M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. LIST OF ATTACHMENTS
Annexure – 1
List of Product
Page 19
Annexure – 2
Raw Material & Consumption
Page 20
Annexure – 3
Manufacturing Process Details
Page 21
Annexure – 4
Site Plan
Page 24
Annexure – 5
Plot Plan, Google Image
Page 25
Annexure – 6
Land Purchase Document
Page 27
Annexure – 7
List of Directors
Page 57
Annexure – 8
Water Consumption & Wastewater Generation
Page 58
Annexure – 9
Water Balance
Page 59
Annexure – 10
Details Effluent Treatment Plant
Page 60
Annexure – 11
List of Hazardous Wastes
Page 62
Annexure – 12
Details of Flue Gas & Process Emissions
Page 63
Annexure – 13
List of Hazardous Materials
Page 64
Annexure – 14
Project Cost, C. A. Certificate
Page 65
Material Safety Data Sheets
26 Pages
Page 18 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 1
PRODUCTS & PRODUCTION CAPACITY
SN
PRODUCTS
1
Viscose Rayon
PROPOSED PRODUCTION CAPACITY
(MT/MONTH)
500
Page 19 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE - 2
RAW MATERIAL & CONSUMPTION
SN
1
2
3
4
5
RAW MATERIAL
Wood Pulp / bleached cotton pulp
Caustic Soda
Carbon Disulphide
Sulphuric Acid
Zinc Sulphate Monohydrate
RAW MATERIAL CONSUMPTION
MT / MONTH
550
350
150
500
5
Page 20 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 3
MANUFACTURING PROCESS DETAILS
Rayon is manufactured by Xanthation of rayon grade pulp using Carbon Disulphide (CS2) and
Caustic Soda (NaOH) and subsequent regeneration of cellulose as rayon. The industry shall
manufacture Rayon in the form of Viscose Filament Yarn. Carbon Disulphide (CS2) used in the
process shall be procured from the other sources as raw material.
Rayon is made from cellulose, a constituent of all land-growing plant life. Spruce and
Eucalyptus yield much of the high-grade cellulose required for Rayon. Their bark, lignin, etc. are
removed in pulp mills, and the extracted cellulose is pressed and cut into sheets.
Rayon Manufacturing process shall include following steps:
1. Slurry steeping
The cellulose is steeped in caustic soda (derived from salt) with which it combines to form alkali
cellulose. The excess soda is then pressed out and drained off for recovery and re-use (stage5).
2. Grinding
The alkali cellulose is shredded into crumbs to make the processes in stage 3 and 4 quicker and
easier (stage 1,2,3 and 4 are all to make the cellulose soluble so that it can be 'spun').
3. Pre-ageing
The alkali cellulose is stored to allow the oxygen in the air to oxidise it. This reduces the
'molecular size' of the cellulose, which is necessary to obtain a 'spinning' solution (stage5) of the
correct viscosity.
4. Xanthation
The alkali cellulose is combined with carbon disulphide (derived from carbon and sulphur) to
give sodium xanthate.
5. Dissolving
The sodium cellulose xanthate is dissolved in caustic soda to form the syrup-like 'spinning'
solution known as viscose.
6. Ripening
To improve its 'spinning' qualities, the viscose is allowed to ripen. Meanwhile it is held under
vacuum to remove air bubbles.
7. Filtration
The viscose is filtered to remove any un-dissolved particles which might block the jets in the
next process.
8. Extrusion
The viscose is extruded through the fine holes of a jet into a coagulating bath of sulphuric acid
and salts which neturalises the alkaline content of the viscose and regenerates the original
Page 21 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. cellulose as continuous filaments. The filaments from a single jet are drawn together as a
continuous filament yarn.
9.
Collecting
Yarn is collected continuously on to thread-advancing reels.
10. Washing, Desulphurising and Drying
The yarns or fibres are washed to remove chemicals left on them from the acid bath, and then
dried. This is done continuously as the yarn passes from the back to the front of each threadadvancing reel; it is dried on the last reel which is heated and enclosed.
At the end of the processes: Yarn is given a twist and wound on to a bobbin. All consist of pure
cellulose (plus a slight content of moisture and lubricant) and are ready for use by the textile
industries. Yarn can be woven or knitted direct.
The process is schematically shown in below.
Page 22 of 68 M/s Subh
hlon Industriies Pvt Ltd, Moti
M Naroli, Mangrol, Su
urat, Gujarat. MANUFAC
CTURING PR
ROCESS – CONTINOUS
C
S VISCOSE
E FILAMENT
T YARN
Page 23 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 4
SITE PLAN
Page 24 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 5
FACTORY LAYOUT
Page 25 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. LOCATION GOOGLE MAP
Page 26 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 6
LAND PURCHASE DOCUMENTS
Page 27 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 28 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 29 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 30 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 31 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 32 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 33 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 34 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 35 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 36 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 37 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 38 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 39 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 40 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 41 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 42 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 43 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 44 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 45 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 46 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 47 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 48 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 49 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 50 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 51 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 52 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 53 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 54 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 55 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 56 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 7
LIST OF DIRECTORS
SN
Name
1
Shri Narayan Ratilal Bhagat
2
Shri Tejas Nareshkumar Jeriwala
3
Smt. Anita Narayan Bhagat
Address
Contact No.
135, Balaji Nagar Society, Ved 9824400387
Dubholi Road, Surat-395004
6/407, Lal Darwaja, Pipla sheri, 9426773622
Surat -395004
135, Balaji Nagar Society, Ved 9824400387
Dubholi Road, Surat-395004
Page 57 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE - 8
WATER CONSUMPTION AND WASTE WATER GENEARTION
WATER CONSUMPTION:
Source of Water: Ground water from bore well / River Water
SN
1
2
3
Particular
Domestic
Process
Utilities(Boiler & Cooling)
Total Industrial
Total Industrial & Domestic
Consumption , KLD
20
3697
1283
4980
5000
WASTE WATER GENERATION:
SN
Particular
Consumption , KLD
1
2
3
Domestic
Process
Utilities(Boiler & Cooling)
Total Industrial
Total Industrial & Domestic
16
3291
568
3859
3875
Disposal: The Industrial & Domestic effluent would be treated in ETP and would be reused in
process to the extent possible and/or disposed to on land for plantation and/or to the in-land
surface water nearby natural nalla.
Page 58 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 10
WATER BALANCE
20
3697
Processing
Domestic
16
568
Boiler & Cooling
3291
1283
5000
Bore Well
ETP
3875 KLD
Treated Effluent
reuse/onland for
plantation/surface
water disposal
Note: Mentioned figures are in KL/day
Page 59 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 10
DETAILS OF EFFLUENT TREATMENT PLANT
Viscose Rayon manufacturing generates effluent from many operations and can be categorized
as Acidic, Alkaline and Combined effluent stream.
Acidic Effluent stream consists of stream generated from revolving buckets of spinning
machines, spin bath make-up tanks, evaporators and washing processes, cooling and
condensate waters. The acidic waste water is a mixture of the spent spin bath, make up tanks
and spinning machines, evaporator and washings. It has a low pH, high acidity, dissolved solids,
sulphate and zinc. The sulphate is in the form of sodium sulphate and as sulphuric acid. The
organic content of the acidic wastes is quite low. Notwithstanding its small volume this waste
consists of the strongest and most highly toxic component of rayon wastes.
Alkaline Effluent stream consists of stream generated from dialysers, ripening and deaerating
vessels, filter presses from desulphurizing process and washing operations. The alkaline waste
water has a high pH, a variable total dissolved
solids and suspended solids.
Combined Effluent stream consists of stream generated from bleaching and antichlor wastes.
The combined waste is generally acidic and has high total dissolved solids and low biochemical
and chemical oxygen demand. Zinc is present in variable concentration, often exceeding the
permissible limits. The sulphate content is high but the chloride content is low.
The alkaline effluent shall be collected for Caustic Soda Recovery and its reuse. The acidic
effluent shall be subjected to Zinc Recovery at pH 9.0 followed Sodium Sulphate Recovery by
Evaporation. The other acidic, alkaline and combined effluent streams shall be collected and
equalized in the Equalisation Tank. The equalized effluent shall be subjected to neutralization
followed with flocculation in Flash Mixing Tank and Flocculation Chamber. The neutralized
effluent shall be held under quiescent condition in the Primary Clarifier for the separation of
solids from the neutralized effluent. The clear supernatant from the top of the Primary Clarifier
shall be mixed with domestic sewage and then be subjected to Aerobic Biological Treatment in
Aeration Tank. The biologically treated effluent shall be clarified of the suspended biomass in
the Secondary Clarifier. The bottom of Secondary Clarifier shall be recirculated to Aeration Tank
to maintain the desired level of active biomass. The clear supernatant from the top of the
Secondary Clarifier shall be subjected to Tertiary Treatment comprising of Pressure Sand Filter,
Activated Carbon Filter and followed with Ultra filtration. The treated effluent shall be reused for
on land plantation, cooling towers, process and washing operations. Excess treated effluent
shall be disposed in the nearby surface water body.
The schematic diagram of the effluent treatment plant would be as shown in the figure.
Page 60 of 68 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. PROPOSED EFFLUENT TREATMENT SCHEME
Caustic
Recovery Plant
Alkaline Effluent
Stream
pH makeup
Tank
Acidic Effluent
Stream
Zn(OH)2
Recovery
Combined
Effluent Stream
Equalisation
Tank
Caustic Soda
Reuse
Clarifier
Evaporator
Belt
Press
Na2SO4
Recovery
Neutralisation
Tank
Flocculation
Tank
Belt
Filter Press
Primary
Clarifier
Sludge
Tank
Dewatered
Sludge to TSDF
Aeration
Tank
Secondary
Clarifier
Filter Feed
Tank
Pressure
Sand Filter
Ultra
Filtration
Treated Water
for Reuse /
Onland Plantation /
Disposal to
Surface Water
Body
Page 61 of 66 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. .
ANNEXURE – 11
DETAILS OF HAZARDOUS WASTE
SN
Type
Category
Schedule 1
36.4
Quantity
Mode of Disposal
1
ETP
Sludge
185
MT/Year
Collection, Storage, Transportation and
Disposal at TSDF/ By Dumping in low
lying areas
2
Used Oil
5.1
Discarded
Containers
33.3
1200
L/Year
500
Nos/Year
Reused within the premises/ sell to
authorized recyclers
Collection, Storage, Decontamination,
reuse within premises/sale to registered
recycler
3
Page 62 of 66 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 12
DETAILS OF FLUE GAS & PROCESS EMISSION
SN
1
2
2
Stack
Attached
to
Boiler
(25 TPH)
D.G.Set
Process
vents
APCM
Stack
Height
Fuel &
Consumption
Parameter
Multi
Cyclone +
Bag Filters
Alkali
scrubbers/
Claus Kiln
30m
Lignite-4.0 TPD /
Natural Gas 8500 m3/day
LDO
-
PM
SO2
NOx
<150 mg/NM3
<100 ppm
<50 ppm
CS2
H2S
<21 Kg/t of fibre
<6.3 kg/t of
fibre
9m
1x 60m
Permissible
Limit
Page 63 of 66 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 13
LIST OF HAZARDOUS MATERIALS
SN
1
2
Hazardous Material
Carbon Disulphide
Sulphuric Acid
Storage Capacity
200 MT
200 MT
Type of Storage
SS Tanks
HDPE Tanks
Page 64 of 66 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. ANNEXURE – 14
PROJECT COST, C. A. CERTIFICATE
Page 65 of 66 M/s Subhlon Industries Pvt Ltd, Moti Naroli, Mangrol, Surat, Gujarat. Page 66 of 66