day will be
from domestic activities and rest 120 KL/Day from industrial activities. 120 KL/Day will be
taken to ETP plant for its treatment and further disposed to CETP of NIA.
Sr. No.
Breakup Existing Water Consumption
(M3/Day)
Proposed Water Consumption
(M3/Day)
1. Domestic 2 10
2.
Industrial
a) Process 31 105
b) Boiler Makeup 2 10
c) Cooling tower make up 2 10
3 Washing 1 15
4 Gardening 1 2
Total 39 152
EFFLUENT TREATMENT SCHEME.
Effluent Treatment Scheme: Domestic waste water and industrial waste water will be sent to the effluent treatment plant
for treatment. The treated waste water will be sent to CETP of NIA, GIDC, Nandesari for its
further disposal after meeting its inlet norms.
PROPOSED TREATMENT SCHEME :
The waste water from the plant will be collected in the waste water collection tank. The
composite COD will be about 8500 mg/L. As per the recommendation received from the
CETP of Nandesari Industries Association, we will be installing the hydrodynamic cavitation
process for the treatment of the waste water.
The setup for the hydrodynamic cavitation reactor is given in the figure below: The waste
water is equalised over organic matter and flow. The pH of the waste water is raised to 10 by
hydrated lime and filtered. The waste water is then pumped through a venturi. At the suction
side, chlorine is injected to achieve hydrodynamic cavitation. This is a batch process and the
system is kept under recirculation till the COD is reached to desired limit. This is again
filtered in the filter press and the filtered waste water will be sent to the CETP.
DETAILS OF AIR EMISSIONS
Details on Existing Air Emissions:
Sources of gaseous emissions
Existing Thermic Fluid heater
No. 1
Existing Thermic Fluid heater
No. 2 Capacity 4 lac KCL/HR 4 lac KCL/HR Fuel used Piped Natural Gas Agro waste/ briquette / woodQuantity of fuel 350 SCM/Day 5 MT/day Type of emissions NOx, PM SO2, NOx, PM Stack height 11 meters 11 meters Stack diameter at top 13 inches 13 inches APC Provided None Built in Particulate Matter
collection Mechanism
Details of the New Thermic Fluid Heater
Flowchart of Dust collector From the firing in the combustion chamber (furnace), Gas will travel to radiative heat exchanger through Dust collector and from there to preheater to ID fan and Chimney. All the dust is collected in Dust collector through bottom connective heat exchanger.
Other sources of Utility Emissions There is no change in other utility emissions.
Sources of gaseous emissions
Existing Boiler DG Set (used only in case of power failure)
Fuel used Wood / Briquettes HSD Quantity of fuel 10 MT/day 200 lts/month Type of emissions SO2, NOx, PM SO2, NOx, PM Stack height 11 meters 3 meters Stack diameter at top 13 inches 4 inches APC Provided Cyclone None
Cyclone in the existing boiler Details of Existing Process Emissions
Process emission Vent attached to Scrubber No.1 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches
Details of Proposed Air Emissions :
Process emission Vent attached to Scrubber No. 2 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches
Process emission Vent attached to Scrubber No. 3 Gas Scrubbed HCl Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Caustic Stack height 15 meters Stack diameter at top 6 inches
Process emission Vent attached to Scrubber Gas Scrubbed Ammonia Number of stages 2 Primary Scrubber 10" dia x 14 ft high Scrubbing liquid used Caustic Secondary Scrubber 8" dia x 18 ft high Scrubbing liquid used Water Stack height 15 meters Stack diameter at top 6 inches
DETAILS OF HAZARDOUS WASTE GENERATION AND
DISPOSAL.
Details of hazardous waste generation and disposal:
Sr. No.
Waste Details
Waste Category
Existing Total Volume to be disposed
Proposed Total Volume to be disposed
Mode of Disposal
1 ETP Sludge
34.3 180 MT/Yr 400 MT/Yr Collection, storage, transportation and disposal to TSDF, NECL for landfilling
2. Waste / Residue
28.1 18 MT/Yr 30 MT/Yr Collection, storage, transportation and disposal to CHWI, NECL for incineration
3. Used Oil 5.1 0.5 MT/Yr 1 MT/Yr Applied on MS structures for
corrosion control or will be sent to NECL for incineration
4.
Liner Bags and discarded containers
1 MT/year 1.5 MT/Yr Used for filling of ETP Sludge and Process residue or is Sold to registered recyclers
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