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Annexure -II
Manufacturing Process
1. Vinyl Sulphone
Process Description
Stage 1: Acetylation
Charge acetic acid in jacketed vessel
Charge aniline in jacketed vessel
Heat reaction mass for reflux
Maintain reflux to obtain product acetanilide.
Excess acetic acid is recovered under vacuum distillation.
Product is flaked and packed as acetanilide
Stage 2: Sulphonation
Charge Chloro sulphonic acid in jacketed vessel.
Charge acetanilide slowly maintaining temperature parameters
Maintain temperature and recover hydrochloric acid in scrubber.
Charge Thionyl chloride slowly addition maintaining temperature.
Maintain temperature to obtain para sulphonyl chloride acetanilide.
Sulphur which is liberated is scrubbed in caustic soda solution to make
sodium bisulphite solution which is used in reation operation of product
vinyl sulphone.
Drown and isolate Chloro sulphonated mass in ace.
Isolated products ASC filtered, wash free of acid and charged for
reduction operation.
Stage 3: Coupling
Charge chilled water add sodium bisulphite in jacketed reactor.
Charge caustic lye to bring PH of sodium bisulphite solution.
Add product ASC maintaining temperature and PH parameter.
Reduced product is clarified in filter press and transferred to ethoxylation
reactor
Stage 4: Ethoxylation
Receive reduction material in jacketed reactor.
Add gradually at uniform rate ethylene oxide maintaining temperature
parameters. Dilute spent acid is added to maintain PH.
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Filter material in neutsch, washed, centrifuged and dried as condensate
product.
Dried product is weighed and charged in small lot of etherification
process.
Stage 5: Esterification
Charge ethoxylated (condensed) product.
Add required quantity of sulphuric acid under stirring.
Maintain temperature parameter till reaction is complete. Recover acetic
acid liberated by condensation method under vacuum.
Unload product vinyl sulphone in trollies.
Pulverize.
Charge in blender Mix for 2 hours.
Unload and pack as product vinyl sulphone.
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Chemical reaction
ClSO3H
SOCl2
NHCOCH3 NHCOCH3
SO2Cl
Dumpig
+ Ice
NHCOCH3 NHCOCH3
SO2Cl SO2Cl
NaHSO3
NaOH
NHCOCH3 Reduction NHCOCH3
SO2Cl SO2H
E.O.
NHCOCH3 H2SO4
NHCOCH3
SO2H SO2CH2CH2OH
Esterification
H2SO4
NHCOCH3 NHCOCH3
SO2CH2CH2OH SO2CH2CH2OH
(V.S.)
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Mass Balance
Mass Balance for Vinyl Sulphone
INPUT KG OUTPUT KG
Acetanilide 2000
Chloro sulphonic aci 6000 Sulphonation HCl 1150
Thinoyl chloride 1800 S.B.S. Slurry 1325
Drying
Moiture 2050
Final Product 3835
Total 40950 40950
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2. Acetanilide:
Production of acetanilide is simply one stage process. Aniline is acetylated
by Acetic acid at high temperature. Excess acetic acid is recovered and then
it is flaked and packed in bags.
Process flow diagram:
Mass Balance of Acetanilide
INPUT KG OUTPUT KG
Acetylation
Aniline oil 780
Acetic Acid 570
Acetic Anhydride 50
Recovery of
Acetic Acid
Flaking
Packing
Product 1000
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Annexure-III (A)
Water consumption & w/w generation details
Sr. Break up Water w/w
No. Consumption Generation
KLD KLD
I Domestic 3.5 3.0
II Gardening 4.0* --
III Industrial
(a) Process 09 15
(b) Water treatment 04 04
(c) Scrubber 05 --
(d) Washing 02* 02
(e) Cooling 7.5 2.5
(f) Boiler 2.5 0.5
Total Industrial 30.0 24.0
Total (I + II + III) 37.5 27.0
Recycle 6.0 --
Actual fresh water 31.5
requirement
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Annexure-III (B)
Water Balance Diagram
All units are in KLD
ETP
2+2.5+0.5+4 = 9
To G. Salt Eva. Loss
sale 3.0 12.0
Reject SD Salt
3 3 0.1
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Annexure -IV
Details of ETP
Primary Treatment & RO:
Estimated quantity of industrial effluent from process is nil and only source of
effluent is from plant/equipment washing & utilities and it is estimated 9.0
KLD. Industrial Effluent will be treated at own Effluent Treatment Plant
comprising of primary treatment followed by tertiary treatment and after RO
process.
The effluent generated is first collected in neutralization pits, where it is
neutralized, depending upon the acidity/alkalinity of raw influent. Alum &
Polyelectrolyte will be added as per requirement. Then neutralized industrial
effluent is taken to the primary settling tank, heavier particles then allow
retaining for certain time period for the settlement. Clear overflow taken
collect in treated water collection tank. Then it is pass though send filter and
finally pass though RO. Where permeate which ever will be reuse in greenbelt
development and pant washing and reject stream periodically sprayed dried
into spray dryer. Thus unit is achieving zero discharge of industrial effluent.
ETP Details
Sr. Name of Unit Size of Unit in Capacity
No. meter m3
1 Equalization/Neutralization 2.0 x 2.0 x 3.0 10
Tank (0.5 FD)
2 Primary Settling Tank 2.0 x 3.0 x 3.0 12
(1.5 FD)
3 Water collection Tank 2.0 x 2.0 x 3.0 10
(0.5 FD)
4 Sand Filter 0.450x1.8 mm 1.5 m3
Filtration rate
5 RO Treatment Standard supply 1.5 m3
Filtration rate
6 Sludge Drying Bed (2 Nos) 2.0 x 2.0 x 1.2 4 m2 surface
area
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Flow diagram of ETP
Effluent
from plant
Permeate Reject to
Reuse SD
Sludge Drying Bed
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Annexure -V
Details of Air Emissions
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Annexure-VI
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