Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
Annexure-I
List of Products & Raw Materials
Sr.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Name of Products
Existing
Product
Zinc Sulphate/ Sodium Nitrate (Existing Existing
Product As Per GPCB CCA NO: AWH74769)
Ammonium Formate
Ammonium Acetate
Ammonium Propionate
Methyl 3 – Amino Crotonate
Sodium 2. Ethyl Hexonate
Sodium formate
Methanolic ammonia
Methanolic MMA
Propyl propionate
1 Chloromthyl Naphthalene
N-Ethyl-2-nitromethylenepyrrolidine
Barbituric acid
N-methyl-1Naphthalene methaneamine
Veratraldehyde
Solvent
distillation(MDC,Methanol,toluene,acetone,
IPA,ethyl acetate,THF,n-hexane)
Proposed
Product
--
proposed
Existing
Proposed
prod. cap
prod. cap
200
0.0
MT/Month
--
Total Quantity
(MT/Month)
200
MT/Month
200
MT/Month
List of byproduct
Sr. No
Name of byproducts
1
HCL 22%
Existing
byproduct
Note: Our total production= existing + proposed200 MT/month
1
Proposed
byproduct
Proposed
Quantity (MT/Month)
30.00
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
List of Raw Material
Sr.
No
1
2
3
Qunatity
MT/Month
Name of Raw Material
Ammonium Formate
Formic Acid
Ammonia
Ammonium acetate
Acetic Acid
Ammonia
24.3
9.0
26.0
7.4
Ammonium Propionate
15.9
3.7
10.4
Propionic Acid
Ammonia
Water
4
Methyl 3 Amino Crotonate
33.3
4.9
Methyl Acetoacetate
5
Ammonia
Sodium 2 Ethyl Hexanoate
26.0
7.2
2-Ethyl Hexanoic Acid
6
Caustic soda
Sodium Formate
21.9
19.1
Formic Acid
7
Sodium hydroxide
Methanolic Ammonia
52.9
7.1
Methanol
8
Ammonia
Methanolic MMA
48.0
12.0
Methanol
9
Monomethyl amine
Propyl propionate
32.8
26.7
Propanoic acid
Propanol
10
1 Chloro Methyl Naphthalene in toluene
21.0
4.9
52.5
21.0
Naphthalene
Para Formaldehyde
HCl (34%)
Toluene
2
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
Sr.
No
11
Qunatity
MT/Month
Name of Raw Material
N-ethyl-2-nitromethylenepyrrolidine
4.5
5.1
7.3
3.3
18.1
2.3
1-ethyl-2-pyrrolidinone
dimethyl sulfate
sodium methoxide
nitromethane
MDC
12
Toluene
Barbituric acid
Methanol
sodium
Diethyl melonate
urea
Water
13
HCl
N-methyl-1Naphthalene methaneamine
1-chloromethyl naphthalene
N-methyl formamide
Sodium hydride (50% in parafin)
N,N-Dimethylformamide
Toluene
Water
Sodium hydroxide
Hydrochloric acid
Carbon
14
29.6
1.2
7.2
2.8
17.2
6.5
4.5
2.2
1.4
10.5
54.5
48.8
6.6
32.0
0.23
Veratraldehyde
5.3
9.3
2.8
4.4
0.8
Vanillin
Water
Sodium hydroxide
Dimethyl sulphate
Sulphuric Acid-50%
3
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
Annexure-II
Manufacturing process, PFD and Mass Balance
1. Ammonium Formate
MANUFACTURING PROCESS:
In SS reactor, formic acid is charged. Start ammonia gas purging at 30 to 400C under cooling circulation till pH is raised up
to 7.0 to 7.5. Keep the reaction mass for 1 hr. cool the reaction mixture at room temperature to crystallize & then filter
the reaction mass in centrifuge. Collect the mother liquor as solution of ammonium formate and it is recycled in next
batch and pack the wet cake as finished product ammonium formate.
CHEMICAL REACTION:
H
C
H
H
H
Formic Acid
N
H
H
Ammonia
NH4
C
Ammonium Formate
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Formic Acid
Ammonia
Total
FLOW DIAGRAM:
OUTPUT QUANTITIES
QTY
PRODUCTS
730.0 Kg Ammonium Formate
270.0 Kg ML (ammonium formate-Recycle)
1000.0 Kg Total
QTY
900.0 Kg
100.0 Kg
1000.0 Kg
4
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
2. Ammonium Acetate
MANUFACTURING PROCESS:
In SS reactor, acetic acid is charged. Start ammonia gas purging at 30 to 400C under cooling circulation till pH is raised up
to 7.0 to 7.5. Keep the reaction mass for 1 hr. cool the reaction mixture at room temperature to crystallize & then filter the
reaction mass in centrifuge. Collect the mother liquor as solution of ammonium acetate and it is recycled in next batch and
pack the wet cake as finished product ammonium acetate or dry it & pack it as per requirement.
CHEMICAL REACTION:
CH3
C
H
H
H
60 g/mol
Acetic Acid
N
H
CH3
17 g/mol
Ammonia
NH4
C
77 g/mol
Ammonium acetate
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Acetic Acid
Ammonia
Total
FLOW DIAGRAM:
OUTPUT QUANTITIES
QTY
PRODUCTS
779.0 Kg Ammonium acetate
221.0 Kg ML (ammonium acetate-Recycle)
1000.0 Kg Total
QTY
900.0 Kg
100.0 Kg
1000.0 Kg
Acetic acid - 779 Kg
Ammonia gas - 221 Kg
1000 Kg
Mix under Cool
& Crystallize
Centrifuge
Wet cake
900 KG
100 kg ML (Recycle)
Drying
45 Kg Evaporation
Unload & Pack
855 Kg
5
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
3. Ammonium Propionate
MANUFACTURING PROCESS:
Charge propionic acid & water in reactor. Start addition of ammonia gas till the reaction complies. Unload the liquid finish product
Ammonium Propionate in carboys and pack it.
CHEMICAL REACTION:
CH3CH2COOH
+
Propionic Acid
NH3
CH3CH2COONH4
Ammonia
Ammonium Propionate
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Propionic Acid
Ammonia
Water
Total
OUTPUT QUANTITIES
QTY
PRODUCTS
609.0 Kg
140.0 Kg
400.0 Kg
1149.0 Kg
QTY
Ammonium Propionate
1149.0 Kg
Total
1149.0 Kg
FLOW DIAGRAM:
Propionic Acid - 609 Kg
Ammonia
- 140 Kg
Water
- 400 Kg
MIX UNDER COOL
1149 Kg
Ammonium Propionate
65 % 1149 Kg
PACKING CARBOY
6
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
4. METHYL 3 AMINO CROTONATE
MANUFACTURING PROCESS:
Charge methyl acetoacetate in reactor at room temp. Start charging of ammonia in reactor at 30°-40°C till reaction over. Cool the
reaction mass to crystallize. Centrifuge the mass and dry the wet cake. Pack the dry material in bags as finish product.
CHEMICAL REACTION:
CH3 – CO - CH2 - COOCH3 +
CH3 – C = CH – COOCH3
NH3
+
H2O
NH2
Methyl Acetoacetate
Ammonia
Methyl 3 Amino Crotonate
Water
MATERIAL BALANCE FOR KG PRODUCT:
INPUT QUANTITIES
OUTPUT QUANTITIES
RAW MATERIALS
Methyl Acetoacetate
Ammonia
QTY
1126.0 Kg
165.0 Kg
PRODUCTS
Methyl 3 Amino Crotonate
Mother Liquor (M3AC-Recycle)
Evaporation Loss
QTY
1013.0 Kg
175.0 Kg
103.0 Kg
Total
1291.0 Kg
Total
1291.0 Kg
FLOW DIAGRAM:
Methyl Acetoacetate - 1126 Kg
Ammonia
- 165 Kg
1291 kg
Mix heat
& Cool
Centrifuge
175 Kg Mother Liquor Recycle in Next Batch
Wet cake
1116 KG
Drying
103 Kg Evaporation Loss
1013 kg
Packing
7
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
5. SODIUM-2-ETHYL HEXANOATE
MANUFACTURING PROCESS:
Charge 2-Ethyl Hexanoic acid in SS reactor and add caustic soda (Sodium Hydroxide) in it at 30° to 40°C till pH is raised up to 9.0 to
9.5. After completion of the reaction vacuum dry the reaction mass to crystallize. Then multimill the powder and pack it.
CHEMICAL REACTION:
C8H16O2
+
NaOH
C8H15O2Na
2 Ethyl Hexanoic acid Caustic soda
+
H2O
Sodium 2 ethyl hexanoate
water
MATERIAL BALANCE FOR PRODUCT
INPUT QUANTITIES
OUTPUT QUANTITIES
RAW MATERIALS
2-Ethyl Hexanoic Acid
Caustic soda
QTY
289.0 Kg
80.0 Kg
PRODUCTS
Sodium 2 Ethyl Hexanoate
Evaporation Loss
QTY
333.0 Kg
36.0 Kg
Total
369.0 Kg
Total
369.0 Kg
FLOW DIAGRAM:
8
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
6. Sodium Formate
MANUFACTURING PROCESS:
In SS reactor, formic acid is charged. Add Sodium hydroxide flakes lot wise at 30 to 40 0C under cooling circulation till pH is raised up
to 7.0 to 7.5. Keep the reaction mass for 1 hr. cool the reaction mixture at room temperature to crystallize & then filter the reaction
mass in centrifuge. Collect the mother liquor as solution of sodium formate and it is recycled in next batch. Dry the wet cake and pack
the finished product sodium formate.
CHEMICAL REACTION:
HCOOH
Formic acid
+
NaOH
HCOONa
sodium hydroxide
+
sodium formate
H2O
water
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
OUTPUT QUANTITIES
RAW MATERIALS
Formic Acid
QTY
730.0 Kg
Sodium hydroxide
635.0 Kg
Total
1365.0 Kg
PRODUCTS
Sodium Formate
ML (Recycle)
251 Kg water, 79 Kg sodium formate
Evaporation loss
Total
Flow Diagram
Formic acid - 730 Kg
Sodium hydroxide - 635 Kg
1365 Kg
Mix under Cool
& Crystallize
330 kg ML (Recycle)
Centrifuge
Wet cake
1035 KG
Drying
35 Kg Evaporation
9
QTY
1000.0 Kg
330.0 Kg
35.0 Kg
1365.0 Kg
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
Unload & Pack
1000 Kg
7. METHANOLIC AMMONIA
MANUFACTURING PROCESS:
In SS reactor, methanol is charged. Start ammonia gas purging at 10-150C under chilled water circulation till it complies the
percentage. Once the desired percentage achieved unload the mass to pack in carboys or drum.
CHEMICAL REACTION:
CH3OH
+
Methanol
NH3
CH3OH•NH3
Ammonia
Methanolic Ammonia
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Methanol
Ammonia
Total
OUTPUT QUANTITIES
QTY
881.0 Kg
119.0 Kg
1000.0 Kg
PRODUCTS
Methanolic Ammonia
QTY
1000.0 Kg
Total
1000.0 Kg
FLOW DIAGRAM
Methanol - 881 Kg
Ammonia - 119 Kg
Mix under Cool
Unload & Pack
1000 Kg
10
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
8. METHANOLIC MONOMETHYLAMINE
MANUFACTURING PROCESS:
In SS reactor, methanol is charged. Start Monomethyl amine gas purging at 10-150C under chilled water circulation till it complies the
percentage. Once the desired percentage achieved unload the mass to pack in carboys or drum.
CHEMICAL REACTION:
CH3OH
Methanol
+
CH3NH2
CH3OH•CH3NH2
Monomethylamine
Methanolic MMA
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Methanol
Monomethyl amine
Total
OUTPUT QUANTITIES
QTY
800.0 Kg
200.0 Kg
1000.0 Kg
PRODUCTS
Methanolic MMA
QTY
1000.0 Kg
Total
1000.0 Kg
FLOW DIAGRAM:
Methanol - 800 Kg
MMA - 200 Kg
Mix under Cool
Unload & Pack
1000 Kg
11
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
9. PROPYL PROPIONATE
MANUFACTURING PROCESS:
Charge propanoic acid and propanol in a reactor. Heat the mass to reflux till reaction complies. Cool the mass to 25°C. separate out
water. Remaining product to pack in carboys or drum.
CHEMICAL REACTION:
CH3CH2COOH
+ CH3CH2OH
Propanoic acid
Propanol
CH3CH2COOCH2CH2CH3 + H2O
Propyl propionate
Water
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Propanoic acid
Propanol
Total
OUTPUT QUANTITIES
QTY
1050.0 Kg
853.0 Kg
1903.0 Kg
PRODUCTS
Propyl propionate
QTY
1600.0 Kg
Water ( Reuse)
Evaporation loss
Total
255.0 Kg
48.0 Kg
1903.0 Kg
FLOW DIAGRAM
Propanoic acid - 1050 Kg
Propanol - 853 Kg
1903 kg
Heat & reflux
Cool & water
separation
255 Kg Water is reused in process.
Distill the
material & Pack
1600 Kg
12
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
10. Chloro Methyl Naphthalene in toluene
MANUFACTURING PROCESS:
Charge naphthalene, paraformaldehyde and HCl (34%) in reactor. Heat to 800C and maintain till reaction completes. Cool the reaction
mass and settle and separate the HCl (22%) layer to other vessel. Charge Toluene to remaining reaction mass to make 1 chloro methyl
naphthalene 80% finish product. Pack it to HDPE Drum.
CHEMICAL REACTION:
CH2Cl
(CH2O)n
Napthalene
p-Formaldehyde
HCl
Hydrochloric Gas
H2O
1 Chloro methyl Naphthalene
Water
MATERIAL BALANCE FOR PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Naphthalene
Para Formaldehyde
HCl (34%)
Toluene
OUTPUT QUANTITIES
QTY
800.0 Kg
187.5 Kg
2000.0 Kg
PRODUCTS
1 Chloro Methyl Naphthalene in toluene
HCl (22%)
QTY
1903.0 Kg
1884.5 Kg
Total
3787.5 Kg
800.0 Kg
Total
3787.5 Kg
Naphthalene - 800 Kg
Paraformaldehyde - 187.5 Kg
HCl (34%) - 2000 Kg
Reaction mass
Mix heat & Cool
Separation
Toluene – 800 Kg
HCl (22%) - 1884.5 Kg
Packing
1903.5 Kg
1 Chloro Methyl Naphthalene sale with toluene
13
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
11. N-Ethyl-2-nitromethylenepyrrolidine
MANUFACTURING PROCESS:
Charge NE2P,DMS, Sodium methoxide & Nitro methane in reactor. Mix and maintain the reaction mass at 25°C for 8 hrs. Charge
Dichloro methane to the reactor & separate out remaining methanol. Distill out dichloro methane completely. Add toluene to
reactor.mix the reaction mass. Centrifuge the mass and dry the wet cake. Pack the dry material in bags as finish product.
CHEMICAL REACTION:
C6H11NO + C6H6O4S + 2CH3NaO + CH3NO2
NE2P
DMS
sodium
nitro
Methoxide
methane
C7H12N2O2 +
NE2NMP
Na2SO4 + 2CH3OH + C2H6O
sodium
methanol DME
sulphate
MATERIAL BALANCE FOR KG PRODUCT:
INPUT QUANTITIES
OUTPUT QUANTITIES
RAW MATERIALS
1-ethyl-Z-pyrrolidinone
QTY
300.0 Kg
dimethyl sulfate
336.0 Kg
sodium methoxide
486.0 Kg
nitromethane
220.0 Kg
MDC
Toluene
Total
1200.0 Kg
150.0 Kg
2692.0 Kg
PRODUCTS
N-ethyl-2-nitromethylenepyrrolidine
Methanol
350 kg methanol recovery, 20 kg evaporation
loss, 122 kg dimethyl ether.
377 kg sodium sulphate, 73 kg impurity
MDC
1120 kg recovery, 60 kg evaporation loss
Toluene ML
140 kg toluene, 40 kg NE2NMP, 20 kg MDC
Drying loss
Total
QTY
325.0 Kg
492.0 Kg
450.0 Kg
1180.0 Kg
200.0 Kg
45.0 Kg
2692.0 Kg
14
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
FLOW DIAGRAM:
NEAP – 300 Kg
DMS - 336 Kg
Sodium methoxide – 486 Kg
Nitro methane – 220 Kg
1342 kg
Mix heat
& Cool &
MeOH
recovery
MDC – 1200 kg
Toluene- 150 kg
2542 kg
seperation &
MDC
recovery
942 kg Methanol layer
1120 kg MDC Recovery, 60 kg evap. loss
570 kg
Mix
Centrifuge
200 kg toluene ML (to be recover & reuse)
Wet cake
370 KG
Drying
45 kg evaporation loss
325 kg
Packing
15
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
12. BARBITURIC ACID
MANUFACTURING PROCESS:
Charge methanol to reactor then charge sodium metal to it lot wise while chilling water circulation to jacket.mix the mass. Now
charge diethyl melonate & urea to it.heat the reaction mass to 70-80°C & maintain for 8 hours.Distill out methanol completely.Now
charge water & then HCl to the reaction mass to recrystallize the product. Centrifuge the mass and dry the wet cake. Pack the dry
material in bags as finish product.
CHEMICAL REACTION:
C7H12O4 + CH4N2O +
Diethyl
malonate
Urea
CH3ONa +
HCl
C4H4N2O3 + 2C2H6O + CH3OH + NaCl
sodium Hydrochloric
Methoxide
Acid
Barbituric
Acid
Ethanol
Methanol Sodium
Chloride
MATERIAL BALANCE FOR KG PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
Methanol
sodium
Diethyl melonate
urea
Water
HCl
Total
OUTPUT QUANTITIES
QTY
2176.0 Kg
85.0 Kg
531.0 Kg
208.0 Kg
1260.0 Kg
480.0 Kg
4740.0 Kg
PRODUCTS
Barbituric acid
Mix solvent
2102 kg methanol,275 kg ethanol, 125 kg
evaporation loss
Mother Liquor
1245 kg water, 359 kg HCl, 194 kg sodium
chloride
Drying Loss
Total
QTY
360.0 Kg
2502.0 Kg
1798.0 Kg
80.0 Kg
4740.0 Kg
16
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
FLOW DIAGRAM:
Methanol – 2176 Kg
sodium - 85 Kg
Diethyl melonate – 531 Kg
Urea – 208 Kg
3000 kg
Mix heat
& Cool &
MeOH
recovery
water – 1260 kg
HCl – 480 kg
2502 kg Methanol+ethanol Recovery
2238 kg
Chilling &
Recrystelliza
tion
Centrifuge
1798 kg ML separation by dist. process
Wet cake
440 KG
Drying
80 kg evaporation loss
360 kg
Packing
17
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
13. N-METHYL-1-NAPHTHALENE-METHANEAMINE
MANUFACTURING PROCESS:
Step-1:
Charge N,N-Dimethylformamide to reactor then charge sodium hydride (50% inparafin oil) to it lot wise while chilling water
circulation to jacket.mix the mass. Now charge N-methyl formamide to it. Maintain the reaction mass at 25-30°C. Now charge 1chloromethylnaphthalene solution in toluene. Maintain the reaction mass at 40-45°C.Once the reaction is over quench the mass to
water. Add toluene to reaction mass & extract with toluene. Separate organic layer & distill out toluene completely to get N-methyl-N(1-Naphthylmethyl)-formamide which is directly used in next step.
Step-2:
To the reactor containing N-methyl-N-(1-naphthylmethyl)-formamide charge 20% aqueous sodium hydroxide and heated at 60-70°C
for a period of 7hr. Cool the reaction mass and extract with toluene. Separate organic layer and extract with Hydrochloric acid.
Decolorize the aqueous layer with activated charcoal. Filter the mass & collect the filtrate. Add 20% aqueous sodium hydroxide and
toluene to it. Separate the organic layer. Distill out toluene completely to get Methyl-1-naphthalene-methaneamine. Pack to carboys.
CHEMICAL REACTION:
Step-1
C11H9Cl
+
1-chloromethyl
naphthalene
C2H5NO
+
N-methyl
formamide
NaH
C13H13NO
Sodium
hydride
+
NaCl
+
H2
N-methyl-N-(1-naphthyl Sodium Hydrogen
methyl)-formamide
chloride
MATERIAL BALANCE FOR KG PRODUCT:
INPUT QUANTITIES
RAW MATERIALS
1-chloromethyl
naphthalene
OUTPUT QUANTITIES
QTY
100.0 Kg
N-methyl formamide
50.0 Kg
Sodium hydride (50% in
parafin)
32.0 Kg
N,N-Dimethylformamide
236.0 Kg
Toluene
Water
Total
519.0 Kg
500.0 Kg
1437.0 Kg
PRODUCTS
QTY
N-methyl-N-(1-Naphthylmethyl)-formamide
132.0 Kg
Aqueous layer
500 kg water, 236 kg DMF, 16 kg paraffin oil,
33 kg sodium chloride
785.0 Kg
Toluene recovery
493.0 Kg
Evaporation Loss
26.0 Kg
Hydrogen gas
1.0 Kg
Total
1437.0 Kg
18
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
FLOW DIAGRAM:
DMF – 236 Kg
Sodium hydride - 32 Kg
( 50% in paraffin oil)
N-methyl formamide – 50 Kg
1-CMN – 100 Kg
Toluene – 86.5 Kg
504.5 kg
Mix heat
& Cool
water – 500 kg
toluene – 432.5 kg
1 kg Hydrogen gas evolved
1436 kg
layer
separation
785 kg Aq. Layer separation by dist. Process.
651 kg
Distillation
519 kg toluene recovery
132 kg
Stage-1
132 Kg N-methyl-N-(1-Naphthylmethyl)-formamide directly used in next stage
19
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
14. VERATRALDEHYDE
MANUFACTURING PROCESS:
Charge water and vanillin to reactor. Add sodium hydroxide and dimethyl sulfate.Mix the reaction mass. Add sulphuric acid to the
reaction mass.Once the reaction completes settle down the mass for one hour. Discard the water layer and crystallize the organic layer.
Centrifuge the mass & dry it. Pack the product.
CHEMICAL REACTION:
C8H8O3
Vanillin
+
2NaOH
+
Sodium
hydroxide
(CH3)2SO4
C9H10O3
Dimethyl
sulphate
+
Veratraldehyde
CH3OH + Na2SO4 + H2O
Methanol
Sodium
sulphate
Water
MATERIAL BALANCE FOR KG PRODUCT:
INPUT QUANTITIES
OUTPUT QUANTITIES
RAW MATERIALS
Vanillin
QTY
325.0 Kg
Water
571.0 Kg
Sodium hydroxide
171.0 Kg
Dimethyl sulphate
Sulphuric Acid-50%
Total
269.0 Kg
52.0 Kg
1388.0 Kg
PRODUCTS
3,4-dimethoxybenzaldehyde
Aquous Layer
65 kg methanol,304 kg sodium sulphate, 590 kg
water, 50kg sulphuric acid
Mother Liquor
10 kg water, 2 kg methanol, 25 kg 3,4dimethoxybenzaldehyde
Drying Loss
Total
QTY
300.0 Kg
1009.0 Kg
37.0 Kg
42.0 Kg
1388.0 Kg
20
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
FLOW DIAGRAM:
Vanillin – 325 Kg
Water - 571 Kg
Sodium hydroxide – 171 Kg
Dimethyl sulphate – 269 Kg
1336 kg
Mix &
heat
Sulphuric acid – 52 Kg
1388 kg
Mix, Settle
& Seperate
Aq layer-1009 Kg separation by dist. process
Centrifuge
3
7 kg ML
Wet cake
342 KG
Drying
42 kg evaporation loss
300 kg
Packing
21
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
15. Solvent distillation (MDC, Methanol, toluene, acetone, IPA, ethyl acetate,THF,n-hexane)
Dist. Solvent
Condenser
Solvent from Process
Reactor
22
Vishwa Chemicals
Plot No. 4801/A/13, GIDC Ankleshwar Dist: Bharuch
Annexure-III
Sr. No
1.
2.
3.
Water Consumption and Waste water generation Details
Source
Water consumption
Waste water generation
kl/day
kl/day
Domestic
2.0
1.5
Gardening
1.0
-Industrial
4.0
0.0
1. Source of water supply : GIDC supply
2. Domestic effluent will be disposed through septic tank/ soak pit system
Annexure-IV
Sr.
No
Stack attach to
1.
Boiler
2.
Process
Stack(From
reactors and
vacuum pump
outlet)
Stack
Height
(Mtr)
9.0
9.0
Detail of Air Pollution
Fuel
Fuel
APCM
Used
Consumption
rate
Natural 300 M3/day
N.A.
Gas
--
--
Dip pipe in to
water and then
passes through
chiller
Pollutants
SPM < 150 mg/Nm3
SO2 < 100 ppm
NOx < 50 ppm
----
Annexure-V
Hazardous Waste Details
Category of Waste
Quantity
33.1
6.0 MT/Year
Sr. No
1
Type of Waste
Discarded Containers/
Barrels/ Liners
2
Used oil
5.1
12.0 Lit/Hr
3.
Distillation Residue
--
30
MT/month
23
Method of Disposal
Collection, Storage,
Transportation and
disposal by selling to
registered recycler.
Collection, Storage, Sale to
registered recycler / reuse
for machine lubricants.
Collection, storage, reuse,
disposal by CHWIF