Asha Cellulose Plans for Expansion of its Organic Chemicals Unit...
Industrial Directory Of India
RELEASED : ISSUE NOVEMBER 25 /12
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Asha Cellulose Plans for Expansion
of its Organic Chemicals Unit
(Ref: Our Earlier Report: 25.02.2012)
Asha Cellulose (India) Private Limited plans for expansion of the capacity of its Organic Chemicals (Ethyl Cellulose) Production from 20 Ton/Month to 99.69 Ton/Month at Abrama Village in Valsad District, Gujarat.
Project cost : Rs.105 Crore
Capacity Expansion :
Ethyl Cellulose -
20 Ton/Month to 99.69 Ton/Month.
By Product :
Spent Caustic (18 – 20%0 : : 369.20 Ton/month
Location : Abrama Village,Valsad District,
Gujarat.
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As on November 27, 2012 : The Project is under Planning Stage .
The proposed expansion project will be accommodated in the existing plots with a total plot area of 22062 m2 .
The required expansion of 3912 m2 will be carried out in the existing open area of 10306 m2 .
No additional land required for proposed expansion.
Green Belt will be developed in toal 6325 m2 of land.
Existing Green Belt Area is 5125 m2.
IMPORTANT: As per the the discussion we had
on 21.11.2012 with Asha Cellulose (India) Private Limited
the Project is under Panning Stage.
The company is waiting for the clearance from State Pollution Control Authority.
The Project is Scheduled to be Completed
by October, 2013.
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The Main Scope of Supply includes:
1. Boiler: 5 TPH - 1 No
Fuel : Natural Gas.
2. Hot Air Generators
Capacity :10 Lakh.kcal/hr-2 Nos.
Fuel : Natural Gas
Note : Provision for using LDO in all utility of installation incase
of non availability of natural gas.
Heat Exchangers, Air Pre-heater/Economiser)
Wet Scrubber for arresting fly ash
Existing Status of Heating Equipment:
In existing operations,
1. Boilers : 850 Kg/Hr - 3 nos.
each is stand-by installations & remain as stand-by during proposed operations also.
2. Boiler: 3 TPH - 1 No
This Boiler is existing utility installation & it will be act as standby arrangement
after expansion.
3. Hot Air Generator:
Capacity : 6 Lakh.kcal/hr -2 Nos.
This Hot Air Generator is an existing installation & it will be utilized
after expansion too.
Spin Flash Dryer: 200 Kg/hr
Capacity : 200 kg/hr -2 Nos
The unit has presently 1 No. of 50 kg/hr Spin Fash Dryer.
Air Polution Control:
There are few chances of fugitive emissions from material handling of solvents during the process.
However, fugitive emissions may be released in case of any leaks from
pumps.
Following measures are adopted for control of fugitive emissions:
- Fugitive emissions over Reactors, chemical loading, transfer area, are collected through hoods and ducts by induced draft and controlled by Dust Collector.
2. The toluene tank will be provided Nitrogen blanketing besides breather valve cum flame arrestor.
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Other Equipments:
Pulverizer : 2 Nos.
For Expansion : 2 Nos.(Existing: 2 Nos.)
---------------------------------------------
Granulator : 2 Nos.
For Expansion : 2 Nos (Existing: 1 No.)
---------------------------------------------
Auto Clave : 2 Nos.
For Expansion : 2 Nos.(Existing: 3 Nos.)
--------------------------------------------
Chilling Water plant : 2 Nos.
For Expansion : 1 No.(Existing: 1 No.)
---------------------------------------------
Filter Press : 4 Nos.
For Expansion : 4 Nos. (Existing: 2 Nos.)
-----------------------------------------------
Cooling Tower : 2 Nos.
For Expansion : 2 Nos (Existing: 2 Nos.)
---------------------------------------------
Chilled Brine Unit : 1 No.
For Expansion : 1 No (Existing: 1 No.)
-------------------------------------------
DM plant : 1 No.
For Expansion : 1 No. (Existing: 1 No.)
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Water Softener : 1 No.
For Expansion : 1 No.(Existing: 2 Nos.)
---------------------------------------------
Air Compressor : 2 Nos.
For Expansion : 2 Nos (Existing: 2 Nos.)
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Effluent Treatment Plant : 1 No.
For Expansion : 1 No. (Existing: 1 No.)
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Pumps : 12 Nos.
For Expansion : 12 Nos. (Existing: 12 Nos.)
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Lift : 4 Nos.
For Expansion : 4 Nos.(Existing: 2 Nos.)
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*Storage Tanks : 17 Nos
For Expansion : 17 Nos. (Existing: 31 Nos.)
(*for various Purposes: Solvent Process tanks Washing tanks, Holding Tank, Filtered Slurry Tanks, Ethyl Chloride Day Tanks, Solvent Process tanks, Water Storage Tanks)
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Manufacturing Process:
The bleached Cotton Linter/Wood Pulp are fed to a shredding mill.
The shredded bleached Cotton Linter or Wood Pulp is charged into a Reactor containing Caustic solution, through Alkali Cellulose Tank and Screw Conveyor.
The Reactor is a jacketed and agitated type Autoclave.
The temperature, time and concentration depend on the intrinsic viscosity desired in the product. The required amount of diluents (crude solvent) and Ethyl Chloride are added to the Alkali Pulp and viscosity is controlled by air as an Oxidizing Agent.
The reaction is carried out in jacketed and agitated Autoclave.
Ethyl Chloride and crude solvent are also charged along with Caustic during the course of reaction if necessary.
The reactor content is heated by passing steam through jacket.
Working pressure of about 28 kg/cm2 is obtained maximum and the reaction is continued till the desired degree of substitution of Ethyl Cellulose is obtained.
After completion of reaction, Ethyl Cellulose gets separated from Solvent, Salt, Water & Sodium Hydroxide. Solvent vapors along with Water are stripped off from the reactor and condensed in series of condensers and collected. Part of mixed solvent is used in the process and balance is sold off.
As the solvent is removed, Ethyl Cellulose precipitates in the liquor containing Caustic and Salt. The slurry is then discharged from the reactor into a Holding Tank, where alkali solution along with Salt is recovered. After giving adequate water wash, the product is neutralized by the addition of acid and centrifuged. Wet Ethyl Cellulose is subjected to wet grinding in Hammer Mill. After grinding, the material is discharged into Washing Tank for further purification. After purification, the slurry is subjected to centrifuging for maximum water separation and wet cake is fed to a Spin Flash Dryer.
Dried product is packed in Fibre Drum/Paper Bags.
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DG sets :
500 KVA - 1 No.
110 KVA - 1 No.
35 KVA - 1 No
----------------------
Total : 645 KVA
For back up in the common areas as well as for essential services
Three D.G.sets with cumulative capacity of 645 KVA will be installed.
Water Treatment Plant:
Pumps, Valves, Custom Pipeline Work, Plumbing Work
The total water demand for this project has been estimated as
285.70 KLD., where in 52.7 KLD water will be fresh water consumption and 233 KLD will be recycled water.
The source of water supply for the project will be Ground Source.
(For proposed project 233 KLD water will be required in addition to the existing requirement of 52.7 KLD)
Details of Water Consumption
1.Domestic : 2.2 M3/Day
2.Process Water : 162 M3/Day
3.Boiler : 78.5 M3/Day
4.D.M. Plant : 10 M3/Day
5. Cooling : 28 M3/Day
6. Washing : 2 M3/Day
7. Irrigation-Gardening : 3.5 M3/Day
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Total: 285.70 M3/ Day
Effluent Treatment Plant
The total industrial Effluent Generation after proposed expansion will be 242 m3 /day.
Details of Wastewater Generation
1.Domestic : 1.5 M3/Day
2.Process Water : 178 M3/Day
3.Boiler : 46.5 M3/Day
4.D.M. Plant : 10 M3/Day
5. Cooling : 4 M3/Day
6. Washing : 2. M3/Day
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Total: 242 M3/ Day
Wash water will be collected and sent to ETP. Cooling tower overflow/blow down will be sent to the ETP. Cooling tower loss compensated by fresh water.
Floor/Container/Equipment Washings will be collected and sent to the ETP.
The entire quantity of effluent will be treated in the Primary, Secondary & Tertiary Effluent Treatment Plant followed by Reverse Osmosis (RO) & Multiple Effect Evaporator (MEE) system. Thus, after installation of RO & MEE, the entire treated water will be recycled.
The RO Permeate & MEE condensate shall be recycled. RO reject will be taken into MEE. Salt from MEE shall be disposed off into TSDF.
After the proposed project, the domestic waste water will increase to
1.5 m3/day and it will be diverted to Septic Tank/Soak Pit system of adequate capacity
Other Equipments:
Dosing Systems, Heat Exchangers, Ball Mills, Drum Mixers, Agitators, Pulverizes, Dryers, Solvent Calibration Tank, S S Reaction Vessel with Stirrer, Gear & Elec. Motor, Holding Vessel, Automatic Filling, Pluging & Capping Machine, Patent Automatic Liquid Filling / Weighing Machine, AIR Scrubber with hoodes, Hot Water Bath, Semi Automatic Box Strapping Machine, Heat Shrink Wrapping Machine, Induction Sealing Machine, Water Pumps, Chemical Pumps, Storage Tanks, Water & Acid line Valves, Control Vales, Cooling Towers, Custom Pipeline Work.
Ventilation & Exhaust System
Complete Laboratory Equipments
Fire fighting System as per TAC norms,
Green Belt Development plan in 33 % area and a scheme for Rainwater Harvesting have to be put in place.
Companies/ General Industries/ Manufacturers / Contractors/ Sub Contractors/ Manufacturers of Chemical Plant & Machineries, Water & Effluent Treatment Plant , Fire Fighting Equipments, Air-conditioning, Boilers, Air Pollution Control Equipment, Pumps, Motors Valves For Acid line, Pipeline Jobs for the above project may Contact for etc.etc. may Contact for Specified Enquiry at :
Asha Cellulose (India) Private Limited
Asha House, Plot No 808/C, Dr B.A. Ambedkar Road, Dadar TT
Mumbai - 400014, Maharashtra, India.
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Tel : : + 91-22-24140020/24178050
Fax : + 91-22-24137190
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Email : in...@ashacel.com
Website : www.ashacel.com
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