form- 1 ins dahej · 2018-10-13 · 3 e-mail [email protected] [email protected] telephone...

1

FORM-I

for

PROPOSED UTILITIES AND MULTIPLE EFFECT

EVAPORATOR IN EXISTING MANUFACTURING

UNIT WITHOUT INCREASING PRODUCTION

CAPACITY AND POLLUTION LOAD

of

M/s. INSECTICIDES INDIA LIMITED

PLOT NO. CH/21, G.I.D.C. INDUSTRIAL ESTATE, DAHEJ,

DIST: BHARUCH, GUJARAT

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

2

APPENDIX I

(See paragraph - 6)

FORM 1

(I) Basic Information:

Sr.

No.

Item Details

1. Name of the project/s M/s. Insecticides India Limited

2. S. No. in the schedule 5(b)

3. Proposed capacity/area/length/tonnage to

be handled/command area/lease

area/number of wells to be drilled

Please refer Annexure –I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. Please refer Annexure –I

6. Category of Project i.e. ‘A’ or ‘B’ 'A'

7. Does it attract the general condition? If yes,

please specify.

No

8. Does it attract the specific condition? If yes,

please specify.

No

9. Location

Plot/Survey/Khasra No. 21 – 22

Village GIDC Industrial Estate, Dahej

Tehsil Dahej

District Bharuch

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Nearest Railway Station : Bharuch: 39 kms

Nearest Airport: Baroda: 90 kms

11. Nearest Town, city, District Headquarters

along with distance in kms.

Nearest town: Bharuch : 39 kms,

Nearest District Head quarter: Bharuch : 39 kms

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Notified Area Authority of GIDC, Dahej

13. Name of the applicant M/s. Insecticides India Limited

14. Registered Address Plot No. CH/21, G.I.D.C. Industrial Estate, Dahej,

Dist:- Bharuch, Gujarat

15. Address for correspondence:

Name Mr. Anil Gupta

Designation (Owner/Partner/CEO) A.G.M. (Commercial)

Address Plot No. CH/21, G.I.D.C. Industrial Estate, Dahej,

Dist:- Bharuch, Gujarat

Pin Code 392130

3

E-mail [email protected]

[email protected]

Telephone No. Phone: + 91 11 27679700-05

Mobile: +91 9667213558

Fax No. NA

16. Details of Alternative Sites examined, if any.

Location of these sites should be shown on

a topo sheet.

No

17. Interlinked Projects No interlinked project

18. Whether separate application of interlinked

project has been submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

21. Whether the proposal involves

approval/clearance under: if yes, details of

the same and their status to be given.

(a) The Forest (Conservation) Act, 1980?

(b) The Wildlife (Protection) Act, 1972?

(c) The C.R.Z. Notification, 1991?

Not applicable, as the project is located in G.I.D.C.

Industrial Estate, Dahej

22. Whether there is any Government

Order/Policy relevant/relating to the site?

No

23. Forest land involved (hectares) No

24. Whether there is any litigation pending

against the project and/or land in which the

project is propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if any

and its relevance with the proposed

project.

No

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing, mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.,)

4

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes/No Details thereof with approximate

quantities frates, wherever possible) with

source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase intensity of land use (with respect to local land use plan)

No Proposed project is located in GIDC

Industrial Estate, Dahej. Hence, the land

use pattern will not be changed due to the

proposed expansion project

1.2 Clearance of existing land, vegetation

and

Buildings?

No Land to be utilized will be a part of

designated industrial land and necessary

clearance already obtained by developers

1.3 Creation of new land uses? No Notified industrial area

1.4 Pre-construction investigations e.g.

bore Houses, soil testing?

No Proposed Expansion is within the existing

premises.

1.5 Construction works? No Proposed Expansion is within the existing

premises.

1.6 Demolition works? No No Demolition work carried out because it a mostly plan land in developed industrial estate.

1.7 Temporary sites used for construction

works or housing of construction

workers?

No Not Required

1.8 Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

Yes For details refer Annexure-II

1.9 Underground works mining or

tunneling?

No N / A

1.10 Reclamation works? No N.A

1.11 Dredging? No N.A

1.12 Off shore structures? No N.A

1.13 Production and manufacturing

processes?

Yes Annexure –III

1.14 Facilities for storage of goods or

materials?

Yes Specified storage area shall be provided for storage of goods, Raw materials & Finished products.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes For detail please refer Annexure – IV & V.

1.16 Facilities for long term housing of

operational workers?

No The workers will be available from nearby local area and hence such facilities will not be required

1.17 New road, rail or sea traffic during

Construction or operation?

No Not Required

5

1.18 New road, rail, air waterborne or other

transport infrastructure including new

or altered routes and stations, ports,

airports etc?

No No new roads and rail are envisaged

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in Traffic

movements?

No No closure or diversion of existing route is required

1.20 New or diverted transmission lines or

Pipelines?

No Not applicable

1.21 Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No No change to the hydrology or aquifers

1.22 Stream crossings? No N / A

1.23 Abstraction or transfers of water form

ground or surface waters?

No Raw water will be sourced from existing GIDC water supply system.

1.24 Changes in water bodies or the land

surface Affecting drainage or run-off?

No Will not be affected as all the effluents will be treated in ETP followed by MEE. After treatment the water will be reused.

1.25 Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel, raw

materials and products will be primarily

by road only.

1.26 Long-term dismantling or

decommissioning or restoration works?

No Not applicable

1.27 Ongoing activity during

decommissioning which could have an

impact on the environment?

No Not applicable

1.28 Influx of people to an area either

temporarily or permanently?

No Temporarily during construction phase and permanent during operation phase

1.29 Introduction of alien species? No Not applicable

1.30 Loss of native species or genetic

diversity?

No Not applicable

1.31 Any other actions? No No additional action

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

Sr. No. Information/checklist confirmation Yes/No Details there of (with approximate

quantities frates, wherever possible) with


2.1 Land especially undeveloped or

agricultural land (ha)

No Land falls under the industrial area

developed by Gujarat Industrial

Development Corporation.

2.2 Water (expected source & competing

users) unit: KLD

Yes Source of water is GIDC Water supply-

Dahej. For details please refer Annexure –

VI

6

2.3 Minerals (MT) No N / A

2.4 Construction material – stone,

aggregates, and / soil (expected source –

MT)

Yes Construction materials, like steel, cement,

crushed stones, sand, rubble, etc. required

for the project shall be procured from the

local market of the region.

2.5 Forests and timber (source – MT) No Not applicable

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes For detail please refer Annexure – VI

2.7 Any other natural resources (use

appropriate standard units)

No No other natural resource will be utilized

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.

Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate

quantities/rates, wherever possible) with


3.1 Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes All the hazardous materials will be stored

in M.S. tanks & drums at NTP

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No Not applicable

3.3 Affect the welfare of people e.g. by

changing living conditions?

No The living conditions of people will not be

affected as the proposed production

activities are going to take place within the

notified industrial area

3.4 Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the elderly

etc.

No Not applicable as the unit is set-up in GIDC

industrial area away from residential area

3.5 Any other causes No Not applicable

4. Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate



4.1 Spoil, overburden or mine wastes No Not applicable

4.2 Municipal waste (domestic and or

commercial wastes)

No Not applicable

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Please refer Annexure – V

7

4.4 Other industrial process wastes Yes Please refer Annexure – V

4.5 Surplus product No Not applicable

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Please refer Annexure – V

4.7 Construction or demolition wastes

No

Construction wastes and demolition wastes

are inert in nature and will be collected and

utilized in filling of low-lying areas within

the unit

4.8 Redundant machinery or equipment No Not applicable

4.9 Contaminated soils or other materials No Not applicable

4.10 Agricultural wastes No Not applicable

4.11 Other solid wastes No

Please refer Annexure – V

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr.

No.

Information/Checklist confirmation Yes/No Details there of (with approximate



5.1 Emissions from combustion of fossil

fuels from stationary or mobile

sources

Yes For details Please refer Annexure – VII

5.2 Emissions from production processes Yes For details Please refer Annexure – VII

5.3 Emissions from materials handling

storage or transport

No For details Please refer Annexure – VII

5.4 Emissions from construction activities

including plant and equipment

No During construction work, only dust

contamination will be there, water sprinklers

shall be utilized whenever necessary.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

No Generation of dust will be due to

construction activities. However care will be

taken to minimize it.

Domestic sewage will be treated and

recycled. All the reactions will be carried out

in closed vessels. Therefore, odour will be

controlled.

5.6 Emissions from incineration of waste Yes Adequate pollution control measures and

stack height will be maintained as the norms.

5.7 Emissions from burning of waste in

open air e.g.slash materials,

construction debris)

No Not applicable

5.8 Emissions from any other sources No There will be no other source

8

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.



source of information data with source of

information data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes Please refer Annexure – VIII

6.2 From industrial or similar processes Yes Please refer Annexure – VIII

6.3 From construction or demolition Yes Noise during construction activities will be

within prescribed limit.

6.4 From blasting or piling No Not applicable.

6.5 From construction or operational traffic Yes There will be momentary increase in the

noise level due to traffic.

6.6 From lighting or cooling systems Yes Please refer Annexure – VIII

6.7 From any other sources No Not applicable 7. Risks of contamination of land or water from releases of pollutants into the ground or

into sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No.




7.1 From handling, storage, use or spillage

of hazardous materials

Yes Proper care for handling of hazardous

material will be taken as per the MSIHC rules

& HW management Rules. 7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes Sewage will be disposed off into soak pit

through septic tank and necessary care will

be taken.

Industrial waste water around 82 KL/d will

be disposed off after treatment to effluent

disposal pipeline constructed by GIDC.

7.3 By deposition of pollutants emitted to

air into the and or into water

No No major impact is anticipated as all the

necessary pollution control measures will be

adopted for controlling the pollution within

the norms of Central Pollution Control

Board.

7.4 From any other sources No Not applicable

7.5 Is there a risk of long term build up of

pollutants in the environment from

these sources?

No No major impact is anticipated

9

8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment

Sr.

No.




8.1 From explosions, spillages, fires, etc.

from storage, handling, use or

production of hazardous substances

Yes Industry will carry out risk assessment study

and all the recommendations of safety

committee will be incorporated during

construction.

8.2 From any other causes No Not applicable

8.3 Could the project be affected by natural

disasters causing environmental damage

(e.g. floods, earthquakes, landslides,

cloudburst etc)?

Yes May effect by earthquakes because industry

will be located in earth quake zone-III. The

structure will be design on the base of

earthquake resistance.

9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr. No.

Information/Checklist confirmation

Yes/No

Details there of (with approximate



9.1 Lead to development of supporting. utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g. • Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.)

• housing development • extractive industry • supply industry • other

No Site is located in GIDC Industrial Area, Dahej

having the entire required infrastructure.

This industrial zone is having existing road

infrastructure & power supply are to be

utilized.

Local people will be employed and no

housing is required. For detail please refer

Annexure – IX

9.2 Lead to after-use of the site, which

could have an impact on the

environment

No Not applicable

9.3 Set a precedent for later developments No Not applicable

9.4 Have cumulative effects due to

proximity to other existing or planned

projects with similar effects

No Dahej is a industrial area and there are

chances for cumulative effect due to

activities by surrounding existing unit.

10

(I) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance (within 5 km.) Proposed

project location boundary

1 Areas protected under international

conventions, national or local legislation

for their ecological, landscape, cultural or

other related value

No Proposed project is located in GIDC

Industrial Estate, Dahej

2 Areas which important for are or

sensitive Ecol logical reasons – Wetlands,

watercourses or other water bodies,

coastal zone, biospheres, mountains,

forests

No No water body or wetland nearby

3 Area used by protected, important or

sensitive Species of flora or fauna for

breeding, nesting, foraging, resting, over

wintering, migration

No There are no such areas within 15 Km from

the proposed site

4 Inland, coastal, marine or underground

waters

No No inland, costal or marine within 15 km

from the proposed project

5 State, National boundaries No --

6 Routes or facilities used by the public for

access to recreation or other tourist,

pilgrim areas

No Not applicable

7 Defense installations No Not applicable

8 Densely populated or built-up area No Not applicable

9 Area occupied by sensitive man-made

land uses Hospitals, schools, places of

worship, community facilities)

No Not applicable

10 Areas containing important, high quality

or scarce resources (ground water

resources, surface resources, forestry,

agriculture, fisheries, tourism, minerals)

No Not applicable

11 Areas already subjected to pollution

environmental damage. (those where

existing legal environmental standards

are exceeded)or

No Not applicable

12 Areas susceptible to natural hazard

which could cause the project to present

environmental problems (earthquakes,

subsidence ,landslides, flooding erosion,

or extreme or adverse climatic

conditions)

No Not applicable

IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – X.

12

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE PAGE NOS.

I List of Products with their Production Capacity 13

II Layout Map of the Plant 25

III Brief Manufacturing Process Description 26

IV Description of Effluent Treatment Plant with flow diagram 139

V Details of Hazardous Waste 142

VI Water, Fuel & Energy Requirements 143

VII Details of Stacks and Vents 148

VIII Noise level at Different source within the premises 150

IX Socio-economic Impacts 151

X Proposed Terms of Reference for EIA studies 152

13

ANNEXURE-I

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

A. PESTICIDES TECHNICAL

Sr.

No

Products Production Capacity

(MT/Annum)

Existing Additional Total

A. Pesticide Technical

Phenoxy Herbicides

1. 2-4-D Ethyl Ester

1950 -- 1950 2. 2-4-D Sodium salt

3. Quizalofop

Imidazolinone herbicide

4.

Imazethapyr 300 -- 300

Sulfonyl Urea Herbicides

5. Met sulfuron methyl 80 -- 80

Organochlorine Herbicides

6. Butachlore 1600 -- 1600

7. Pretilachlor

Other Herbicides

8. Glyphosate

5050 --

5050

9. Oxyfluorfen

10. Paraquate

Carbamate insecticide

11. Thiodicarb 150 -- 150

Neo nicotinoid insecticide

12. Acetamiprid

1300 -- 1300 13. Imidacloprid

14. Thiacloprid

Organophosphorus insecticide

15. Attrazine

3600 -- 3600 16. Chlorpyriphos

17. DDVP

Pyrethroid Insecticides

18. Allethrin

2420 --

2420

19. Alpha cypermethrin

20. Cyfluthrin

21. Cypermethrin

22. Delta cypermethrin

23. d-transallethrin

24. Lambda cyhalothrin

25. Permethrin

26. Prallethrin

14

27. Transfluthrin

Other Insecticides

28. Fipronil

1600 -- 1600

29. Buprofezin

30. Cartap hydrochloride

31. Metalexyl

32. Novaluron

Conazole Fungicides

33. Difenconazole

1400 --

1400

34. Hexaconazole

35. Ipconazole

36. Paclobutrazol

37. Propeconazole

38. Tebuconazole

39. Tricyclozole

Other Fungicides

40. Indoxacarb 200

--

200

41. Thiophenate methyl

Fermentation Technology

42. Abamectin

350 -- 350 43. Azoxy strobin

44. Emmamectin benzoate

TOTAL 20000 20000

B. Intermediate Chemicals

1. Mono Chloro acetic acid 7000 -- 7000

2. IDA 6000 -- 2000

3. PMIDA 4000 -- 4000

4. CMAC 600 -- 600

5. MPBD 600 -- 600

6. CCMP 500 -- 500

7. CMMA 300 -- 300

8. Triazoles 1000 -- 1000

TOTAL 20000 20000

Formulations

1. Liquid Pesticide 3000 -- 3000

2. Granular Pesticide 40000 -- 40000

3. Powder Pesticide 10000 -- 10000

4. Emulsifier Formulation 600 -- 600

TOTAL 53600 -- 53600

15

LIST OF RAW MATERIALS:

Sr.

No

Raw Material Quantity (MT/Month)


1. 2-4-D Ethyl Ester

2,4-D acid 164.125 -- 164.125

Ethyl alcohol 146.25 -- 146.25

2. 2-4-D Sodium Salt

2,4 -DCP 117.81 -- 117.81

MCA 84.175 -- 84.175

Caustic lye 176.6 -- 176.6

3. Abamectin

streptomycess

avermitis 16.19

--

16.19

Anthelminic 32.40 -- 32.40

Acaricidal 32.40 -- 32.40

Methanol 64.81 -- 64.81

4. Acetamiprid

NCMA 53.62 -- 53.62

CMAMP 77.67 -- 77.67

Methanol 223.05 -- 223.05

5. Allethrin

Cychlo hexane 187.54 -- 187.54

Allethrelone 108.89 -- 108.89

pyridine 71.18 -- 71.18

Acid chloride 128.65 -- 128.65

HCl 24.60 -- 24.60

NaOH 2.01 -- 2.01

6. Alpha Cypermethrin

MPBAD 143.98 -- 143.98

Sodium cyanide (NaCN) 39.32 -- 39.32

n- Hexane(F) 99.21 -- 99.21

n-Hexane(R) 767.92 -- 767.92

CMAC 168.38 -- 168.38

Catalyst 20.16 -- 20.16

IPA-solvent(F) 127.24 -- 127.24

IPA-solvent(R) 394.85 -- 394.85

Sodium hypochlorite 433.56 -- 433.56

7. Attrazine

Toluene 2100 -- 2100

Cynauric Chloride 271.5 -- 271.5

Isopropyl amine 126 -- 126

Mono ethyl amine 96.3 -- 96.3

Soda ash 79.8 -- 79.8

16

Water with caustic

soda

958.5 -- 958.5

Caustic lye 58.5 -- 58.5

8. Azoxy strobin

MDC 39.84 -- 39.84

TiCl4 447.42 -- 447.42

Methyl formate 12.61 -- 12.61

DMA 50.58 -- 50.58

Triethyl amine 43.55 -- 43.55

HCl 420.00 -- 420.00

Methanol 188.71 -- 188.71

DMS 35.32 -- 35.32

Na2CO3 336.00 -- 336.00

Aq. Na2S2O3 112.00 -- 112.00

9. Buprofezin

PNNCC 190.26 -- 190.26

Toluene 654.65 -- 654.65

Thiourea 113.86 -- 113.86

Lime 37.59 -- 37.59

EDC 654.65 -- 654.65

TEA 66.13 -- 66.13

10. Butachlore

2,6-DEA 66.66 -- 66.66

Benzene 35.59 -- 35.59

Paraformaldehyde

(PFA)

22.66 -- 22.66

TEA 0.399 -- 0.399

Chloro Acetyl Chloride

(CAC)

52.66 -- 52.66

N-Butanol 140.263 -- 140.263

NH3 gas 8.266 -- 8.266

11. Cartap Hydrochloride

2-Dimethylamino-1, 3-

dichloropropane

90.66 -- 90.66

Sodium thiosulphate 16.26 -- 16.26

Sodium Cyanide 10.39 -- 10.39

Solvent 213.32 -- 213.32

HCl 20.26 -- 20.26

12. Chlorpyriphos

NaTCP 197.4 -- 197.4

DETC 168.3 -- 168.3

EDC 830.4 -- 830.4

Catalyst 2.4 -- 2.4

Caustic Soda lye 12.9 -- 12.9

13. Cyfluthrin

Fluro Meta Phenoxy 99.62 -- 99.62

17

Benzaldehyde (FMPBD)

CMAC 116.55 -- 116.55

Sodium Cyanide (NaCN) 28.63 -- 28.63

Hexane 217.38 -- 217.38

Hypochlorite 324.06 -- 324.06

PTC 1.00 -- 1.00

14. Cypermethrin

CMAC 118.97 -- 118.97

MPB 97.80 -- 97.80

NaCN 29.24 -- 29.24

PTC 1.20 -- 1.20

Hexane 219.80 -- 219.80

Hypochlorite 328.70 -- 328.70

15. DDVP

Chloral 211.8 -- 211.8

TMP 169.5 -- 169.5

16. Delta Cypermethrin

Ester of Bicisthemic

acid

103.85 -- 103.85

Thionyl Chloride 30.45 -- 30.45

M-

phenoxybenzaldehyde

97.80 -- 97.80

Sodium cyanide 30.24 -- 30.24

Caustic soda 51.82 -- 51.82

DIPA/IPA 129.86 -- 129.86

DMF 4.23 -- 4.23

Hypo Solution 69.16 -- 69.16

17. Difenconazole

4-methyl-1, 3-

dioxolane

32.78 -- 32.78

2-chloro-4-(4-

chlorophenoxy) benzyl

chloride

108.14 -- 108.14

Dimethyl

Formamide(DMF)

172.89 -- 172.89

1,2,4-Trizole 27.53 -- 27.53

KOH 65.56 -- 65.56

K2O3 6.53 -- 6.53

18. d-transallethrin

Cyclo hexane 187.34 -- 187.34

Allethrelone 108.69 -- 108.69

Pyridine 71.18 -- 71.18

Acid chloride 128.45 -- 128.45

HCl 24.60 -- 24.60

NaOH 2.01 -- 2.01

19. Emmamectin

18

Streptomycess

avermitis 13.27

--

13.27

Anthelminic 26.51 -- 26.51

Acaricidal 26.51 -- 26.51

Methyl amine 5.31 -- 5.31

Methyl benzoate 6.62 -- 6.62

Methanol 79.54 -- 79.54

20. Fipronil

Fipronil Pyrazole 161.59 -- 161.59

NH4SCN 103.46 -- 103.46

Oxone® 499.85 -- 499.85

MeOH 3877.10 -- 3877.10

SO2(g) 64.66 -- 64.66

HCOONa (46 %) 712.78 -- 712.78

CF3Br 40625 -- 40625

Dimethyl Formamide 1353.83 -- 1353.83

Isopropyl acetate 1989.95 -- 1989.95

NaHCO3 3155.78 -- 3155.78

CF3COOH 1181.30 -- 1181.30

Hydrogen peroxide 56.13 -- 56.13

Chlorobenzene 623.45 -- 623.45

Na2SO3 31.33 -- 31.33

Ethanol 1217.56 -- 1217.56

21. Glyphosate

PMIDA 837.45 -- 837.45

FeSO4 125.82 -- 125.82

Hydrogen Peroxide 313.93 -- 313.93

Catalyst 4.20 -- 4.20

C.S. lye 301.31 -- 301.31

22. Hexaconazole

2,4-Dichloro valero

phenol

96.59 -- 96.59

Dimethyl sulphide 139.99 -- 139.99

Dimethyl sulphate 83.64 -- 83.64

KOH flakes 83.64 -- 83.64

Oxarine 88.54 -- 88.54

Dimethyl formamide 212.43 -- 212.43

1,2,4, triazol 30.56 -- 30.56

K2CO3 5.59 -- 5.59

Heptane 106.16 -- 106.16

23. Imazethapyr

EPCA 20.45 -- 20.45

DMMI 17.05 -- 17.05

DMF 50 -- 50

Sodium carbonate 15.9 -- 15.9

Catalyst 0.225 -- 0.225

19

Methanol 9.1 -- 9.1

Caustic lye 1.125 -- 1.125

24. Imidacloprid

CCMP 92.73 -- 92.73

N-NII 77.45 -- 77.45

DMF 226.51 -- 226.51

Catalyst 1.08 -- 1.08

Na2CO3 72.68 -- 72.68

Methanol 41.16 -- 41.16

Caustic soda lye 5.19 -- 5.19

25. Indozacarb

Monoglyme 22.22 -- 22.22

NaH 2.67 -- 2.67

Chloromethyl formate 6.30 -- 6.30

Oxadiazine carboxylate 10.43 -- 10.43

MDC 22.22 -- 22.22

HCl-1N 2.27 -- 2.27

Sodium sulphate 2.22 -- 2.22

Silica 1.95 -- 1.95

26. Ipconazole

Cyclopentanol 19.48 -- 19.48

Dimethyl Sulphide 67.66 -- 67.66

4-Chloro Benzyl

Chloride

38.84 -- 38.84

KOH 38.84 -- 38.84

DMF 102.66 -- 102.66

1,2,4-Trizole 16.33 -- 16.33

K2O3 3.84 -- 3.84

Isopropanol 13.64 -- 13.64

PFA 8.51 -- 8.51

27. Lambda Cyhalothrin

Meta Phenoxy

Benzaldehyde(MPBAD)

90.34 -- 90.34


TFP Acid Chloride 123.01 -- 123.01

N-Hexane(F) 22.98 -- 22.98

N-Hexane(R) 457.16 -- 457.16

catalyst 2.01 -- 2.01

Soda ash 191.98 -- 191.98

Cyhalothrin oil 201.66 -- 201.66

IPA solvent(F) 10.48 -- 10.48

IPA solvent (R) 191.17 -- 191.17

Catalyst-2 30.65 -- 30.65

NaCN layer 120.79 -- 120.79

Sodium hypochlorite

layer

288.17 -- 288.17

20

28. Met sulfuron methyl

O-sulfo isocyante

Methyl Benzoate

4.22 -- 4.22

2-Amino 4-Methoxy 6-

Methyl 1,3,5 Triazine

2.44 -- 2.44

Toluene (R) 5.328 -- 5.328

Toluene (F) 0.666 -- 0.666

29. Metalexyl

N-(2, 6 – Dimethyl

Phenyl) Alanine –

Methyl Ester

99.99 -- 99.99

Methoxy Acetyl

Chloride

52.93 -- 52.93

Toluene 294.12 -- 294.12

Catalyst 1.99 -- 1.99

C.S. lye 6.53 -- 6.53

30. Novaluron

2,6-difluoro benzoyl isocyanate

42.79 -- 42.79

2-chloro-4-amino

phenoxy ether

105.86 -- 105.86

Mono chloro benzene 72.93 -- 72.93

Toluene 107.46 -- 107.46

31. Oxyfluorfen

2-Chloro Trichloro p-

Tolyl 3-Ethoxy phenyl

Ether

369.06 -- 369.06

Nitric Acid 106.04 -- 106.04

Catalyst 2.104 -- 2.104

Sulphuric Acid 41.662 -- 41.662

32. Pacloburazol

Tert-pentan-3-ol 44.22 -- 44.22

4-Chloro Benzyl

Chloride 80.50

--

80.50

KOH 80.50 -- 80.50

DMF 212.45 -- 212.45

1,2,4 triazole 33.83 -- 33.83

K2O3 8.05 -- 8.05

33. Paraquate

4,4’ bipyridine 397.26 -- 397.26

Methyl iodide 785.68 -- 785.68

Silver chloride 360.23 -- 360.23

34. Permethrin

Meta Phenoxy Benzyl

Alcohol(MPBAL)

105.66 -- 105.66

Cypermethric Acid

Chloride(CMAC)

123.21 -- 123.21

21

Solvent(F) 38.31 -- 38.31

Solvent (R) 537.82 -- 537.82

Soda ash solution 191.98 -- 191.98

C.S. lye 9.67 -- 9.67

35. Prallethrin

Cyclo penten 1-hydroxy 107.88 -- 107.88


Chrysanthemic acid

chloride

138.13 -- 138.13

Hexane 508.18 -- 508.18

TEBA 3.02 -- 3.02

Hypo Solution 120.996 -- 120.996

Soda Ash 3.02 -- 3.02

Acetic Acid 0.60 -- 0.60

36. Pretilachlor

DEPA 93.730 -- 93.730

Chloro acetyl chloride 60.39 -- 60.39

Hexane 145.86 -- 145.86

Ammonia Gas 7.33 -- 7.33

37. Propeconazole

4-propyl-1, 3-dioxolane 47.25 -- 47.25

Dimethyl Sulphide 137.20 -- 137.20

2,4-dichloro Benzyl

Chloride 98.58

--

98.58

KOH 78.87 -- 78.87

DMF 208.13 -- 208.13

1,2,4, triazol 33.13 -- 33.13

K2O3 7.93 -- 7.93

Isopropanol 27.53 -- 27.53

38. Quizalofop

R- (p hydroxyl phenoxy)

propionic acid

65.81 -- 65.81

Potassium carbonate 23.23 -- 23.23

6-Chloroquinoxaline 119.11 -- 119.11

DMF 92.78 -- 92.78

Methanol 154.7 -- 154.7

39. Tebuconazole

Dimethyl sulfate 58.57 -- 58.57

Sodium sulphate 3.03 -- 3.03

Ketal 88.08 -- 88.08

KOH 37.68 -- 37.68

DMF 165.67 -- 165.67

1,2,4 triazole 29.75 -- 29.75

K2O3 4.67 -- 4.67

40. Thiacloprid

2-Chloro, 5-Chloro 92.83 -- 92.83

22

methyl Pyridine

Thiazolidinylidene

Cyanamide

77.34 -- 77.34

DMF 226.95 -- 226.95


C.S. lye 5.19 -- 5.19

41. Thiodicarb

Methomyl Tech –

Powder

389.68 -- 389.68

Toluene(F) 100.15 -- 100.15

Toluene (R) 1191.36 -- 1191.36

SCl2 127.09 -- 127.09

42. Thiophenate Methyl

Ethylene dichloride 33.33 -- 33.33

Sodium Thiocyanate 8.77 -- 8.77

Methyl chloro Format 10.00 -- 10.00

OPDA 5.83 -- 5.83

43. Thansfluthrin

Tetra fluoro benzyl

alcohol

105.06 -- 105.06

CMAC 127.65 -- 127.65

Hexane 375 -- 375


Acetic acid 0.60 -- 0.60

44. Tricyclozole

3-methyl-(1,2)-

benzothiazole

Chloride

85.52 -- 85.52

KOH 77.82 -- 77.82

DMF 205.33 -- 205.33

1,2,4 triazole 32.67 -- 32.67

K2O3 7.82 -- 7.82

Intermediate Chemical

1. Mono Chloro Acetic Acid

Acetic Acid 466.67 -- 466.67

SMC 11.67 -- 11.67

Chlorine gas 641.67 -- 641.67

2. IDA-HCl

Calcium hydroxide 573.00 -- 573.00

MCA 738.00 -- 738.00

HCl 32% 1844.50 -- 1844.50

Ammonia soln. 398.00 -- 398.00

3. PMIDA

IDA-HCl 340.00 -- 340.00

Phosphorus acid 231.00 -- 231.00

HCl 194.67 -- 194.67

23

Formaldehyde 264.00 -- 264.00

C.S. lye 521.33 -- 521.33

4. CMAC

CTC 84.80 -- 84.80

CAN 25.25 -- 25.25

Acetonitrile 1.80 -- 1.80

Catalyst 0.95 -- 0.95

HCl 0.95 -- 0.95

H2SO4 80.50 -- 80.50

SOCl2 98.90 -- 98.90

DMF 1.35 -- 1.35

IB 29.75 -- 29.75

Hexane 120.85 -- 120.85

TEA 31.50 -- 31.50

NaHCO3 41.30 -- 41.30

Caustic lye 74.40 -- 74.40

Sulphuric acid 11.75 -- 11.75

Hexane 127.25 -- 127.25

Catalyst-2 0.45 -- 0.45

5. MPBD

Benzaldehyde 37.40 -- 37.40

AlCl3 61.50 -- 61.50

EDC 110.00 -- 110.00

Br2 27.50 -- 27.50

Cl2 12.90 -- 12.90

Formic Acid 1.00 -- 1.00

MEG 28.65 -- 28.65

Toluene 104.50 -- 104.50

KOH 16.75 -- 16.75

Phenol 28.10 -- 28.10

Catalyst 1.10 -- 1.10

H2SO4 39.50 -- 39.50

NaOH 1.25 -- 1.25

C S lye 2.45 -- 2.45

6. CCMP

6-Chloronicotinic Acid 45.58 -- 45.58

Phosphorus

Pentachloride 60.17

--

60.17

Phosphorus

Oxychloride 44.00

--

44.00

Sodium Borohydride 10.67 -- 10.67

Thionyl Chloride 31.50 -- 31.50

Toluene 48.62 -- 48.62

7. Chloro-3-Pyridyl-n-Methyl Amine (CPMMA)

Mono Methyl Amine

25% 21.88

--

21.88

24

Methanol 30.00 -- 30.00

2-Chloro-5-Chloro

Methyl Pyridine (CCMP) 9.13

--

9.13

NaOH 3.12 -- 3.12

8. Triazoles

Formic Acid 166.67 -- 166.67

Ammonia Gas 58.33 -- 58.33

Formamide 131.67 -- 131.67

Hydrazine hydrate 99.99 -- 99.99

Formulations

1. Liquid Pesticide

Technical 22.5 -- 22.5

Emulsifier 20 -- 20

Solvent/water 207.5 -- 207.5

2. Granular Pesticide

Technical 150.00 -- 150.00

Intermediate 133.33 -- 133.33

Granules 3050.00 -- 3050.00

3. Powder Pesticide

Technical 50.00 -- 50.00

Intermediate 66.67 -- 66.67

Filter 716.67 -- 716.67

4. Emulsifier Formulation

Na-salt of alkyl aryl

sulphonate

8.33 -- 8.33

Poly-oxy ethylene ether 6.25 -- 6.25

Ethylene oxide

condensate of alkyl

phenol sulphonate alkyl

benzee

10.42 -- 10.42

Naphthalene

sulphonate 8.33

--

8.33

Alaphatic lauryl

sulphonate

4.17 -- 4.17

Calcium salt of alkyl

benzyl sulfonate

12.5 -- 12.5

25

ANNEXURE-II

LAYOUT MAP OF THE PLANT

26

ANNEXURE-III

MANUFACTURING PROCESS

PESTICIDES TECHNICALS:

(1) 2-4-D Ethyl Ester

Manufacturing Process:

Charge all raw materials in to the reactor with agitation at room temp. Start heating by

applying steam in jacket of the reactor. Start reflux through reflux condenser. Water will

start coming out along with the organics at it is an azeotropic distillation. Temp will start

increasing. Continue distillation till no more water is coming out. Final temp will increase up

to 120°C. Now no more water is coming. Cool the reaction mass to 50°C. With agitation.

Now in separate tank prepare sodium sulfite solution. Take 1000 Lit. Water and charge 30

kgs of Sodium Sulfite powder. pH will be 7 .5 to 8 .0 . Charge this solution to t he reactor Stir

it for about one hr. and allow it to settle. Two layers will be observed. Separate bottom

organic layer and take it to distillation kettle for distillation. Take vacuum up to 758 mm Hg.

Increase the temp. Up to 120°C, and maintain the temp. For 2 Hrs. Cool it to 30 °C. Now

filters the mass. Separate aqueous layer from the sludge by filtration.

Chemical Reaction:

28

(2) 2-4-D Sodium Salt


Stage 1

Charge 2,4-DCP and caustic lye in the reaction vessel. Stir the reaction mass for 1 hour.

Charge Mono Chloro Acetic Acid slowly in the reaction mass in 3-4 hrs and stir the reaction

mass at 80-900C and reflux the reaction mass for 2 hrs at 90-100

0C. Until the reaction is

complete.

Stage 2

Cool it and filter the reaction mass to remove mother liquor.

Stage 3

Wash wet cake with water and dry the wet 2,4-D Sodium salt in drier at 80-900C.

Chemical Reaction:

29

Flow diagram & Mass Balance:

IN PUT Kg OUT PUT Kg

2,4-DCP 700

MCA 500 Reaction mass 2250

Caustic lye 47% 1050

Reaction mass 2250 Aqueous effluent 1150

Crude 2,4-D Sodium salt 1100

Crude 2,4-D Sodium salt 1100 Aqueous effluent 184

Water for washing 50 2,4-D Sodium salt 966

Total 5650 5650

Mass balance of 2,4-D Sodium salt

Stage 1

2,4-D Sodium salt

formation

Stage 2

Filteration

Stage 3

Centrifuge

30

(3) Abamectin

Manufacturing process:

It is a mixture containing 80% avermectin-B1a (i) and 20% avermectin B1b (ii). It is isolated

from fermentation of streptomycess avermitis with an anthelminic and acaricidal. The

molecular formula is as below:

C48H72O14 (avermectin B1a) + C47H70O14 (avermectin B1b)

31

Chemical Reaction:

32



Streptomycess avermemitis 50 Aqueous mass 2250

Anthelminic 100

acaricidal 100

Water 2000

Aqueous mass 2250 Crude abamectin 150

Aqueous effluent 2100

Crude abamectin 150 Abamectin 90

Recovered Methanol190

Methanol 200 Mother liquor 60

Methanol loss 10

Total 4850 4850

Mass balance of Abamectin

Stage 1

Formentation

Stage 2

Isolation

Stage 3

Purification &

Crystalization

33

(4) Acetamiprid

MANUFACTURING PROCESS:

N-Cyano methyl Acetamidate (NCMA) is reacted with 2-Chloro 5-(methyl amino methyl)

Pyridine (CMAMP) in solvent media. After the reaction is completed the product is filtered

and solvent is concentrated to yield more products as well as recover solvent which is

recycled.

CHEMICAL REACTION:


INPUT KG OUTPUT KG

NCMA 505 Organic reaction mass 3236

CMAMP 731

Methanol 2000

Organic reaction mass 3236 Acetamiprid Tech. 1020

Methanol for washing 100 ML + Washings 2238

Methanol loss 85

ML + Washings 2238 Recovered solvent 1942

Methanol loss 81

Residue 208

Total 8810 8810

Stage 1

Condensation

Stage 2

Filtration &

Drying

Stage 3

Distillation of

ML

C

H3C

H3C

N CN +

N Cl

CH2NHCH3

Cl N

CH2

N C

CH3

CH3

N CN + CH3OH

ACETAMIPRID

34

(5) Allethrin


Stage 1

Charge cyclo hexane, allethrelone and pyridine in the reaction vessel. Stir the reaction mass

for 1 hour. Charge acid chloride slowly in the reaction in 3-4 hrs and maintain the reaction at

400C for 3 hrs until reaction is complete.

Stage 2

After completion of the reaction stage 1 charge water and hydrochloric acid. Stir for ½ an

hour for pyridine hydrochloride separation.

Stage 3

After hydrochloride separation, neutralize reaction mass with NOH and wash organic layer

with water.

Stage 4

Separate the organic layer. Recover cyclo hexane under vacuum. Partially cool it and filter

the allethrin for packing.

35

CHEMICAL REACTION:

36


IN PUT kg OUT PUT kg

Allethrelone 825 Crude allethrin 3762

Cyclohexane 1422

Pyridine 540

Acid chloride 975

Crude allethrin 3762 Crude allethrin 3222

water for washing 1500 Pyridine (Rec.) 324

HCl 30% 180 Pyridine Loss 216

Aqueouseffluent 1680

Crude allethrin 3222 Crude allethrin 3222

water for washing 4500 Aqueouseffluent 4521

HCl 30% 6

NaOH 15

Crude allethrin 3222 allethrin 1530

Cyclo hexane Rec. 1632

Cyclo hexane Loss 60

Total 20169 20169

Mass balance of allethrin

Stage 1

allethrin

formation

Stage 2

Pyridine

Hydrochloride

separation

Stage 3

washing

Stage 4

Cyclohexane

Recovery

37

Alpha Cypermethrin


Metaphenoxy Benzaldehyde is reacted with sodium cyanide to form Metaphenoxy

Benzaldehyde cyanohydrin as intermediate. This on Reaction with Cyprmethric acid chloride

(CMAC) of high cis > 96% form the product Alpha-Cypermethrin oil. In this process n-Hexane

is used as solvent along with phase transfer catalyst.

The reaction is washed by Soda-ash solution and plane water.

The n-Hexane is then stripped off to get pure Alpha-Cypermethrin oil in Racemic form which

is epimerised by catalyst in presence of IPA- solvent to form the final product Alpha

Cypermethrin of >95% Purity.

Aqueous layers of reaction as well as washing which contains traces of sodium cyanide is

treated by sodium hypochlorite 8% solution to kill cyanide up to 0.2 PPM level, which is ten

mixed up with main effluent treatment streams (ETP) and after further treatment drained to

gutter.

38

Chemical Reaction:

C = CH – CH – CH – C – Cl + NaCN + C

Cl

Cl

CH3 H3C O

O

O

H CMAC

(MW- 227.5)

Sodium

Cyanide

(MW- 49.1) MPBAD

(MW-198)

C = CH – CH – CH – C – O – C

O H

CN O CH3 H3C

+ NaCl

Cl

Cl

Alpha-Cypermethrin Oil (MW- 416.3)

Epimerization

IPA - Catalyst

Alpha-Cypermethrin (MW- 416.3)

C = CH – CH – CH – C – O – C

Cl

Cl

CH3 H3C

O

O CN

H

39


Alpha - Cyperrmethrin Tech.INPUT KG OUTPUT KG

MPBAD 714

CMAC +High Cis 835 Aq. Eff of Soda Ash wash to ETP 1417

NaCN 195 Aq. Eff of water wash to ETP 1385

Water 1428 Recovered Hexane 3908

n-Hexane (F) 492 Hexane loss 430

n-Hexane (R) 3808

Catalyst 14 NaCN layer 1695

Soda ash Soln. 5% 1400

Water for Washings 1400 Alpha Cyper Oil 1450

Organic ML 351

Alpha Cyper Oil 1450 ML of Epimerisation 1460

IPA-Solvent (F) 351

IPA-Solvent (R) 1098 Catalyst Loss 35

Catalyst 86

Crude Aphacyper Power 1140

Crude Aphacyper 1140 MI 1000

Power

Solvent Loss 280

IPA + Solvent (F) 280

IPA + Solvent (R) 860 Alph Cypermethrin 1000

NaCN layer 1695

10% Sodium

Hypochlorite 2150

Detoxified Effluent(TEE) 3845

TOTAL 19396 TOTAL 19396

Condensation&

Washing

Stage

Epimerisation

Stage

Detoxification

Stage III(B)

Detoxification

Stage

40

(6) Attrazine


First Toluene is taken in rector then Cynauric Chloride is charged in to the solvent and is

dissolved completely. Then isopropyl amine is added slowly.

Then Sodium Hydroxide is added to neutralize the liberated hydrochloride acid. Then again

mono ethyl amine is added slowly. Again sodium hydroxide or soda ash is added to

neutralize the mixture. Then solvent is recovered by steam distillation. Atrazine is filtered

off. Centrifuged, dried and pulverized. Pulverized Atrazine is then packed according to the

requirement.

ATRAZINE 50% WP

Measured quantity of Technical is taken and blander. Then weighted quantity of dispersing

agent, wetting agent, precipitated silica and china clay are added in it under stirring as per

recipe. Blending is carried out for three hours to make it homogeneous. Then micro

pulverized to get fine particle size. Then it is packed in various sizes according to customers

requirements.

41

Chemical Reaction:

42


INPUT KG OUTPUT KG

Toluene 7000

Cyanuric chloride 905

Isopropyl amine 420

Caustic lye 195

Mono ethyl amine 321

Soda ash 266

Water with caustic 195 Toluene Recovery 6980.00

Water for soda + caustic 3000 CO2 losses 108

Steam 4800 Water losses 241.00

Liquid effluent 11420.70

Water - 10759.4

Salt -568.4

Atrazine- 36.2

Water for washing 2650

Solid waste 2.00

Product 1000

Total 19752 19752

REACTION

Distillation

Filtration

Drying

Washing

43

(7) Azoxy strobin


STEP A: In the reaction vessel, MDC and TiCl4 is charged at room temperature. Methyl

formate is added in the reaction mixture at 20°c within half an hour. Reaction mass cooled

up to 5°c and DMA + MDC solution is added within half an hour. Reaction mass stirred for 30

min and tri ethyl amine is added with in two hours. Reaction mass stirred for 2 – 3 hrs until

DMA content in reaction mass is below 2%. Reaction mass is quenched with dilute HCl and

layers are separated. Water wash is given to organic phase and clear organic phase is taken

for step B.

STEP B: In the organic phase obtained in step A, charge di methyl sulphate, aq. Na2CO3

solution and catalyst. The resulting mixture is stirred till no raw material present in the

reaction mixture. Layers are separated. Sodium thiosulphate treatment is given to organic

phase. Organic phase is washed with water and MDC is recovered from organic phase. In the

resulting concentrated mass, MeOH is added and product is crystallised, filtered and dried in

the dryer.

Chemical Reaction:

N N

O O

O M e

O

C N

T iC l4 , M eForm ate

N -E t3, M D C

M e2SO 4,

M D C , H 2O

N N

O O

O M e

O

C NO

N N

O O

O M e

O

C NM eO

D es-M ethoxy A zoxy

(D M A )

D es-m ethyl A zoxy

A zoxystrobin

44


AZOXYSTROBIN

Input

Quantity,

Kg Out put

Quantity

Kg DMA 1734.4

Methyl formate 432.2 Process Step-I Organic Phase 17520

TiCl4 1365.6 Aq. Phase 9840

MDC 15840

Triethyl amine 1493.2 Main Aq. phase 17420

Water 9600

HCl 14400 Solvent Loss 86

Org. Phase 17520

DMS 1211 Main Aq. layer 12680

Na2CO3 11520

Aq. Na2S2O3 3840 Aq. phase 6100

MeOH 6470 Rec. MDC 15480

Water 3840

Recovered

MeOH 5570.4

Organic Residue 960

Drying Loss 3010

Product 1000

Total 89266.4 Kg 89266.4

Phase Separation Step-2

Reaction Water Washing

Layer Separation

Solvent Reaction, Crystallization &

Filtration

Drying

Packaging

45

(8) Buprofezin


Step-1 Charge PNNCC, Toluene, and lime in the reaction vessel. Stir the reaction mass for 2-

3 hours. Charge Thiourea slowly in the reaction mass in 2-3 hours and stir the reaction mass

at higher temperature until raw material is totally consumed.

Step-2 After completion of reaction, Filter the reaction mass to isolate inorganic solid.

Step-3 Wash inorganic solid with toluene. Recover toluene under vacuum from clear organic

phase.

Step-4 Add EDC in the crude solid. Charge TEA slowly at room temperature and stir the

reaction mass for 3 hours.

Step-5 Reaction mass is washed with water. Separate the layers. Recover EDC under vacuum

partially.

Step-6 Cool the conc. mass slowly and filter the crystals. Dry the wet product at 50 –65%.

CHEMICAL REA CTION:

N

CH2Cl

C

O

NO2

+ CS

NH

NH

i-Pr

t-Bu

S

N

N i-Pr

N t-Bu

p - Nitrophenyl N - Chloromethyl Carbamate

N-isopropyl- N-tert-butyl Thiourea

BUPROFEZIN

O

46


Input Qty Kg Out put Qty, Kg

PNNCC 1426.8

Reaction (High Temp)

Toluene 4910.4

Lime 282.3.

Thio urea 854.5

Filteration & Wash

Inorganic salt

150

To

incineration

EDC

4910.4

495.9

Recovered EDC

2010 For recycling

TEA

Recovery & washing

Recovered

Toulene 4488

To Step 3

Water

2160

Aqueous

phase 2458 To incineration

Crystallization & Filtration

Recovery Recovered EDC

2300 To Step 3

Organic

residue 394 To incineration

Drying Dying loss 1957.9

Packing

Product 1000

Total

14758

14758

47

(9) Butachlore


Stage 1

Charge 2,6-DEA, Benzene, Paraformaldehyde in to the reactor and heat the reaction mixture

at 800C temperature for 4 hrs in the presents of catalyst. When reaction is over, the material

is cooled at 400C temperature. Distilled out Benzene under vacuum at 80

0C temperature

and cool it.

Stage 2

Charge Chloro acetyle chloride into the reactor and charge intermediate (stage 1) slowly in

the reaction mass at 200C temperature and maintain the reaction for 5 hrs.

Stage 3

Charge n-Butanol into the reactor and react with intermediate (stage 2) at 400C

temperature. Maintain the mass for 4 hrs. Neutralized the reaction mass with ammonia gas

till pH-8. Wash the reaction mass with water. Separate organic layer and take it to

distillation vessel for Butanol recovery under vacuum up to 900C temperature. Cool it to

100C and filter the Butachlor for packing.

48

Chemical Reaction:

49



2,6-DEA 760 Schiffs Base 820

PFA 258 Recovery of Bz 320

Benzene 405 Benzene Loss 95

TEA 5 PFR loss 98

Aqueous effluent 95

( Formaldehyde Solution)

Schiffs Base 820 BRM 1420

CAC 600

BRM 1420 Crude Butachlor 3020

n-Butanol 1600

Crude Butachlor 3020 Crude Butachlor 2870

NH3 gas 95 Aqueouseffluent 2145

water 1900

Crude Butachlor 2870 Butachlor 1520

n-Butanol (Rec.) 880

Butanol Loss 470

Total 13753 13753

Mass balance of Butachlor Technical

Stage 1 Schift's Base

formation

Stage 2 BRM formation

Stage 3

BCL formation

Stage 4

Neutralization

Stage 5 Butanol Recovery

50

(10) Cartap hydrochloride


Cartap Hydrochloride (1, 3-bis carbamoylthio-2-dimethylamino propane hydrochloride) is

synthesized in the following sequence starting from 2-dimethylamino-1, 3-dichloropropane.

Step – I

2-Dimethylamino-1, 3- dichloropropane is taken in aqueous solvent and reacted with

sodium Thiosulphate at elevated temperature. Reaction mass is stirred for five hours and

solvent is partially removed. Reaction mass is cooled to room temperature and sodium

cyanide is added slowly. Reaction is continued for four hours. Product, thus formed is

filtered and washed with water and suck dried.

Step-II

Cake of the product, 2-dimethylamino-1, 3-dithiocyanate propane is transferred to reactor

and slurried with the solvent. Slurry is filtered to remove by-product and filtrate is again

taken to reactor. Hydrochloric acid is added at room temperature and stirred for two hours.

Cartap hydrochloride thus formed is filtered and dried.

Chemical Reaction:

51



2-Dimethylamino-1,3-

dichloropropane 850 Reaction mass 1702

Sodium thiosulphate 152 Recovered Water 500

Water 1200

Reaction mass 1702 Crude Cartap 1150

Sodium cyanide 98

Mother liquor 650

Crude cartap 1150 Cake of Cartap 1325

Water 2200 Aqueous effluent 2025

Cake of Cartap 1325 Cartap solution 3150

Solvent 2000 Solid waste 175

Cartap solution 3150 Cartap hydrochloride 1250

Hydrochlorid Acid 190 Solvent with impurities 2090

Total 14017 14017

Mass balance of Cartap hydrochloride

Stage 1

Reaction at high

temperature

Stage 2

Reaction &

Filtration

Stage 4

Purification

Stage 3

Water washing &

Filtration

Stage 5

Formation of

Hydrochloride

52

(11) Chlorpyriphos


Sodium Salt of trichloro Pyridinol (NaTCP) is reacted with Diethyl Thio Phosphoryl Chloride

(DETC) in presence of catalyst and solvent to get Chlorpyrifos Tech. of 94% purity.

Recovered solvent is recycled in next batch.

Finally Toxin Effluent which contains traces of pesticides is taken to Hydrolysis stage for

detoxification. Where Aqueous Mass is treated at high temp. By Alkali for the rapid

hydrolysis of pesticides to simpler non- toxic compounds.

Chemical Reaction:

N ONa

Cl Cl

Cl

+ P Cl

S OC2H5

OC2H5

+ EDC + CATALYST

N O

Cl Cl

Cl P

S OC2H5

OC2H5

+ NaCl

53

Flow Diagram & Mass Balance:

INPUT KG OUTPUT KG

NaTCP 763 Chlorpyrifos 1160

DETC 650 Recovered solvent- EDC 2895

Water for Reaction 760 EDC loss 320

Water for washing 3150 Aqueous effluent 4095

Catalyst 9 Water loss 62

EDC 3200

Aqueous effluent 4095 Wet cake NaTCP 35

C. S. lye 48% 50 DETOXIFIED Aq. Mass 4110

Detoxified Aq. Mass 4110 Distilled Water 3854

Detoxified Aq. Mass 214

Water loss 42

Total 16787 16787

Mass balance of Chlorpyrifos

Stage 1

CPP

Preparation

Stage 2

Alkali

Hydrolysis

Stage 3

TEE

Distillation

54

(12) Cyfluthrin


Fluro Meta Phenoxy Benzaldehyde is reacted with sodium cyanide to form fluro Meta

Phenoxy Benzaldehyde Cyanohydrin as an intermediate. This on reaction with Cypermethric

Acid chloride forms the final product Cyfluthrin. In this process n-Hexane is used as solvent

along with phase transfer Catalyst.

The reaction mass of Cyfluthrin is washed by soda ash solution and water.

Finally n-Hexane is distilled off to get pure Cyfluthrin. Aqueous layer which contain traces of

sodium cyanide is detoxified by the treatment of Sodium Hypochlorite 10% solution to < 0.2

ppm level.

Chemical Reaction:

55



CMAC 590 Aqueous effluent 423

Fluro MPBD 504 Organic Layer 2271

NaCN 145

PTC 5

Water 350

Hexane 1100

Organic Layer 2271 Aqueous effluent 1561

Cyfluthrin with solvent 2140

Hypochlorite 1430

Cyfluthrin with solvent 2140 Crude Cyfluthrin 2120

Water 1200

Hypochlorite 210 Aqueous effluent 1430

Crude Cyfluthrin 2120 Cyfluthrin 1020

Hexane Recovery 1050

Hexane Loss 50

Total 12065 12065

Mass balance of Cyfluthrin

Stage 1

Condensation

Stage 2

Cyanide

detoxification

Stage 3

Washing

Stage 4

Distillation

56

(13) Cypermethrin


Meta Phenoxy Benzaldehyde is reacted with Sodium Cyanide to form Meta Phenoxy

Benzaldehyde Cyanohydrin as an intermediate. This on reaction with Cypermethric Acid

Chloride forms the final Product Cypermethrin. In this process n-Hexane is used as solvent

along with phase transfer Catalyst.

The reaction mass of Cypermethrin is washed by Soda Ash solution & Water.

Finally n-Hexane is stripped off to get pure Cypermethrin.

Aqueous layer which contain traces of Sodium Cyanide is detoxified by the treatment of

Sodium Hypochlorite 8 – 10% Solution to < 0.2 ppm Level.

Chemical Reaction:

57


INPUT KG OUTPUT KG

CMAC 590 Aqueous effluent 2406

MPB 485

NaCN 145

PTC 6

Water 350

Hexane 1090

Hypochlorite 1430

Water 200

Hypochlorite 200

Hexane recovery 1045

Heaxane loss 45

Cypermethrin 1000

Total 4496 4496

Mass balance of Cypermethrin

Condensation

Washing

Distillation

Cyanide

detoxification

58

(14) DDVP


Stage 1

Charge Chloral in the reaction vessel. Stir the reaction mass at room temperature. Charge

TMP slowly in the reaction mass in 8-10 hrs and stir the reaction mass at room temperature

until reaction is complete.

Stage 2

After completion of the reaction (stage 1) degas the reaction mixture for methylene chloride

removal. After degassing is completed, material is filtered and packed.

Chemical Reaction:



Chloral 3000 DDVP Mass 5400

TMP 2400

DDVP Mass 5400 DDVP Mass 4250

Chloral Loss 150

CH3Cl 1000

Total 10800 10800

Mass balance of DDVP

Step 1

DDVP Preparation

Step 2

DDVP Degasing

59

(15) Delta cypermethrin


Stage 1

Ester of Bicisthemic acid is reacted with Thionyl Chloride to form Bicisthemic acid chloride.

In presence of Caustic soda.

Stage 2

M-phenoxybenzaldehyde is reacted with Sodium cyanide to form Metaphenoxy

benzaldehyde cyanohydrin as an intermediate. This on reaction with Bicisthemic acid

Chloride forms the product deltamethrin. The reaction mass of deltamethrin is washed with

water.

Aqueous layer which contain traces of Sodium cyanide is detoxified by the treatment of

Sodium hypo chlorite 10-12% solution to < 0.2 ppm level.

Stage 3

Deltamethrin is epimerized in presence of Di isopropyl amine and isopropyl alcohol at low

temperature to form deltamethrin.

Stage 4

Finally DMF is distilled off to get pure deltamethrin technical.

60

Chemical Reaction:

62



Ester of Bicisthemic Acid 1200 Bicisthemic acid Chloride 1350

Caustic soda 600 Methyl chloride 250

Thionyl Chloride 350 Gaseous discharge 550

Bicisthemic acid Chloride 1350 Crude Deltamethrin 2380

M-phenoxybenzaldehyde 1130

Sodium cyanide 350 Sodium Cyanide effluent 2100

Water 800 (Treatment with Hypo solution)

DMF 50

Hypo solution 800

Reaction mass 3880

Crude Deltamethrin 2380

DIPA/IPA 1500

Reaction mass 3880 Deltamethrin 2330

DIPA/IPA Recovery 1250

DMF loss 50

DIPA/IPA loss 250

Total 14390 14390

Mass balance of Deltamethrin

Stage 1

Bicisthemic acid

Chloride formation

Stage 2 Crude

Deltamethrin

Stage 3

Epimerization of Deltamethrin

Stage 4DMF Recovery

63

(16) Difenconazole


Stage 1

Charge 4-methyl-1, 3-dioxolane in the reactor and stir for 30 minute and charge 2-chloro-4-

(4-chlorophenoxy) benzyl chloride slowly in the reaction mass for 2-3 hrs and maintain the

temperature for 3 hrs and check the sample for reaction complete. After reaction is

complete add KOH flakes slowly. Maintain the reaction mass for 4 hrs until the reaction is

complete.

Stage 2

Charge intermediate, Dimethyl Formamide, 1,2,4-Trizole and K2CO3 in the reactor and

maintain the reaction for 3 hrs at high temperature until the reaction is complete.

Stage 3

Recover DMF under vacuum partially.

Stage 4

Wash the reaction mass with water. Dry the wet cake of difenoconazole in drier.

64

Chemical Reaction:

65



2-chloro-4-(4-chlorophenoxy)

benzyl chloride 825 Intermediate 950

4-methyl-1, 3-dioxolane 250

KOH 500 Organic effluent 625

Intermediate 950 Crude difenoconazole 2530

DMF 1320

1,2,4 Triazol 210

K2CO3 50

Crude difenoconazole 2530 Crude difenoconazole 1365

DMF Recovery 1165

Crude difenoconazole 1365 Difenoconazole 890


DMF loss 155

Total 9000 9000

Mass balance of Difenoconazole

Stage 1

Intermediate

Stage 2

Difenoconazole

Stage 4

Washing

Stage 3

DMF Recovery

66

(17) D-Transallethrin


Stage 1

Charge cyclo hexane, allethrelone and pyridine in the reaction vessel. Stir the reaction mass

for 1 hour. Charge acid chloride slowly in the reaction in 3-4 hrs and maintain the reaction at

400C for 3 hrs until reaction is complete.

Stage 2

After completion of the reaction (stage 1), charge water and hydrochloric acid. Stir for ½ an

hour for pyridine hydrochloride separation.

Stage 3

After hydrochloride separation, neutralize reaction mass with NOH and wash organic layer

with water.

Stage 4

Separate the organic layer. Recover cyclo hexane under vacuum. Partially cool it and filter

the d-Transallethrin for packing.

67

Chemical Reaction:

68


IN PUT kg OUT PUT kg

Allethrelone 825 Crude d-Transallethrin 3762

Cyclohexane 1422

Pyridine 540

Acid chloride 975

Crude d-Trans 3762 Crude d-trans 3222

water for washing 1500 Pyridine (Rec.) 518

HCl 30% 180 Pyridine Loss 22

Aqueouseffluent 1680

Crude d-trans 3222 Crude d-trans 3222

water for washing 4500 Aqueouseffluent 4521

HCl 30% 6

NaOH 15

Crude d-Trans 3222 d-Trans allethrin 1530

Cyclo hexane Rec. 1332

Cyclo hexane Loss 360

Total 20169 20169

Mass balance of d-Transallethrin

Stage 1 d-Trans allethrin

formation

Stage 2

Pyridine Hydrochloride

separation

Stage 3 d-trans washing

Stage 4

Cyclohexane Recovery

69

(18) Emmamectin


It is a composite mixture of 90% emamectin B1a and 10% emamectin B1b as their benzoate

salts. It is isolated from fermentation of streptomycess avermitis with an anthelminic and

acaricidal. Then methylamine is added in the mixture. Finally benzoate salt is prepared by

reaction with methyl benzoate.

The molecular formula is as below:

C49H75NO13 (emamectin B1a) + C48H73NO13 (emamectin B1b)

70



Streptomycess avermemitis 50 Aqueous mass 2250

Anthelminic 100

acaricidal 100

Water 2000

Aqueous mass 2250 Crude emamectin 160

Methyl amine 20 Aqueous effluent 2110

Crude emamectin 160 Crude Emamectin benzoate 290

Methyl benzoate 25


Water 1000

Crude Emamectin benzoate 290 Abamectin 110

Recovered Methanol 240

Methanol 300 Mother liquor 180

Methanol loss 60

Total 6295 6295

Mass balance of Emamectin benzoate

Stage 1 Formentation

Stage 2

Addition & Isolation

Stage 3

Benzylation

Stage 4 Purification & Crystalization

71

(19) Fipronil


STEP – I: Fipronil Pyrazole to Fipronil Thicyanate (FPP to FPT):

♦ Fipronil Pyrazole and Ammonium Thiocyanate are condensed in the presence of

oxidant Oxone® and MeOH as solvent.

♦ Reaction is completed in 3.0 hrs at 39 – 40 °C.

♦ An inorganic salt is filtered, washed with MeOH and dried.

♦ MeOH is recovered from filtrate partially under reduced pressure. Recovered MeOH

is recycled.

♦ Partially concentrated mass is dumped in to water at RT. Stirred for 3 – 4 Hrs at RT.

♦ Product (FPT) is filtered at RT and washed with water.

♦ Product (FPT) is dried at 50 °C till constant weight is obtained.

STEP – II: Fipronil Thicyanate to Desoxy Fipronil (FPT to DOF):

♦ Fipronil Thiocyanate and CF3Br are reacting in the presence of SO2 (g), Sodium

formate and DMF as solvent.

♦ Reaction is carried out under pressure in Auto clave at 70°c.

♦ Reaction mixture is cooled down at 40 °C.

♦ The pressure in autoclave is released and scrubbed in 7 % NaOCl soln.

♦ Reaction mass is transferred to mixture of water + Isopropyl acetate solution and

stirred for ½ hrs at RT.

♦ Organic and Aq. phases are separated. Aq. phase is extracted with IPAc and then

treated with NaOCl solution and incinerated.

♦ Combined organic phase is washed with water. Washed organic phase taken for

partial IPAc recovery under reduced pressure. Recovered IPAc is recycled. Partial

concentrated mass is taken for crystallization.

♦ Product is crystallized out and filtered out and dried.

♦ Mother liquor is subjected for isopropyl acetate recovery. Reco. IPAc is recycled and

organic residue is incinerated.

72

STEP – III: Des-oxy Fipronil to Fipronil (DOF to FP):

♦ Des-Oxy Fipronil, Trifluoro acetic acid and chloro benzene are mixed at RT.

♦ H2O2 is added for 30 min. at low temperature.

♦ After completion of reaction chloro benzene is charged and CF3COOH is distilled out.

♦ Product is crystallized out in Ethanol and water, filtered and dried.

Chemical Reaction:

NN

CN

H2N

Cl Cl

CF3

NN

CN

H2N

Cl Cl

CF3

SNC

NN

CN

H2N

Cl Cl

CF3

SF3C

NN

CN

H2N

Cl Cl

CF3

SF3C

O

Fipronil Pyrazol Fipronil Thiocyanate DOF Fipronil

Mol. Wt.: 321,09 Mol. Wt.: 378,16 Mol. Wt.: 421,15 Mol. Wt.: 437,15

Oxone

NH4SCN

MeOH CF3BrDMF

HCOONaSO2

CF3COOHH2O2

CH2Cl2

Fipronil Synthesis - Step 1 to 3 - and possible impurities

NN

CN

H2N

Cl Cl

CF3

S

NN

NC

NH2

ClCl

CF3

S

Fipronil Disulfide

Mol. Wt.: 704,28

NN

CN

H2N

Cl Cl

CF3

SF3C

O

Fipronil Sulfon

O

Mol. Wt.: 453,15

NNH2N

Cl Cl

CF3

SF3C

O O

NH2

Fipronil Amide

Mol. Wt.: 455,16

/MN

NN

CN

H2N

Cl Cl

CF3

HS

Mol. Wt.: 353,15

Fipronil Sulfide

+

73


INPUT OPERATIONS OUTPUT

STEP - I: Fipronil Pyrazole to Fipronil Thiocyanate:

RMs Kg Streams Kg

Fipronil Pyrazole (95 %) 1.2632

Oxidation /

Condensation

Reaction mass 29.6781 NH4SCN (98.5 %) 0.8089

Oxone® 3.906

MeOH 23.7

Total

29.6781

Total 29.6781

Reaction mass 29.6781

Inorganic salt isolation

Inorganic salt (Dry) 3.32

MeOH for washing 6.6 Filtrate (ML) 31.9581

Filtr. Loss 1.0000

Total 36.2781 Total 36.2781

Filtrate (ML)

31.9581 Partial MeOH recovery

Partial conc. Mass 7.7520

Reco. MeOH 23.4061

Loss 0.8000

Total

31.9581

Total 31.9581

Partial Conc. 7.7520 Water Dumping Reaction mass 23.0520

Water 15.3000

Total 23.0520 Total 23.0520

Reaction mass

23.0520

Product filtration

Fipronil Thiocyanate

(Wet cake) 1.5747

Water for washing 15.3000 Filtrate (Aq.+ MeOH)) 36.7773

Total 38.3520 Total 38.3520

Fipronil Thicyuanate (Wet Cake)

1.5747

Product drying

Fipronil Thiocyanate

(Dry) 1.3789

Drying loss 0.1958

Total 1.5747 Total 1.5747

74

STEP - II: Fipronil Thiocyanate to Desoxy-Fipronil:

RMs Kg Streams Kg

FPT

1.3789

Reaction


SO2(g) 0.5052

HCOONa (46 %) 5.5704 HCN (g) 0.1120

CF3Br 3.1753 Reco. CF3Br 2.34

Dimethyl Formamide 10.5804

Total 21.4763 Total 21.4763

10 % NaOCl solution

Reaction mass 19.0243 DMF recovery

Mass after DMF

reco. 10.56

Reco. DMF 8.4643

Total 19.0243 Total 19.0243

Mass after DMF reco.

10.56

Product extraction in

IPAc (i.e. IPAc wash

to org. mass) Org. layer

19.6220

Isopropyl acetate (Including

washing) 15.5520

Aq. layer

31.1536

Water 24 Kg + NaHCO3 0.6636 Kg 24.6636

Total 50.7756 Total 50.7756

Organic layer

19.6220

Partial IPAc recovery

Partial Conc. Mass

12.1220

Reco. IPAc 6.9

Reco. Loss 0.6

Total 19.6220

Total

19.6220

Partial Conc. Mass

12.1220 Product

Crystalization /

Filtration / Drying

Desoxy - Fipronil

1.18

Mother liquor 10.8640

Filtration loss 0.078

Total 12.1220 Total 12.122


IPAc reco. from ML

Reco. IPAc 7.2

Organic residue 5.644

Reco. loss 0.52

Total 10.8640 Total 10.864

75

STEP - III: Desoxy-Fipronil to Fipronil:

RMs Kg Streams Kg

Desoxy - Fipronil (96 %)

1.416

Reaction

Reaction mass 12.7195CF3COOH 9.2323

H2O2 (35 %) 0.4392

Chlorobenzene 1.632

Total 12.7195 Total 12.7195


Quenching by

Na2SO3

Quenched mass 12.9643

Na2SO3 0.2448

Total 12.9643

Total 12.9643

Quenched Mass 12.9643

Distillation of

CF3COOH & Cl-

Benzene

Reco. Cl-benzene 1.284

Chlorobenzene (2 x 1.62) 3.24 CF3COOH 8.236

Water 0.4153

Slurry after reco. 6.0290

Loss

0.2400

Total 16.2043 Total 16.2043

Chlorobenzene distillation then recycling

Slurry after reco. 6.0290

Disti. of Cl. Benzene

and water

Reco. Cl-benzene 2.7676

Water (2 x 3.24) 6.4800

Water 3.1

Slurry 6.4014

Loss 0.2400

Total 12.5090 Total 12.5090

Slurry 6.4014

Product

crystallization

Crystallized slurry 15.2569 Ethanol 7.8163

Water 1.0392

Total 15.2569 Total 15.2569

Crystallized slurry 15.2569

Product filtration /

washing

Fipronil wet cake

1.0800

Ethanol (1.1328) + water (0.5669)

for washing 1.6997


Filtration loss 0.1200

Total 16.9566 Total 16.9566

Fipronil wet cake

1.0800

Product drying

Fipronil (Dry) 1.0420

Drying loss 0.0380

Total 1.0800 Total 1.0800

76


EtOH reco. from ML

Reco. EtOH 7.03

Water as residue 8.4866

Reco. Loss 0.2400

Total 15.7566 Total 15.7566

(20) Glyphosate


PMIDA react with Hydrogen Peroxide in presence of Catalyst and cooler after Oxidation,

reaction mass treat with Ferrous Sulphate solution get Glyphosate in slurry form during this

formaldehyde generates is converted to Foric Acid. Slurry filtered and washes with water.

Wet cake dry to get Glyphosate Tech of 95% purity. Finaly Toxic Effluent which contains

traces of Pesticides is taken to Hydrolysis stage for detoxification. Where Aq. Mass is treated

at high temp. by Alkali for the rapid hydrolysis of presticides to simpler non-toxic

compounds.

Chemical Reaction:

Glyphosate (TECH)

P - CH2 - NHO

PMIDA

(MW- 227)

CataystO

+

Hydrogen Peroxide

(MW- 34)

HO CH2COOH

CH2COOH

H2O

2

P - CH2 - N

HO

Glyphosate

(MW- 169)

O

+

M.W.- 30

HO

CH2COOH HCHO CO

2H

2O+ +

M.W.- 44 M.W.- 18

77


INPUT KG OUTPUT KG

FeSO4(10%) 300

PMIDA 2000

H2O2(50%) 750

Wate 1000

Catalyst 10

Water Wash 200

Vapour loss 100

Org. Residue 100

C.S. Lye 48% 720 Reco. Water 2272

Salt mix to TSDF 1084

Water loss 248

Drying Loss 171

Glyphosate 95% 1005


Glyphosate

Glyphosate Preparation

Filtration

Drying TEE

Water + Formic acid

Detoxifn. By Hydrolysis &

TEE Dist.

78

(21) Hexaconazole


Stage 1

Charge 2,4-Dichloro valero phenol and Dimethyl sulphide in the reactor and stir for 30

minute and charge Dimethyl sulphate slowly in the reaction mass in 2-3 hrs. Maintain the

temperature for 5 hrs and check the sample for reaction for Valero phenol content. After

reaction is complete, add KOH flakes slowly. Maintain the reaction mass for 4 hrs until the

reaction is complete.

Stage 2

Charge oxarine, Dimethyl formamide, 1,2,4-Trizole and K2CO3 in the reactor and maintain

the reaction for 3 hrs at high temperature until the reaction is complete.

Stage 3


Stage 4

Wash the reaction mass with water.

Stage 5

Add heptane in the crude Hexaconazole and stir for 2 hrs. Cool the reaction mass and filter

the Hexaconazole.

Stage 6

Dry the product Hexaconzole in drier.

79

Chemical Reaction:

80



2,4-DVP 600 Oxiraine 550

Dimethyl sulphide 870 Organic effluent 2010

Dimethyl sulphate 520

KOH 520

Water 50

Oxarine 550

DMF 1320 Reaction mass 2095

1,2,4 Triazol 190

K2CO3 35

Reaction mass 2095 Crude Hexaconazole 775

DMF Recovery 1220

DMF loss 100

Crude Hexaconazole 775 Aqueous effluent 650

Water for washing 600 Crude Hexaconazole 1385

Heptane 660

Crude Hexaconazole 1385 Hexaconazole Wet 750

Haptain Recovery 635

Hexaconazole Wet 750 Hexaconazole 725

Heptane lose 25

Total 10920 10920

Mass balance of Hexaconazole

Stage 1 Oxiraine

formation

Stage 2

Hexaconazole formation

Stage 4Washing

Stage 5Chill ing and

filteration

Stage 3 DMF Recovery

Stage 6Hexaconazole

Drying

81

(22) Imazethapyr


Stage 1

5-ethyl-3-pyridine carboxylic acid (EPCA) is reacted with 4,5 Dihydro-4 methyl 4 (1 methyl

ethyl)-5-oxo-1 H-imidazoline in present of catalyst and DMF solvent. The Hydrochloric acid,

which is formed during the reaction, is scavenged by putting Sodium carbonate as acid

scavenger.

Stage 2

The resulting mass is diluted by water and filtered to remove the salts of Sodium Chloride

(NaCl) & Sodium bicarbonate. The organic mass is then treated with water and finally

solvent is removed by distillation.

Stage 3

The concentrated mass is then crystallized to get pure product – Imazethapyr technical.

Stage 4

Finally toxic effluent, which contains traces of pesticides, is taken to hydrolysis stage for

detoxification. Where aqueous mass is treated at high temperature by Alkali for the rapid

hydrolysis of pesticides to simpler non-toxic compounds.

Chemical Reaction:

82



EPCA 900 Organic Mass 2410

DMMI 750 Recovered solvent DMF 2040

DMF 2200 DMF Loss 110

Catalyst 10

Sodium Carbonate 700

Organic Mass 2410 Crude Imazethapyr 1468

Water 1000

Aqueous layer 1942

Crude Imazethapyr 1468 Imazethapyr 1100

Methanol 400 Recovered Methanol 295

Methanol Loss 105

Organic mass 368

Aqueous layer 1942 Recovered water 930

Caustic lye 50 Water Loss 50

DMF Loss 50

Mix salt 962

Total 11830 11830

Mass balance of Imazethapyr

Stage 1 Condensation &

solvent recovery

Stage 2

Water Wash

Stage 3 Crystallization

Filtration & Drying

Stage 4 Salt Recovery

83

(23) Imidacloprid


2 – Chloro, 5 – Chloro methyl Pyridine (CCMP) is reacted with N – Nitro imino Idmidazolidine

(N-Nll) in present of catalyst and solvent.

The Hydrochloric acid, which is formed during the reaction, is scavenged by putting Sodium

carbonate as acid scavenger. The resulting mass is diluted by water and filtered to remove

the salts of Sodium Chloride (NaCl) & Sodium bicarbonate.

The organic mass is then treated with water and finally solvent is removed by distillation.

The concentrated mass is then crystallized to get pure product – Imidacloprid (Tech).

Finally Toxic Effluent which contains traces of Pesticides is taken to Hydrolysis stage for

detoxification. Where aqueous mass is treated at high temperature. By Alkali for the rapid


Chemical Reaction:

N

CH2CL

CL

+ NA2CO3 + H-N N-H H-N

CATALYST

+

SOLVENT

N-NO2

CCMP

M.W.162 N-NII

N CL

CH2 - N N-H

N-NO2

+ NACL

NAHCO3

+

IMIDACLOPRID

84


INPUT KG OUTPUT KG

CCMP 900 Organic mass 2412

N-NII 752 Recovered solvent DMF 2046

DMF 2200 DMF loss 110

Catalyst 10

Na2CO3 706

Organic mass 2412 Crude Imidacloprid mass 1470

Water 1000 Aqueous layer 1942

Crude Imidacloprid mass 1470 Imidacloprid Tech. 1052


Methanol loss 105

Organic mass 418


C.S.Lye 50 Water loss 50

DMF Loss 44

Mix salt 958

Total 11842 11842

Stage 1 Condensation

& solvent recovery

Stage 2 Water wash

Stage 3 Crystallization,

Filtration & Drying

Stage 4 Salt

recovery

85

(24) Indozacarb


Stage 1

Charge Monoglyme, NaH 60% and Chloromethyl formate in the reaction vessel. Stir the

reaction mass for 2-3 hrs. Charge oxadiazine carboxylate slowly in the reaction mass in 3-4

hrs and stir the reaction mass until reaction is complete.

Stage 2

After completion of the reaction, recover Monoglyme under vacuum.

Stage 3

After Monoglyme recovery, acidify the material with Hydrochloric acid-1N and separate

organic layer. Add MDC in the crude indoxacarb

Stage 4

After acidification of reaction mass, dehydration is done with sodium sulphate and silica.

Recover MDC under vacuum and filter the crystals. Dry the wet product.

Chemical Reaction:

86



Monoglyme 2000 Reaction mass 3746

NaH 60% 240

Oxadiazine Carboxylate 939

Chloromethyl formate 567

Crude Indoxacarb Acid 1746

Reaction mass 3746 Monoglyme Recovered 1980

Monoglyme Loss 20

Crude Indoxacarb Acid 1746 Organic Layer 3500

HCl-1N 204

MDC 2000 Aqueous effluent 450

Organic Layer 3500 Indoxacarb Tech. 1500

Sodium Sulphate 200 MDC (Rec.) 1900

Silica 175 MDC (Loss) 100

Sodium Sulphate 200

Silica 175

Total 15317 15317

Mass balance of Indoxacarb

Stage 1

Indoxacarb

formation

Stage 2

Monoglyme

Recovery

Stage 3

Acidification

Stage 4Dehydration &

Distillation

87

(25) Ipconazole


Stage 1

Charge cyclopentanol and Dimethyl Sulphide in the reactor and stir for 30 minute and

charge 4-Chloro Benzyl Chloride slowly in the reaction mass 2-3 hrs and maintain the

temperature for 3 hrs and check the sample for reaction complete. After reaction is


complete.

Stage 2

Charge intermediate Dimethyl Formamide, 1,2,4-Trizole, K2CO3, Iso propanol and PFA in the

reactor and maintain the reaction for 3 hrs at high temperature until the reaction is

complete.

Stage 3


Stage 4

Wash the reaction mass with water. Wet Ipconazole drying in drier.

IN P U T Kg OU T PUT K g

4- C hlo ro B e nzyl C hlo rid e 50 0 In ter m e dia te 65 0

Cyclop en tan ol 25 0

D im eth yl su lph id e 87 0 Or ga nic e ffl ue nt 14 70

K O H 50 0

Inter m e dia te 65 0 C ru de Ip con azo le 25 15

D M F 1 32 0

1,2,4 T ria zo l 21 0

K 2C O3 5 0

Iso P ro pa no l 17 5

PFA 11 0

Cru de Ip con azol e 2 51 5 C ru de Ip con azo le 13 50

D M F R e cove ry 11 65

C ru de Ip con azo le 1 35 0 Ip con azo le 70 0

W ater fo r wa shin g 1 00 0 Aq ue ou s eff lue nt 14 95

D M F lo ss 15 5

Tot al 9 50 0 95 00

M a ss balan ce of Ipc ona zole

S t ag e 1

In te rm ed ia te

S t ag e 2

Ip co n az ole

S t ag e 4

W as hin g

S t ag e 3

D M F R ec ove ry

88

(26) Lambda Cyhalothrin


Meta Phenoxy Benzaldehyde is reacted with Sodium Cyanide to form Meta Phenoxy

Benzaldehyde Cyanhydrin as an intermediate. This on reaction with Fluoro Propenyl Acid

Chloride (TFP Acid Chloride) form the Product Cyhalothrin. in this process n - Hexane is used

as solvent along with phase transfer catalyst.

The reaction mass of Cyhalothrin is washed by Soda Ash solution as well as water.

Solvent n-Hexane is stripped off toget pure Cyhalothrin oil. Finally Cyhalothrin oil is

epimerised to give Lambda Cyhalothrin of 85%.

An aqueous layer which contains traces of Sodium Cyanide is detoxified by the treatment of

Sodium Hypochlorite Solution (8-10%) up to < 0.2 ppm level. Then it is mixed up with main

ETP stream for further treatment & finally drained to gutter.

89

Chemical Reaction:

C = CH - CH - CH - C - Cl

F3C

Cl

H3C CH

3

Cyhalothrin

(MW- 449.9)

+ NaCN

Sodium

Cyanide

(MW- 49.1)

n-Haxene

Catalyst

F3C

Sodium

Chloride

(MW- 58.5)

O

+

O

C

H

O

Meta Phenoxy

Benzaldehyde

(MW- 198)

C = CH - CH - CH - C - O - C

O

CN

HCl

H3C CH

3

Cyhalothrin

(MW- 449.9)

+ NaCl

Epimerization

IPA, Catalyst

C = CH - CH - CH - C - O - C

O

CN

H

F3C

Cl

H3C CH

3

Lambda Cyhaloyhrin

(MW- 449.9)

Lambda Cyhalothrin

O

O

90


INPUT KG OUTPUT KG

MPBAD 470

TP Acid Chloride 640 Aq. Washing to ETP 2029

NaCN 128

Water for Rexn 470 Recovered Hexane 1960

n-Hexane (F) 550 Hexane loss 550

n-Hexane (R) 1950

Catalyst 10 NaCN layer 629

Soda ash Soln. 5% 1000

Water for Washings 1000 Cyhalothrin Oil 1050

IPA loss 105

Cyhalothrin Oil 1050 Recovered IPA 945

IPA-Solvent (F) 105 Recovered Catalyst 98

IPA-Solvent (R) 945 Catalyst Loss 62

Catalyst - 2 160

Lambda

Cyhalothrin Tech. 1050

NaCN layer 629

8-10 % Sodium

Hypochlorite 1500

Detoxified Effluent

(To Incineration) 2129


Lambda Cyhalothrin

Condensation, Washing

&Distillation

Stage

Epimerisation

Stage

Detoxification

Stage

91

(27) Met sulfuron methyl


O-sulfo isocyante Methyl Benzoate reacts with 2-Amino 4-Methoxy 6-Methyl 1,3,5 Triazine

in presence of Solvent-Toluene. Since this reaction is addition reaction, no Bi-Product of

Effluent is generated. On coling crystal form which is filtered out and solvent distilled out

and recycled.

Chemical Reaction:

M etsulfuron Methyl (Tech.)

S - NCO

O=C- O - CH3

O

O

+

O CH3

NH2

H3C

O- su lfo Iso Cyanate M ethyl Benzoate

(M W - 241.4)

N

N

N

2- Am ino 4- M ethoxy 6-M ethyl 1,3,5

Triazine

(M W - 139.97)

Toluene

S - N - C - N

O

O

C H3

NH

O HO C H

3

N

N

O=C- O - CH3

M etasulfuron M ethyl

(M W - 381.37)

92


INPUT KG OUTPUT KG

O-sulfo isocyante

Methyl Benzoate 634

2-Amino 4-methoxy

6-methyl 1,3,5 Triazine 367

Toluene(F) 100

Toluene(R) 700 Org. Mass of

Metsulfuron methy 1801

Org. Mass of Metsulfuron Methyl Tech 1000

Metsulfuron methy 1801

Toluene (F) 100 Residue (Organic) 2

Recovered Toluene 700

Solvent loss 199


Met sulfuron methyl

Preparation of

Metsulfuron Methyl

Stage

Filtration, Washing and

Solvent Recovery

Stage

93

(28) Metalexyl


N-(2, 6 – Dimethyl Phenyl) Alanine – Methyl Ester reacts with Methoxy Acetyl Chloride in

presence of catalyst and solvent to get Metalaxyl solution. This solution is then wasted with

water & solvent is distilled out to get Metalaxyl (Tech).

Finally Toxic Effluent which contains traces of Pesticides is taken to Hydrolysis stage for

detoxification Where Aqueous Mass is treated at high temp. By Alkali for the rapid


Chemical Reaction:

CH3

CH3

N

CH-COOCH3

CH3

H

+ CH3-0CH2COCl CATALYST

TOLUENE +WATER

CH3

N

CH3

CH-COOCH3

CH3

C-CH2OCH3

O

+ HCl

METALXYL

94


INPUT KG OUTPUT KG

N-(2,6- Dimethyl phenyl)

alanine-methyl ester 765 Organic mass 3270

methoxy acetyl chloride 405

Catalyst 15 Aqueous Effluent 80

Toluene 2250

Water for washing 50 30% HCl solution 447

Water for HCl scrubbing 312

Organic mass of 3270 Metalaxyl Tech. 1020

Recovered solvent 2025

Solvent loss 225

Aqueous Effluent 80 Detoxified Aqueous 130

C.S.Lye 48% 50 mass

Total 7197 7197

Stage 1

Preparation

Stage 2 Solvent recovery

Stage 3 Alkali Hydrolysis

(Detoxification)

95

(29) Novaluron


1. Novaluron technical is prepared by reaction of 2,6-difluoro benzoyl isocyanate with 2-

chloro-4-amino phenoxy ether in presence of monochloro benzene as a solvent.

2. After completion of the reaction, the reaction mass is cooled, filtered and washed with

water.

3. Novaluron wet cake is then recrystallised with toluene, filtered and dried to get

Novaluron technical

Chemical Reaction:

96



2,6-difluoro benzoyl isocyanate 995 Organic solution 5150

2-chloro-4-amino phenoxy ether 2460

Monochloro benzene 1695

Organic solution 5150 Crude Novaluron 3450

Mother liquor 1700

Crude Novaluron 3450 Wet Novaluron 3350

Water 3000 Aqueous effluent 3100

Wet Novaluron 3350 Novaluron 3100

Toluene 2500 Recovered toluene 2750

Total 22600 22600

Mass balance of Novaluron

Stage 1

Reaction

Stage 2

Cooled & Filtered

Stage 4

Crystalisation

Stage 3

Water washing

97

(30) Oxyfluorfen


2-Chloro Trichloro p-Tolyl 3-Ethoxy phenyl Ether (TFTEPE) reacts with Nitric Acid in presence

of Catalyst to get the finished product Oxyfluorfen. The slurry formed is cool to room

temperature and filtered out to get wet cake which is wash out and dried on dryer to get

pure Oxyfluorfen Tech. On cooling crystal form which is filtered out and solvent distilled out

and recycled.

Chemical Reaction:


INPUT KG OUTPUT KG

2-Chloro ααα- Trichloro p- 886 Organic mass of 1246

tolyl 3- Ethoxy phenyl Ether Oxyfluorfen

Nitric acid 255

Catalyst 5

H2SO4 100

Organic mass of 1246 Oxyfluorfen 1010

Oxyfluorfen Aqueous spent acid 224

Water 100 Water loss on drying 112

Total 2592 2592

Stage 1

Preparation of

Oxyfluorfen

Stage 2

Filtration &

Solvent

recovery

F3C O

O-CH2CH3

+

CATALYST

F3C

Cl

O

O-CH2CH3

NO2 + H2O

OXYFLUORFEN

Cl

98

(31) Pacloburazol


Stage 1

Charge tert-pentan-3-ol in the reactor and stir for 30 minute and charge 4-Chloro Benzyl

Chloride slowly in the reaction mass for 2-3 hrs and maintain the temperature for 3 hrs and

check the sample for reaction complete. After reaction is complete add KOH flakes slowly.

Maintain the reaction mass for 4 hrs until the reaction is complete.

Stage 2

Charge intermediate, Dimethyl Formamide, 1,2,4-Trizole and K2CO3 in the reactor and


Stage 3


Stage 4

Wash the reaction mass with water. Dry the wet cake of paclobutrazole in drier.

Chemical Reaction:

99



Intermediate 675

tert-pentan-3-ol 275

4-Chloro Benzyl Chloride 500 Organic effluent 600

KOH 500

Intermediate 675 Crude paclobutrazole 2255

DMF 1320

1,2,4 Triazol 210

K2CO3 50

Crude paclobutrazole 2255 Crude paclobutrazole 1090

DMF Recovery 1165

Crude paclobutrazole 1090 Paclobutrazole 725


DMF loss 155

Total 7875 7875

Mass balance of Paclobutrazole

Stage 1

Intermediate

Stage 2 Paclobutrazole

Stage 4

Washing

Stage 3

DMF Recovery

100

(32) Paraquate


Stage 1

Charge 4,4’ bipyridine in the reactor and stir for 30 minute. Charge methyl iodide slowly in

the reaction mass 2-3 hrs at 1050C and maintain the temperature for 3 hrs and check the

sample for reaction complete.

Stage 2

Charge crude paraquate in the reactor and a two-fold excess of barium chloride is added to

promote ion exchange. Wash the reaction mass with water to get pure paraquate technical.

Chemical Reaction:



Crude Paraquate 2530

4,4' bipyridine 850

Methyl iodide 1680

Crude Paraquate 2530 Paraquate 900

Silver Chloride 770 Aqueous effluen 2400

Total 5830 5830

Mass balance of Paraquat

Stage 1 Paraquate

formation

Stage 2

Washing

101

(33) Permethrin


Meta Phenoxy Benzyl Alcohol is reacted with Cypermethric Acid Chloride (CMAC) in

presence of solvent n-Hexane to give the permethrin mass. Hydrochloric acid gas is

generated during the reaction which is scrubbed in water to get 30% solution of

hydrochloric acid.

The resulting mass is then washed by soda ash solution as well as water. Finally solvent is

stripped off to recover it & to get the pure Permethrin Tech.

Chemical Reaction:

C = CH - CH - CH - C - Cl

Cl

Cl

H3C CH3

CMAC

(MW- 227.5)

Solvent-n-Hx

Cl

Hydrochloric

Acid

(MW- 36.5)

O

+

O

HOH2C

MPBAL

(MW- 200.3

C = CH - CH - CH - C - O - CH2

O

CN

HCl

H3C CH

3

Permethrin

(MW- 391.3)

+ HCl

Permathrin (Tech.)

O

102


INPUT KG OUTPUT KG

MPBAL 550

CMAC 642

30% HCl Solution 335

Solvent(F) 300

Solvent(R) 2700

Water for HCl srubbing235

Organic Mass 4092

Solvent loss 300

Organic Mass 4092

Recovered Solvent 2715

5% Soda-ash soln 1000

Permethrin Tech. 1050

Water 500

Aqeous Effluent 1527

Aqeous Effluent 1527

C.S. lye. 48% 50

Detxified Aq. Mass 1577


Condensation&

Washing

Stage I

Epimerisation

Stage

Detoxification

Stage

103

(34) Prallethrin


Stage 1

Cyclo penten 1-hydroxy is reacted with Sodium cyanide to form as an intermediate. This on

reaction with Chrysanthemic acid chloride forms the final product Prallethrin. In this process

n-Hexane is used as solvent along with TEBA.

Stage 2

The reaction mass of Prallethrin is washed by Soda ash solution and water.

Stage 3

n-Hexane is distilled off to get pure prallethrin.

Aqueous layer, which contains traces of Sodium cyanide, is detoxified by the treatment of

Sodium hypochlorite 10% solution to < 0.2 ppm level.

104

Chemical Reaction:

105



Chrysanthemic acidchloride 658 Sodium Cyanide effluent 1112

Cyclo penten 1-Hydroxy 535 (Treatment with Hypo solution)

Sodium cyanide 162 Organic Layer 3728

Water 450

Hexane 2520

TEBA 15

Hypo solution 500

Organic Layer 3728

Soda Ash 15 Aqueous effluent 2626

Acetic acid 3 Crude Prallethrin 3720

Water 2500

Hypo solution 100

Crude Prallethrin 3720 Prallethrin Tech. 1000


Hexane Loss 500

Mother Liquor 200

Total 14906 14906

Mass balance of Prallethrin

Stage 1 Prallethrin

formation

Stage 2Washing

Stage 3Hexane Recovery

106

(35) Pretilachlor


Charge DEPA and Hexane into the reactor with agitation at 300C temperature and charge

chloro acetyle chloride slowly in the reaction mass at 300C. When the reaction is over, cool

the material and neutralize with ammonia gas till pH-8. Wash the material with water. After

washing organic layer, take it to distillation vessel for hexane recovery under vacuum upto

800C. Cool it to 20

0C. Filter the Pretilachlor for packing.

Chemical Reaction:

Stage-I

107

Stage-II

108



DEPA 900 Effluent HCl gas 200

Chloro acetyle chloride 580 Reaction mass 2680

Hexane 1400

Reaction mass 2680 Crude Pretilachlor 2750

Ammonia gas 70

Crude Pretilachlor 2750 Pretilachlor with solvent 2680

Water for washing 2000


Pretilachlor with solvent 2680 Pretilachlor 1280


Hexane Loss 200

Total 13060 13060

Mass balance of Pretilachlor

Stage 1

Pretilachlor formation

Stage 2 Neutralization

Stage 3

Washing

Stage 4

Hexane Recovery

109

(36) Propeconazole


Stage 1

Charge 4-propyl-1, 3-dioxolane and Dimethyl Sulphide in the reactor and stir for 30 minute

and charge 2,4-dichloro Benzyl Chloride slowly in the reaction mass for 2-3 hrs and maintain

the temperature for 3 hrs and check the sample for reaction complete. After reaction is


complete.

Stage 2

Charge intermediate, Dimethyl Formamide, 1,2,4-Trizole, K2CO3 and Iso propanol in the

reactor and maintain the reaction for 3 hrs at high temperature until the reaction is

complete.

Stage 3


Stage 4

Wash the reaction mass with water. Dry the wet cake in drier.

110

Chemical Reaction:

111



2,4-dichloro benzyl chloride 625 Intermediate 800

4-propyl-1, 3-dioxolane 300

Dimethyl sulphide 870 Organic effluent 1495

KOH 500

Intermediate 800 Crude propiconazole 2555

DMF 1320

1,2,4 Triazol 210

K2CO3 50

Iso Propanol 175

Crude propiconazole 2555 Crude propiconazole 1390

DMF Recovery 1260

Crude propiconazole 1390 Propiconazole 740


DMF loss 60

Total 9795 9795

Mass balance of Propiconazole

Stage 1 Intermediate

Stage 2

Propiconazole

Stage 4Washing

Stage 3 DMF Recovery

112

(37) Quizalofop


Stage 1

R- (p hydroxyl phenoxy) propionic acid is reacted with 6-Chloroquinoxaline in solvent

dimethyl formamide in presence of potassium carbonate. After the reaction is completed

the product is filtered.

Stage 2

Wash organic layer with water and crystallized with methanol for purification. Recover

methanol under vacuum partially. Cool the concentrate mass slowly and filter the crystals.

Dry the wet product at 50-550C.

Chemical Reaction:

113


IN PUT Kg OUT PUT KgR-(p hydroxyl phenoxy)

propionic acid 850 Reaction mass 3890

Potassium Carbonate 300

6-Chloroquinoxaline 1540

DMF 1200

Reaction mass 3890 Quizalofop Tech. 2100


Water 1500 Aqueous Layer 2420

Mother liqour 1170

Total 11280 11280

Mass balance of Quizalofop

Stage 1

Quizalofop

formation

Stage 2

Purification by

crystallization

114

(38) Tebuconazole


Step: - 1 Process for the preparation of Dimethyl Sulfide (Solvent)

Dimethyl sulfate is reacted with aqueous solution of Sodium sulfide at 75 - 800C, to form

dimethyl sulfide. The Product is condensed and collected in receiver. Then nitrogen is

purged into the reactor to get maximum possible dimethyl sulfide recovery.

Spent liquor containing sodium sulfate is then transferred to ETP.

(CH3)2SO4 + Na2S +H2O = (CH3)2S + Na2SO4 + H2O

Step: - 2 Process for the preparation of Oxirane

1-(4-Chlorophenyl)-4, 4’-dimethyl-pent-3- one (CPDP) is made to react with dimethyl

sulphate and potassium hydroxide in presence of dimethyl sulfide to give tebuoxirane. The

solvent dimethyl sulfide is recovered by distillation and then the intermediate product

(tebuoxirane) separated from the reactor. Then water is added in the reactor to dissolve salt

formed during the reaction and transferred to ETP.

TEBU OXIRANE SYNTHESIS

CH2Cl CH

2COC(CH

3)3

CH2Cl CH

2-C-C(CH

3)3

CH2

O

+ (CH3)2SO4 + 2 KOH

DMS

1-(4-CHLOROPHENYL)-4,4'-DIMETHYL-PENT-3-ONE (CPDP)

+ K2SO4 + H2O

Oxirane

Step: - 3 CONDENSATION

In dimethyl formamide, potassium carbonate, 1, 2, 4-triazole is added and then above

prepared oxirane is added at reflux temperature. After completion of the reaction the mass

is filtered and then solvent DMF is distilled out. Then the product Tebuconazole is isolated

by adding water. The slurry is filtered, centrifuged and dried.

115

The filtered potassium carbonate sludge is washed with DMF to recover the product.

Treated sludge is then transferred to solid waste.

The mother liquor is transferred to ETP.

CH2Cl CH

2-C-C(CH

3)3

CH2

N

NN

H

K2CO

3

CH2Cl CH

2-C-C(CH

3)3

OH

CH2

N

NN

K2CO

3

O

Oxirane1H-1,2,4-

Triazole

+ +DMF

Tebuconazole

+


INPUT KG OUTPUT KG

Dimethyl Sulfate 502

Sodium sulfide 26

Ketal 755

KOH 323

1,2,4-triazole 255

K2CO3 40

DMF 1420 DMF Recovery 1395.00

Water 7750 losses 185

Steam : 4900

Liquid effluent 13343

KCH3SO4- 499.31

Pot. Sulfate -73.6

Water -12571.35

Solid waste 48.43

Tebuconazole 1000

Total 15971 15971

REACTION

Filtration

Separation

Drying

116

(39) Thiacloprid


2-Chloro, 5-Chloro methyl Pyridine (CCMP) is reacted with Thiazolidinylidene Cyanamide in

present of catalyst and solvent. The Hydrochloric acid, which is formed during the reaction,

is scavenged by putting Sodium carbonate as acid scavenger. The resulting mass is diluted

by water and filtered to remove the salts of Sodium Chloride (NaCl) and sodium

bicarbonate.

The organic mass is then treated with water. Finally solvent is removed by distillation. The

concentrated mass is then crystallized to get pure product – Thiacloprid Technical.

Finally Toxic Effluent, which contains traces of pesticides, is taken to hydrolysis stage for

detoxification. Where aqueous mass is treated at high temperature by Alkali for the rapid


Chemical Reaction:

117


CCMP 900 Organic mass 2366Thiazolidimylidene

Cynamide 750

DMF 2200 Recovered solvent DMF 2050

Catalyst 10 DMF Loss 150

Na2CO3 706

Organic mass 2366

Water 1000 Crude Thiacloprid mass 1470

Aqueous layer 1896

Crude Thiacloprid mass 1470 Thiacloprid Tech. 1050

Methanol 400 Recovered Methalnol 295

Methanol Loss 105

Mother liquor 420


C.S. Lye 50 Water Loss 50

Mix salt 956

Total 11748 11748

Mass balance of Thiacloprid

Stage 1 Condensation & solvent recovery

Stage 2Water wash

Stage 3Crystallization,

Filtration & Drying

Stage 4Salt recovery


118

(40)Thiodicarb


In a glass lined reactor charge Methomyl Tech – Powder and solvent Toluene at room

temperature then add sulphur dichloride to get Thiodicarb Tech. During reaction HCl gas

generates is absorbs in water in scrubbing system this HCl is used for neutralisation or to sell

out.

Chemical Reaction:

Thiocarb (TECH)

+

Sulphur dichloride

(MW- 103)

SCl2

+

Thiodicarb

(MW- 354.5)

2HCl

Hydrochloric Acid

MW- 2 Mole (36.5)

CH3

2 CH3 - C = N - O - C - NH - CH3

Methomyl

MW- 2 Mole (162)= 324

SH3

+ Solvent

CH3 - N - COON = CSCH

3

CH3

CH3 - N - COON = CSCH

3

S

O

119


INPUT KG OUTPUT KG

Thiodicarb Tech. 1042

Methomyl 972

HCl 30% 730

SCl2 315

Water for HCl 511 Toluene loss 115

Toluene(F) 250 Mother Liquor 3111

Toluene(R) 2950

Mother Liquor 3111

Reco. Toluene 2950

Toluene loss 135

Residue Orgainc 26


Thiodicarb Tech.

Preparation

Stage

I

Distilation

Stage

II

120

(41) Thiophenate methyl


Step 1

Ethylene dichloride is taken into a reactor provided with gear – motor agitator and

distillation column – condenser assembly.

Sodium Thiocyanate is added in Ethylene dichloride. Then is reacted with Methyl chloro

formate in the ratio of 1 mol: 1 mol at temp. < 5 0C and Methyl Thiocyanate formate is

formed.

Step 2

In above ethylene dichloride layer, solution of O-Phenylene Diamine prepared in EDC is

added and after addition the reaction mass is heated to reflux for 3.0 hrs and then Reaction

product is filtered off, washed with water and then dried and pulverized and packed as

Thiophanate Methyl Technical.

Filtrate and washes are collected and distilled to recover EDC. Final aqueous layer is then

sent to ETP.

Chemical Reactions:

CH3OCOCl NaSCN CH

3OOCNCS

NH2

NH2 NH

NH

CSNHCOOCH3

CSNHCOOCH3

CH3OOCNCS

+ + NaCl

O-Phynelene

Diamine

+ 2

Thio PhanateMethyl

Methyl - ThiocynateFormate

Methyl ChloroFormate

Sodium

0 - 5 0 C

1. 0 - 5 0 C

2. 80 0 C

121


INPUT KG OUTPUT KG

EDC 2000

Sodium Thio cyanate 526

Methyl chloro formate 600

OPDA 350 EDC Recovery 1920

Water 3100

Liquid effluent 3277.70

Water -2707.26

EDC-80

organic matter- 30.53

NaCl-353

Solid waste 2.00

Solid waste from incinerator 376

Product 1000

Total 6576 6576

REACTION

Filtration

Separation

Packing

122

(42) Thansfluthrin


Stage 1

Tetrafluoro benzyl alcohol is reacted with CMAC to form the product Transfluthrin in

presence of catalyst.

Stage 2

Add Hexane in crude Transfluthrin for separation in water washing. The reaction mass of

Transfluthrin is washed by Sodium carbonate solution and water.

Stage 3

Finally hexane is stripped off to get pure Transfluthrin technical.

Chemical Reaction:

123



CMAC 595 HCl gas 90

Tetrafluoro benzyl alcohol 490 Reaction mass 995

Reaction mass 995

Hexane 1750 Aqueous effluent 3053

Water 3000 Transfluthrin with solvent 2745

Sodium Carbonate 50

Acetic Acid 3

Transfluthrin with solvent 2745 Transfluthrin Tech. 940


Hexane Loss 175

Mother liquor 55

Total 9628 9628

Mass balance of Transfluthrin

Stage 1

Transfluthrin

Stage 2

Washing

Stage 3

Hexane Recovery

124

(43) Tricyclozole


Stage 1

Charge solvent in the reactor and add 3-methyl-(1,2)-benzothiazole Chloride slowly in the

reaction mass for 2-3 hrs and maintain the temperature for 3 hrs. Add KOH flakes slowly.

Maintain the reaction mass for 4 hrs until the reaction is complete.

Stage 2

Charge intermediate Dimethyl Formamide, 1,2,4-Trizole and K2CO3 in the reactor and


Stage 3


Stage 4

Wash the reaction mass with water. Dry the wet cake of tricyclazole in drier.

125

Chemical Reaction:

126



3-mythyl-(1,2)-benzothiazole 550 Intermediate 600

Water 1000

KOH 500 Organic effluent 1450

Intermediate 600 Crude tricyclazole 2180

DMF 1320

1,2,4 Triazol 210

K2CO3 50

Crude triclazole 2180 Crude Tricyclazole 1015

DMF Recovery 1165

Crude Tricyclazole 1015 Tricyclazole 750


DMF loss 155

Total 8925 8925

Mass balance of Tricyclazole

Stage 1 Intermediate

Stage 2

Tricyclazole

Stage 4

Washing

Stage 3

DMF Recovery

127

Intermediate Chemicals:

1.Mono Clhoroacetic acid

Description:

Take 10 MT Acetic Acid in empty 12 .5 KL Reactor. Add 75 to 80 Kg of SMC and 20 Kg of

Acetic Anhydride as catalysts. Start heating through jacket. Increase temp up to 100 C.

Start chlorine gas addition @ 200 Kg per Hr. After charging 13750 kg Chlorine check Sp gr.

It should be 1. 380.

After achieving 1.380 Sp gravity starts air purging in t he kettle. Continue for three Hrs to

remove dissolved gases from the reactor. Separately collect the catalysts during air purging.

Unload the batch in static crystallizer. Start cooling water in the jacket. Reduce temp up to

room temp. Decent mother liquor and remove DCAA from MCAA.

After removing DCAA heat the reaction mass and start flaking of the batch. Get flakes of

MCAA. Crush the material to fee d it to the centrifuge. Give hot water wash to remove DCAA

from MCAA. Pack the material from centrifuge.

128

Crystallize mother liquor after distillation t o get further recovery of MCAA from ML. 50 %

recovery we will get. Filer the ML in neutch filter Make up t he crystals in main product.

Mother liquor will be having 40 to 4 5 % MCAA and rest of DCAA. It will be having 5 to 8 %

water. Sell it as a by product.

129

FLOW DIAGRAM & Mass Balance

130

2. IDA - HCl

Stage 1

Charge DM water, Calcium hydroxide and Ammonia solution in the reaction vessel. Stir

the reaction mass for 1 hour. Charge Mono Chloro acetic acid slowly in the reaction

mass in 4-6 hrs and stir the reaction mass at 4 0GC ±5 until reaction is complete an d

heat the reaction mixture at 70 0 C temperature for acidification with HCI.

Stage 2

After complete the reaction material, coo l it at 10 0 C and filter the IDA-HCI.

Dry the wet product at 80 0 C.

131

3. PMIDA

Stage 1

Charge OM water, IDA-HCI, Phosphorus acid and HCI in the reaction vessel. Stir there

action mass for 1 hour. Charge Formaldehyde solution slowly in the react ion mass in 4

hrs and stir there action mass at 100DC until reaction is complete.

Stage 2

After complete the reaction material, cool it at 30 °C and neutralize with 30% caustic

solution.

Stage 3

After neutralization cool it th e material at ro-c and filter and wash with water. Dry the

wet PMIDA at 100°e.

Mass Balance:

132

4. CMAC

CNB Formation:- carbonatetra chloride is reacted with acrilonitrile in MSGL reactor.

catalyst is used and solvent is acetonitrile.

CBN Purification: - CBN is purified by distillation, forecut is collected separately and pure

CSN is sent down for further processing.

CBA Formation: - Pure CBN is hydrolyzed by dilute Sulfuric acid in MSGL reactor to yield

CSA.

CBC Reaction: - CBA is reacted with Thionyl chloride. Hydrochloric acid gas and S02 gas

are generated during this reaction. These gases are scrubbed through a sequential

scrubbing system.

CBC Purification: - Crude CBC and purified by vacuum distillation in MSGL reactor.

Vacuum device used is rejector.

2CB Reaction: - Pure CBC and Isobutylene are reacted in presence of Tri ethyl amine HCI

in solvent Hexane Tri ethyl amine. HCI dissolved in water in the process is sent for Tri

ethyl amine recovery.

2CB Purification and Crystallization:- 2CB reaction mass is transferred to crystallizer.

Excess solvent is recovered and reaction mass is chilled below 50 and then centrifuged.

4CB Reaction:-The 2CB crystals are charged in MSGL reactor and isomerized using Tri

ethyl amine.

Favorski reaction:-The above mass is heated with caustic solution to get sodium salt of

CMA.

Dehydrohalogenation:-The above mass is heated with caustic solution to get sodium

salt of CMA.

Isolation: - This mass is acidified with sulfuric acid to get Cypermethric Acid (CMA) with

Hexane as solvent.

CMA Concentration: - from the above mass excess Hexane is distilled out and CMA

slurry is transfer red for CMAC reaction.

CMAC Reaction: - CMA is reacted with Thionyl chloride. S02 and HCI gas are generated

in this process. These gases are scrubbed through a sequential scrubbing system.

CMAC Purification: - Crude CMAC is distilled out by vacuum distillation in MSGL purified

CMAC is packed in lined drums as per requirement.

133

Flow Diagram & Mass Balance :

134

5. MPBD


A. Chloro Bromination

Bromination of Benzaldehyde is carried out in a glass- lined reactor in presence of

Aluminum Chloride and in solvent EDC.

The organic layer of this reaction mixture is drowned in water and given a water wash.

The solvent is distilled out to given pure intermediate metaBromoBenazaldehyde (MBB).

B. MBB Condensation _

This intermediate reacts with Phenol is SS reactor in presence of Potassium hydroxide

and a catalyst to give crude Metaphenoxyenzaldehyde (MPBD). This mass is fraction

distilled under vacuum to yield the pure product, and subsequently packed indrums.

135


136

6. CCMP


Stage 1

6- Chloronicotinic acid is converted to 6- Chloronicotinoyl chloride by treatment with

phosphorus pentachloride and phosphorus oxychloride.

Stage 2

6-Chloronicotinoyl chloride is then reduced to the corresponding alcohol using sodium

borohydride.

Stage 3

2-Chloro-5-hydroxy methyl pyridine is converted to 2-Chloro -5Chloro methyl pyridine

(CCMP) by using thionyl chloride.

Mass Balance:

137

7. Chloro-3- Pyridyl-n-Methyl Amine (CPM MA)

Stage 1

Charge Mono Methyl Amine 25% solution and Methanol in reactor. Stir the reaction

mass for 1 hour. Charge 2-Chloro -5-Chloro Methyl Pyridine (CCMP) slowly over a period

of 1 hour. Stir mass after CCMP solution addition for 30 minute with cooling a reaction

mass to 30 °C.

Remove a sample for CCMP content.

After completion of reaction, start addition of NaOH flakes into reaction mass slowly

over a period of 1 hour and stir mass for 30 minutes.

Start distillation of MMA from the mass. Distill out MMA by heating the reaction mass

slowly to reflux temperature with scrubbing MMA gas into fresh methanol.

This recovered MMA gas can recycle in next batch.

8. Triazoles

Manufacturing Process

Stage 1

Charge Formic acid in t he reaction mixture. Purse Ammonia gas slowly in the reaction

mass in 3-4 hrs and stir the reaction mass at 30°C temperature until reaction is

complete.

Stage 2

Charge Formamide in the reactor and react with Hydrazine hydrate at high temperature

for 2-3 hrs until the reaction is complete.

Stage 3

Cool the concentrate mass slowly and filter the 1,2,4 -Triazol. Dry t he wet product at

50 -60°C.

138

Mass Balance:

139

ANNEXURE-IV

DESCRIPTION OF ETP WITH FLOW DIAGRAM

142

ANNEXURE-V

DETAILS OF HAZARDOUS WASTE

CAT.

NO.

HAZARDOUS

WASTE

Quantity (MT/Year) METHOD OF DISPOSAL

EXISTING PROPOSED TOTAL

35.3 ETP Waste 150 - 150 Collection, storage,

Transportation, disposal

to common TSDF site.

29.1 Process waste 1200 - 1200 Collection, storage,

disposal by own

incineration or approved

common incinerator

facility.

35.3 Evaporation Salt 300 - 300 Collection, storage,


to common TSDF site.

5.1 Used spent oil 1.0 - 1.0 Collection, storage,


by selling to register

recyclers or use for

lubrication of machine.

33.1 Drum & Container.

Bags & Liners.

25000

NOS/Annum

- 25000

Nos./An

num

Collection, storage,

Decontamination and sold

to approved vendors.

29.3 Date Expired and

29.3 Off-

Specification

Pesticides

0.1 - 0.1 Collection, storage,

disposal by own

incineration or approved

common incinerator

facility.

143

ANNEXURE-VI

WATER, FUEL & ENERGY REQUIREMENTS

WATER CONSUMPTION (NO CHANGE):

SR.

No.

DESCRIPTION WATER CONSUMPTION (KL/DAY)


INDUSTRIAL

1. Process & Lab 40 -- 40

2. Boiler 70 -- 70

3. Cooling 86

(55 fresh+

31 MEE

Condensate)

-- 86

(55 fresh+

31 MEE

Condensate)

4. Washing 70 -- 70

TOTAL 235 -- 235

5. Domestic 25 -- 25

6. Other (Gardening) 20 -- 20

GRAND TOTAL 280 -- 280

WASTEWATER GENERATION (NO CHANGE):

SR.

No.

DESCRIPTION WATER CONSUMPTION (KL/DAY)


INDUSTRIAL

1. Process 30 -- 30

2. Boiler 27 -- 27

3. Cooling

4. Washing 70 70

TOTAL 127 -- 127

5. Domestic 20 -- 20

6. Other (Gardening) -- -- --

GRAND TOTAL 147 -- 147

Note:

EXISITING:

1) 30 KL/day of concentrated stream of industrial effluent from manufacturing

process containing organic and pesticides residue is sent along with 2 KL/day of

highly concentrated stream of MEE for in-house incinerator.

2) Domestic wastewater is send to ETP for primary, secondary and tertiary

treatment, after treatment the treated wastewater send for disposal in to Dahej-

vilayat pipeline.

3) 35 KL/day of concentrated/high salt stream containing heavy inorganic & organic

load stream of industrial effluent from process (washing) is sent to MEE And

condensate (31 KL/day) from MEE is reused back in Cooling tower.

4) 82 KL/day (27 KL/day from Boiler + Cooling, 35 KL/day from washing and 20

Kl/day from domestic) of biodegradable industrial wastewater is sent to ETP for

primary, secondary and tertiary treatment and after treatment the treated

wastewater is sent for disposal in to Dahej-vilayat pipeline.

144

PROPOSED:

1) 30 KL/day of concentrated stream of industrial effluent from manufacturing

process containing organic and pesticides residue shall be sent along with 2

KL/day of highly concentrated stream of MEE for in-house incinerator.

2) Domestic wastewater shall be send to ETP for primary, secondary and tertiary

treatment, after treatment the treated wastewater send for disposal in to

Dahej-vilayat pipeline.

3) 35 KL/day of concentrated/high salt stream containing heavy inorganic &

organic load stream of industrial effluent from process (washing) shall be sent

to MEE-1(Existing MEE Capacity of 48 KL/day) or MEE-2 (Additional

MEE Capacity of 250 KL/day). And condensate (31 KL/day) from MEE is

reused back in cooling tower.

4) 82 KL/day (27 KL/day from Boiler + Cooling, 35 KL/day from washing and 20

Kl/day from domestic) of biodegradable industrial wastewater shall be sent to

ETP for primary, secondary and tertiary treatment and after treatment the

treated wastewater is sent for disposal in to Dahej- vilayat pipeline.

145

WATER BALANCE DIAGRAM (Unit – KL/day)(EXISTING):

31

2.0 35

35

Fresh Water = 280 KL/Day

Domestic = 25 Gardening = 20 Industrial = 235

Domestic= 20

Process = 40 Washing = 70 Boiler = 70

Cooling = 86 (55

FRESH+ 31 MEE

CONDENSATE)

Process = 30 Washing = 70

Boiler+ Cooling = 27

ETP

Disposal in to Dahej-

vilayat pipeline

MEE Incinerator

30+2=32

146

WATER BALANCE DIAGRAM (Unit – KL/day)(PROPOSED):

Fresh Water = 280 KL/Day

Domestic = 25 Gardening = 20 Industrial = 235

Domestic= 20

Process = 40 Washing = 70 Boiler = 70

Cooling = 86 (55

FRESH+ 31 MEE

CONDENSATE)

Process = 30 Washing = 70

Boiler+ Cooling = 27

ETP

Disposal in to Dahej-

vilayat pipeline

MEE-1/MEE-2

Incinerator

30+2=32

147

FUEL CONSUMPTION:

SR.

NO.

NAME OF FUEL QUANTITY

EXISTING ADDITIONAL TOTAL

1. Natural gas -- 200 m3 /day 200 m3

/day

2. FO 10 MT/day -- 10 MT/day

3. Coal/

Rice Husk

50.4 MT/day/

74.4 MT/day

-- 50.4 MT/day/

74.4 MT/day

4. HSD 450 lit/day -- 450 lit/day

148

ANNEXURE-VII

DETAILS OF STACKS & VENTS

SOURCE OF EMMISION AND AIR POLLUTION CONTROL MEASURES (APCM):

FLUE GAS EMISSION AND APCM:

Sr.

No.

Stack

Attached to

Height

meter

APCM Parameter Permissible Limit

Existing

1.

Boiler-1

(Capacity 8 TPH)

40* Alkali Scrubber* PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

2. Boiler-2

(Capacity = 8 TPH)

40 Alkali Scrubber PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

3. Boiler (Coal fired)

(14 TPH)

30 ESP followed

by water

scrubber

PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

4. Incinerator

30 Ventury

Scrubber

Followed by

Alkali scrubber

PM

HCl

SOX

CO

TOC

Total Dioxins and

furans

Sb+As+Pb+Cr+CO

+Cu+Mn+Ni+V

and their

compounds

50 mg/Nm3

50 mg/Nm3

200 mg/Nm3

100 mg/Nm3

20 mg/Nm3

0.1 ng TEQ/ Nm3

1.5 mg/Nm3

5. D G Set

(500 KVA)

10 -- PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

6. D G Set

(500 KVA)

10 -- PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

7. D G Set

(1500 KVA)

30 -- PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

Proposed

Thermopack

(Capacity 600000

Kcal/Hr.)

40* Alkali Scrubber* PM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

* Common Stack and APCM between existing Boiler (8 TPH) and Proposed Thermopack

149

PROCESS GAS EMISSION AND APCM

Sr.

No.

Stack

Attached to

Stack Height

(meter)

Air Pollution Control

Measure

Parameter Permissible Limit

EXISTING

1.

Reaction/Process

vessels (4 sets)

15 Four stage HCL+

SO2

Scrubber

SO2

HCl

40 mg/Nm3

20 mg/Nm3

2. Reaction/Process

vessels (2 sets)

15 Ammonia

Scrubber

NH3 175 mg/Nm3

3. Reaction/Process

vessels (4 sets)

15 Water Scrubber

+caustic Scrubber

Cl2

HCl

09 mg/Nm3

20 mg/Nm3

PROPOSED

4. Spin flash Dryer-1 11 Cyclone PM 150 mg/Nm3

5. Spin flash Dryer-2 11 Cyclone PM 150 mg/Nm3

150

ANNEXURE-VIII

_______________________________________________________________________

NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES

Various sources of noise in industry have been identified as under,

• Pumps

• Boiler

• Reaction vessel

The typical noise levels of equipments, as indicated by the equipment manufacturers are

given below:

Sr. No. Name of Machinery / Units Noise level, dB(A)

1 Pumps 60 – 65

2 Boiler 65 – 75

3 Reaction Vessel 55 – 60

NOISE LEVELS:

SR.

NO.

SOURCE OF NOISE PERMISSIBLE LIMIT

(DAY/NIGHT)

dB(A)

NOISE LEVEL dB(A)

1. Near Security Gate 75/70 61

2. Near Administration Building 75/70 62

3. Near Boiler & Utility Block 75/70 66

4. Near ETP 75/70 65

5. Near Process Plant 75/70 67

6. Near Canteen 75/70 50

• DG set with acoustic enclosure, housed in a separate room, erected on anti vibrating

pad.

• Ear muffs & ear plugs are provided to operators.

• Regular preventive maintenance of equipments is carried out.

151

ANNEXURE-IX

_______________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

During construction phase, skilled and unskilled manpower will be needed. This will

temporarily increase the employment opportunity. Secondary jobs are also bound to be

generated to provide day-to-day needs and services to the work force. This will also

temporarily increase the demand for essential daily utilities in the local market. The

manpower requirement for the proposed diversification is expected to generate some

permanent jobs and secondary jobs for the operation and maintenance of plant. This will

increase direct / indirect employment opportunities and ancillary business development to

some extent for the local population. This phase is expected to create a beneficial impact on

the local socio-economic environment.

2) INDUSTRIES

During construction of the project, the required raw materials and skilled and unskilled

laborers will be utilized maximum from the local area. The increasing industrial activity will

boost the commercial and economic status of the locality, to some extent.

3) PUBLIC HEALTH

During construction period, workers will be provided with basic amenities like safe water

supply, low cost sanitation facilities, first aid, required personal protective equipment, etc.

Otherwise, there could be an increase in diseases related to personal hygiene. Emission, if

uncontrolled from process and utility stacks may cause discomfort, burning of eyes to the

recipients in the down wind direction. This may be caused due to the failure of control

equipment / process. The company regularly examines, inspects and tests its emission from

sources to make sure that the emission is below the permissible limit. Hence, there will not

be any significant change in the status of sanitation and the community health of the area,

as sufficient measures will be taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the existing factory is having proper linkage for the transport and communication, the

development of this project will not cause any additional impact. In brief, as a result of the

project there will be no adverse impact on communication, as sufficient measures will be

proposed to be taken under the EMP. The proposed project is not expected to make any

significant change in the existing status of the socio - economic environment of this region.

152

ANNEXURE-X

_______________________________________________________________________

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

1. Executive Summary

2. Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3. Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether

adequate land is available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of

transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their

management.

vii. Requirement of water, power, with source of supply, status of approval, water

balance diagram, man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow

sheet (quantities) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

a. Copy of all the Environmental Clearance(s) including Amendments thereto

obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A

certified copy of the latest Monitoring Report of the Regional Office of the

Ministry of Environment and Forests as per circular dated 30th May, 2012 on the

status of compliance of conditions stipulated in all the existing environmental

clearances including Amendments shall be provided. In addition, status of

compliance of Consent to Operate for the ongoing I existing operation of the

project from SPCB shall be attached with the EIA-EMP report.

b. In case the existing project has not obtained environmental clearance, reasons

for not taking EC under the provisions of the EIA Notification 1994 and/or EIA

Notification 2006 shall be provided. Copies of Consent to Establish/No Objection

Certificate and Consent to Operate (in case of units operating prior to EIA

Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be

submitted. Further, compliance report to the conditions of consents from the

SPCB shall be submitted.

4. Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State,

Justification for selecting the site, whether other sites were considered.

153

ii. A toposheet of the study area of radius of 10km and site location on

1:50,000/1:25,000 scale on an A3/A2 sheet. (Including all eco-sensitive areas and

environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area,

plant area, greenbelt area, utilities etc. If located within an Industrial

area/Estate/Complex, layout of Industrial Area indicating location of unit within the

Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show

photographs of plantation/greenbelt, in particular.

viii. Landuse break-up of total land of the project site (identified and acquired),

government/private - agricultural, forest, wasteland, water bodies, settlements, etc

shall be included. (Not required for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall

be incorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1

km radius of any major river, peak and lean season river discharge as well as flood

occurrence frequency based on peak rainfall data of the past 30 years. Details of

Flood Level of the project site and maximum Flood Level of the river shall also be

provided. (Mega green field projects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition

process and expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy

5. Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, and

recommendations of the State Forest Department. (if applicable)

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site

delineating the forestland (in case of projects involving forest land more than 40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along

with latest status shall be submitted.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit

the map duly authenticated by Chief Wildlife Warden showing these features vis-à-

vis the project location and the recommendations or comments of the Chief Wildlife

Warden there on

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the

State Government for conservation of Schedule I fauna, if any exists in the study area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act,

1972, to the Standing Committee of the National Board for Wildlife

6. Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific

micrometeorological data using temperature, relative humidity, hourly wind speed

and direction and rainfall.

154

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other

parameters relevant to the project shall be collected. The monitoring stations shall

be based CPCB guidelines and take into account the pre-dominant wind direction,

population zone and sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given

in the NAQQM Notification of Nov. 2009 along with – min., max., average and 98%

values for each of the AAQ parameters from data of all AAQ stations should be

provided as an annexure to the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge

point) and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the

CPCB/MoEF&CC, if yes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of

materials, additional traffic due to proposed project, parking arrangement etc.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study

area shall be given with special reference to rare, endemic and endangered species.

If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall

be prepared and furnished.

xi. Socio-economic status of the study area.

7. Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission

based on site-specific meteorological features. In case the project is located on a hilly

terrain, the AQIP Modelling shall be done using inputs of the specific terrain

characteristics for determining the potential impacts of the project on the AAQ.

Cumulative impact of all sources of emissions (including transportation) on the AAQ

of the area shall be assessed. Details of the model used and the input data used for

modelling shall also be provided. The air quality contours shall be plotted on a

location map showing the location of project site, habitation nearby, sensitive

receptors, if any.

ii. Water Quality Modelling – in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding

environment shall be assessed and provided. In this regard, options for transport of

raw materials and finished products and wastes (large quantities) by rail or rail-cum

road transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled

and reused for different purposes shall be included. Complete scheme of effluent

treatment. Characteristics of untreated and treated effluent to meet the prescribed

standards of discharge under E (P) Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and

management. Copies of MOU regarding utilization of solid and hazardous waste in

cement plant shall also be included. EMP shall include the concept of waste-

155

minimization, recycle/reuse/recover techniques, Energy conservation, and natural

resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A

detailed plan of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less

than 1,500 trees per ha. Giving details of species, width of plantation, planning

schedule etc. shall be included. The green belt shall be around the project boundary

and a scheme for greening of the roads used for the project shall also be

incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to

harvest rainwater from the roof tops and storm water drains to recharge the ground

water and also to use for the various activities at the project site to conserve fresh

water and reduce the water requirement from other sources.

xi. Total capital cost and recurring cost/annum for environmental pollution control

measures shall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency

Management Plan including Risk Assessment and damage control. Disaster

management plan should be linked with District Disaster Management Plan.

8. Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract

and casual workers

ii. Details of exposure specific health status evaluation of worker. If the workers’ health

is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry,

Vision testing (Far & Near vision, Colour vision and any other ocular defect) ECG,

during pre placement and periodical examinations give the details of the same.

Details regarding last month analyzed data of above mentioned parameters as per

age, sex, duration of exposure and department wise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of

hazards and whether they are within Permissible Exposure level (PEL)? If these are

not within PEL, what measures the company has adopted to keep them within PEL so

that health of the workers can be preserved

iv. Annual report of health status of workers with special reference to Occupational

Health and Safety.

9. Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its Board

of Directors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process / procedures

to bring into focus any infringement / deviation / violation of the environmental or

forest norms / conditions? If so, it may be detailed in the EIA.

iii. What is the hierarchical system or Administrative order of the company to deal with

the environmental issues and for ensuring compliance with the environmental

clearance conditions? Details of this system may be given.

iv. Does the company have system of reporting of non compliances / violations of

environmental norms to the Board of Directors of the company and / or

156

shareholders or stakeholders at large? This reporting mechanism shall be detailed in

the EIA report

10. Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be

provided to the labour force during construction as well as to the casual workers including

truck drivers during operation phase.

11. Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the

Enterprise Social Commitment and item-wise details along with time bound action

plan shall be included. Socio-economic development activities need to be elaborated

upon.

12. Any litigation pending against the project and/or any direction/order passed by any

Court of Law against the project, if so, details thereof shall also be included. Has the unit

received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant

Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s)

and present status of the case.

13. ‘A tabular chart with index for point wise compliance of above TORs.

14. The TORs prescribed shall be valid for a period of three years for submission of the EIA-

EMP reports.

The following general points shall be noted:

i. All documents shall be properly indexed, page numbered.

ii. Period/date of data collection shall be clearly indicated.

iii. Authenticated English translation of all material in Regional languages shall be

provided.

iv. The letter/application for environmental clearance shall quote the MOEF file No. and

also attach a copy of the letter.

v. The copy of the letter received from the Ministry shall be also attached as an

annexure to the final EIA-EMP Report.

vi. The index of the final EIA-EMP report must indicate the specific chapter and page no.

of the EIAEMP Report

vii. While preparing the EIA report, the instructions for the proponents and instructions

for the consultants issued by MOEF vide O.M. No. J-11013/41/2006-IA.II (I) dated 4th

August, 2009, which are available on the website of this Ministry shall also be

followed.

viii. The consultants involved in the preparation of EIA-EMP report after accreditation

with Quality Council of India (QCl) /National Accreditation Board of Education and

Training (NABET) would need to include a certificate in this regard in the EIA-EMP

reports prepared by them and data provided by other organization/Laboratories

including their status of approvals etc. Name of the Consultant and the Accreditation

details shall be posted on the EIA-EMP Report as well as on the cover of the Hard

Copy of the Presentation material for EC presentation.

TORs’ prescribed by the Expert Appraisal Committee (Industry) shall be considered for

preparation of EIA-EMP report for the project in addition to all the relevant information as

per the ‘Generic Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006.

Where the documents provided are in a language other than English, an English translation

shall be provided. Public hearing is exempted under the provisions as per para 7(i) Stage III

3(i)(b) of the EIA Notification,2006. The EIA report shall be submitted to the Ministry for

obtaining environmental clearance.

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