List of Annexure

Annexure

No. Contents

1. a. EC copy of existing plant b. Letter seeking validity of EC extension

2. MEK Capacity

3. Land Breakup of Existing - MEK & Expansion MIBK

4. Topo Map of The Study Area

5. Layout of The MIBK Plant

6. Process Description And Flow Chart For Erection of MIBK

7. Effluent Treatment Plant Details

8. MoU Letter Made With Common TSDF in Tamilnadu For Hazardous Waste Disposal

Annexure 1a EC copy of existing plant

Annexure 1b Letter seeking validity of EC extension

Annexure 2

MEK Plant Capacity

S.No Name of the product Existing

capacity TPA

capacity after expansion TPA

(EC obtained on 16th Sep 2008)

1 Methyl Ethyl Ketone 5000 10000 2 Secondary Butyl Alcohol 6000 12000

Fine Chemicals 3 Cinnamic Alcohol 180 1080 4 Anisyl Alcohol 180 276 5 Styrallyl Alcohol 180 228 6 Styrallyl Acetate - 150 7 Oximone - 20 8 Phenyl Enthyl Alcohol - 96 9 Tertiary Butyl Cyclohexyl Acetate - 200 11540 24050

MIBK Proposed Project

S.No Name of the product Proposed (MTPA)

1 Methyl Iso Butyl Ketone 30000 By products 2 Methyl Iso Butyl Carbinol 10000 3 Di Acetone Alcohol 5000 4 Hexylene Glycol 5000

Annexure 3

Land Breakup of MEK & MIBK

Description

Area (in acres) Area in

percentage MEK plant I MEK Expansion MIBK

(Proposed) Total Area

Build up area 2.25 2.19 9.0 13.44 49.4 Solid waste

disposal 0.20 0.50 0.20 0.90 3.3

Green Belt 2.00 2.50 2.84 7.34 27.0 Roads 1.00 1.00 3.52 5.52 20.3 Total 5.45 6.19 15.56 27.20 100.00

Annexure 4 Topo Map

Annexure 5

Annexure 6

MIBK Process Description Introduction Cetex petrochemicals propose to produce MIBK commercially using acetone and hydrogen

as raw material in a three step route. The key raw material in the manufacture of Methyl

Isobutyl Ketone (MIBK) is Acetone and shall be imported as bulk via M/s Mitsui & Co. at

Ennore port and stored at port storage tanks. The same will be transported via tankers to

factory site.

The first step in process is Acetone converted to Diacetone alcohol (DAA) by Aldol

condensation, followed by dehydration of DAA to Mesityl oxide (MO) and mild

hydrogenation of Mesityl oxide to MIBK. MIBK on further hydrogenation yields MIBC.

Diacetone alcohol (DAA) section Aldol condensation of acetone takes place in the presence of strong base as catalyst

resin

Formation of DAA is an equilibrium reaction which is favored at low temperature

below 15°C

Conversion of Acetone to DAA is mainly governed by the quality of acetone feed

(Since, low converter activity is due to aldehydes, oxides and acids in recycle or fresh

makeup stream), temperature of the feed to the converters and the activity of the

catalyst.

Stabilizing agent (here Citric acid is used) is added to the product stream at a point

downstream from the converters before it is heated for distillation to prevent the

reversion of DAA to Acetone

Two stage converters with inter-stage cooling system provided, since the reaction is

slightly exothermic

For maintaining low temperature of converter feed, butane chilling system will been

employed at both before and after first stage converter

Product effluent from second stage converter after dosing stabilizing agent, fed to

Acetone recycle column to separate unreacted acetone and DAA product

Crude DAA separates at bottom of recycle column and taken out to MO section

Top distillates of recycle column condensed and recycled back to converters along

with fresh makeup

Mesityl Oxide (M.O) section

Mesityl oxide is produced by dehydration of Crude DAA in the presence of acid

catalyst (2% Sulphuric acid) along with water as dehydration product in DAA

dehydration column

Reaction take place at 125 – 130 °C in liquid phase

M.O along with light components is distilled out as top product

Bottoms sent to M.O flash kettle for flash separation of M.O from unreacted DAA

Heavier component at the bottom of M.O flash kettle is sent to recovery column for

neutralization and recovery of DAA and acetone from aqueous phase

Top distillate from dehydration column is sent to M.O distillation column for

separation of M.O from acetone and water

Acetone along with water is getting separated out from M.O in M.O distillation

column as top distillate

M.O and some quantity of water stays at bottom in M.O distillation column is pumped

to M.O Phase separator for separation of Organic at top and Aqueous at bottom in

separator

Top organic phase is taken as reflux for DAA dehydration Column and a part is stored

in intermediate storage tank for MIBK / MIBC section

Methyl Isobutyl Ketone (MIBK) section

Mesityl Oxide along with hydrogen is superheated and fed to MIBK reactors

MIBK is formed by mild hydrogenation of Mesityl Oxide in the presence of

Palladium based catalyst

MIBK reaction is taking place in vapour phase @ 175 °C and 4 barg

Crude MIBK is then sent to distillation section for purification and to obtain finished

MIBK product

During MIBK reaction, MIBC also formed as by product, separated in distillation

section and sent to MIBC section

Methyl Isobutyl Carbinol (MIBC) section

Crude MIBK shall be feed to MIBC reactors along with hydrogen after superheated to

170 °C

MIBC is formed on intense hydrogenation of MIBK in the presence of Nickel based

Catalyst

MIBC reaction is taking place in vapour phase @ 170 °C and 11 barg

Crude MIBC is then sent to distillation section for purification and to obtain finished

MIBK product

Heavy ends (High boiling components) formed during reaction are separated in

distillation section and taken as by-product

Hexylene Glycol (HG) section

A part of Fin. DAA is fed to HG reactor along with Hydrogen after DAA purified via

distillation

Raney nickel is used as catalyst since the reaction is liquid phase

Crude HG obtained from reactor is taken for purification section

High boiling and unreacted DAA are separated and fed back into system, finished HG

is taken as product

Recovery Section

Purpose of this section is to recover organics that come from the water cuts collected

from all other sections

Organic separated in phase separator is fed back in corresponding purification section

and aqueous phase is taken out and sent to effluent treatment plant

Utilities

For process heat supply, high pressure steam shall be supplied from boiler having

capacity of 25 tons per hour

For high temperature applications such as superheating required before MIBK/MIBC

reactor, thermic fluid/oil shall be supplied from thermic fluid heater having capacity

of 4 Million Kcal / day

Common stack for boiler and thermic fluid heater will be installed as per norms

Fuel for Boiler & Thermic fluid heater will be design as multi-fuel fired with Wood,

Biomass and COAL

Process Flow Diagram

Annexure 7 Description of Proposed Effluent Treatment Plant Collection Tank

Effluent like cooling tower blow down, acid and alkali effluent from process waste water will be

collected in the equalization tank for homogenizing the effluent. From the collection tank the

homogenized effluent will be pumped through the Flash mixer for further treatment.

Flash Mixer & Flocculator

Collected effluent is pumped to flash mixer and flocculator where suitable coagulant, flocculent and

polymer are used to remove the suspended solids, turbidity.

Lamella Clarifier

The effluent from the flocculator will be fed in to lamella clarifier tank where the precipitated flocs

produced in flash mixer and flocculator will settle and the supernatant liquid overflows to the clarified

water tank.

UASB Reactor

The clarified water is pumped to anaerobic digester. During this process suitable alkaline chemical

(Na2CO3) is dosed for increasing the alkalinity of the effluent to make the effluent ambient for

anaerobic process. Since the BOD & COD load is heavy in the effluent, anaerobic reactor is designed

to reduce the load. The gas produce from the UASB reactor will lead into the bio gas flare system.

Primary use of the bio gas flare system is to combust the flammable or toxic gases to less

objectionable compounds.

Aeration tank

Effluent will be pumped at a constant flow rate from UASB reactor into the aeration tank. An

activated sludge treatment process occurs as a reaction between sewage and attached micro organisms

in the aeration tank. Air diffusers supply oxygen for biochemical processes as well as mixing sewage

with return sludge from the settling tank.

An air pump (positive displacement type roots blower) delivers air to a battery of fine bubble diffusers

at a constant rate thereby ensuring the growth of micro organisms in the sewage.

These include: Pseudomonas, Flavobacterium, Comamonas, Bacillus, Archromobacter, Alacingenes,

Sphaerotilus, Zoogloea, Archromobacter, Alacingenes, Flavobacterium, Pseudomonas / heterotrophic

bacteria, which disintegrate organic substances into a floc like substance. This is otherwise known as

an aerated suspended growth treatment process.

Secondary Settling Tank

The aerated effluent is then piped to the settling tank where the sludge sinks to the bottom. The clear

water overflows via a weir and is then fed to a disinfection tank. Suspended solids are collected at

bottom of clarifier; some of the active micro organism in the form of sludge is recirculated back to

aeration tank and mixed with the primary effluent with excess sludge pumped to sludge drying bed for

drying & disposal.

Disinfection cum clarified water tank

A suitable disinfectant, e.g. Hypo chlorite is dosed in the disinfection cum clarified water tank to

ensure that any remaining pathogenic micro organisms are eliminated and the water is fit for further

polishing & recycling.

Polishing Filters

The clarified water after disinfection and DM regeneration waste is pumped through Dual Media

Filter for filtering the suspended impurities and for removing free residual chlorine, organics & bad

odor through adsorption process. The filtered water at the outlet of the ACF is suitable for gardening

applications.

UF System

UF Automation

Operation of the Ultra filtration unit will be completely automated

Service & backwash sequence will be controlled by a PLC in the control panel

PLC will perform a programmed set of operations consisting of service’ backwash

and forward flush of the membranes at a preset sequence

It will also initiate the addition of chemicals during backwash to enhance the cleaning

efficiency during backwashing

The Ultra filtration unit will be provided with all safety features and any fault or

abnormal condition will be indicated by an audiovisual alarm in the control panel

RO System

UF permeate is pumped through the Micron Cartridge filter using the RO feed pump. It is primarily

used for the removal of turbidity.

Prior to the micron filter suitable Anti Scalant, Anti oxidant & Acid dosing are dosed to prevent any

low soluble salts settling over the surface of the membranes, to neutralize any oxidizing agents &

adjusting the pH entering into membranes respectively.

The conditioned water from the micron cartridge filter is pumped to the RO system by RO high

pressure pump.

The membrane separates the feed water into two streams namely permeate with low dissolved solids

& reject with high solid concentration. RO reject is fed into multiple effect evaporator system

followed by basket centrifuge.

Effluent Treatment Plant Schematic Diagram

REJECT REJECT

PERMEATE PERMEATE

Bar Screen

Raw Sewage Inlet

Equalization Tank

Flocculator Flash Mixer

Lamella clarifier Clean Water Tank

Bag Filter Dual Media Filter

Filter Feed Tank

Secondary Settling Tank

Aeration Tank

UF Permeate Tank

UASB Reactor

Micron Cartridge Filter

RO Module 1 RO Reject Tank 1 Micron Cartridge Filter

RO Module 2

RO Reject Tank 2

RO Sludge Settling Bed

Collection Tank

RO Permeate Tank

To Evaporation Feed Tank

Solar Pond Evaporation

Lamella Filtration

Annexure 8 MoU Letter Made with Common TSDF in Tamilnadu For Hazardous Waste Disposal