M/s Jemby Chem Limited is a working unit at Plot No. C-1/335 ...

M/s. Jemby Chem Limited, Ahmedabad - 1 -

1. INTRODUCTION

M/s Jemby Chem Limited is a working unit at Plot No. C-1/335-337,

Phase-II, GIDC Vatva, Ahmedabad, for manufacturing Dyes Intermediates

Sulpho Tobias Acid of 2 MT/Month, J-Acid of 2.528 MT/Month, J-Acid

derivatives of 12.67 MT/Month. Unit now proposed expansion of existing

products as well as manufacturing of new product N-Methyle Gamma Acid

of 5 MT/Month. Total production capacity shall be 200 MT/Month. The

proposed expansion will be carried out within the same premises.

The unit is promoted by Mr. Bharatbhai K. Patel with other technical

Director.

2. COST OF PROJECT

Existing cost of project is Rs. 2.5 crore. Cost for proposed expansion will

be Rs. 1.5 crore. Out of which 0.4 Crore will be used for EMS.

3. LAND REQUIREMENT

The unit is already developed at Plot No. C-1/335-337, Phase-II, GIDC

Vatva, Ahmedabad, having total area of the premises of 2210 m2.

4. PRODUCTION CAPACITY

Production capacity is prescribe below:

List of Products

Sr.

No.

Name of Product Existing

Production MT/Month

Proposed

addition MT/Month

Total After

expansion MT/Month

01 Sulpho Tobias Acid 2 23 25

02 J-Acid 2.528 47.472 50

03 J-Acid derivatives 12.67 87.33 100

1. N-Acetyl J-Acid

2. N-Methyl J-Acid

3 N-Benzoyl J-Acid

4. N-Phenyl J-Acid

04 RW-Acid(Di-J Acid) 10 10

05 Sulpho J- Acid 10 10

06 N-Methyl Gamma Acid

00 5 5

Total 17.198 182.802 200


5. LIST OF RAW MATERIALS

Sr. No. Name of Products Name of Raw Materials Quantity Kg/MT

1. Sulpho Tobias Acid Oleum (23%) 2400

Tobias Acid 800

Salt 2000

2. J-Acid

Tobias Acid 1430

Oleum (23%) 4715

NaOH 1715

Dil. H2SO4 3300

3. N-Acetyl J-Acid J-Acid 950

NaOH 190

Acetic Anhydride 530

Salt 1140

4. N-Methyl J-Acid J-Acid 1190

MMA (40%) 1785

Sodium Bisulphite 2975

H2SO4 (98%) 180

Caustic Soda 300

Dilute H2SO4 1190

5.

N-Benzoyl J-Acid J-Acid 770

Ben. Chloride 655

Sodi. Acetate 925

NaOH 155

Soda Ash 75

Salt 385

6. RW-Acid(Di-J Acid)

J-Acid 1430

NaOH 200


HCl (30%) 480

Salt 3140

7. Sulpho J-Acid J-Acid 1500

Oleum 65% 6750

H2SO4(98%) 1075

Salt 4250

8. N-Phenyl J-Acid J-Acid 910

Aniline Oil 365

Soda Ash 55


Dilute H2SO4 910

9. N-Methyl Gamma Acid Gamma Acid 1000

MMA (40%) 1500


H2SO4 (98%) 150

Caustic Soda 250

Dilute H2SO4 1000


6. MANUFACTURING PROCESS

1. Sulpho Tobias Acid

Process Description:

Oleum & Tobias Acid is charged in Sulphonator vessel. After 12 hrs the reaction

completes & the reaction mass is dumped into drowning vessel where ice & salt

are added. After drowning, reaction mass is filtered through Nutch filter. The

product remains at the top of Nutch filter & the filtrate as wastewater goes to

the effluent treatment plant. The product from the Nutch filter is taken into the

centrifuge for drying. After drying, the product is packed & dispatched.

Chemical Reaction

Mass Balance:

INPUT Kgs Kgs OUTPUT

Oleum (23%) 3000

Tobias Acid 1000

Ice 9000

Salt 2500

12075 Effluent

1500 Effluent

1925 Final Product(65%)

1250 Kg Real Basis

Total 15500 15500

Products Wet

cake

Mass balance of Sulpho Tobias Acid

Centrifuge

Nutch Filter

Sulphonation

Drowning


2. J-Acid


Oleum (23%), Tobias Acid is charged into vessel for Sulphonation. Then water is

added for hydrolysis process. The reacted mass is filtered & centrifuged. The

wastewater generated is recycled in isolation process. The crude mass is

fusioned with NaOH. Then isolation is carried out with charging of dil. Sulfuric

acid. The reaction mass is filtered through Nutch filter. Then the wet cake of

product is dried in centrifuge, which is then after packed & dispatched.

Chemical Reaction:


Mass Balance:


Oleum (23%) 3300

Tobias Acid 1000

Water 3600

2310 Reuse for Isolation

1500 Reuse in other products

990 Reuse in other products

NaOH 1200

Dilute H2SO4 2310

4200 Effluent

1135 Effluent


700 Kg Real Basis

Total 11410 11410

Mass balance of J- Acid

Sulphonation

Centrifuge

Nutch Filter

Centrifuge

Products Wet

cake

Hydrolysis

Fusion

Isolation

Nutch Filter


3. N-Acetyl J-Acid


J-Acid, Caustic Lye, or flakes Acetic Anhydride & soda Ash and Salt are charged

in the reactor for Acetylation process for 22 hrs. The Acetylate reaction mass is

filtered through Nutch filter. The wet cake retains on the top of Nutch filter &

the filtrate as wastewater goes to the Effluent Treatment Plant. Then the wet

cake of product is dried in centrifuge, which is then packed & dispatched.

Chemical reaction:

Mass Balance:


J-Acid 1000

NaOH 290

Acetic Anhydride 560

Salt 1200

Water 6000

6300 Effluent

1350 Effluent


1050 Kg Real Basis

Total 9050 9050

Products Wet cake

Mass balance of N-Acetyl -J- Acid

Acetylation

Nutch Filter

Centrifuge


4. N-Methyl J-Acid


J-Acid, Mono Methyl Amine, Sodium Bi Sulphite solution are added in the reactor

for Methylation. The reaction continues for 34 hrs. The MMA vapors are

condensed & refluxed back into the reactor. As the reaction completes, the

reaction mass is dumped into the drowning vessel, where dilute sulfuric acid are

added & SO2 gas is generated. The isolated mass is filtered through Nutch filter.

The wet cake retains on the top of Nutch filter & the filtrate as wastewater goes

to the effluent treatment plant. The wet cake is dumped into the vessel, where

caustic soda &dilute sulfuric acid are charged. The reaction mass i.e. product is

filtered through Nutch filter. The product is retained on the Nutch filter & filtrate

is allowed to pass to effluent treatment plant. The wet cake of product is dried in

dryer, which is then packed & dispatched.

Chemical reaction:


Mass Balance:


5. N-Benzoyl J-Acid


Take water and add J-Acid, caustic, Benzoyl chloride, soda and salt in reaction

vessel. Then mass filter in Nuetch. Cake is centrifuge and dried after dried

material is packed and dispatch.

Chemical reaction:

Mass Balance:


J-Acid 1000

Benzoyl Chloride 850

Sodium Acetate 1200

NaOH 300

Soda Ash 200Salt 300

Water 5000

5000 Effluent

1250 Effluent


1300 Kg Real Basis

Total 8850 8850

Centrifuge

Products Wet

cake

Mass balance of N-Benzoyl J-Acid

Benzoylation

Nutch Filter


6. N- Phenyl J-Acid:


J-Acid, Aniline oil, SBS, Soda and water are added in the reactor for reflux. The

reaction continued for 40 hrs. As the reaction is completed the reaction mass is

filtered through Nutch filter / filter press. The wet cake retains on the top of

Nutch filter and the filter is used in next batch. The wet cake is centrifuged

above, and the cake is taken for second stage of purification, in to vessel where

Sulphuric acid and water are charged. The batch is filtered through Nutch filter/

filter press. The product is retained on the Nutch filter and filtrate is allowed to

pass through Effluent Treatment Plant. The wet cake is centrifuged and dried

which is then packed and dispatched.

Chemical reaction:


Mass Balance:


7. RW Acid/Rhoduline Acid/Di-J-Acid


This is two-stage process, one is refluxing & another is purification. In the

refluxing process, J-Acid, caustic lye,or flakes sodium bisulphite, salt are

charged into vessel for 40 hrs. The reaction mass is filtered through Nutch filter.


to the effluent treatment plant. Then the wet cake is centrifuged. The crude

cake is taken for 2nd stage i.e. for purification. The crude cake is taken into

vessel where HCl, salt & water are charged. The reaction mass i.e. product is



centrifuge, which is then packed & dispatched.

Chemical reaction:


Mass Balance:


J-Acid 1000

NaOH 140

SBS Sollution (R) 1250

Salt 1015

Water 1100

3000 Effluent

HCl 340

Salt 950

Water 7215

7235 Effluent

1375 Effluent


700 Kg Real Basis

Total 13010 13010

Centrifuge

Products Wet

cake

Purification

Nutch Filter

Mass balance of RW -Acid

Reflux

Isolation

Nutch Filter


8. Sulpho J- Acid


Oleum and J-Acid is charged in Sulphonator vessel and heated to maintain

required temperature. add sulphuric acid and After 12 hrs the reaction is

complete and the reaction mass is dumped in to drowning vessel where ice,

water, high flow and carbon are charged. The batch is filtered through Nutch

filter/ filter press. The filtrate is taken for second stage of isolation. The filtrate is

taken in to vessel where salt are charged. The batch is filtered through Nutch

filter/ filter press. The wet cake of product is centrifuged and dried which is

packed and dispatched. The filtrate is passed through ETP.

Chemical reaction:

Mass Balance:


J-Acid 1500

Oleum(65%) 6450

Sulphuric Acid 1075

Water 15000

Ice 8250

Salt 4250

27950 Effluent

6575 Effluent


1000 Kg Real Basis

Total 36525 36525

Centrifuge

Products Wet

cake

Drowning

Isolation

Mass balance of Sulpho -J- Acid

Reflux

Clarification

Nutch Filter


9. N-Methyl Gamma Acid


Gama-Acid, Mono Methyl Amine, Sodium Bi Sulphite solution are added in the

reactor for Methylation. The reaction continues for 34 hrs. The MMA vapors are

condensed & refluxed back into the reactor. As the reaction completes, the

reaction mass is dumped into the drowning vessel, where dilute sulfuric acid are

added & SO2 gas is generated. The isolated mass is filtered through Nutch filter.


to the effluent treatment plant. The wet cake is dumped into the vessel, where

caustic soda & dilute sulfuric acid are charged. The reaction mass i.e. product is



dryer, which is then packed & dispatched.

Chemical reaction:


Mass Balance:

7. DETAILS OF MANPOWER

Present 40 nos. of skilled and unskilled persons are employed by the unit.

After expansion, total manpower requirement at all level of plant will be

increase up to 55.


8. WATER CONSUMPTION & WASTE WATER GENERATION

Water Balance-Water Consumption

Sr.

No.

Source Water Consumption

Existing

(lit/day)

Water Consumption

After expansion

(lit/day)

1. Domestic 2500 5000

2. Green Belt 1000 5000

3. Industrial

A Water treatment 000 5000

B Process 19000 45000

C Boiler 9000 10000

D Cooling Tower 1000 15000

E Washing 1500 20000

Total Industrial 30500 95000

TOTAL (1 +2 + 3) 34000 105000

Water Balance-Wastewater Generation

Sr.

No.

Source W/w Generation

Existing

(lit/day)

W/w Generation

After expansion

(lit/day)

1. Domestic 2000 3000

2. Industrial

A Water treatment 0 5000

B Process 16000 92000*

C Boiler 500 1000

D Cooling Tower 500 5000

E Washing 15000 20000

Total Industrial 32000 123000

TOTAL (1 +2) 34000 126000

* Greater quantity of wastewater generation due to use of Ice and Water

retain with products. Out of total wastewater generation, 24.0 KLD Dilute

Sulphuric Acid will be sent to NOVEL for reuse by actual users or for treatment

and 68.0 KLD after primary treatment will be sent for common MEE/evaporator

to achieve zero discharge and 31.0 KLD dilute effluent from washing and

utilities will be sent for final treatment and final disposal to CETP-GESCSL,

Vatva.


9. SOURCE OF POLLUTION

Details of Air Pollution

The main source of emission will be of flue gas emission. Proper Stack

height and APC measure will be provided in order to achieve norms

prescribed by statutory authority. At present the main source of gaseous

emission is flue gas due to combustion of bio fuel for boiler & Thermic

Fluid heater. The flue gas emission contains SPM, SO2 and NOx as air

pollutants. The process gas stack is attached to SO2 scrubber having

stack height of 15 m. The process gas emission contains SO2 as air

pollutants. After expansion, additional source will be one stack for

additional boiler and other one is for process vent. Two stage scrubber

systems will be provided to recover Sodium bi sulphite and meeting the

emission norms laid down by GPCB. The details of stacks are given

below:

Sr.

No.

Stack

attached to

Fuel Type Stack

Height,

in m

APC

measures

Probable emission

Existing

Flue Gas Stacks

1. Steam Boiler Bio

fuel/Coal

15 Cyclone

separator

SPM<150 mg/Nm3

SO2<100 ppm

NO2<50 ppm

2. Thermic Fluid

Heater

Bio

fuel/Coal

15 Cyclone

separator

SPM<150 mg/Nm3

SO2<100 ppm

NO2<50 ppm

3. D G set

(125 kVA)

Diesel –

30 lit/hr.

11 -- SPM<150 mg/Nm3

SO2<100 ppm

NO2<50 ppm

Process Gas Stacks

1. Reaction Vessels

- 15

Alkali Scrubber

(Ventury +

Packed

column)

SO2<40 mg/Nm3

Proposed

Flue Gas Stacks

1 Steam Boiler Bio

fuel/Coal

15 Cyclone

separator

SPM<150 mg/Nm3

SO2<100 ppm

NOx<50 ppm

Process Gas Stacks

2. Reaction Vessels

- 15

Alkali Scrubber

(Ventury +

Packed

column)

SO2<40 mg/Nm3


Source of wastewater

Greater quantity of wastewater generation due to use of Ice and Water

retain with products. Out of total wastewater generation, 24 KLD Dilute

Sulphuric Acid will be sent to NOVEL for reuse by actual users or for

treatment and 68 KLD after primary treatment will be sent for common

MEE/evaporator to achieve zero discharge and 31 KLD dilute effluent from

washing and utilities will be sent for final treatment and final disposal to

CETP-GESCSL, Vatva. Domestic wastewater will be disposed through soak

pit.

Source and disposal of Hazardous wastes

There will be three types of hazardous waste generation i.e. ETP sludge,

used oil and discarded containers/liners. ETP sludge will be disposed off at

TSDF site, used will be disposed by selling to registered re-processors and

discarded containers/liners will be disposed by selling to registered

recyclers. Detail of hazardous waste is given below:

Sr.

No.

Type of

Waste

Category

No. as

per HWM

rules,

2016

Quantity Method of

Disposal Existing Propose

d

Total

1. ETP

sludge

35.3 40

MT/Month

250

MT/Month

290

MT/Month

Sold to cement

manufacturer or

Disposal to TSDF

site Eco Care,

Surendranagar.

2. Discarded

containers/

barrels/

liners

33.1 12 nos.

Liner-8

kg/Month

30 nos.

Liner-50

kg/Month

42 nos.

Liner-58

kg/Month

Being used for

packing of ETP

sludge in case of

excess it will be

sold to approved

recycler or traders

3. Used

Lubricating

Oil

5.1 200

Lt/Year

200

Lt/Year

400

Lt/Year

It will be sold to

approved recycler

With CPCB

M/s Jemby Chem Limited is a working unit at Plot No. C-1/335 ...

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