M/s. Balaji Formalin Pvt. Ltd.

Annexure-I

Size of the Project:

Sr. Product Description Capacity MTPM Capacity MTPA

No. Existing Additional Total Total
1 Formaldehyde 5000 7500 12500 150000
2 Para Formaldehyde 00 835 835 10020
3 Reprocessing of Silver 00 1.5 1.5 18
(Purification of Silver)

List of Raw Materials

Sr. Name of Raw Materials Consumption (MTPM)

No Existing Proposed Total
Formaldehyde -12500 MTPM
1 Methanol 2325 3490 5815
Para Formaldehyde - 835 MTPM
1 Methanol 0 1090 1090
Purified Silver – 1.5 MTPM
1 Silver Metal (98%) 0 1.530 1.530
2 HNO3 0 2.400 2.400

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Annexure-II
Manufacturing Process

1. Formaldehyde Production Technique:

1.1 Feed Methanol, air, water vapour
Catalyst: Silver
1.2 The methanol in the measuring storage tank is pumped up to an elevated
tank by a methanol pump. After being controlled by measuring, the
methanol coming out from the elevate tank flows into an evaporator for
vaporization of which the temperature is controlled within 44 0C ~ 470C
and the liquid level is controlled as 50%,then the vaporized methanol
gets into a super heater. The heat for the vaporization of methanol is
provided by the 700C circulating fluid in the 1# formaldehyde absorber.
1.3 The air is filtered by a filter before being delivered to the evaporator by a
blower. It mixes with the methanol in the evaporator and enters into then
super heater together. The air flow is regulated by the blower through
frequency conversion to control the flow ratio of air to methanol
(A/M=1.8 ~1.95).
1.4 When the pressure gets stable, the vapour (0.3MPa) gets into a mist
eliminator for dehumidification through the pipeline before entering into
the superheat. The flow ratio of air to methanol shall be controlled at
desired level. In the formaldehyde production technique using silver as
catalysis, the water vapor is an inert gas which does not participate in
chemical reactions. The added water vapor changes the explosive range
of the methanol and air, the production of formaldehyde thereby becomes
far from the explosive area and stays safe and reliable.
1.5 After the flow rates are regulated and proportioned, the methanol, air and
water vapor enter into the super heater and the superheating
temperature shall be controlled at 1200C. Then, these materials enter into
a reactor.
1.6 In the reactor, under the catalysis of silver of 6500C, the methanol is
dehydrated and oxidised, generating Formaldehyde. Dehydration reaction
is an endothermic reaction and oxidation reaction is an exothermic

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reaction, but the heat release is more than that can adsorbed, therefore
the reaction system is an state of heat energy surplus. The water vapour
is not involved in reactions but it can absorb a lot of heat of reaction,
maintaining the temperature at 6500C.
Chemical Reaction
CH3OH CH2O + H2 - 20Kcal-----------------1
CH3OH + ½ O2 CH2O + H2O + 38 Kcal------2
1-2=18Kcal
The 6500C reaction gas leaves the reaction and gets into heat exchanger.
For the heat exchanger, the medium is water. The outlet temperature of
heat exchanger is 1600C. The water absorbs heat, forming the water
vapour of 0.35 MPa which will be used to arranging the raw materials for
production in the super heater after its pressure stabilized.
1.7 The generated gas of about 1600C enter into 1# and 2# formaldehyde
absorber in proper order and gets absorbed by the cooled circling fluid
through spraying. The temperature of the circulating fluid at the botton of
1# absorber shall be control at 700C and fluid is pumped to the
evaporator by circulating pump to supply the heat for the evaporation of
methanol. In the 1# absorber, the concentration shall be controlled as
37%, and temperature of the top shall be controlled at 45 0 to 500C. The
circulating fluid is also a composition of the Formaldehyde product by this
technique. The temperature of the top of 2# absorber shall be controlled
at 300 to 350C and keep adding water by 300-500 kg/h from top to
reduce the release of formaldehyde.
The tail gas is discharged from the top of the absorber and sent to an tail
gas treatment unit. The tail gas contain 18 to 20% hydrogen and small
amount of Formaldehyde, methanol and methane, which will generate
heat after burning to produce 0.6 MPa water vapor for the application of
other devices. Through tail gas treatment unit, the pollution of
formaldehyde, methanol and methane to atmosphere is reduced and the
recycling of combustion heat is very effective to reduce pollution
discharge and take advantage of wasted energy.

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Flow diagram

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2. Process of making Para-formaldehyde from Methanol using rake

type drying method
First step process of Para Formaldehyde is production of formaldehyde from
Methanol with above mentioned process.
Formaldehyde is firstly concentrated and dehydrated until the formaldehyde
concentration is increased 65%. Then it is sent to the vacuum type dryer for
further dehydration and drying to make powder/ Prills.
The whole drying process is operated under vacuum condition. The
evaporation condensate contains 10-15% of formaldehyde fumes, which is
condensate and collect as diluted formaldehyde for recycling in formaldehyde
plant.
Condenser 1: The vapor, which contains formaldehyde & water vapor from
evaporator and concentrated receiving vessel pump into 1# condenser for
cooling. The condensate is dilute formaldehyde solution which is finally
discharged into dilute formaldehyde storage tank, which is return back to
formaldehyde plant.
Condenser 2: The vapor, which contains formaldehyde & water vapor from
dryer into 2# condenser for cooling. The condensate is dilute formaldehyde
solution which is finally sent to dilute formaldehyde storage tank, which is
return back to formaldehyde plant.
Absorber: Off gas of 1# condenser, 2# condenser and vent of Dryer are
taken into absorber tower where water circulates from circulation tank.
Formaldehyde which ever in off gas is absorb in water and convert into dilute
formaldehyde. When absorption liquid formaldehyde solution reaches certain
concentration, then it is taken into dilute formaldehyde storage tank and it is
used in formaldehyde plant.
All source of dilute Formaldehyde from Condenser 1 & 2 + Absorber
are collected into Dilute formaldehyde storage tank which have
around (4 to 4.5%) concentration of Formaldehyde which is recycled
in formaldehyde plant.

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Process Flow Diagram:

Packing
Heat out Powder form

FM solution Evaporator Concentrate Rake dryer

(65-75%) receiving vessel

Off gas Off gas Off gas

Heat in

Cooling water in Condenser 1 Condenser 2 Cooling water in

Cooling water out Cooling water out

Absorber

Circulation
tank

Dilute formaldehyde
storage tank
(4 to 4.5%)

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3. Process of Silver Refining

Stage-I
Process of making silver nitrate
In a vessel 50 Ltr of water/dilute solution of Silver Nitrate is taken to which 16
Kg of silver is added @ 50-55 Degree C, under constant stirring. Nitric Acid
9.3 Kg is added in the same to convert silver to silver nitrate. During reaction
nitrous fumes are evolved which is absorbed in scrubber.

Stage-II
In a tank containing refining cells with hood, connected to scrubber, which can
hold silver.
Silver nitrate solution is added to tank in which current from 20 to 200 Amp &
DC voltage of 2 to 20 Volts is applied.
Silver crystals are deposited on silver cathode plate.
Silver crystals are removed from cathode plate by scrapping, then collected
and washed with DM water to remove silver nitrate. Water used in washing is
recycled back to electrolysis tank.
Wet crystals are dried and sieved to obtain different sizes.
The fumes generated are absorbed in a scrubber.
In scrubber NaOH solution is circulated to absorb nitrus fumes.
Neutralize solution is taken to common Evaporator.

Stage-III
Melting Process
Silver crystals to be reprocessed are melted in electric/gas furnace @ 900
Degree C and converted into ingots / small pieces.

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Flow Diagram

Stage 1 process (silver refining process)

Silver metal AgNO3 Preparation

HNO3

Silver plate AgNO3Solution

Silver electrolysis
D.C. current

Dilute
Recovered silver AgNO3reused

D.M. water

Washing

Drying

Silver Catalyst

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Stage 2 process Silver recovery fromAgNO3

Reducing AgNO3from silver

agent refining process

NaOH Silver recovery unit

Filtration To effluent

Water

To evaporator Silver Washing

Drying

Melting

Ingots/small
process

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Annexure-III
Water Balance Existing

Water
consumption
104 m3/d

Domestic Process Utilities Greenbelt

3.5m3/d 63m3/d 35m3/d 2.5m3/d

RO treatment
Evop loss Water
generation from
5.0m3/d Reject
reaction 47m3/d
10m3/d

Soak pit Retained

2.5m3/d with product
Boiler Cooling
105m3/d 10+25m3/d
15m3/d

Condensate
25m3/d

Multi Effect
evaporator
30m3/d

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Water Balance Proposed

Water consumption
535 m3/d

Domestic RO/DM Utilities Greenbelt

8.0 m3/d 298 m3/d 225 m3/d 4 m3/d

RO/Softening

Soak pit
Product Reject
7.0 m3/d
water 30* m3/d
268 m3/d Product water Reject
205 m3/d 20 m3/d

Cooling
Water PF Formaldehyde Steam Silver 205+75 m3/d
with RM 0+40m3/d 0+40m3/d 267 m3/d 1 m3/d
42 m3/d

Water Bleed of
generation
Water scrubber for 70 m3/d
from inter-
PF (4.0 -4.5% of reaction 68
Formaldehyde m3/d
40 m3/d Force effect evaporator
System loss
Live steam 70+20+30*+1* = 43 m3/d
147 m3/d 121 m3/d
Effluent
1.0* m3/d
Water retain with
Formaldehyde Mechanical Salt
40+68+147 = Evaporator 500 kg
255 m3/d 75 m3/d 78 m3/d

System loss
2.5 m3/d

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Annexure –IV
Details of Stacks
Sr. Stack attached Stack Velocity Stack Dia of Fuel SPM SO2 NOX
No. to Temp. m/s Height Stack Used mg/ mg/ mg/
0 3 3
In K in m in m Nm Nm Nm3
01 Tail gas stack 525 8.5 18 0.300 Waste -* -* -*
(Waste Heat
gas
Recovery Boiler)
02 D.G. set (400 180 11.3 11 0.25 HSD- 80 25 30
kVA) 45 l/hr

Tail gas*

Quality of CO2 CO CH4 O2 H2O N2 H2 CH2O CH3OH

tail gas 2.96 0.0 0.0 0.84 15.26 80.94 0.0 0.0 0.0
Unit %
V/V

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Annexure V
Hazardous wastes

Sr. Name of Schedule Quantity Method of

No. Waste Existing Proposed Total Disposal
1 Evaporation 34.3 5 10 15 Collection, Storage,
Salt MT/month MT/month MT/month transportation,
disposal at TSDF-
SEPPL
2 Discarded 33.3 500 500 1000 Collection, Storage,
decontamination,
Containers Nos./yr Nos./yr Nos./yr
transportation,
disposal by selling
to authorized
recycler or reuse.
3 Used Oil 5.1 50 L/Yr -- 50 L/Yr Collection, Storage,
transportation,
disposal by selling
to registered re-
processor or
reused as lubricant

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Annexure-VI

Noise Survey

Location Spot Noise levels in dB(A)

Nr. Main Gate 63.1
Back side of plant 59.2
Inside Plant Building 63.4
Nr. Methanol storage tanks 59.6
Nr. Ejector 74.3

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