PAINTS & RESINS MANUFACTURING PLANT

KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

3 ANNEXURES

Annexure 1: Production Details

S. No. Name of the Product Production Capacity, MT/Annum
A EC Products
1 Resin 40080
B Non EC Products (NOC Received)
1 Paint and varnish, Enamels, Lacquer 68280
2 Thinner 18000
Total B 86280
Total Production (A + B) 126360

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

Annexure 2: Copy of NOC Received

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

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KANSAI NEROLAC PAINTS LIMITED ESTATE FORM I

Annexure 3: Site Location Map

Point Latitude Longitude Point Latitude Longitude

A 21°47'57.69"N 72°53'34.96"E D 21°48'14.67"N 72°53'51.59"E
B 21°47'59.66"N 72°53'46.93"E E 21°48'22.12"N 72°53'41.71"E
C 21°48'12.82"N 72°53'43.55"E F 21°48'19.45"N 72°53'31.63"E

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Annexure 4: Site Layout Map

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

Area Break up at Site

S. No. Title Area, m2 % of total Area

1 Processing Area 12524.63 8.23

2 Storage Area 0.00
a Hazardous Chemicals 12642.89 8.31
b Other Non-hazardous chemicals - 0.00
c Hazardous Waste 521.98 0.34
d Water Storage 420 0.28
e Fuel & solvent Storage 5752.66 3.78
3 Effluent Treatment Plant 2439 1.60
4 Boiler 244 0.16
5 Cooling tower 28.72 0.02
6 DG & LT room 286.91 0.19
7 Roads 40213.6 26.43
8 Administrative Building 241.05 0.16
9 Open Space 4915.6 3.23
10 Greenbelt Area 50209.87 33.00
11 Area for proposed Expansion 6314.62 4.15
12 Others - Parking area, weigh house, driver rest room etc 15395.58 10.12
Total 152151.11 100.00

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KANSAI NEROLAC PAINTS LIMITED AT SAYKHA INDUSTRIAL ESTATE FORM I

Annexure 5: List of Equipments

For Non EC
S. No Name of Equipments For EC Products Total
Products
1 Sand Mill 9 0 9
2 Basket mill 5 0 5
3 Ball mill 18 0 18
4 Alumina mill 2 0 2
5 Dyno mill 16 0 16
6 Mixers 122 0 122
7 High speed Disperser 9 0 9
8 Twin Shaft Disperser 14 0 14
9 Filtration assembly/skid 42 0 42
10 Filling Machine 59 0 59
11 Drum /barrel Cleaning Machine 11 0 11
12 Cap seal Machine 22 0 22
13 Bell applicator 2 0 2
14 Reactor 0 16 16
15 Thinning vessel 0 9 9
16 DG Set (2000 KVA) 2 1 3
17 Gas Gen Set 0 2 2
18 Thermopac 0 4 4
19 Boiler 2 0 2
20 Chilling plant 12 0 12
21 Cooling tower 8 0 8
22 Air Compressor 3 0 3
23 Nitrogen Generation Plant (180 Nm3/hr) 1 0 1

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Annexure 6: Manufacturing Processes

There will be basically two types of processes:

I. Manufacturing of intermediate like resins for internal consumption

II. Manufacturing of products like paints, lacquer, enamels and Thinner

The paint manufacturing unit is set up with vertical integration of the corresponding manufacture of
synthetic resins that are needed in the manufacturing of the paints.

MANUFACTURING PROCESS FOR EC PRODUCTS

1. Resins

Synthetic resins are basically obtained through a reaction (in an inert atmosphere in a stainless steel
vessel) of polyhydric alcohol and polybasic acids. Alternatively, a solvent process also could be utilized in
the manufacture of these resins. Further, resins are also obtained by polymerization of monomers. The
resins that are proposed to be manufacture by the company are Alkyd resins, Phenolic resins, Maleic
resins, amino resins, Acrylic resins, Cathodic Electro deposition resins etc.

The chemical reactions for some of the resins are as follows:

Alkyd resins:
It is polyester of polybasic acid & Polyol, modified with oil. Mainly it is an esterification reaction

Temperature: Max 260 – 285 0C

Pressure: Atmospheric

The input is 100%, whereas the output is 98%. The flow chart for the manufacturing process is given in
Figure 1 and material balance is given Table 1. The reaction efficiency is 98%, which also included the
solvent efficiency. Through condenser, the solvent is recovered and reused for consumption.

Amino resins:
Manufacturing includes the reaction between Paraform and Melamine to form Methylolation of the product.
Further, it is butylated by Butanol to form Amino Resins.

Temperature: 150 – 200 0C

The reaction efficiency is 45 – 50%, as water of reaction is generated, which is discharged to ETP.
Recovery in the case of solvent, which is reused in subsequent batch, will account for 42.35% & ETP will
be 6.15%. Balance 1.05% is handling loss. The flow chart for the manufacturing process is given in Figure
2 and material balance is given Table 2.
Acrylic resins:
Reaction of Acrylic monomer forming co- polymers with monomers like styrene, Butyl acrylate, Methacrylic
acid and other type of monomers in presence of catalyst Benzoyl Peroxide, tertiary Butyl Perbenzoate with
xylene & C-9 solvents. This mainly involves exothermic reaction.

Temperature: 200 0C

Pressure: Atmospheric

The flow chart for the manufacturing process is given in Figure 3 and material balance is given Table 3.
The reaction efficiency is 95 -98 % which includes the solvent efficiency.

Polyster Resins:
Provide details for Polyster resins also.

The flow chart for the manufacturing process is given in Figure 4 and material balance is given Table 4.

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Figure 1: Process flow diagram for Alkyd Resins

Table 1: Mass Balance for Alkyd Resin

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)
1 Powder 0.183
2 MTO 0.378
3 Mix Xylene 0.023
4 Linseed 0.192
5 DCO 0.192
6 Catalyst 0.064
Total 1.031
Output MT/MT of Product
S.
Liquid Air Recovery/ Remark
No. Product Solid Waste
Effluent Emission Product

1 Alkyd Resin 1.0 Product

2 Losses 0.010 To Incineration
To ETP for
3 Waste Water 0.021
Treatment
0.021 0.000 1.000 0.010
Total
1.031

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KANSAI NEROLAC PAINTS LIMITED PLANT AT SAYKHA INDUSTRIAL ESTATE FORM I

Figure 2: Process flow diagram for Amino Resin (Melamine Formaldehyde Resin)

Table 2: Mass Balance for Amino Resin (Melamine Formaldehyde Resin)

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)
1 Solvents 1.362
2 Catalyst 0.000002
3 Thinners 0.075
4 Others 0.544
Total 1.980
Output MT/MT of Product
S.
Liquid Air Recovery/ Remark
No. Product Solid Waste
Effluent Emission Product
1 Melamine Formaldehyde Resin 1.000 Product
2 Recycled Solvents 0.839 To Incineration
To ETP for
3 Losses 0.020
Treatment
Waste Water 0.122
0.122 0.000 1.839 0.020
Total
1.980

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KANSAI NEROLAC PAINTS LIMITED PLANT AT SAYKHA INDUSTRIAL ESTATE FORM I

Figure 3: Process flow diagram for Acrylic Resin

Table 3: Mass Balance for Acrylic Resin

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)
1 Monomer 0.543
2 Solvents 0.448
3 Catalyst 0.014
4 Others 0.005
Total 1.010
Output MT/MT of Product
S.
Liquid Air Recovery/ Solid Remark
No. Product
Effluent Emission Product Waste

1 Acrylic Resin 1.000 Product

To
2 Losses 0.010
Incineration
0.000 0.000 1.000 0.010
Total
1.010

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KANSAI NEROLAC PAINTS LIMITED PLANT AT SAYKHA INDUSTRIAL ESTATE FORM I

Figure 4: Process flow diagram for Polyster Resins

Table 4: Mass Balance of Polyster Resin

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)
1 Powder 0.509
2 Solvents 0.027
3 Thinner 0.338
4 Others 0.237
Total 1.111
Output MT/MT of Product
S.
Liquid Air Recovery/ Solid Remark
No. Product
Effluent Emission Product Waste

1 Polyster Resins 1.000 Product

2 Losses 0.011 To Incineration
3 Waste Water 0.100 To ETP for Treatment
0.100 0.000 1.000 0.011
Total
1.111

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KANSAI NEROLAC PAINTS LIMITED PLANT AT SAYKHA INDUSTRIAL ESTATE FORM I

MANUFACTURING PROCESS FOR NON-EC PRODUCTS

Paint manufacturing process
Solvent based paints are made by dispersing pigments and extenders in a base of resins (acting as
binders). It is diluted to the required viscosity and various physical and application properties are
adjusted by specialty additives.
Basic process consists of-
 Premixing: Pigments powders are wetted with optimum quantity of resin/ solvents. This is done in
high speed dispersers.
 Grinding: The slurry is ground in high speed sand Mills to achieve the desired particle size, which
is at micron levels.
 Blending: Adjustment with remaining resins, solvents, additives etc. to achieve desired physical
properties like viscosity, sp. Gravity, drying properties etc. Dry film properties like elasticity,
strength, scratch resistance etc also adjusted.
 Tinting: Tinting is done by adding various strainers/pigment concentrates to bring the product to
the desired shade
 Filtration: Final product is filtered through fine filters before filling in specified containers
 Filling: Final product is filled in required pack sizes, carbonized, palletized and sent to warehouse
for storage and dispatch.

Figure 5: Process flow diagram for Paint

Table 5: Mass Balance for Industrial Paint Solvent Based

Input/MT of Product
S.
No.
Raw Materials Quantity (MT/MT)

1 Resins 0.612

2 Powder 0.153

3 Additives 0.051

4 Solvents 0.204

Total 1.020

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Output MT/MT of Product

S.
Liquid Air Recovery/ Solid Remark
No. Product
Effluent Emission Product Waste

1 Solvent based industrial paint 1.000 Product

2 Losses 0.020 To Incineration
0.000 0.000 1.000 0.020
Total
1.020

Figure 6: Process flow diagram of CED paint (F-1)

PREMIXER TANK
(3F)
4 KL- 45 kW/ 1440 RPM
IMPELLER TYPE STIRRER

LOAD CELL

JACKET

DISPERSING MACHINE MIXING TANK

5 KL- 7.5 kW/1440 RPM
IMPELLER TYPE STIRRER

(2F)

50 L INNOUE MILL (RS-16) - 22 kW * 2

MEDIA:GLASS 1.0-1.4 mm
MEDIA - 65 %

(1F)
FILLING MACHINE
200 L
Paint
FILTRATION - FILLING
Load Cell
PREFILTER-100 MESH
6 CARTRIDGE FILTER
FILTRATION GRADE: 10 µm Spl
GRADE. ( C 7 )

Table 6: Mass Balance of CED paint (F-1)

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)

1 Resins 0.102

2 Pigments/extenders 0.439

3 Water 0.428

4 Additives 0.051

Total 1.020

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Output MT/MT of Product

S.
Liquid Air Recovery/ Solid Remark
No. Product
Effluent Emission Product Waste

1 Water based industrial paint 1.000 Product

2 Losses 0 0 0 0.020 To Incineration
0.000 0.000 1.000 0.020
Total
1.020

Figure 7: Process flow diagram of CED paint (F-2)

Table 7: Mass Balance of CED paint (F-2)

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)
1 Resins 0.449
2 Water 0.561
3 Additives 0.010
Total 1.020
Output MT/MT of Product
S.
Liquid Air Recovery/ Solid Remark
No. Product
Effluent Emission Product Waste
1 Water based industrial paint 1.000 Product
2 Losses 0 0 0 0.020 To Incineration
0.000 0.000 1.000 0.020
Total
1.020

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Thinner Manufacturing process:

Basic process consist of ---

 Mixing: 2 - 3 type of solvents as per formulation is mixed in mixer to make the uniform mixture.

 Filtration: The mixed solvent is filtered through fine filters before filling in specified containers

 Filling: Final product is filled in required pack sizes, carbonized, palletized and sent to warehouse
for storage and dispatch
Thinner is mixture of different solvent. The operation is closed loop system. There is no loss in the process.

Figure 8: Process flow diagram for thinner manufacturing process

Table 8: Mass Balance for Thinner

S. Input/MT of Product
No. Raw Materials Quantity (MT/MT)
1 Solvent 1 (Mixed Xylene) 0.655
2 Solvent 2 (Recovered distilled MIBK) 0.101
3 Solvent 3 ( Mostanol – 120) 0.05
4 Butyl Acetate 0.201
Total 1.007

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Output MT/MT of Product

S.
Liquid Air Recovery/ Remark
No. Product Solid Waste
Effluent Emission Product

1 Thinner 1.000 Product

2 Losses 0.004 0.003 0 To Solvent recovery plant
0.004 0.003 1.000 0.000
Total
1.007

Solvent recovery plant

Dirty solvent (waste/spent solvent) are generated during cleaning of equipments like filtration unit, mixer,
reactor etc in paint & resin manufacturing process. This solvent is sent to solvent recovery plant for
distillation. The distilled solvent is reused in the process where as the distillation sludge is disposed off
through incineration.

Brief description of solvent distillation process

Basic process consists of…..

 Collection of dirty solvent: All the production facility locations have been provided with cleaning
buss (tank) where dirty solvents are collected. The collected solvents are pumped to collection
tank and allowed it to settle the solid material.

 Solvent distillation: The distillation reactor is purged with N2 with flow rate 10 LPM. After that dirty
solvents are fed into the reactor and stirred to make the mass uniform. The gradual heating is
started till the reflux starts. The maximum temperature is maintained at 1400C. The reflux is then
passed through separator where distilled solvents are separated from water. The water is drained
into ETP whereas the distilled solvents are pumped into storage tank. The distillation sludge is
collected in barrel and disposed off through incineration.

 Cleaning of the reactor: After distillation process, the reactor is cleaned with 2% caustic solution
upto 60% operating volume and boil for 1 hrs. The caustic solution is drained into ETP for
treatment.

 Distilled solvent is issued to individual section for process use.

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Figure 9: Process flow diagram of solvent recovery plant

Dirty
solvent
CW OUT

Condensor

CW IN
N2

TG

PG
TG

Dirty Solvent
collection tank 3.5 m To Drain
PG

WIC WE Water
STEAM

CWR
10 Kl CWS
PG
Distill Solvent Trap
Tan k

PG
Storage Tank- 10 Kl
COND DR Drain

STEAM

CWR
W in
TG
5 Kl distillation PG

CWS Tank
COND DR

Drain
ETP Catch Tank
To
To drain Sludge Paint
0m section

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KANSAI NEROLAC PAINTS LIMITED ESTATE FORM I

Annexure 7: Raw Material & Product Storage Details

Table 9: Storage Details of Raw Material
Operating Condition Storage Maximum
(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

EC Products
1 Iso Pthalic acid Solid 12.24 Fibre drums atmospheric ambient 41 25 kg 1.2 MT
2 Bezoic acid Solid 129.30 bag atmospheric ambient 431 25 kg 11 MT
3 Maleic Anhydride Solid 3.75 bag atmospheric ambient 13 25 kg 0.5 MT
4 Phthalic Anhydride solid 1682.63 bag atmospheric ambient 5610 25 kg 140 MT
5 Pentaerythritol Powder 196.12 bag atmospheric ambient 654 25 kg 17 MT
6 Trymethylol propane Solid 319.49 bag atmospheric <25 1065 25 kg 27 MT
7 Neopentyl glycol Solid 336.67 bag atmospheric ambient 1122 25 kg 28 MT
8 1 6 Hexanediol Liquid 101.20 Barrel atmospheric ambient 42 200 Litr. 9 MT
9 Bisphenol A solid 761.96 Bag atmospheric ambient 2540 25 kg 64 MT
10 Paraformaldehyde solid 1056.26 bag atmospheric ambient 3521 25 kg 90 MT
11 Melamine crystals Powder 818.46 Fibre drum atmospheric ambient 2728 25 kg 69 MT
12 Adipic acid Solid 196.03 bag atmospheric <25 653 25 kg 17 MT

Hexa hydro phthalic

13 Liquid 275.94 Barrel atmospheric ambient 115 200 Kg 23 MT
anhydride
AIBN (azo-bis iso-
14 powder 222.61 Fiber drum atmospheric 15-20 742 25 kg 19 MT
butyronitrile) ind.
15 Benzoyl peroxide solid 19.37 Fiber drum atmospheric <40 65 25 kg 2 MT
Methyl ethyl ketoxime/mek
16 Liquid 186.23 Barrel atmospheric ambient 78 200 Litr. 16 MT
oxime (aska)
17 Placcel m (Capralactone) Liquid 143.45 Barrel atmospheric ambient 60 200 Litr. 12 MT
18 Mono ethanol amine Liquid 55.45 barrel atmospheric ambient 23 200 Litr. 5 MT

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KANSAI NEROLAC PAINTS LIMITED ESTATE FORM I

Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

19 Diethanol amine Liquid 227.19 barrel atmospheric ambient 95 200 Litr. 20 MT

20 Alkali refined linseed oil Liquid 62.86 Storage Tank atmospheric ambient 1 30 KL 30 KL
Dehydrated castor oil/
21 Liquid 191.5 Storage tank atmospheric ambient 1 30 KL 30 KL
commercial castoroil
Refined Soyabean oil
22 Liquid 1038.67 Storage Tank atmospheric ambient 1 60 KL 60 KL
(indl.grade)
23 Refined coconut oil Liquid 116.02 Storage Tank atmospheric ambient 1 30 KL 30 KL
24 Cardura e 10 p Liquid 53.54 Barrel atmospheric ambient 12 200 Ltr. 5 MT
25 D C O Fatty acid Liquid 27.95 Barrel atmospheric ambient 12 200 Ltr. 3 MT
26 Soya Fatty acid Waxy solid 31.84 Drum atmospheric ambient 27 50 Kg 2.6 MT
27 Castor oil fatty acid Liquid 26.52 Barrel atmospheric ambient 11 200 Ltr. 2.2 MT
28 Mineral turpentine oil Liquid 693.65 Storage Tank atmospheric ambient 1 100 KL 100 KL
29 Dist. C IX Solvent Liquid 1653.75 Storage Tank atmospheric ambient 1 100 KL 100 KL
30 Toluene Liquid 204.82 Storage Tank atmospheric ambient 1 50 KL 50 KL
31 Mixed Xylene Liquid 5056.97 Storage tank atmospheric ambient 1 150 KL 150 KL
32 Methanol Liquid 182.60 Storage tank atmospheric ambient 1 50 KL 50 KL
33 Butanol Liquid 2259.14 Storage tank atmospheric ambient 1 100 KL 100 KL
34 Octonal (2 ethyl hexanol) Liquid 32.29 Barrel atmospheric ambient 13 200 Ltr. 3 MT
35 Butyl cellosolve Liquid 768.45 Storage Tank atmospheric ambient 1 50 KL 50 KL
36 Ethyl acetate Liquid 5.84 Storage Tank atmospheric ambient 1 50 KL 50 KL
37 Butyl acetate Liquid 901.87 Storage Tank atmospheric ambient 1 50 KL 50KL
Cellosolve acetate (hiso solve
38 Liquid 87.39 Storage Tank atmospheric ambient 1 50 KL 50 KL
acetate)
39 Methyl ethyl ketone (MEK) Liquid 51.45 Barrel atmospheric ambient 21 200 Litr. 14 KL

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KANSAI NEROLAC PAINTS LIMITED ESTATE FORM I

Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

Methyl iso butyl ketone

40 Liquid 984.85 Storage Tank atmospheric ambient 1 50 KL 50 KL
(MIBK)
41 Iso butanol Liquid 290.03 Storage Tank atmospheric ambient 1 50 KL 50 KL
42 Dowanol P M Liquid 79.54 Barrel atmospheric ambient 33 200 Litr. 7 MT
43 Lactic acid Liquid 54.30 Barrel atmospheric ambient 23 200 Litr. 5 MT
44 Sorbitol 70 %.paint grade Liquid 25.40 Barrel atmospheric ambient 11 200 Litr. 2.5 MT
45 Ethylene glycol Liquid 75.12 Barrel atmospheric ambient 31 200 Litr. 6 MT
46 Glycerine water white Liquid 449.42 Storage Tank atmospheric ambient 1 40 KL 40 KL
47 A (DI-Ethylene Triamine) Liquid 16.37 Barrel atmospheric ambient 7 200 Litr. 1.5 MT
48 Styrene Liquid 1624.21 Storage Tank atmospheric <22 1 50 KL 50 KL
49 Methyl methacrylate Liquid 1148.28 Storage Tank atmospheric <25 1 60 KL 60 KL
50 Glycidyl methacrylate Liquid 32.36 Barrel atmospheric <25 14 200 Litr. 3 MT
51 Hydroxy ethyl acrylate (HEA) Liquid 45.30 Storage Tank atmospheric <25 1 30 KL. 30 KL
52 Butyl acrylate monomer Liquid 1113.08 Storage Tank atmospheric <25 1 60 KL. 60 KL
2 ethyl hexyl acrylate
53 Liquid 70.51 Barrel atmospheric <25 29 200 Litr 6 MT
monomer
54 Ethyl acrylate Liquid 160.61 Barrel atmospheric <25 67 200 Litr. 15 MT
2 ethyl hexyl methacrylate
55 Liquid 97.14 Barrel atmospheric ambient 40 200 Litr. 10 MT
monomer
56 Butyl methacrylate monomer Liquid 927.34 Storage Tank atmospheric <25 1 60 KL 60 KL
57 Iso-butyl methacrylate Liquid 15.68 Barrel atmospheric ambient 7 200 Litr. 1.5 MT
58 Hydroxy propyl acrylate Liquid 160.14 Storage tank atmospheric <30 1 30 KL. 30 KL
59 Acrylic acid Liquid 73.77 Barrel atmospheric ambient 31 200 Litr. 8 MT
60 Lauryl methacrylate Liquid 91.19 Barrel atmospheric <25 38 200 Litr. 8 MT

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KANSAI NEROLAC PAINTS LIMITED ESTATE FORM I

Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

61 Isobutyl acrylate Liquid 13.50 Barrel atmospheric ambient 6 200 Litr. 1.5 MT
62 2 Hydroxy ethyl methacrylate Liquid 1010.84 Storage Tank atmospheric ambient 1 60 KL 60 KL
HMDI (Hexa methylene di-
63 Liquid 196.28 Barrel atmospheric ambient 82 200 Litr. 17 MT
isocyanate)
64 IPDI Monomer Liquid 104.37 Barrel atmospheric ambient 44 200 Litr. 9 MT

Diethylene glycol mono ethyl

65 Liquid 312.04 Drum /Barrel atmospheric ambient 130 50/ 200 Kg 30 MT
ether
66 Distill fatty Acid Liquid 41.38 Drum atmospheric <35 69 50 kg 3.5 MT
67 Duranate-TPA-100 Liquid 70.04 Barrel atmospheric ambient 29 200 Litr. 6 MT
68 Diethylamine Liquid 13.35 Drum atmospheric ambient 267 50 Litr. 14 MT

Dimethyl Ethanol Amine

69 Liquid 47.34 Barrel atmospheric ambient 20 200 Litr. 4 MT
(Indigenous)
70 Placcel FM-3 Liquid 113.06 Barrel atmospheric ambient 47 200 Litr. 10 MT
71 N heptane Liquid 45.63 Barrel atmospheric ambient 19 200 Ltrs. 4 MT
72 LA Solvent Liquid 38.67 Barrel atmospheric ambient 16 200 Litrs. 7 MT
73 Methyl Acrylate Liquid 5.24 Barrel atmospheric <21 2 200 Litrs. 0.5 MT
74 Acrylonitrile Liquid 4.70 Barrel atmospheric ambient 2 200 Litrs. 0.5 MT
75 THEIC Powder 39.13 bag atmospheric ambient 16 25 kg 3.5 MT
76 Mostanol -120 Liquid 43.84 Barrel atmospheric ambient 18 200 Litrs. 4 MT
77 Monomer 60 S Liquid 52.39 Barrel atmospheric ambient 22 200 Litrs. 4.5 MT
78 Diethyl malonate Liquid 11.11 Barrel atmospheric ambient 5 200 Ltrs. 1 MT
79 PG Monopropyl ether Liquid 33.55 Barrel atmospheric ambient 14 200 Ltrs. 3 MT
80 Palm kernel oil Liquid 100.72 Barrel atmospheric ambient 42 200 Ltrs. 8.5 MT
81 Noigen EA 142B Liquid 7.29 Carbouy atmospheric ambient 25 25 kg 0.7 MT

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Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

82 Triphenyl phosphite Liquid 3.68 Carbouy atmospheric ambient 10 30 Ltr. 0.5 MT

t-Butyl Peroxy 2-ethyl
83 Liquid 13.11 Carbouy atmospheric <10 37 30 Litr. 1.2 MT
hexanoate
84 Z-6018 Intermediate Liquid 6.12 Barrel atmospheric ambient 3 200 Ltr. 0.5
Thermosetting acrl resin
85 Liquid 43.51 bag atmospheric ambient 18 200 Ltr. 3.8 MT
55%kh 730
86 Rosin W G grade Solid 11.39 Bag atmospheric ambient 38 25 kg 1 MT
87 Araldite Liquid 142.49 Barrel atmospheric ambient 59 200 Ltr. 12 MT
88 Epikote Liquid 1933.41 Barrel atmospheric ambient 805 200 Ltr. 162 MT
89 Hartol-M-33 Liquid 54.48 Barrel atmospheric ambient 23 200 Ltr. 4.5 MT

Cosmonet M-200 / Desmodur

90 Liquid 661.44 Barrel atmospheric <50 276 200 Ltr. 55 MT
44 V 20 L
91 Resin 15 E Liquid 10.20 Barrel atmospheric ambient 5 200 Ltr. 1 MT
92 SUMI EPOXY ESCN-195 LB Liquid 7.45 Barrel atmospheric ambient 3 200 Ltr. 0.8 MT
93 Resin 16 D Liquid 143.11 Barrel atmospheric ambient 60 200 Ltr. 12 MT
94 FUJICURE FXK # 930 Liquid 123.51 Barrel atmospheric ambient 51 200 Ltr. 11 MT
95 70 % DFA base alkyd Liquid 20.39 Barrel atmospheric ambient 9 200 Ltr. 2 MT
96 Base for Epoxy silicone Resin Liquid 47.82 Barrel atmospheric ambient 20 200 Ltr 4 MT
97 DOW CORNING 3074 Liquid 12.30 Barrel atmospheric <25 5 230 Kg 1.5 MT
98 SUMIDUR N 3300 Liquid 17.67 Barrel atmospheric ambient 8 200Ltr. 1.5 MT
60% KH-940 Intermediate
99 Liquid 33.47 Barrel atmospheric ambient 14 200 Ltr. 3 MT
for NB-014_KPJ
58%FTB-433 Intermediate
100 Liquid 32.57 Barrel atmospheric ambient 14 200 Ltr. 3 MT
for NAD Rsn_KPJ

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Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

101 43% KU-921 Liquid 9.91 Drum atmospheric ambient 42 20 Ltr 1 MT

102 60% KHB - 981 Liquid 6.46 Drum atmospheric ambient 27 20 Ltr. 1 MT
Non EC Products (NOC Received)
1 Mixed xylene Liquid 488 Storage tank atmospheric ambient 1 150 KL 150 KL
2 Butanol Liquid 147 Storage Tank atmospheric ambient 1 100 KL 100 KL
3 Butyl Cellosolve Liquid 121 Storage Tank atmospheric ambient 1 50 KL 50 KL
4 Toluene Liquid 121 Storage Tank atmospheric ambient 1 50 KL 50 KL
5 Distilled C9solvent Liquid 117 Storage Tank atmospheric ambient 1 100 KL 100 KL
6 Mostanol 120 Liquid 112 Storage Tank atmospheric ambient 1 50 KL 50 KL
7 Mineral Turpentine oil Liquid 110 Storage Tank atmospheric ambient 1 100 KL 100 KL
Methyl Iso butyl ketone Liquid
8 72 Storage Tank atmospheric ambient 1 50 KL 50 KL
(MIBK)
9 Butyl Acetate Liquid 66 Storage Tank atmospheric ambient 1 50 KL 50 KL
Cellosolve Acetate (Hiso Solve Liquid
10 55 Storage Tank atmospheric ambient 1 50 KL 50 KL
acetate)
11 Iso Propyl Alcohol Liquid 50 Storage Tank atmospheric ambient 1 50 KL 50 KL
12 Ethyl Acetate Liquid 50 Storage Tank atmospheric ambient 1 50 KL 50 KL
13 Methanol Liquid 44 Storage Tank atmospheric ambient 1 50 KL 50 KL
Di ethylene glycol mono ethyl
14 Liquid 31 Drum atmospheric ambient 13 50/200 kg 30 MT
ether
15 Cellosolve (Indigenous) Liquid 22 Storage Tank atmospheric ambient 1 50 KL 50 KL
16 Iso Butanol Liquid 22 Storage Tank atmospheric ambient 1 50 KL 50 KL
17 Methyl Ethyl Ketone (MEK) Liquid 20 Barrel atmospheric ambient 8 200 Ltr. 14 KL
18 HMDI (Hexa methylene di- Liquid 17 Barrel atmospheric ambient 7 200 Litr. 2 MT

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Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

isocyanate)
19 Butyl glycol acetate Liquid 15 Barrel atmospheric ambient 7 200 Ltr. 8.4 MT
20 DBE Solvent Liquid 9 Barrel atmospheric ambient 4 200 Ltr. 7 MT
21 Acetic Acid ( Glacial) Liquid 7 Carbouy atmospheric ambient 3 30 Kg 1 MT
2- Octanate ( Methyl Hexyl Liquid
22 13 Barrel atmospheric ambient 6 200 Ltr. 1.2 MT
Ketone)
23 Butyl Carbitol Liquid 7 Barrel atmospheric ambient 3 200 Ltr 5.4 MT
24 Solvent GR Liquid 5.5 Barrel atmospheric ambient 3 200 Ltr 4 MT
25 3 Methoxy Butyl Acetate Liquid 5.5 Barrel atmospheric ambient 3 200 Ltr 4 MT
26 Acrylic Acid Liquid 5.5 Carbouy atmospheric ambient 3 200 Ltr 8 MT
27 Lecithin (Alcolec) Powder 13 Bag atmospheric <25 44 25 Kg 1.2 MT
28 Formic Acid 85% Liquid 7 Carbouy atmospheric ambient 24 25 Ltr 0.7 MT
29 Titanium di oxide Powder 216 Bag atmospheric ambient 720 25 Kg 20 MT
30 China Clay Powder 70 Bag atmospheric ambient 233 25 Kg 6 MT
31 Calcite powder 244 Bag atmospheric ambient 813 25 Kg 22 MT
32 Red oxide powder 345 Bag atmospheric ambient 1150 25 Kg 29 MT
33 Dolomite solid 103 Bag atmospheric ambient 343 25 Kg 9 MT
34 Soap stone solid 61 Bag atmospheric ambient 203 25 Kg 6 MT
35 Aluminium paste Solid 28 Bucket atmospheric <25 94 25 kg 3 MT
36 Cyclohexanone Liquid 2.4 Barrel atmospheric ambient 1 200 Ltr. 1 MT
37 Dipentene Liquid 2.4 Barrel atmospheric ambient 1 200 Ltr. 2 MT
38 Tetra ethyl ortho silicate Liquid 3.7 Barrel atmospheric ambient 2 200 Ltr. 1 MT
39 Monomer 60S Liquid 5.5 Barrel atmospheric ambient 3 200 Ltr. 1 MT

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Operating Condition Storage Maximum

(Storage) Nos. of
S. Consumption Means of capacity of Storage
Chemical State vessel/
No. (MT/Annum) Storage Press Bag / Drum / Capacity
Temp. (°C) drums/bags
(Kg/cm2) Tank (MT) (MT)

40 Hydrocarbon Resin Liquid 4.6 Barrel atmospheric ambient 2 200 Ltr. 1 MT

41 DOTO Powder Solid 5.5 Drum atmospheric ambient 19 25 Kg 1 MT
42 M.F.Resin Liquid 191 Storage Tank atmospheric ambient 1 30 KL 30 KL
43 Acrylic resin Liquid 391 Storage Tank atmospheric ambient 1 30 KL 30 KL
44 CED Resin Liquid 121 Storage Tank atmospheric ambient 1 30 KL 30 KL
45 Alkyd resin Liquid 110 Storage Tank atmospheric ambient 1 30 KL 30 KL
46 Zinc dust Powder 6.7 Drum atmospheric <23 23 25 kg 1 MT
47 Yellow oxide of iron Powder 3.3 Bag atmospheric ambient 11 25 kg 1 MT
48 Carbon black Powder 2.0 Bag atmospheric ambient 7 25 kg 0.5 MT
49 Lemon chrome Powder 2.0 Bag atmospheric ambient 7 25 kg 0.5 MT
50 Matting agent TSA 270L Liquid 2.0 Drum atmospheric ambient 9 20 kg 0.5 MT
51 Mapico yellow oxide XLO Powder 1.7 Bag atmospheric ambient 7 25 kg 0.5 MT
52 Scarlet chrome BS Powder 1.3 Drum atmospheric ambient 5 25 kg 0.5 MT
53 Blue ESP Powder 0.7 bag atmospheric ambient 6 10 kg 0.1 MT
54 Signal red Powder 0.6 bag atmospheric ambient 3 20 kg 0.1 Mt
55 K- White- 140 E Powder 2.9 bag atmospheric ambient 2 20 kg 0.5 MT
56 Bismuth hydroxide Solid 6.1 Bag atmospheric ambient 21 25 kg 1 MT

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Table 10: Storage Details of Products

Operating Condition Storage
Sr. Production, Means of (Storage) capacity vessel or Capacity
Chemical State No of vessel
No. (MT/Annum) Storage Press Temp Drum
(Kg/cm2) (°C)
EC Products

1 Resin Liquid 40080 Storage tank Atmospheric Ambient 17 30 KL 510 KL

Non-EC Products (NOC Received)

Drum (20 Litr): 48000

Paint and varnish, Drum & Drum. 20 & 200 litr
1 Liquid 68280 Atmospheric Ambient Drum (200 Litr.):200 2400 MT
Enamels, Lacquer storage tank Storage tank: 30 KL
Storage Tank: 1
Drum (20 Litr): 6000
2 Thinner Liquid 18000 Barrel Atmospheric Ambient 20 lit & 200 Lit 2400 MT
Drum (200 Litr.):1200

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Annexure 8: Water Consumption Details

Fresh Water Quantity, KLD
S. No. Area of Consumption
For Non EC Products For EC Products Total
1 Domestic 40 15 55
2 Industrial
2.1 Manufacturing Process 60 0 60
2.2 Cooling Tower/Chiller/FDV 150 235 385
2.3 Boiler Make up 50 50 100
2.4 Washing 30 50 80
3 Gardening 30 20 50
4 Misc. e.g. Fire Hydrant 15 5 20
Total Water Consumption 375 375 750

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Annexure 9: Waste Water Generation Details

Waste Water Generation Quantity,
KLD
S. No. Area of Consumption Treatment and Disposal Mode
For Non EC For EC
Total
Products Products
To STP for treatment and treated
1 Domestic 35 15 50 water will be used for
gardening/toilet flushing
2 Industrial
2.1 Manufacturing Process 20 0 20 To ETP furnished with UF/RO for
treatment and treated water
2.2 Cooling Tower/Chiller/FDV 15 33 48
(permeate) will be used for cooling
2.3 Boiler Make up 5 3 8
tower and rejects will be sent to
2.4 Washing 25 39 64 MEE for evaporation
3 Gardening 0 0 0
4 Misc. e.g. Fire Hydrant 0 0 0
Total Waste Water Generation 100 90 190

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Annexure 10: Details of Waste Water Treatment Plant

Liquid Effluent treatment facility

During paint manufacturing process, various effluent streams will be generated at various sources due to
carrying out of various manufacturing activities. Effluent streams will be generated from solvent based
paint, CED F1 & F-2 paint and resin manufacturing block during activities such as cleaning of mixers,
cleaning of CED tanker, cleaning of resin reactor and blender. Effluent will also be generated during
calibration of vessels, cleaning of barrels and containers. All the above mentioned effluent streams will be
discharged to the effluent treatment plant (ETP) for treatment. In addition to above, the utility waste water
streams viz. boiler blow down, cooling tower blow down, regeneration & backwash waste water from DM
water unit (neutralized) will also be discharged from the manufacturing plant to ETP. The domestic waste
water i.e. sewage will also be discharged to STP from various blocks such as administration building,
canteens, toilets & washrooms for truck drivers & cleaners.

Above effluent will be treated separately, the industrial effluent will be treated in ETP where as domestic
effluent will be treated in STP (Sewage Treatment Plant).

The Effluent Treatment Facility Will Be Zero Discharge Facility.

Typical characteristics of raw and treated Industrial effluent are given below –

Parameter Unit Raw effluent Treated GPCB permissible limit

effluent
Flow M3/d 125
PH 5.5-6.5 7.0-7.5 6.5– 8.5
COD Mg/l 8500 <100 <100
BOD Mg/l 4000 <30 <30
TSS Mg/l 400 mg/l <100 <100
TDS Mg/l 1500 <2100 <2100
Oil & Grease Mg/l 10- 20 <10 <10

Note: Treated effluent will be input of Zero Liquid discharge plant

Scheme for Industrial Effluent treatment plant

Industrial effluent will be treated in three stages as under-

Stage I - Primary Treatment

The system will be designed to treat 140 m3/day of waste water. This Waste water receives in bar screen
where coarse solids are removed then it flows to oil and grease trap where floating oil and grease is
trapped and removed manually. From oil & grease trap effluent flows to equalization tanks. The effluent
shall be equalized with blown air from coarse bubble diffuser and air blower assembly. The effluent then
pumped to the flash mixer provided with alum dosing as coagulant & to enhance the formation of flocks it
is passed through Flocculation Tank where Polyelectrolyte is added. From Flocculation Tank effluent flows
to primary settling tank where primary sludge will settle at the bottom and the clear overflow will enter the
1st stage bio reactor. Primary settling tank shall be provided with hopper bottom.

Secondary Treatment

As ZLD is intended, Membrane Bio-Reactor (MBR) process is recommended. Bioreactor tank is provided
with suspended biological mass. The mixing and Oxygen transfer is provided by fine bubble diffused
aeration system. As MBR is used, higher concentration of MLVSS can be maintained. The mixing and
oxygen transfer within the aeration tank shall be done by diffusing air from air blowers through high
efficiency fine bubble diffusers. The MLVSS from the aeration tank shall over-flow to Membrane tank. For

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cleaning of membrane surface air scouring is provided. Excess bio-mass shall be wasted periodically. The
clear overflow of MBR is collected in the intermediate tank.

Tertiary Treatment
The biologically treated effluent from intermediate tank shall be pumped through Activated Carbon filter for
removal of Refractory COD and treated water will be collected in the final treated water tank as a RO feed.

Sludge Handling
The sludge generated from the primary and secondary settling tanks will be collected in sludge collection
tank and pumped by screw pumps to filter press. The cake obtained from the filter press will be sent for
disposal to notified Treatment Storage Disposal Facility (TSDF). The filtrate from the filter press will be
recycled to equalization tanks.

Zero liquid discharge plant

Tertiary treated effluent from ACF collected in RO feed tank from where it is pumped to the cartridge filter
for removal of any fine suspended particles. The TSS free water is then fed to the spiral wound RO
membrane module for removal of TDS with the help of high pressure pump. SP type modules of Fouling
Resistant CSM RO membranes are used to give about 80% of water recovery. The reject water is fed to
the Multiple Effect Evaporator. Permeate from RO can be reused. The RO membranes are susceptible to
fouling due to precipitation of sparingly soluble salts in the feed water. Anti scalant dosed at the upstream
of the RO membrane to inhibit the scale formation. RO system must have pH around 6-6.5, so for
maintaining fine tuning for this system, Acid dosing system is required. To avoid bio-fouling problems
typical to the ETP-RO system, we have proposed special Fouling Resistant RO Membranes.

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Figure 10: Schematic Effluent treatment facility

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Sewage Treatment Plant:

Typical characteristic of Sewage – Domestic effluent are given below –

Parameter Unit Raw effluent Treated effluent

Flow M3/d 50
PH -- 5.5-8.5 7.0-7.5
COD Mg/l 400- 500 <60
BOD Mg/l 250 -300 <30
TSS Mg/l 200- 250 <40
Oil & Grease Mg/l 10 – 20 <10

Treated sewage water will be used for gardening & toilet flushing

Scheme for Sewage treatment plant

The sewage water generated at various locations is screened & centrally collected in a sewage collection
cum equalization tank wherein, the surges of flow are contained. The screened sewage is pumped out
from the equalization tank to the Digester which consists of a MBBR reactor and a Tube Deck Clarifier. The
water enters the top of the reactor & flows through the media in the reactor. A continuous stream of air in
counter current mode aerates the sewage which flows down the reactor. The aeration of the sewage is
done by fine pore sub – surface diffusers which provide the oxygen for organic digestion.

Continuous aeration ensures aerobic activity on the surface of the media. Micro – organisms attach
themselves on the media & grow into dense films of a viscous jelly like nature. From the MBBR reactor the
digested sewage overflows into a tube deck clarifier operating on a low hydraulic loading. Before it enters
the tube deck clarifier the water is dosed with a dilute solution of alum & lime. As the water comes up
through the media the suspended particles & sludge are retained & clear water overflows into the overflow
chamber. The sludge collects in the tapered bottom of the settler & is periodically drained out. The clarified
water from the overflow chamber of the digester is pumped through a sand filter & an activated carbon
filter for removal of suspended impurities & traces of organic matter respectively. The filtered water is then
dosed on-line with a dilute solution of chlorine. This water will be used for gardening & toilet flushing
purposes.

Figure 11: Schematic Sewage treatment plant

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Annexure 11: Fuel Consumption

Sr. No. Stack Attached to Nos. Type of Fuel used Fuel consumption

For EC Products
1 Boiler (5000 kg/hr) 2 Dual fired – HSD/PNG 275.2 Kg/hr

2 D G Set (400 KVA) 1 Dual Fired – HSD/PNG 75.7 Kg/hr

3 Gas Genset (1400 KVA) 2 PNG 335 SCM/hr each

4 Thermic fluid heater (15 lac Kcal) 2 Dual fired- HSD/PNG 142 Kg/Hr.

5 Thermic fluid heater (10 lac Kcal) 2 Dual fired – HSD/PNG 94.6 kg/hr

6 Incinerator 1 HSD 69 kg/hr

For Non – EC Products (NOC Received)
1 D. G. Set (2000 KVA) 1 HSD 344 kg/Hr

2 D. G. Set (2000 KVA) 1 HSD 344 kg/Hr

3 Boiler (850 kg/Hr) 1 HSD 43 kg/Hr

4 Boiler (850 kg/Hr) 1 HSD 43 kg/Hr

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Annexure 12: Hazardous Waste Generation

Hazardous Hazardous Waste Generation in MT/Year Source
S. No. Type of Waste Waste For EC For Non-EC Treatment / Disposal
Category Total
Products Products
Paint manufacturing To Incinerator plant for
1 Process wastes, residues and sludge 21.1 73 T 267 340
process disposal by incineration
Paint manufacturing To Incinerator plant for
2 Fillers Residues 21.2 3.0 T 0 3.0
process disposal by incineration
To Incinerator plant for
3 Distillation Residue 20.3 270 T 132 402 Solvent recovery plant
disposal by incineration
Vessel washing, storage To Solvent recovery plant for
4 Spent Organic Solvent 20.2 899 T 441 1340
washing distillation
DG set, Compressor, GPCB approved authorized
5 Used / spent oil 5.1 3T 3 6
gear box recycler
Paint manufacturing
6 Discarded containers/ barrels 33.3 135 T 260 395 Sold to GPCB approved party
process
To Incinerator plant for
7 ETP Sludge 34.3 40T 20 60 ETP
disposal by incineration
Paint manufacturing To Incinerator plant for
8 Contaminated cotton waste/liners 33.3 18 T 7 25
process disposal by incineration
To TSDF for disposal by
9 MEE Salt 34.3 36 T 14 50 ETP
landfill
To incinerator plant for
10 Oil/grease scheming residue 34.4 0 4 4 ETP oil trap
disposal by incineration
To TSDF for disposal by
11 Incinerator ash 36.2 0 180 180 Incinerator
landfill

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Annexure 13: Stack Details

Flue Gas Stacks

Stack Attached to Nos. of Stack Top Dia,

S. No. Stack Height, m APCM Attached
Sources Stacks m
For EC Product
1 Boiler (5000 kg/hr) 2 33 0.500
2 DG set (400 KVA) 1 9 0.600
3 Gas Genset (1400 KVA) 2 30 0.600
Adequate
Thermic fluid heater Stack height
4 2 33 0.500
(15 lac Kcal)
Thermic fluid heater
5 2 33 0.500
(10 lac Kcal)
Ventury Scrubber and
6 Incinerator (200 kg/hr) 1 30 0.500
Packed Bed scrubber
For Non – EC Products (NOC Received )
1 Boiler 850 kg/Hr 33 0.500
2 Boiler 850 kg/Hr 33 0.500 Adequate Stack
3 D.G. Set 2000 KVA 30 0.600 Height

4 D.G. Set 2000 KVA 30 0.600

Process Vents

S. Nos. of Stack Pollutants Air Pollution Control

Stack Attached to
No. Stacks Height in m Emitted Measures Attached
For EC Products
1 Scrubber Stack 1 11 Particulate matter Wet scrubber
2 Fume extraction system 16 11 Traces of VOC Adequate stack height
3 Reactor vents 20 11 Traces of VOC Open to air
For Non – EC Products (NOC Received)
Fume extraction system
1 Mixers 18 11 VOC
followed by carbon filter
Dust Collectors followed by
2 Pre Mixers 6 11 Dust
Pulse jet bag filter

Note: Emission will be well within the Permissible limit

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Details of Air Pollution Control Measures

1. Stack emission from generators, boilers and thermopacs

The control of air pollution from stacks of diesel generators, steam boilers, thermic fluid heaters is
proposed by providing adequate stack height to attain maximum dispersion of flue gases containing SPM,
SO2, NOx and CO.

Gas and dust emission from process reactor vessels, mixers, condensers, blenders, chargers
etc.

During charging, dust collection and fine particle filtration systems will be installed to trap the particulate
matter thus allowing only clean air to be discharged into the atmosphere.

Dust collection system

Pulse jet filters are continuous self-cleaning units. A high-pressure blast of clean, dry compressed air is
injected into each filter element at periodic intervals. This air is stored in a reservoir called a header.
Several purge pipes are attached to the header and extend into the clean air plenum above rows of filter
bags or cartridges. Holes are drilled in the purge pipes directly above each of the filter elements. Several
elements are cleaned by one purge pipe. A solid state timer controls a solenoid that opens a diaphragm
valve allowing air to flow from the reservoir into the purge pipe and filter element. The element
experiences a shock wave while air is forced through it in a direction opposite to the dirty air flow. A
portion of the dust cake will fall away from the bag into the filter’s hopper.

Process Flow Diagram of Dust Collection/Filtration system

Particle laden
gas emitted Dust Collector Filtration Clean air
from handling Mechanism
of pigments
and extenders

Collected
dust recycled

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2. Fume Extraction System with Dry scrubber

Fume Extraction will be provided to all the solvent handling process equipments and vents are connected
with dry scrubbing (activated carbon) mechanism to control the emissions.

3. Air Emission control from Resin reactor:

Air emission streams from resin reactor vessels during resin making will be passed through a condenser
where the solvent vapours and steam (azeotrope) will condensate and will be collected in a separator.
Thereafter, the separation of immiscible liquids is done and the solvent reused. Hence, emission to the
atmosphere will contain almost clean air, as the design efficiency of condensers is almost 100%. Prior to
the reaction emissions, there will be emission of pthalic during charging (while manufacturing alkyd resin
only). Pthalic is odorous. Emission during charging will be sucked into scrubber, where most of the pthalic
will be removed before venting. The scrub air will be then passed through charcoal bed which will absorb
all the odour and clean air will be released into the atmosphere. During the manufacturing of acrylic
resin, a fume extraction system on the monomer pre-mix tank will be installed.

Scrubbing system (Process flow diagram)

Scrubbing Liquid Clean Air stream

(Water/caustic solutions)

Scrubber

Volatile organic compound Effluent to ETP

(VOC) emitted during
mixing and dispersion

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Resin reactor scrubbing system:

The scrubber system is designed as the gas transfers using the vacuum created by the centrifugal
corrosion resistance blower. First the oil drain box attracts the oil transferring to the ducts, where the
heavy oil is trapped. The hot fumes generated from the reactors are exhausted through the header duct
line connecting all the reactors transfers to the oil separation column for complete separation of oil and
manually collected in a pot by gravity and centrifugal action created by the column.

The hot gas (2500C) transfers to the Venturi to bring down the temperature and drastically absorb the
acidic fumes of Phathalic, Penta and Maleic generated by the hot Phtalic anhydradide solution by the
chemical mixer with water solution. When it passes through the venturi chamber, the maximum quantity of
fumes get wet due to jet spray of liquid placed inside the venture throat.

Subsequently, the gas pass through the PP/FRP ceramic pall rings packed jet flashed distributor built in
second column for scrubbing the left out acidic fumes of Phathalic , Penta, Maleic fume absorbed by Lime
solution. The circular spray nozzles to trap the left out oil and then it passes through the ceramic bed
column having one more circular spray nozzle which sprays the neutralizing solution to scrub the phthalic,
penta, ma;eic fumes. Now the gas temperature is 900C . Then it passes through charcoal bed tower where
the odour is elimination takes place and then passes through the demister pad to trap any traces of
escapes at this charcoal tower. Finally, the clean air let out through stack to the atmosphere.

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Annexure 14: Incinerator

Incineration system will have a firing rate 200 kg/hr. incineration system comprising of primary chamber,
post combustion chamber, ventury scrubber, packed column, ID fan, Stack, Control panel, BMS panel for
burner having waste firing rate 200 kg/hr at overall calorific value 2977 Kcal/kg and HSD as fuel. It will
have waste recovery boiler of 1400 kg/hr steam generation capacity. It will be mainly a shell and smoke
tubes assembly type.
The system proposed for destruction of the solid waste generated from a paint processing plant consists
of the following:
 Waste feeding system
 Incineration system
 Waste heat recovery system
 Flue gas cleaning system

Waste Preparation & Feeding System

The incinerable waste (solid waste, slurry & Viscous streams) are collected near incinerator waste storage
area. The same is weighed on a weighing scale & mixed together in desire proportion. The waste in
mixed condition is packed together in polythene bags and charged through DFDV (Double flap dump
valve) into the primary chamber. DFDV is located on the primary chamber and works on 2flaps manual
mechanism. The flap of DFDV opens one by one (to be opened manually with help of hand lever) &
drops the waste into the primary chamber. It also ensures safety of operation as well as not allowing any
gases to escape out.

Waste water
Waste water waste is unloaded into a waste water tank & is then pumped to primary chamber via
metering pump through waste water injector using compressed air as atomizing media. This ensures
even distribution of the waste on the hearth thus ensuring compete destruction. Waste water injector
specially developed for this kind of application.

Incineration System
The incineration system consists of
- Primary furnace
- Post combustion chamber

Primary furnace
The primary chamber is cylindrical furnace duly lined with refractory material of adequate thickness. An
hearth is located inside the furnace on which the waste burns continuously. The hearth is provided by the
combustion air. The air is admitted through manifold located at the bottom of the furnace. All the waste
is fed manually at a regular interval through the burner. The main function of the chamber is burning the
waste under starved air conditions. All the volatiles are liberated and other carbonaxeous matter is totally
burned in the primary chamber.
Prior to waste firing, chamber is heated up initially by firing HSD through burner. The temperature of
furnace is raised upto around 800 ± 500C . The ignition is automatic through UV cell and flame relay
(burner programmer). Once the flue gas temperature has reached around 800 ± 500C, solid waste is
charged through the feeding mechanism.

Ash Handling System

Ash pit is provided at the end of the deashing chamber and the ash is dragged out at the end of the shift
and quenched in the pit. The pit has a capacity of 3 days and can be transferred to the landfill at one
stretch.

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Post combustion chamber

This is horizontal, cylindrical side fired furnace lined with refractory and insulating material. The chamber
is initially heated up to the operating temperature using burner. The function of this chamber is compete
combustion of volatiles/ smoke coming from primary chamber. Temperature in this chamber is
maintained at 1050 ± 500C.
Under controlled conditions of temperature, time and turbulence the unburnt in the flue gas get
completely oxidized to harmless products. The function of the PCC is to complete the gas phase reactions
initiated in the primary Chamber.
The incinerator is provided with controls to ensure smooth operation. The temperature at the outlet of
PCC is sensed by a temperature element located at the outlet of the furnace in the path of the flue gas.
The fuel firing is controlled by the solenoid valve on ON/OFF basis per signal from temperature indicator
controller.

The waste Heat recovery System

Waste heat recovery Boiler (design pressure 10.54 kg/cm2 (g)) – heat is recovered from the flue gas to
generate saturated steam at 9.0 kg/cm2. The gases are cooled from 10500C to 2800C in waste heat
boiler.
The proposed waste heat recovery system consists of a smoke tube boiler with integral steam space. The
boiler is of fixed tube sheet type, with both the end tube sheets welded to the shell. The boiler is
connected to the incinerator.

Flue gas cleaning system

The flue gas cleaning system consists of
a. Venturi Scrubber and packed column
b. Induced draft fan & stack

Venturi scrubber
The flue gas @ 2800C is cooled in venture scrubber by spraying water through tangentially placed
nozzles. The temperature of the flue gas is reduced to the adiabatic saturation temperature i.e. around
65 – 700C. The saturated flue gas also facilitates higher removal of particulate matter by initiating particle
agglomeration.
The VS is designed to serve as a control device for applications requiring very high collection efficiencies
for fine particulate matter. It employs gradually converging and then diverging sections to clean the flue
gases. As the re-circulating scrubber solution is atomized, it begins to collect particle s from the gas
impacting into the liquid as result of the difference in velocity of gas streams and atomized droplets. As
the mixture decelerates in the expanding section, further impaction occurs causing the droplets to
agglomerate. Once the liquid has trapped the particles, separation of the same can be done easily the
pressure drop is provided in the venturi to ensure trapping of the particulate and is decided while sizing
the throat. The venture scrubber is designed for a maximum pressure drop of 1000 mmWC.
Partial SO2 removal also takes place in the VS. Caustic solution (5%) is re-circulated in packed column to
achieve the desired results.

Packed column
The gas enters into packed column wherein the gases pass through a packed section. Caustic solution is
circulated across counter currently for the removal of pollutants to bring it down to PCB norms. A
separate pump is provided for the circulation of the liquid in packed column.

Demister
The flue gases then further passes through demister for removal of water mist. A separate spray is
provided to clean the demistor periodically.

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ID Fan & stack

The flue gas is drawn through an ID fan before being let out to the atmosphere via a 30 mtr. High stack.
The pressure in the furnace is maintained below the atmospheric pressure within certain limits by
controlling the suction damper manually at inlet of the ID fan.

Emergency system
It is important that the downstream equipment do not get heated up by the flue gases hence in case of
any emergency (e.g. power failure) the emergency stack opens pneumatically & vents the gases to the
atmosphere. An emergency overhead tank is also provided which on power failure will flood in the
Venturi Scrubber to reduce the temperature and thus protect the downstream equipment.

Bleed transfer system

The system is designed for transfer of bleed coming out of scrubbing system to ETP. The system consists
of
- Bleed collection sump/seal tank
- Bleed pumping system
The bleed coming out of the scrubbers is sent by gravity to a underground sump/seal tank (RCC) with
baffle for bleed to overflow. The tank shall act as intermittent holding tank. The first part of the tank shall
be used for collection of bleed. This bleed is then pumped to ETP.
The stack height of incinerator will also be provided as per CPCB/GPCB standards. The proposed height
of the stack is 30 mtr height. The flue gas generated will then be passed through a venture scrubber and
packed column for complete cleaning of the pollutants. The emission of this incineration and flue
treatment system will conform to the following:
S. Parameter Emission (mg/Nm3)
No.
CPCB Norms Anticipated Emissions
1 Suspended Particulate Matter (SPM) 50 50
2 HCL 50 NA
3 SO2 200 7.76 mg/m3
4 CO 100 11.45
5 TOC 20 NA
6 HF 4 NA
7 NOx 400 20.96
Hydrocarbon shall be 10 ppm over an hourly rolling average dry basis, measured as propane.
Dioxins/Furans will not exceed 0.1 Ng TEC/Nm3. To reduce levels of pollutant emission, fuel with low
sulphur content will be used. Also the pollutants in the plant vicinity will be abated by greenbelt
plantation.

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Figure 12: Process flow diagram of Incinerator

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Annexure 15: Soil Testing Report

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Environmental Consultants
www.kadamenviro.com

Environment for Development

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