RESIST SALT Shed No. A1/ 3806, GIDC, Ankleshwar Email · Ankleshwar Email: MFG OF: RESIST SALT Shed...

MFG OF: RESIST SALT

Shed No. A1/ 3806, GIDC, Ankleshwar-393002. Phone: 02646 221155, 252975 Fax: 02646 252893 Email: [email protected]

Web: www.nilkanthgroup.com

Sr. No.

Name of Enclosure

1. Name of Product with its quantity.

2. Packing, Storage and Final use of Product.

3. Name of Raw Material with its quantity.

4. Storage facility of Raw Material

5. Properties of Raw Material

6. Details of Hazardous Chemicals

7. Mass Balance with Chemical Reactions

8. Details of water consumption and waste water generation

9. Effluent Treatment Plant Details

10. Details of Flue gas emission and process gas emission with APCM system

11. Details of hazardous waste generation with its management.

12. Name & Address of Directors.

13. Land Supporting documents

14. Site Plan & Layout Plan of Unit.

15. CA certificate

16. SSI Certificate

17. CCA Copy

18. Membership certificate

MFG OF: RESIST SALT



Enclosure: 1

Name of Product and Its Quantity

Sr. No.

Product Name Quantity MT/Month

Existing Proposed Total

1 Resist Salt 50 300 350

2 Metanilic Acid 0 200 200

3 3,3 Di Nitro Di Phenyl Sulphone 0 25 25

Total 50 525 575

MFG OF: RESIST SALT



Enclosure: 2

Packing & Final Use of Products

Name of Product CAS No. Type of Packing

Final Application of Product

Resist Salt 127-68-4 Material is packed as per requirement 25Kg, 50Kg, HDPE bags

including liner.

Intermediate For Dyes, Textiles, Oxidizing Agent For Electroplating, Food Products, Auxiliary For Printing Fabrics

Metanilic Acid 121-47-1 Used As Raw Material For Production Of M-Amino Phenol And N-N Di Ethyl-M-Amino Phenol

3,3 Di Nitro Di Phenyl Sulphone 1228-53-1 Intermediate For Dyes, Textiles, Oxidizing Agent For Electroplating

MFG OF: RESIST SALT



Enclosure: 3

Name of Raw Material with Its Quantity

Raw Material Consumption Detail Product Wise

1. Resist Salt:

Sr. No.

Name of Raw Material

CAS No. MT/MT MT/Month


1. Nitro Benzene 98-95-3 0.60 29.99 179.95 209.94

2. Oleum (65%) 8014-95-7 0.57 28.71 172.24 200.95

3. Hydrated Lime 1305-60-0 0.28 14.14 84.83 98.97

4. Soda Ash 497-19-8 0.25 12.43 74.55 86.98

2. Metanilic Acid:

Sr. No.




1. Nitro Benzene 98-95-3 0.77 0 153.56 153.56

2. Oleum (65%) 8014-95-7 0.74 0 147.57 147.57

4. Soda Ash 497-19-8 0.30 0 59.93 59.93

3. Hydrated Lime 1305-62-0 0.40 0 80.15 80.15

5. Cast Iron Powder 7439-89-6 0.19 0 37.45 37.45

6. Hydrochloric Acid 7664-93-9 0.02 0 4.49 4.49

7. Sulphuric Acid 7647-01-0 0.07 0 14.98 14.98

3. 3,3 Di Nitro Di Phenyl Sulphone:

Sr. No.




1. Wet Cake of DNDS from Resist Salt

1228-53-1 0.04 0 14.5 14.5

2. Wet Cake of DNDS from Metanilic Acid

1228-53-1 0.05 0 10.5 10.5

MFG OF: RESIST SALT



Overall Raw Material Consumption:

Sr. No

Raw Material CAS Number Quantity MT/Month

1. Hydrated Lime 1305-62-0 179.00

2. Hydrochloric Acid 7664-93-9 4.5000

3. Iron Powder 7439-89-6 37.500

4. Nitro Benzene 98-95-3 364.00

5. Oleum 65% 8014-95-7 349.00

6. Soda Ash 497-19-8 147.00

7. Sulphuric Acid 7664-93-9 15.000

* We will maintain as minimum inventory as possible.

MFG OF: RESIST SALT



ENCLOSURE: 04 CHEMICAL NAME & PHYSICAL FORM OF

RAW MATERIALS WITH ITS STORAGE FACILITY

Sr. No.

Raw Material Physical form Type of Packing MOC

Max. at a time

storage capacity

MT 1. Nitro Benzene Liquid Tank-50 MT*3 MS 85

2. Oleum 65% Liquid Tank-50 MT*3 MS 120

3. Sulphuric Acid Liquid Tank-10 MT*2 MS 10

4. Hydrochloric Acid Liquid Tank-10 MT HDPE 05

5. Hydrated Lime Solid Bag-25 kg HDPE 60

6. Iron Powder Solid Bag-25 kg HDPE 20

7. Soda Ash Solid Bag-25 kg HDPE 50

MFG OF: RESIST SALT



ENCLOSURE: 05 PROPERTIES OF THE RAW MATERIAL

Product

Physical & Chemical Composition

B.P. F.P. LEL

TLV

LD50 mg/k

g

Sp.Gr. (Water=1)a

t

V.D. at

(air=1)

Odor Threshold

Solubility in

Water Chemic

al Formul

a

State MW oC

oC %

ppm or mg/nm

3

ppm, mg/Nm

3

Hydrochloric Acid

HCl Liquid 36.46 52.7

7 NA 5 7 NA 1.16 1 NA Soluble

Nitro Benzene

C6H5NO

2 Liquid 123.11

210.

8

87.7

8 NA NA 590 1.2 4.25S 0.37 In cold

water

Oleum H2S2O7

Liquid 178.14 45 16.8 NA NA 2140 1.92 3.4

Penetrating

Soluble

Sulphuric Acid

H2SO4 Liquid 98 270 NA NA NA 2140 1.84 3.4 NA Soluble

Hydrated Lime

Ca(OH)2 Solid 74.1 NA 580 NA 5 7300 2.24 NA Odorless Slightly Soluble

Iron Powder Fe Solid 55.85 3000 1535 NA NA 30000 NA NA NA NA

Soda Ash Na2CO3 Solid 106 NA NA NA NA 4090 2.532 NA NA Soluble

MFG OF: RESIST SALT



ENCLOSURE: 06 DETAILS OF HAZARDOUS CHEMICALS

The Raw Materials, which are termed as Hazardous Chemicals as per the "Manufacturing, Storage and Import of Hazardous Chemicals Rules, 1989", are as listed in below Table:

Name of Hazardous Chemical

The Manufacturer, storage & Import of

Hazardous chemical Rules 1989

Maximum quantity that

can be stored at a time (MT)

Threshold Quantity in

(MT)

Type of storage

Nitro benzene Sr. No. 425 (Part II, Sch. 1 of MSICR, 1989)

100 (50 MT ×3) Not available MS Tank

Oleum (65 %) Sr. No. 444 (Part II, Sch. 1 of MSICR, 1989)

100 (50 MT ×3) Not available MS Tank

Hydrochloric acid Sr. No. 313(Part II, Sch. 1 of MSICR, 1989)

05 Not available HDPE Tank

Sulphuric acid Sr. No. 591 (Part II, Sch. 1 of MSICR, 1989)

10 Not available MS Tank

MFG OF: RESIST SALT



Enclosure: 7

Mass balance, chemical reaction and manufacturing process

MFG OF: RESIST SALT



PROCESS FLOW DIAGRAM OF NITRO BENZENE SODIUM SULFONATE

Sulfonator

2740 kg

Drowning

4940 kg

Filtration (Filter press) - 6440 kg

Vacuum Distillation unit (Agitator) – 6605 kg

Resist Salt press cake 3500 kg

Nitrobenzene: 1400 Kg

Oleum 65%: 1340 Kg

Gypsum Washing Water:

2200 kg

Recycled Water: 1700 Kg (water

from filtrate DDS washing -1200

Kg & Gypsum washing water –

500 kg)

Soda Ash: 520 Kgs

Hydrated Lime: 660 Approx

Filtrate (Neutralization)

7970 kg

Press Cake (DDS) – 150

kg

Filtration (Filter press)

Soda test Tank -

6830 kg Press cake (Gypsum) - 1700 kg

50% Moisture

Moisture removal &

condensate into water –

3105 kg, Which is used

in cooling in Vacuum

Distillation for makeup

of water evaporation.

Post Filtration Fresh Water

Washing - 1500 Kg.

Wash Water = 1200 kg (Reused

in Soda lime slurry preparation

Post Filtration Fresh

Water Washing– 2700

kg

Wash Water = 2700 kg (Reused in Soda

lime slurry & drawing)

RFD

Resist Salt - 2334 kg

Moisture Removal – 1166 kg

Dryer

DDS – 96 KG Moisture removal – 54 kg

Soda Ash- 60 kg.

Fresh water – 500 kg

Nutsche Filter

Press Cake

– 75 kg

Settling tank – 6755 kg

Settled Slurry – 75 Kg. Sparkler Filter – 6680 kg

Press Cake – 75 Kg.

MFG OF: RESIST SALT



Chemical reaction:

NO2 NO2

+ H2SO4.SO3 + H2SO4

Nitro Benzene Oleum MW: 123 MW: 178 SO3H

NO2 NO2

H2SO4 + Na2co3 + Ca (OH)2 + CaSO4 +2 H2O + CO2 + NaOH

SO3H SO3Na

Resist Salt

MW: 225

NO2 NO2 NO2

+ H2S2O7 O + H20 + H2SO4

Nitro Benzene S

O

3, 3’ – Dinitro diphenyl sulfone

MFG OF: RESIST SALT



PROCESS FLOW DIAGRAM OF METANILIC ACID

Sulfonator

2010 kg

Drowning

3710 kg

Filtration (Filter press) - 4710 kg

Nitrobenzene: 1025 Kg

Oleum 65%: 985 Kg

Gypsum Washing Water:

1700 kg

Recycled Water: 1200 Kg (water

from filtrate DDS washing -1000

Kg & Gypsum washing water –

200 kg)

Soda Ash: 400 Kgs

Hydrated Lime: 485 Approx

Filtrate (Neutralization)

5675 kg

Press Cake (DDS) –120

kg

Filtration (Filter press)

Reduction -

4755 kg Press cake (Gypsum) - 1200 kg

50% Moisture

Post Filtration Fresh Water

Washing - 1000 Kg.

Wash Water = 1000 kg (Reused

in Soda lime slurry preparation

Post Filtration Fresh

Water Washing– 1900

kg

Wash Water = 1900 kg (Reused in Soda

lime slurry & drawing)

Dryer

DNDS – 70 KG Moisture removal – 50 kg

Iron Powder: 250 kg

HCL: 30 kg

Filtration Iron Sludge: 250 kg (Transfer to TSDF)

ISOLATION – 4605 kgs Sulphuric Acid: 100 kg

Filtration & Centrifuging Mother liquor: 1585 KG Recycled

DRYING – 3070 kgs. Evaporation loss: 1735 kgs

Metanilic Acid: 1335 kgs. Gypsum: 100 KG

50% Moisture

To ETP/SPRAY DRYING: 1485 KGS

Hydrated Lime: 50 kgs.

MFG OF: RESIST SALT



CHEMICAL REACTION OF METANILIC ACID

NO2 NO2

+ H2SO4.SO3 + H2SO4

Nitro Benzene Oleum MW: 123 MW: 178 SO3H

NO2 NO2

H2SO4 + Na2co3 + Ca (OH)2 + CaSO4 +2 H2O + CO2 + NaOH

SO3H SO3Na

Resist Salt MW : 225 NO2 NH2

+ 2Fe + 2HCI + 2 FeO + Fe CI3

SO3Na SO3 Na

NO2 NO2 NO2

+ H2S2O7 O + H20 + H2SO4

Nitro Benzene S

O

3, 3’ – Dinitro diphenyl Sulfone (DNDS)

MFG OF: RESIST SALT



Enclosure: 8

Details of Water Consumption and Waste Water Generation

Water Consumption in KL /Day Effluent Generation in KL /Day

Existing Proposed Total Existing Proposed Total

Domestic(A) 1 4 5 1 4 5

Gardening(B) 0 2 2 0 0 0

Industrial (C)

Process 5.7 79 84.7 0 62.5 62.5

Washing 0 2 2 0 2 2

Cooling 1 1 2 0 0.1 0.1

Boiler 0 2 2 0 0.2 0.2

Industrial Total (C) 6.7 84.0 90.7 0 64.8 64.8

Grand Total (A+B+C)

7.7 90.0 97.7 1.0 68.8 69.8

Total water requirement: 97.7 KLPD Total Effluent Generation: 69.8 KLPD

Total Ind. Water Consumption: 90.7 KLPD

Total Ind. Effluent Generation: 64.8 KLPD

Domestic Effluent Generation: 5 KLPD

Total Recycled Water : 53.5 KLPD (Process)

Total Recycled Water : 53.5 KLPD (Process)

Sent to Soak Pit/Septic Tank

Total Fresh Water requirement: 43.7 KLPD

Total Effluent Generation: 11.3 KLPD (Spray Dryer, Ankleshwar)

Note: When discharged permission to ETL starts, we will discharge to ETL after obtain permissible

norms.

MFG OF: RESIST SALT



Existing Water Balance Diagram:

All unit in KL/D

Water Consumption 7.7 KLPD

Process: 5.7

Domestic Effluent goes to septic Tank

1

Domestic 1

W/W 0

Cooling: 1

W/W 0

Industrial- 6.7

MFG OF: RESIST SALT



After Proposed Expansion:

All Units in KLPD

Water Consumption 97.7 KLPD

(Fresh-43.7 KL/d & Recycle –53.5 KL/d)

Industrial- 90.7

Process: 84.7 (Reused: 53.5 + Fresh: 31.2)

Boiler 2

Domestic Effluent goes to septic Tank

5

Domestic 5

Gardening 2

W/W

62.5

Reuse: 53.5

Effluent to ETP 9.0

B/D 0.2

Washing 2

W/W 2.0

Cooling: 2

W/W 0.1

ETP 11.3

In house Spray Drying 11.3

MFG OF: RESIST SALT

Shed No. A1/ 3806, GIDC, Ankleshwar-393002. Phone: 02646 221155, 252975 Fax: 02646 252893 Email: [email protected] Web: www.nilkanthgroup.com

Enclosure: 09

Details of Effluent Treatment Plant

Existing ETP:

Sr. No. Name of Unit No. Capacity

01 Collection Tank 01 10 KL

02 Collection Tank 01 10 KL

After Modification proposed ETP:

Sr. No. Name of Unit Capacity

01 Collection Tank 20 KL

02 Neutralization Tank 15 KL

03 Filter Press --

04 Holding Tank 20 KL

06 Sludge Drying Bed --

MFG OF: RESIST SALT


Enclosure: 10: Details of Flue Gas Emission

And Process Gas emission system with APC System

Details of Flue Gas Emission

Sr.

No. Stack Attached To

Qty. of Fuel

To be Used Type of Fuel

Stack Height

(m)

Air Pollution

Control Measure Pollutants

1

Thermic Fluid Boiler-I

(Cap.200000 KCAL/Hr.)

(Existing)

Natural

Gas

400 SCM/d(Ex.)+

100 SCM/d (Pro.) 12 Adequate Stack

PM

Sox

NOx

2

Hot Air Generator-I

(Cap. 80000 KCAL/Hr.)

(Existing)

Natural

Gas

250 SCM/d(Ex.)+

1250SCM/d

(Pro.)

10 Adequate Stack PM

Sox

NOx

3

D.G. Sets

(63 KVA)

(Existing)

Diesel 15 lit/hr 9 ---- PM

Sox

NOx

4

Small industrial Boiler-I

(Cap.600 Lit/Hr.)

(Proposed)

Natural

Gas 1000 SCM/d 10 Adequate Stack

PM

Sox

NOx

5

Thermic Fluid Boiler-II


(Proposed)

Natural


PM6

Sox

NOx

6

Thermic Fluid Boiler-III


(Proposed)

Natural


PM

Sox

NOx

7

Hot Air Generator-II


(Proposed)

Natural


PM

Sox

NOx

8

Hot Air Generator-III


(Proposed)

Natural


PM

Sox

NOx

MFG OF: RESIST SALT


Details of Process Emission

Sr. No. Stack Attached To Stack Height

in Meter Air Pollution Control

Measure Parameter

1

Spray Dryer (Inbuilt HAG) (500 Lit/Hr.) (Proposed)

11 Wet scrubber and Cyclone

Separator Particulate Matter

2

SFD (Spin Flash Dryer)(Inbuilt HAG) (300 KGS/Hr.) (Proposed)

11 Cyclone Separator And bag

filter Particulate Matter

3 Fluid Bed Dryer 11 Cyclone Separator

followed by bag filter Particulate Matter

Fuel Requirement

Sr. No Name of Fuel Total


1 Natural Gas 650 SCM/Day 4650 SCM/Day 5300 SCM/Day

2 Diesel 10 Lit/Hr 5 Lit/Hr 15 Lit/Hr

MFG OF: RESIST SALT


Enclosure: 11

Details of Hazardous Waste Generation with its Management

Sr. No.

Type of Waste Source of

Generation Cat. No. Quantity

Facility Existing Proposed Total

1 ETP waste ETP Plant 35.3 0.0 15

MT/Yr 15 MT/yr

Collection, Storage, Transportation & Disposed to TSDF Site.

2 Used Oil Plant &

Machinery 5.1

0.006 KL/Year

0.02 KL/Year r

0.026 KL/Year

Collection, Storage, Transportation, Disposal by selling to Register refiners.

3

Discarded Drums Bag/Liners/Containers.

Raw Material Storage

Area

33.3 2

MT /Year 1

MT/Year 3

MT/Year

Used for Packing of ETP Waste or return back to Raw material Supplier.

3 Gypsum Waste from Process

Resisit Salt &

Metanilic Acid

26.1 240

MT/Year 4956

MT/Year 5196

MT/Year

Collection, Storage, Transportation, Sell to Cement Mfg. Unit (1) M/s. Narmada Cement Company, Amreli Co.

4 Iron Waste from process.

Metanilic Acid

26.1 0 MT/Year 450

MT/Year 450

MT/Year

Collection, Storage, Transport to Cement Industries for co-processing.

MFG OF: RESIST SALT


Enclosure: 12

Name and Address of Director

Sr. No. Name of Directors Address of Directors

1 Mr. Vipulbhai V. Gajera 402/08/B, Alkapuri Society, G.I.D.C. Estate, Ankleshwar-393002 (M) 9824150500

2 Mr. Balubhai V. Gajera 405/11/B, Sardar Patel Society, G.I.D.C. Estate, Ankleshwar ‐ 393 002. Phone : 02646 220214

MFG OF: RESIST SALT


Enclosure: 13

Land Supporting Document

MFG OF: RESIST SALT


Enclosure: 14

Site Plan and Layout Plan

MFG OF: RESIST SALT


Enclosure: 15

Valuation Certificate

MFG OF: RESIST SALT


Enclosure: 16

SSI Copy

MFG OF: RESIST SALT


Enclosure: 17

CCA Copy

MFG OF: RESIST SALT


MFG OF: RESIST SALT


MFG OF: RESIST SALT


MFG OF: RESIST SALT


Enclosure: 18

Member Ship Certificate

Date post:	29-Nov-2018
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RESIST SALT Shed No. A1/ 3806, GIDC, Ankleshwar Email · Ankleshwar Email: MFG OF: RESIST SALT Shed...

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