ANNEXURE 1 KEY PLAN. Project site. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd.

Size: px

Start display at page:

Download "ANNEXURE 1 KEY PLAN. Project site. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd."

Oswin Jordan
5 years ago
Views:

1 ANNEXURE 1 KEY PLAN Project site Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 18

2 ANNEXURE 2 PLANT LAY-OUT Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 19

3 ANNEXURE 3 MANUFACTURING PROCESS (1) Process of Formaldehyde - Formaldehyde Liquid Form 1. Feed Methanol, air, water vapour Catalyst: Silver 2. The methanol in the measuring storage tank is pumped up to an elevated tank by a methanol pump. After being controlled by measuring, the methanol coming out from the elevate tank flows into an evaporator for vaporization of which the temperature is controlled within 44 0 C ~ 47 0 C and the liquid level is controlled as 50%,then the vaporized methanol gets into a super heater. The heat for the vaporization of methanol is provided by the 70 0 C circulating fluid in the 1# formaldehyde absorber. 3. The air is filtered by a filter before being delivered to the evaporator by a blower. It mixes with the methanol in the evaporator and enters into then super heater together. The air flow is regulated by the blower through frequency conversion to control the flow ratio of air to methanol (A/M=1.8 ~1.95). 4. When the pressure gets stable, the vapour (0.3 MPa) gets into a mist eliminator for dehumidification through the pipeline before entering into the superheat. The flow ratio of air to methanol shall be controlled at desired level. In the formaldehyde production technique using silver as catalysis, the water vapour is an inert gas which does not participate in chemical reactions. The added water vapour changes the explosive range of the methanol and air, the production of formaldehyde thereby becomes far from the explosive area and stays safe and reliable. 5. After the flow rates are regulated and proportioned, the methanol, air and water vapour enter into the super heater and the superheating temperature shall be controlled at C. Then, these materials enter into a reactor. 6. In the reactor, under the catalysis of silver at C, the methanol is dehydrated and oxidised, generating Formaldehyde. Dehydration reaction is an endothermic reaction and oxidation reaction is an exothermic reaction, but the heat release is more than that can adsorbed, therefore the reaction system is an state of heat energy surplus. The water vapour is not involved in reactions but it can absorb a lot of heat of reaction, maintaining the temperature at C. Chemical Reaction CH 3OH CH 3OH + ½ O 2 CH 2O + H2-20Kcal CH 2O + H 2O + 38 Kcal =18Kcal The C reaction gas leaves the reaction and gets into heat exchanger. For the heat exchanger, the medium is water. The outlet temperature of heat exchanger is C. The water Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 20

4 absorbs heat, forming the water vapour of 0.35 MPa which will be used to arranging the raw materials for production in the super heater after its pressure stabilized. The generated gas of about C enter into 1# and 2# formaldehyde absorber in proper order and gets absorbed by the cooled circulating fluid through spraying. The temperature of the circulating fluid at the bottom of 1# absorber shall be control at 70 0 C and fluid is pumped to the evaporator by circulating pump to supply the heat for the evaporation of methanol. In the 1# absorber, the concentration shall be controlled as 37%, and temperature of the top shall be controlled at 45 0 to 50 0 C. The circulating fluid is also a composition of the Formaldehyde product by this technique. The temperature of the top of 2# absorber shall be controlled at 30 0 to 35 0 C and keep adding water from top to control the release of formaldehyde. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 21

5 PROCESS FLOW DIAGRAM Formaldehyde ( ppm) Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 22

6 (2) Urea Formaldehyde Resin (Liquid / Powder) Manufacturing Process Stage: 1: Liquid Resin:- First all the raw materials Urea & Formaldehyde will be added in Limped reaction vessel. ph will be adjusted to ph 9.0. Stirring & heating will be done up to 95 C for 50 Minutes. Heating will be continued until tolerance (10:40) is achieved. ph will be adjusted to 9 by adding Caustic. Cooling will start Liquid Urea Formaldehyde Resin will be ready for Packing. Stage 2: Powder Resin:- The prepared Liquid resin stored in the MS storage tank carries out in the feed tank of the spray drier by means of SS pump. The atomizer is located at the top side of the spray Drier it rotates the resin in to very high speed so the resin scattered in micro drops. Also hot air at the temperature C C in very high pressure comes from the hot air generator to the top of the spray drier it contacts to the resin scattered micro drops. So however the resin scattered in micro drops comes to the bottom side of the spray drier with contact of the hot air in pressure so it dries and removes the water contents in the liquid resin. So when it reaches at the bottom valve of the spray drier it totally converts in to the powder form and then it cool down by the cooled air from the cooling plant then after it collects directly in 25 kg. Polythene bags. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 23

7 Chemical Reaction: Process Flow Chart for Liquid / Powder Resin : Urea Formaldehyde Limped Reaction Vessel ph adjusted to 9 Stirring and Heating up to 95 C for 50 Minutes Caustic Storage Tank of Liquid Resin Spray Drier Urea Formaldehyde Resin Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 24

8 (3) Melamine Formaldehyde Resin (Liquid / Powder) : Manufacturing Process Step 1 : Liquid resin : First all the raw materials melamine, formaldehyde & caustic will be added in Limped reaction vessel. Stirring & heating will be done up to 95 C for 1 Hr. Cooling will start up at 30 C. Melamine Formaldehyde Resin will be ready for packing. Reaction Chemistry N H 2 N N N NH 2 + H 2 C O fast N N N NH 2 H 2 C N CH 2 melamine Stage 2: Powder Resin:- formaldehyde OH HO melamine formaldehyde resin The prepared Liquid resin stored in the MS storage tank carries out in the feed tank of the spray drier by means of SS pump. The atomizer is located at the top side of the spray Drier it rotates the resin in to very high speed so the resin scattered in micro drops. Also hot air at the temperature C C in very high pressure comes from the hot air generator to the top of the spray drier it contacts to the resin scattered micro drops. So however the resin scattered in micro drops comes to the bottom side of the spray drier with contact of the hot air in pressure so it dries and removes the water contents in the liquid resin. So when it reaches at the bottom valve of the spray drier it totally converts in to the powder form and then it cool down by the cooled air from the cooling plant then after it collects directly in 25 kg. Polythene bags. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 25

9 Process Flow Diagram (Liquid / Powder Resin) Melamine Formaldehyde & Caustic Limped Reaction Vessel Stirring and Heating up to 95 C for 1 hr Cooling up to 30 C Dilution Storage of Melamine Formaldehyde Resin (Liquid) Spray Dryer Melamine Formaldehyde Resin (Powder) Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 26

10 (4) Phenol Formaldehyde Resin (Liquid / Powder) : Manufacturing Process Stage: 1: Liquid resin First all raw materials like phenol, formaldehyde & caustic will be added into closed vessel. Stirring & heating will be done up to 60 C. After 60 C stop heating. Reflux is done for 30 minutes up to 98 C. Cooling down to 40 C. Phenol Formaldehyde Ready for Packing. Stage 2: Powder Resin:- The prepared Liquid resin stored in the MS storage tank carries out in the feed tank of the spray drier by means of SS pump. The atomizer is located at the top side of the spray Drier it rotates the resin in to very high speed so the resin scattered in micro drops. Also hot air at the temperature C C in very high pressure comes from the hot air generator to the top of the spray drier it contacts to the resin scattered micro drops. So however the resin scattered in micro drops comes to the bottom side of the spray drier with contact of the hot air in pressure so it dries and removes the water contents in the liquid resin. So when it reaches at the bottom valve of the spray drier it totally converts in to the powder form and then it cool down by the cooled air from the cooling plant then after it collects directly in 25 kg. Polythene bags. Reaction Chemistry OH OH H CHO CH 2OH Fast Phenol Phenol Formaldehyde Resin Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 27

11 Process Flow Diagram (Liquid / Powder Resin) Phenol Formaldehyde Limped Reaction Vessel Stirring and heating up to 60 C Reflux for 30 Minutes Cooling Dilution Storage of Phenol Formaldehyde Liquid Resin Spray Dryer Phenol Formaldehyde Powder Resin Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 28

12 (5) Hexamine: Hexamine is being produced by reaction of formaldehyde with ammonia. The Formaldehyde is taken in the form of formaldehyde gas and is introduced in the reactor containing saturated solution of Hexamine. Ammonia from the Ammonia storage tank is evaporated and purged in the reactor where it reacts with the Formaldehyde to produce Hexamine as per following reaction. 6HCHO + 4 NH3 (CH2)6 N4 + 6H20 The Reaction between Formaldehyde and Ammonia is exothermic in nature. The heat of reaction is utilized in evaporating the water, which is formed during reaction. As the reactions proceed and the upper saturation limit exceeds, the hexamine start crystallizing in the mother Liquor. The mother liquor containing hexamine crystal is withdrawn though slurry pumps and pumped to centrifuge where the crystals are separated out. These crystals are dried in rotary drum dried and packed in jute bags for dispatch. The mother liquor from centrifuge is re-circulated back to the reactor. This is a highly energy efficient process where in the heat of gaseous formaldehyde and heat of reaction are utilized to evaporate the water formed during the reaction. No extra steam is required in reactor and only a small quantity of steam is required for drying of crystallized hexamine. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 29

13 Mass Balance Vacuum Exhaust 950 kg 99% Water and traces of Ammonia Formaldehyde 1550 to 1575 kg of Methanol Ammonia 510 to 515 kg R e a c t o r HEXAMINE 1000 kg Centrifuge Spent Mother Liquor 140 kg output recycled into process Input: 2090 KG Output: 2090 KG Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 30

14 (6) Para Formaldehyde Para formaldehyde is manufactured from Aqueous Formaldehyde (37%) solutions by the process involving distillation and concentration at a point at which solidification or precipitation of polymer takes place. The process of concentration is carried out by vacuum evaporation. The main sections of the PLANT are: a. Concentration of aqueous Formaldehyde b. Polymerization and drying c. Concentration of distillates for recycling. d. Conveying, pulverization and storage / packaging of the Product. Concentration of aqueous Formaldehyde (37% or 55% with predecided Formic acid content) to (65-75)% is carried out by feeding the material from a storage tank to proprietary concentration equipment (Evaporator I). The distillate containing (10-20) % Aldehyde content is condensed, sub cooled in heat exchangers and collected in an Intermediate Tank. Polymerization and Drying up to 96% Formaldehyde concentration is carried out in proprietary special drying equipment which operates in a cyclic manner for polymer precipitation, cooling and unloading formed Para formaldehyde lumps. The (20-20) % Formaldehyde Concentration distillate obtained from the Evaporator I and the distillate from the drying section are fed to concentration Evaporator II for concentration and recycling. Functionally Evaporator II is similar to Evaporator I with certain differences in construction features. Use of secondary evaporation step helps in achieving the following: (1) Recovery of Formaldehyde to improve overall yield. (2) Facilitation of continuous operation of the PLANT by feed recycles. (3) Recovery of final distillates below (3-4) % Formaldehyde concentration grade which can be recycled to the Formaldehyde PLANT supplying AF-37 / AF-55 feed stock thereby virtually eliminating liquid effluents. Depending on the Paraformaldehyde grade to be produced the solubility of the product, reactivity and ph requirements, a proprietary Liquid Catalyst is added before the polymer precipitation process. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 31

15 Dilute Formaldehyde solution can be sent to Formaldehyde PLANT for recovery and to avoid effluent generation. Process Steam generation Package Boiler, D.M. Water Unit, Chilled Water Unit, Instrument Air System and Cooling Tower shall be required as Utilities. Product from Drying Equipment is dumped onto the Belt Conveyor from where it is conveyed to a Precrusher. Crushed product is pneumatically conveyed to a Cyclone through a rotary air lock valve. The product from the cyclone is taken to a Sieve Shaker in which particles below 1mm size are separated and sent to mix Product Silo via pneumatic conveying system. The oversize material from sieve shaker goes to a Pin Pulverize for further grinding and then through same pneumatic conveying system to mixed Product Silo. The mixed product is separated in II Sieve Shaker and transferred to separate silos for powder and granular products. Typically about 40% product is in powder form (particle passing through 65 mesh) and remaining 60% particles are in granular form (retaining on 65 mesh). In case required, almost 100% product can be in granular form, by compacting finer powder. Two independent Dust Collection Systems are provided for the two conveying, and pulverizing sections. An Aspirator System with third bag filter and blower is installed for keeping the whole material handling system under slightly negative pressure. The aspirator system helps in collecting fine dust particles during conveying, crushing and sieving operations thus improving recovery and reducing pollution. The dust handling systems provide dust collecting for each set of cyclones / bag filters / blowers. Air from the three bag filters is passed through scrubbers for further cleaning before venting into open atmosphere. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 32

16 Flow Diagram of Para Formaldehyde Para Formaldehyde Flakes Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 33

17 ANNEXURE 4 DETAI LS OF SOLID WASTE Sr. No. Description Category Quantity Mode of Disposal 1 Used Oil MT/Month Collection, storage and used within premises as a lubricant / sold to registered recycler. 2 Discarded Plastic Bags MT/Month Collection, storage & sold to approved vendor. 3 ETP Sludge + Evaporation Residue MT/month Collection, storage & sent to approved TSDF site. Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 34

18 ANNEXURE 5 EFFLUENT TREATMENT PLANT RO Reject 5 KLD Collection cum Neutralization Tank Nutch Filter Evaporator Sludge Sludge Drying Bed ZERO LIQUID DISCHARGE Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 35

19 ANNEXURE 6 WATER BALANCE DIAGRAM Source of Water Supply: Borewell Raw water Industrial Domestic Gardening Cooling (Hexamine) Boiler Para formaldehyde Cooling DM Formaldehy de Process Reject Cooling/ Boiler (Formalin) Drinking Condensate 12 Goes to Soak Pit Condensed water Blow Down Blow down 36 Permeate 31 RO Raw Water Wastewater Reject 5 Evaporator Recycle/reuse Note: All values are in KLD Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 36

20 ANNEXURE 7 DETAILS OF FLUE GAS STACK Sr. No. Stack attached to 1 Steam Boiler (600 kg/hr.) 2 D. G. Set (3 X 250 KVA) 3 D. G. Set (2 X 350 KVA) (1 X 400 KVA) 4 Hot Air Generator (8 Lac Kilo Calories x 1) 5 Hot Air Generator (10 Lac Kilo Calories x 1) 6 Hot Air Generator (10 Lac Kilo Calories x 1) 7 Hot Air Generator (10 Lac Kilo Calories x 1) Height of the stack In meter Fuel Type 30 Bio coal 1.25 MT/M APC System Multi cyclone Dust Collector Expected Pollutant PM SO2 NOx Limit As per Norms 6 HSD - 35 L/Hr -- HC, CO As per Norms 6 HSD L/Hr -- HC, CO As per Norms 20 Waste Hydrogen gas generated from Formaldehyde Plant 20 Waste Hydrogen gas generated from Formaldehyde Plant 20 Waste Hydrogen gas generated from Formaldehyde Plant 20 Waste Hydrogen gas generated from Formaldehyde Plant Cyclone Separator Cyclone Separator Cyclone Separator Cyclone Separator PM SO2 NOx PM SO2 NOx PM SO2 NOx PM SO2 NOx As per Norms As per Norms As per Norms As per Norms Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 37

21 DETAILS OF PROCESS GAS STACK Sr. No. Stack attached to Height of the stack In meter APC System Expected Pollutant Limit 1 Spray Dryer (500 Kg/Hr. x 1) 20 Bag Filter PM As per Norms 2 Spray Dryer (600 Kg/hr. x 1) 20 Bag Filter PM As per Norms 3 Spray Dryer (800 Kg/Hr. x 1) 20 Bag filter PM As per Norms 4 Spray Dryer (800 Kg/Hr. x 1) 20 Bag filter PM As per Norms 5 Fluid Bed dryer (300 Kg/Hr. x 2) Common stack of 18 meter. Bag filter PM As per Norms Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 38

22 ANNEXURE 8 LIST OF PRODUCTS Sr. Product Detail Quantity MT/Annum no. 1 Formaldehyde 1,34,400 2 Formaldehyde Based Resin (Powder) 3 Formaldehyde Based Resin (liquid) 10,800 14,400 4 Para Formaldehyde 10,800 5 Hexamine 3,600 Total 1,74,000 Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 39

23 RAW MATERIAL CONSUMPTION Sr. No. Name of raw materials Total Capacity (MT/Month) Formaldehyde 1 Methanol Water Urea Formaldehyde Resin-Powder 1 Formaldehyde (55%) Urea Melamine Melamine Formaldehyde Resin- Liquid 1 Formaldehyde (37%) Melamine 160 Phenol Formaldehyde Resin- Liquid 1 Phenol Formaldehyde (37%) Caustic 2 Urea Formaldehyde Resin- Liquid 1 Urea Formaldehyde (37%) Caustic 2 4 Acetic Acid 2 Hexamine 1 Ammonia Methanol Para Formaldehyde 1 Formaldehyde (37%) Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 40

24 ANNEXURE 9 LIST OF UTILITIES Sr. No. Name Of Machinery Utilities required for Amendment 1 Steam Boiler 1 x 600 Kg/Hr. 2 Hot ( air) generator 3 x 10 lac kilo calories 1 x 8 lac kilo calories 3 Spray dryer with Bag filter Evaporation capacity 2 x 800 kg/hr 1 x 500 kg/hr 1 x 600 kg/hr 4 D. G. Set 2 x 350 KVA 2 X 250 KVA 1 X 400 KVA 5 P. F., M.F., U.F. Reaction Vessel 2 X 15 MT 2 X 11 MT 2 X 10 MT 3 X 8 MT 2 X 3 MT 5 X 5 MT 6 Formaldehyde plant including all equipment 7 Hexamine plant including all equipment MT/Day 10 MT/Day 8 Fluid bed Drier Evaporation capacity 2 x 300 kg/hr 9 Cooling Tower 6 x 350 TR 10 PARAFORMALDEHYDE plant including all equipment 35 MT/Day Application Form 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 41

Komline-Sanderson Paddle Dryer. Drying technology for biosolids, sludges and by-products

Komline-Sanderson Paddle Dryer Drying technology for biosolids, sludges and by-products Why dry? There are economic and environmental benefits to drying biosolids, sludges and by-products. In municipal