PROPOSED TERMS OF REFERENCE. As per standard ToR of organic manufacturing sector issued by MoEF&CC.

Transcription

1 ANNEXURE- I PROPOSED TERMS OF REFERENCE As per standard ToR of organic manufacturing sector issued by MoEF&CC. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 1

2 ANNEXURE-II LIST OF DIRECTORS Sr. No. Name of Directors Residential Address 01. Mr. Ashok Kumar Mahansaria B-202, Tirupati Apartment, Bhula Bhai Desai Road, Mumbai Mob: Mr. Yogesh Ashok Kumar Mahansaria B-202, Tirupati Apartment, Bhula Bhai Desai Road, Mumbai M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 2

3 ANNEXURE-III PLAN LAY OUT M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 3

4 LIST OF PRODUCTS WITH PRODUCTION CAPACITY ANNEXURE- IV Sr. No. 1. Name of Products All types of Automobile Tyres CAS No. Quantity (MT/Month) End use Use in Automobile Industries for Vehicles ANNEXURE V LIST OF RAW MATERIALS WITH CONSUMPTION QUANTITY Sr. No. Name of the product Name of Raw Materials Quantity (MT/Month) 1 All types of Automobile Tyres Rubber 4520 Filler 1900 Rubber chemical 875 Fabric 1218 Wire 570 ANNEXURE- VI MANUFACTURING PROCESS: Compounding and Mixing: This operation is carried in banbury mixer. FIGURE: COMPOUNDING AND MIXING M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 4

5 Compounding is the operation of bringing together all the ingredients required to mix a batch of rubber compound. Each component has a different mix of ingredients according to the properties required for that component. Mixing is the process of applying mechanical working to the ingredients in order to blend them into a homogeneous substance. Internal Mixers are often equipped with two counter-rotating rotors in a large housing that shear the rubber charge along with the additives. The mixing is done in three or four stages to incorporate the ingredients in a logical order. The shearing action generates considerable heat, so both rotors and housing are water cooled to maintain a temperature low enough to assure that vulcanization does not begin. After mixing the rubber charge is dropped into a chute and fed by an extruding screw into a roller die. Or the batch can be dropped onto an open rubber mill batch off system. A mill consists of twin counter-rotating rolls, one serrated, that provide additional mechanical working to the rubber, and produce a thick rubber sheet. The sheet is pulled off the rollers in the form of a strip. The strip is cooled, dusted with talc, and laid down into a pallet bin. The ideal compound at this point would have a highly uniform material dispersion, however in practice there is considerable non-uniformity to the dispersion. This is due to several causes, including hot and cold spots in the mixer housing and rotors, excessive rotor clearance, rotor wear, and poorlycirculating flow paths. As a result, there can be a little more carbon black here, and a little less there; along with few clumps of carbon black elsewhere, that are not well mixed with the rubber or the additives. Mixers are often controlled according to the power integration method, where the current flow to the mixer motor is measured, and the mixing terminated upon reaching a specified total amount of mix energy imparted to the batch. Component Preparation: This operation is carried out in extruder. FIGURE: EXTRUSION - PREPARATION OF TREADS AND SIDEWALLS M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 5

6 Components fall into three classes based on manufacturing process - calendaring, extrusion, and bead building. Extrusion: The extruder machine consists of a screw and barrel, screw drive, heaters, and a die. The extruder applies two conditions to the compound, heat and pressure. The extruder screw also provides for additional mixing of the compound through the shearing action of the screw. The compound is pushed through a die, after which the extruded profile is vulcanized in a continuous oven, cooled to terminate the vulcanization process, and either rolled up on a spool or cut to length. Tyre treads are often extruded with 4 components in a quadraplex extruder, one with four screws processing 4 different compounds, usually a base compound, core compound, tread compound, and wing compound. Extrusion is also used for sidewall profiles and inner liners. Calendars: FIGURE: CALENDERING MACHINE The calendar is a set of multiple large-diameter rolls that squeeze rubber compound into a thin sheet, usually on the order of 2 meters wide. Fabric calendars produce an upper and lower rubber sheet with a layer of fabric in between. Steel calendars do so with steel cords. Calendars are used to produce body plies and belts. A creel room is a facility that houses hundreds of fabric or wire spools that are fed into the calendars. Calendars utilize downstream equipment for shearing and splicing calenderer components. Bead Building: FIGURE: BEAD BUILDING M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 6

7 The bead component of the Tyre is a non-extensible composite loop that anchors the body plies and locks the Tyre onto the wheel assembly so that it will not slip or rock the rim. The Tyre bead component includes the steel wire loop, apex or bead filler; the chafer, which protects the wire bead components; the chipper, which protects the lower sidewall; and the flipper, which helps hold the bead in place. The bead wire loop is made from a continuous steel wire covered by rubber and wound around with several continuous loops. The bead filler is made from a very hard rubber compound, which is extruded so as to form a wedge. The bead wire loop and bead filler are assembled on a sophisticated machine. The precision of the bead circumference is critical. If too small, Tyre mounting can be a problem; but if too loose, the Tyre can come off the rim too easily under loading and cornering conditions. After the circumference is checked, the bead component is ready for the Tyre building operation. Tyre Building (Assembly): FIGURE: TYRE BUILDING PROCESS Tyre building is the process of assembling all the components onto a Tyre building drum. Tyre Building Machines (TBM) can be manually operated or fully automatic. Typical TBM operations include the first stage operation, where inner liner, body plies, and sidewalls are wrapped around the drum, the beads are placed, and the assembly turned-up over the bead. In the second stage operation the belt package and tread are applied and the green Tyre is inflated and shaped. All components require splicing. Inner liner and body plies are spliced with a square-ended overlap. Tread and sidewall are joined with a skived splice, where the joining ends are bevel-cut. Belts are spliced end-to-end with no overlap. Splices that are too heavy or non-symmetrical will generate defects in force variation, balance, or bulge parameters. Splices that are too light or open can lead to visual defects and in some cases Tyre failure. The final product of the TBM process is called a green Tyre, where green refers to the uncured state. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 7

8 Curing: FIGURE: CURING PROCESS Curing is the process of applying pressure to the green Tyre in a mould in order to give it its final shape, and applying heat energy to stimulate the chemical reaction between the rubber and other materials. In this process the green Tyre is automatically transferred onto the lower mold bead seat, a rubber bladder is inserted into the green Tyre, and the mold closes while the bladder inflates. As the mold closes and is locked the bladder pressure increases so as to make the green Tyre flow into the mold, taking on the tread pattern and sidewall lettering engraved into the mold. The bladder is filled with a recirculating heat transfer medium, such as steam, hot water, or inert gas. Temperatures are in the area of 350 degrees Fahrenheit with pressures around 350 PSI. Passenger Tyres cure in approximately 15 minutes. At the end of cure the pressure is bled down, the mold opened, and the Tyre stripped out of the mold. The Tyre may be placed on a PCI, or post-cure inflator, that will hold the Tyre fully inflated while it cools. There are two generic curing press types, mechanical and hydraulic. Mechanical presses hold the mold closed via toggle linkages, while hydraulic presses use hydraulic oil as the prime mover for machine motion, and locks the mold with a breech-lock mechanism. Hydraulic presses have emerged as the most cost effective because the press structure does not have to withstand the mold opening pressure and can therefore be relatively lightweight. There are two generic mold types, two piece molds and segmental molds. Large off-road Tyres are often cured in ovens with cure times approaching 24 hours. Final Finish: After the Tyre has been cured, there are several additional operations. Tire uniformity measurement is a test where the Tyre is automatically mounted on wheel halves, inflated, run against a simulated road surface, and measured for force variation. Tyre balance measurement is a test where the, Tyre is automatically placed on wheel halves, rotated at a high speed and measured for imbalance. In the final step, human eyes for numerous visual defects such as incomplete mold fill, exposed cords, blisters, blemishes, and others inspect Tyres. Tyre inspection is the last step in the Tyre manufacturing process an important step in ensuring quality in both performance and safety. The Tyre inspection includes: M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 8

9 Trimming of the mould flash and micro-vents Visual inspection for appearance and to spot obvious defects X-ray examination to check internal structure and to spot defects Tyre durability, uniformity, and weight balance inspection. PROCESS FLOW DIAGRAM M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 9

10 MATERIAL BALANCE: M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 10

11 ANNEXURE- VII DETAILS OF WATER CONSUMPTION Sr. No. Particulars Water Consumption KL/Day 1. Domestic Industrial Process Boiler Cooling Washing 0.0 Gardening Waste water recycled from RO plant Total Industrial Total (Industrial + Domestic) DETAILS OF WASTE WATER GENERATION Sr. No. Particulars Waste water generation KL/Day 1. Domestic Industrial Process Boiler 25.0 Cooling Washing 0.0 Gardening 0.0 Total Industrial Total (Industrial + Domestic) M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 11

12 DETAILS OF WATER BALANCE DIAGRAM M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 12

13 ANNEXURE-VIII DETAILS OF ELECTRICITY AND FUEL CONSUMPTIONS Sr. No. Particulars Proposed Quantity Source 1. Coal 9.6 MT/hr Local 2. Furnace Oil 1.0 MT/Hr Local 3. Diesel 500 Lit/Day Local 4. Energy-Electricity 9500 KVA DGVCL DETAILS OF FLUE GAS EMISSIONS ANNEXURE- IX Stack No Stack Attached to Boiler - 1 Nos. (12 TPH) Boiler - 3 Nos. (30 TPH each- 2 nos. running 20 TPH 1 no. Stand By) D.G. Set (2 Nos KVA each) (1 Stand by) (In case of emergency/power failure) Fuel Consumption Furnace Oil 1.0 MT/hr Coal 9.6 MT/hr Stack Height (m) 44 m m ESP Diesel 15 m ---- APCM Parameter Particulate Matter SO2 NOx Permissible Limit 150 mg/nm ppm 50 ppm ANNEXURE- X DETAILS OF PROCESS EMISSION Stack No. Stack Attached to Stack Height (m) APCM Parameter Permissible Limit 1. Master Mixer- 4 nos Carbon Handling System- 2 nos Chemical Preparation 15 Dust Collector Particulate Matter 150 mg/nm 3 M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 13

14 M/s. Mahansaria Tyre Pvt. Ltd., Panoli Sr.No Type of Waste Category 1. Used Spent Oil Oil Soaked Cotton Waste/Gloves Discarded Containers/ Barrels/ Liners contaminated with Hazardous waste/ chemicals DETAILS OF HAZARDOUS WASTE 33.3 Disposal Quantity 270 MT/Year 5.4 MT/Year 48 MT/Year Disposal Facility ANNEXURE- XI Collection, Storage, Transportation, Disposal by selling to MoEF Registered Re-Processor Collection, Storage, Decontamination, Transportation, Disposal by selling to register recycler or send to cement industries for co processing or to common incineration Collection, Storage, Decontamination, Transportation, Disposal by selling to register recycler. 4 Chemical Sludge from Waste water treatment MT/Year Collection, Storage, Transportation, disposal at approved TSDF site DETAILS OF OTHER NON HAZARDOUS WASTE Sr. No. Type of Waste Disposal Quantity (MTA) 1 Rejected Scrap Tyres Rejected/In-Process Rubberised/Non- Rubberised Nylon, Fabrics Rejected/In-Process Rubberised/Non- Rubberised Bead Wires 4 Rejected Rubber Compound 54 5 Floor Sweeping Carbon Black Bladder/Tubes/Flaps Used Non-Contaminated Cotton Waste/Gloves 5.4 Disposal Facility Collection, Storage, Transportation, Disposal by selling to MoEF Registered Re-Processor Or to scrap dealers/ recyclers M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar 14