proposed bulk drugs & bulk drug...
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1
FORM-1
for
PROPOSED BULK DRUGS & BULK DRUG
INTERMEDIATES IN EXISTING INORGANIC
PRODUCTS UNIT
of
M/s. SHREE RAMDEV PHARMA CHEM
PLOT NO. 2314-2315, PHASE – III, GIDC PANOLI,
DIST: BHARUCH (GUJ.)
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:
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
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:
2
APPENDIX I
(See paragraph - 6)
FORM 1
Sr.
No.
Item Details
1. Name of the project/s M/s. Shree Ramdev Pharma Chem
2. S. No. in the schedule 5(f)
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. Proposed Capacity: 75 MT/Month
6. Category of Project i.e. ‘A’ or ‘B’ A
7. Does it attract the general condition? If yes,
please specify.
Yes. Located within 5 km of critically
polluted area (Ankleshwar).
8. Does it attract the specific condition? If yes,
please specify.
No
Location
Plot/Survey/Khasra No. Plot No. 2314-2315
Village GIDC Panoli
Tehsil Ankleshwar – 394 116
District Bharuch
9.
State Gujarat
10. Nearest railway station/airport along with
distance in kms.
Railway Station: Ankleshwar (5 km)
Airport: Surat (60 km)
11. Nearest Town, city, District Headquarters
along with distance in kms.
Panoli Village (2 km),
Bharuch (15 km)
12. Village Panchayats, Zilla Parishad, Municipal
Corporation, local body (complete postal
address with telephone nos. to be given)
Panoli Village, Taluka: Ankleshwar – 394 116,
Dist: Bharuch (Gujarat)
13. Name of the applicant M/s. Shree Ramdev Pharma Chem
14. Registered Address Plot No. 2314-2315, GIDC Panoli, Tal:
Ankleshwar – 394 116, Dist: Bharuch (Guj)
Address for correspondence:
Name Mr. Pragnesh R. Patel
Designation (Owner/Partner/CEO) Partner
Address M/s. Shree Ramdev Pharma Chem
Plot No. 2314-2315, GIDC Panoli,
Ta. Ankleshwar – 394 116,
Dist: Bharuch (Guj)
15.
Pin Code 394 116
3
E-mail [email protected],
Telephone No. Phone : 02646 –650947, 272756
Mob. : +919227607734 & +919824407734
Fax No. NA
16. Details of Alternative Sites examined, if any.
Location of these sites should be shown on
a top of sheet.
NA
17. Interlinked Projects NA
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?
No
22. Whether there is any Government
Order/Policy relevant/relating to the site?
No
23. Forest land involved (hectares) NA
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.
NA
• 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 there of 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 expansion is within the existing
premises of GIDC Panoli. Expected cost of the
expansion project is Rs. 325 Lakhs.
Total Plot Area = 3,766 m2
Green Belt = 400 m2
1.2 Clearance of existing land, vegetation
and Buildings?
No Proposed expansion is within the existing
premises of GIDC Panoli.
1.3 Creation of new land uses? No
1.4 Pre-construction investigations e.g.
bore Houses, soil testing?
No
1.5 Construction works? Yes Plant Layout attached as Annexure - II
1.6 Demolition works? No
1.7 Temporary sites used for construction
works or housing of construction
workers?
No
1.8 Above ground buildings, structures or
earthworks including linear structures,
cut and fill or excavations
No Plant Layout attached as Annexure - II
1.9 Underground works mining or
tunneling?
No
1.10 Reclamation works? No
1.11 Dredging? No
1.12 Off shore structures? No
1.13 Production and manufacturing
processes?
Yes For detail Please refer 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
1.17 New road, rail or sea traffic during
Construction or operation?
No
1.18 New road, rail, air waterborne or other
transport infrastructure including new
or altered routes and stations, ports,
airports etc?
No
1.19 Closure or diversion of existing
transport routes or infrastructure
No
5
leading to changes in Traffic
movements?
1.20 New or diverted transmission lines or
Pipelines?
No
1.21 Impoundment, damming, culverting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water form
ground or surface waters?
No No ground water shall be used. The raw water
shall be supplied by GIDC Authority.
1.24 Changes in water bodies or the land
surface Affecting drainage or run-off?
No
1.25 Transport of personnel or materials for
construction, operation or
decommissioning?
Yes Transportation of personnel, raw material and
products will be primarily by road only
1.26 Long-term dismantling or
decommissioning or restoration works?
No
1.27 Ongoing activity during
decommissioning which could have an
impact on the environment?
No
1.28 Influx of people to an area either
temporarily or permanently?
No This is a well developed GIDC Estate and due to
the expansion of this project, M/s. Shree
Ramdev Pharma Chem will give direct
employment to local people based on
qualification and requirement. In addition to
direct employment, indirect employment shall
generate ancillary business to some extent for
the local population.
1.29 Introduction of alien species? No
1.30 Loss of native species or genetic
diversity?
No
1.31 Any other actions? No
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 source of
information data
2.1 Land especially undeveloped or
agricultural land (ha)
No GIDC land of 3,766 m2.
2.2 Water (expected source & competing
users) unit: KLD
Yes The entire water requirement will be met
through GIDC. Water available from GIDC. For
detail please refer Annexure – VI
2.3 Minerals (MT) No
6
2.4 Construction material: stone, aggregates,
and / soil (expected source – MT)
Yes Construction materials like crushed stones, sand,
rubble, cement, steel, etc. required for the
project shall be procured from the local market of
the region.
2.5 Forests and timber (source – MT) No
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
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 source of information data
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 For detail please refer Annexure –VII.
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
No
3.4 Vulnerable groups of people who could
be affected by the project e.g. hospital
patients, children, the elderly etc.
No
3.5 Any other causes No
(II) Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
4.1 Spoil, overburden or mine wastes No
4.2 Municipal waste (domestic and or
commercial wastes)
No
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Please refer Annexure – V
4.4 Other industrial process wastes No
4.5 Surplus product No
4.6 Sewage sludge or other sludge from
effluent treatment
Yes
Please refer Annexure – V
7
4.7 Construction or demolition wastes No
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes Yes
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 quantities/rates,
wherever possible) with source of information data
5.1 Emissions from combustion of
fossil fuels from stationary or
mobile sources
Yes For details Please refer Annexure – VIII
5.2 Emissions from production
processes
Yes For details Please refer Annexure – VIII
5.3 Emissions from materials handling
storage or transport
Yes All liquid raw materials shall be procured
in tankers and shall be transferred through a closed
circuit pipe lines.
Solid raw materials shall be charged through close
pipeline into reactors and the dust collection hopper
shall be connected to a bag filter and ID fan.
Also all hazardous chemicals storage tanks will be
provided with flame arrestors & breather valves for
safety.
5.4 Emissions from construction
activities including plant and
equipment
Yes 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
Yes Solvent vapors shall be cooled in appropriate
condensers and shall be passed through trap vessel
fitted with condensers. All the waste shall be stored in
designated place and shall be transported to TSDF site
in approved closed vehicles owned by the TSDF
authority.
Dust from drying will be collected in to dust collector
through cyclone separator & recovered powder will be
recycled back to process. Air Handling Unit will be
provided where ever applicable.
5.6 Emissions from incineration of No 5.7 Emissions from burning of waste
in open air e.g. slash materials,
construction debris)
No
5.8 Emissions from any other sources No
8
(III) Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data with source of
information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes All machinery / equipment shall be well
maintained, shall be proper foundation with
anti vibrating pads wherever applicable and at
noise levels within permissible limits. DG set
shall have acoustic enclosure. Expected Noise
level at different locations in the plant is
enclosed as Annexure – IX
6.2 From industrial or similar processes Yes Please refer Annexure – IX
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational traffic No
6.6 From lighting or cooling systems Yes Please refer Annexure – IX
6.7 From any other sources No
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.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
7.1 From handling, storage, use or spillage
of hazardous materials
Yes Hazardous material shall be stored in designated
storage area with bund walls for tanks. Other
material will be stored in bags/drums on pallets
with concrete flooring and no spillage is likely to
occur. All liquid raw materials shall be
transported through pumps and closed pipelines
and no manual handling shall be involved. Spill
Container will be kept at appropriate places to
collect spillage. SOP for collection,
decontamination & disposal of spilled material
will be displaced at necessary locations. For
details please refer Annexure – VII
7.2 From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
Yes The neutralized low COD effluent after primary
treatment will be sent to the CETP of M/s PETL,
Panoli for the further treatment and final
disposal. The neutralize high COD effluent after
primary treatment will be sent to the Common
Spray Dryer of M/s PETL, Panoli for the further
9
treatment and final disposal.
7.3 By deposition of pollutants emitted to
air into the and or into water
No
7.4 From any other sources No
7.5 Is there a risk of long term build up of
pollutants in the environment from
these sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect
human health or the environment
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with source
of information data
8.1 From explosions, spillages, fires etc
from storage, handling, use or
production of hazardous substances
Yes For detail please refer Annexure – VII
8.2 From any other causes No
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No
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
quantities/rates, wherever possible)
with source of information data
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
Yes For detail please refer Annexure – X
9.2 Lead to after-use of the site, which could have an
impact on the environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to proximity to other
existing or planned projects with similar effects
No
10
(IV) Environmental Sensitivity
Sr.
No.
Areas Name/
Identity
Aerial distance (within 15km.) 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 Expansion project site is within the
GIDC Estate of Panoli
2 Areas which important for are or
sensitive Ecol logical reasons –
Wetlands, watercourses or other water
bodies, coastal zone, biospheres,
mountains, forests
No
3 Area used by protected, important or
sensitive Species of flora or fauna for
breeding, nesting, foraging, resting,
over wintering, migration
No
4 Inland, coastal, marine or underground
waters
No No inland, costal or marine within 5 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
7 Defense installations No
8 Densely populated or built-up area Ankleshwa
r
5 km
9 Area occupied by sensitive man-made
land uses Hospitals, schools, places of
worship, community facilities)
No
10 Areas containing important, high quality
or scarce resources (ground water
resources, surface resources, forestry,
agriculture, fisheries, tourism, minerals)
No
11 Areas already subjected to pollution
environmental damage. (those where
existing legal environmental standards
No
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
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – XI
11
12
LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE
I List of Products with their Production Capacity
II Layout Map of the Plant
III Brief Manufacturing Process Description
IV Description of Effluent Treatment Plant with flow diagram
V Details of Hazardous Waste
VI Water, Fuel & Energy Requirements
VII Details of Hazardous Chemicals Storage & Handling
VIII Details of Stacks and Vents
IX Expected Noise level at Different source within the premises
X Socio-economic Impacts
XI Proposed Terms of Reference for EIA studies
XII GIDC Letter for Water Consumption
XIII NCTL Membership Letter for Wastewater Disposal
13
ANNEXURE-I
LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY
Production Capacity (MT/Month) Sr.
No.
Name of Product
Existing Total After Proposed
Expansion
Inorganic Products (Existing)
1 Potassium Sulphate
2 Potassium Chloride
3 Potassium Bromide
4 Potassium Nitrate
5 Zinc Chloride
6 Zinc Sulphate
7 Copper Sulphate
8 Magnesium Sulphate
9 Sodium Nitrate
10 Sodium Bromide
11 Sodium Hypo Bromite
12 Di Calcium Phosphate
500
500
Additional Proposed
13 Diphenyl Acetonitrile -
14 Diphenyl Acetic Acid -
15 2-(Diphenylmethoxy)-N,N-
Dimethylethanamine Hydrobromide
-
16 Diphenyl Methane -
17 P-Chloro Benzophenone -
18 P-Chlorobenzhydryl Chloride -
19 p-Chlorobenzhydryl Piperazine -
20 2-[4-(4-Chlorobenzhydryl)-1-
Piperazinyl] Ethanol
-
21 1-(3-Chloropropyl)-2-
Benzimidazolidinone
-
22 5-Chloro-1-(4-Piperidinyl)-2-
Benzimidazolidinone
-
23 Nosyl Chloride -
75
Total - 75
Grand Total 500 575
14
LIST OF RAW MATERIAL (EXISTING)
SR.
NO.
PRODUCT WISE RAW MATERIALS QUANTITY
(MT/MT)
1. Potassium Sulphate
Potassium Hydroxide (85%) 0.72
Sulfuric Acid 0.56
2. Potassium Chloride
Potassium Hydroxide (85%) 0.85
Hydrochloric Acid (30%) 1.66
3. Potassium Bromide
Potassium Hydroxide (85%) 0.60
Hydrobromic Acid (30%) 2.40
4. Potassium Nitrate
Potassium Carbonate 0.70
Nitric Acid (45%) 1.40
5. Zinc Sulphate
Zinc Metal 0.23
Sulfuric Acid 0.35
6. Zinc Chloride
Zinc Metal 0.48
Hydrochloric Acid (30%) 1.80
7. Copper Sulphate
Copper Oxide 0.50
Sulfuric Acid 0.61
8. Magnesium Sulphate
Magnesium Oxide 0.34
Sulfuric Acid 0.83
9. Sodium Nitrate
Sodium Hydroxide 0.48
Nitric Acid (45%) 1.69
10. Sodium Bromide
Sodium Hydroxide 0.40
Hydrobromic Acid (30%) 2.70
11. Sodium Hypo Bromite
Sodium Hydroxide 0.07
Liq. Bromine 0.14
12. Di Calcium Phosphate
Calcium Hydroxide 0.44
Phosphoric Acid (85%) 0.68
15
LIST OF RAW MATERIAL (ADDITIONAL PROPOSED)
SR.
NO.
PRODUCT WISE RAW MATERIALS QUANTITY
(MT/MT)
1. Diphenyl Acetonitrile
Phenyl Acetonitrile 0.80
Liquid Bromine 1.11
Aluminium Chloride 1.05
Benzene 4.00
Soda Ash 0.004
Methanol 2.00
Hydro 0.004
2 Diphenyl Acetic acid
Diphenyl Acetonitrile 1.00
Sulfuric Acid 0.30
3 Diphenyl methane
Dibenzyl Ether 0.84
Benzene 4.00
Phosphoric Acid 0.10
Soda Ash 0.004
4 2-(Diphenylmethoxy)-N,N-Dimethylethanamine Hydrobromide
Diphenyl Methane 0.56
Liq. Bromine 0.53
N,N-Dimethyl Amino Ethanol 0.31
Mono Chloro Benzene 0.60
5 p-Chloro Benzophenone
Benzoyl Chloride 0.83
Mono Chlorobenzene 0.67
Aluminum Chloride 0.80
Methanol 3.00
Sodium Hydroxide 0.24
6 p-Chlorobenzhydryl Chloride
P-Chloro Benzophenone 1.00
Methanol 1.00
Sodium Borohydride 0.07
Hydrochloric acid 2.00
Sodium Hydroxide 0.40
7 p-Chlorobenzhydryl Piperazine
P-Chloro Benzhydryl Chloride 1.00
Piperazine 1.24
16
Toluene 3.00
Hydrochloric Acid 1.00
Sodium Hydroxide 1.00
8 2-[4-(4-Chlorobenzhydryl)-1-Piperazinyl] Ethanol
P-Chloro Benzhydryl Piperazine 0.87
2-Chloro Ethanol 0.52
Toluene 3.20
Tri Ethyl Amine 0.80
Sodium Hydroxide 0.10
9 1-(3-Chloropropyl)-1,3-Dihydro-2h- Benzimidazol-2-One
o-Phenylene Diamine 0.88
Methyl Aceto Acetate 0.96
o-Xylene 4.00
1-Bromo-3-Chloro Propane 1.28
Methanol 3.00
KOH 0.68
HCl 1.00
10 Nosyl Chloride
P-Nitro Aniline 1.00
Sodium Nitrite 0.56
Sodium Bisulfite 1.43
Copper Sulphate 0.27
o-Xylene 3.00
Acetic Acid 1.00
HCl 9.50
NaOH Lye 1.00
11 5-Chloro-1-(4-Piperidinyl)-2-Benzimidazolidinone
N-Carbethoxy-4-piperidone 1.80
Ammonia gas 0.63
Methanol 26.25
Raney Nickel 0.68
Hydrogen 0.23
2,5-Dichloro Nitrobenzene 1.78
Sodium Carbonate 0.70
Toluene 8.00
Urea 0.45
Sodium Hydroxide 0.80
Activated carbon 0.15
17
ANNEXURE-II
LAYOUT MAP OF THE PLANT
Z
SITE PLAN
18
LAYOUT PLAN
5. 00 MT G.S.
20 MT ROAD No. 23
5. 00 MT G.S.
5.
MT
G.
S.
5.
MT
G.
S.
20.
MT
R
O
A
D
No.
352315 2314
52. 5530. 00
54. 85 30. 00
4
5.
0
0
4
5.
0
0
4
5.
05
N
PLOT NO. AREA
2314 45.00 × 30.00 = 1350.00
2315 54.85 + 52.55 ×45 = 2416.00
2
TOTAL = 3766.00
19
ANNEXURE-III
BRIEF PROCESS DESCRIPTION
EXISTING
BLOCK DIAGRAM FOR MANUFACTURING PROCESS
R.M.-1 R.M.-2
REACTION VESSLE
EVAPORATION
CENTRIFUGE
DRYING
PACKING
Mother Liquor
20
POTASSIUM SULPHATE
Manufacturing Process
Potassium Sulphate Aqueous solution of 8-10% is being evaporated in reactor to remove
Water Contain. After giving adequate temperature (90-120°C) for 6 to 8 hrs. Material is
being shifted to crystallizer for cooling. The mass taking centrifuge to separate crystal of the
product and mother liquor. The Mother liquor is collected and once again charge is reactor
for evaporation. Crystal of the product is collected and dried for the in the dryer if
necessary required to remove surface moisture contain or it is being packed in HDPE Bag
for selling.
Chemical Reaction
2KOH + H2SO4 K2SO4 + 2H2O
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product & Waste QTY
Potassium Hydroxide (85%) 360 Kgs Potassium sulfate 500 Kgs
Sulfuric acid 282 Kgs Water evaporate approx. 1100 Kgs
water 1500 Kgs CF ML add in next batch 542 Kgs
Total 2142 Kgs Total 2142 Kgs
21
POTASSIUM CHLORIDE
Manufacturing Process
Potassium Chloride Aqueous solution of 25-28% is being evaporated in reactor to remove
Water Contain. After giving adequate temperature (90-120oC) for 6 to 8 hrs. Material is
being shifted to crystallizer for cooling. The mass is taking centrifuge to separate crystal of
the product and mother liquor. The Mother liquor is collected and once again charge is
reactor for evaporation. Crystal of the product is collected and dried for the in the dryer if
necessary required to remove surf ace moisture contain or it is being packed in HOPE Bag
for selling.
Chemical Reaction
KOH + HCl KCl + H2O
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Potassium Hydroxide (85%) 425 Kgs Potassium Chloride 500 Kgs
Hydrochloric acid (30%) 830 Kgs Water evaporate approx. 1200 Kgs
water 900 Kgs CF ML add in next batch 455 Kgs
Total 2155 Kgs Total 2155 Kgs
22
KOH + HBr KBr H2O+
M.WT.: 56.12 M.WT.: 80.91 M.WT.: 119.00 M.WT.: 18.01
POTASSIUM BROMIDE
Manufacturing Process
Potassium Hydroxide solution reacts with Hydrobromic Acid to give Potassium Bromide.
Chemical Reaction
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Potassium Hydroxide (85%) 300 Kgs Potassium Chloride 500 Kgs
Hydrobromic acid (30%) 1200 Kgs Water evaporate approx. 800 Kgs
water 200 Kgs CF ML add in next batch 400 Kgs
Total 1700 Kgs Total 1700 Kgs
23
POTASSIUM NITRATE
Manufacturing Process
Potassium Nitrate Aqueous solution of 8-10% is being evaporated in reactor to remove
Water Contain. After giving adequate temperature for 6 to 8 hrs. Material is being shifted
to crystallizer for cooling. The mass will take into centrifuge to separate crystal of the
product and mother liquor. The Mother liquor is collected and once again charge is react or
for evaporation. Crystal of the product is collected and dried for the in the dryer if
necessary required to remove surface moisture contain or it is being packed in HOPE Bag
for selling.
Chemical Reaction
K2CO3 + 2HNO3 2KNO3 + H2O + CO2
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Potassium Carbonate 350 Kgs Potassium Nitrate 500 Kgs
Nitric acid (45%) 700 Kgs CO2 Gas 109 Kgs
water 800 Kgs Water evaporate approx. 800 Kgs
CF ML add in next batch 441 Kgs
Total 1850 Kgs Total 1850 Kgs
24
ZINC SULPHATE
Manufacturing Process
Toke Fresh 585 Kgs 98% Sulphuric Acid & Add 1.5 KL Fresh Water (up to 70%) in a brick line
d vessel. Add slowly 400 Kg Zinc metal into brick Lined vessel. Agitated the vessel for six
hours and maintain temp. Up to 6000C. After that pumped the liquid for Filtration. Filtered
liquid transferred into settling tank in which crystallization will take place in 12 hours to 16
hours. From settling tank Zinc Sulphate separated by centrifuge and Mother liquid from
centrifuge and Filter press and come out from Filter press is unreacted Zinc or pump wash is
recycle back for next batch. Then Zinc Sulphate is packed in bags
Chemical Reaction
Zn + H2SO4 ZnSO4 + 7H2 + H2
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Zinc Metal 115 Kgs Zinc sulfate hepta hydrate 500 Kgs
Sulfuric acid 173 Kgs Water evaporate approx. 588 Kgs
water 1300 Kgs CF ML add in next batch 500 Kgs
Total 1588 Kgs Total 1588 Kgs
25
M.WT.: 65.41
+ 2HCl
M.WT.: 72.92
ZnCl2
M.WT.: 136.32
+ H2
M.WT.: 2.01
Zn2+
Process Flow Diagram
ZINC CHLORIDE
Manufacturing Process
Zinc Chloride is manufactured by using hydrochloric acid instead of Sulphuric acid in above
process
Chemical Reaction
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Zinc Metal 240 Kgs Zinc Chloride 500 Kgs
Hydrochloric acid (30%) 900 Kgs Water evaporate approx. 1190 Kgs
water 600 Kgs CF ML add in next batch 50 Kgs
Total 1740 Kgs Total 1740 Kgs
REACTION
FILTRATION
CRYSTALLIZATION
NUTCH FILTRATION
Zinc (Metal) Fresh H2 SO4 (98 %)
PACKING
DISPATCH
Un- reacted metal (Zinc) for
re-use in next batch
M. L. For re-use
in next batch
M.L. re –use
in next batch
26
COPPER SULPHATE
Manufacturing Process
Required quantity of water is taken in reaction vessel and conc. Sulphuric acid is charged
gradually. Next Copper oxide powder is added slowly. The reaction takes place and CuO
dissolves in the solution forming Copper Sulphate. After complete reaction, the reaction
mass is heated to Crystallize the product which is centrifuged, dried and packed. The
mother liquor is recycled in next batch.
Chemical Reaction
CuO + H2SO4 CuSO4 + H2O
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Copper oxide 250 Kgs Copper sulfate 500 Kgs
Sulfuric acid 305 Kgs Water evaporate approx. 1155 Kgs
water 1200 Kgs CF ML add in next batch 100 Kgs
Total 1755 Kgs Total 1755 Kgs
27
MAGNESIUM SULPHATE
Manufacturing Process
Required quantity of water is taken in reaction vessel and cone. Sulphuric acid is charged
gradually. Next magnesium oxide powder is added slowly. The reaction takes place and
MgO dissolves in the solution forming Magnesium Sulphate. After complete reaction, the
reaction mass is heated to Crystallize the product which is centrifuged, dried and packed.
The mother liquor is recycled in next batch.
Chemical Reaction
MgO + H2SO4 MgSO4 + H2O
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Magnesium oxide 170 Kgs Magnesium sulfate 500 Kgs
Sulfuric acid 415 Kgs Water evaporate approx. 1305 kgs
water 1300 Kgs CF ML add in next batch 80 Kgs
Total 1885 Kgs Total 1885 Kgs
28
SODIUM NITRATE
Manufacturing Process
Sodium Nitrate Aqueous solution of 8-10% is being evaporated in reactor to remove Water
Contain. After giving adequate temperature for 6 to 8 hrs. Material is being shifted to
crystallizer for cooling. The mass will take into centrifuge to separate crystal of the product
and mother liquor. The Mother liquor is collected and once again charge is reactor for
evaporation. Crystal of the product is collected and dried for the in the dryer if necessary
required to remove surface moisture contain or it is being packed in HDPE Bag for selling.
Chemical Reaction
NaOH + HNO3 NaNO3 + H2O
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Sodium Hydroxide 240 Kgs Sodium Nitrate 500 Kgs
Nitric acid (45%) 845 Kgs Water evaporate approx. 1295 Kgs
water 800 Kgs CF ML add in next batch 90 Kgs
Total 1885 Kgs Total 1885 Kgs
29
NaOH + HBr NaBr H2O
M.WT.: 40.00 M.WT.: 80.91 M.WT.: 102.89 M.WT.: 18.01
+
NaOH + 1/2Br2NaOBr
M.WT.: 40.00 M.WT.: 79.9 M.WT.: 118.89
+ 1/2H2
M.WT.: 1.0
SODIUM BROMIDE & SODIUM HYPO BROMITE
Manufacturing Process
Sodium Hydroxide reacts with Hydrobromic Acid to give Sodium Bromide.
Sodium Hydroxide reacts with Liq. Bromine to give Sodium Hypo Bromite.
Chemical Reaction
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Sodium Hydroxide 200 Kgs Sodium Bromide 500 Kgs
Hydrobromic acid (30%) 1350 Kgs Water evaporate approx. 1250 Kgs
water 300 Kgs CF ML add in next batch 100 Kgs
Total 1850 Kgs Total 1850 Kgs
Chemical Reaction
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product & waste QTY
Sodium Hydroxide 34 Kgs Sodium hypo bromite (20%) Sol. 502 Kgs
Liq. Bromine 68 Kgs
water 400 Kgs
Total 502 Kgs Total 502 Kgs
30
Ca(OH) 2H3PO4
M.WT.: 74.08
+
M.WT.: 98.0
CaHPO 4.2H2O
M.WT.: 172.08
DI CALCIUM PHOSPHATE
Manufacturing Process
Calcium Hydroxide reacts with Phosphoric Acid in presence of water to give Di calcium
Phosphate.
Chemical Reaction
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product & waste QTY
Calcium Hydroxide 220 Kgs Di calcium phosphate 500 Kgs
Phosphoric acid
(85%)
340 Kgs Water evaporate approx. 960 Kgs
water 1200 Kgs CF ML add in next batch 300 Kgs
Total 1760 Kgs Total 1760 Kgs
31
PROPOSED
DIPHENYL ACETONITRILE
Process Description
Liq. Bromine is reacting with Phenyl Acetonitrile at 80°C gives α-Bromo Phenyl Acetonitrile.
α-Bromo Phenyl Acetonitrile is react with Benzene in presence of Aluminium Chloride is
gives Diphenyl Acetonitrile
Chemical Reaction
N
+ Br Br
N
Br
+
N
M.WT.: 117.15M.WT.: 159.81
M.WT.: 196.04
+
M.WT.: 80.91
M.WT.: 78.11
M.WT.: 133.34
M.WT.: 193.24
+ BrH
M.WT.: 80.91
BrH + AlCl3
M.WT.: 133.34
AlCl3
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Phenyl Acetonitrile 400.0 Kgs Diphenyl Acetonitrile 500.0 Kgs
Liquid Bromine 554.0 Kgs Benzene 1590.0 Lts
Aluminium Chloride 525.0 Kgs Methanol 950.0 Lts
Benzene 2000.0 Lts Hydrobromic acid 35% 800.0 Kgs
Water 3000.0 Lts Hydrobromic acid + AlCl3
Solution
3103.0 Kgs
Soda Ash 2.0 Kgs Residue 40.0 Kgs
Methanol 1000.0 Lts Water 500.0 Kgs
Hydro 2.0 Kgs
Total 7483.0 Kgs Total 7483.0 Kgs
32
DIPHENYL ACETIC ACID
Process Description
In GLR -hydrolysis of Diphenyl Acetonitrile in Dilute Sulfuric Acid gives Diphenyl Acetic Acid.
Chemical Reaction
N
M.WT.: 193.24
+
M.WT.: 49.04
H2SO4H2O
MWt: 54.06
+
O
OH
(NH4)2SO4
M.Wt.:66.06
+ +1/2 H2O
MWt: 18.02
3
M.WT.: 212.24
1/2
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Diphenyl Acetonitrile 500.0 Kgs Diphenyl Acetic Acid 500.0 Kgs
Sulfuric Acid 150.0 Kgs Water 550.0 Kgs
Water 400.0 Kgs
Total 1050 Kgs Total 1050 Kgs
33
DIPHENYL METHANE
Process Description
In presence of Phosphoric Acid, Dibenzyl Ether is reacted with Benzene gives Diphenyl
Methane.
Chemical Reaction
O +
M.WT.: 156.22M.WT.: 198.26
M.WT.: 336.46
22 Phosphoric acid as Catalyst
+ H2O
MWt: 18.02
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Dibenzyl ether 420.0 Kgs Diphenyl Methane 500.0 Kgs
Benzene 2000.0 Lts Benzene 1600.0 Lts
Phosphoric Acid 50.0 Kgs Phosphoric Acid 48.0 Kgs
Soda Ash 2.0 Kgs Residue 40.0 Kgs
Water 800.0 Kgs Water 1084.0 Kgs
Total 3272 Kgs Total 3272 Kgs
34
2-(DIPHENYLMETHOXY)-N,N-DIMETHYLETHANAMINE HYDROBROMIDE
Process Description
In a Glass Reactor, Bromine Liquid is added to Diphenyl Methane at appropriate temp, to
give Benzydryl Bromide, which is condensed with Dimethyl Amino Ethanol gives 2-
(Diphenylmethoxy)-N,N-Dimethylethanamine Hydrobromide
Chemical Reaction
Br Br
M.WT.: 159.81
+
M.WT.: 168.23
Br
M.WT.: 80.91
BrH+ OH N
M.WT.: 89.14
ON
CH3
CH3BrH
M.Wt.: 336.27
+MCB
M.WT.: 247.13
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product & waste QTY
Diphenyl methane 280.0 Kgs 2-(Diphenylmethoxy)-N,N-
Dimethylethanamine
Hydrobromide
500.0 Kgs
Liq. Bromine 266.0 Kgs Monochlorobenzene 285.0 Lts
N,N-Dimethyl Amino Ethanol 154.0 Kgs Hydrobromic Acid 385.0 Kgs
Mono Chloro Benzene 300.0 Lts Water 100.0 Kgs
Water (Scrubber) 250.0 Lts Residue 30.0 Kgs
Water 50.0 Lts
Total 1300.0 Kgs Total 1300.0 Kgs
35
p-CHLORO BENZOPHENONE
Process Description
In Glass line reactor charge Monochloro Benzene & Aluminium Chloride at RT then slowly
adds Benzoyl Chloride into reaction mass at 48ºC & Stir for 3 hrs. Then heat to 100ºC and
maintained for 2 hrs. Then add slowly water into reaction mass (during addition of water
generate HCl gas – scrub with NaOH soln. using scrubber) separate p-Chloro Benzophenone
Chemical Reaction
ClO
+
Cl
M.WT.: 133.34
AlCl3
O
Cl
+
M.WT.: 140.57 M.WT.: 112.66M.WT.: 216.66
ClH
M.Wt.: 36.46
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Benzoyl Chloride 415.0 Kgs p-Chloro Benzophenone 500.0 Kgs
Mono Chlorobenzene 333.0 Kgs Methanol 1430.0 Lts
Aluminum Chloride 400.0 Kgs AlCl3 Solution (25%) 1600.0 Kgs
Methanol 1500.0 Lts Water 1308.0 Kgs
Water (Scrubber) 600.0 Lts Residue 30.0 Kgs
Sodium Hydroxide (Scrubber) 120.0 Kgs
Water 1500.0 Lts
Total 4868.0 Kgs Total 4868.0 Kgs
36
p-CHLOROBENZHYDRYL CHLORIDE
Process Description
In Reactor charge MeOH and P-Chlorobenzophenone and cool to 25˚C, then slowly add
Sodium Borohydride and maintain for 4 hr, there after distilled out MeOH and charge
hydrochloric acid and stir the mass for 6 hr. discard acidic layer and collect p-
Chlorobenzhydryl Chloride
Chemical Reaction
O
Cl
M.WT.: 216.66
+ NaBH4
M.WT.: 37.81
OH
Cl
M.WT.: 218.68
NaBH2+
M.WT.: 35.81
MeOH
ClH
M.Wt.: 36.46Toluene
Cl
Cl
M.WT.: 237.12
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
p-Chloro Benzophenone 500.0 Kgs p-Chloro Benzhydryl Chloride 500.0 Kgs
Methanol 500.0 Lts Methanol 470.0 Lts
Sodium Borohydride 35.0 Kgs Water 1735.0 Kgs
Hydrochloric Acid 1000.0 Kgs Residue 30.0 Kgs
Sodium Hydroxide 200.0 Kgs
Water 500.0 Lts
Total 2735.0 Kgs Total 2735.0 Kgs
37
p-CHLOROBENZHYDRYL PIPERAZINE
Process Description
In reactor charge Toluene, P-Chlorobenzhydryl Chloride and Piperazine into heat to 70ºC &
maintain for 3 hrs. Then add HCl at RT & product extract with HCl & side up Toluene layer
and recover for next batch. Product contains HCl charge into reactor & adjusts 9 pH by
NaOH soln. & centrifuge the product and dry at 50ºC.
Chemical Reaction
Cl
Cl
M.WT.: 237.12
NH
NH
+
M.WT.: 86.14
TolueneNaOH
M.Wt: 40.00
Na Cl OH2
M.Wt.:58.44 MWt: 18.02
+
N
Cl
NH
++
M.WT.: 286.80
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
P-Chloro Benzhydryl chloride 500.0 Kgs P-Chloro Benzhydryl
Piperazine
500.0 Kgs
Piperazine 620.0 Kgs Toluene 1420.0 Lts
Toluene 1500.0 Lts Piperazine 400.0 Kgs
Hydrochloric Acid 500.0 Kgs NaOH Soln. 900.0 Kgs
Sodium Hydroxide 500.0 Kgs Water 3380.0 Kgs
Water 3000.0 Lts Residue 20.0 Kgs
Total 6620.0 Kgs Total 6620.0 Kgs
38
2-[4-(4-CHLOROBENZHYDRYL)-1-PIPERAZINYL] ETHANOL
Process Description
S.S.R. to be clean and dry. Charge toluene, p-Chloro Benzhydryl Piperazine, Triethyl Amine
and 2-Chloro Ethanol at RT. Then heat up to reflux and maintain reflux for 8 hr. then distilled
out toluene completely & collect product
Chemical Reaction
N
Cl
NH
+
M.WT.: 286.80
NaOH
M.Wt: 40.00
OH Cl +
M.WT.: 80.51
Toluene
Tri Ethyl AmineN
Cl
N
OH
OH2
M.Wt.:58.44
MWt: 18.02
+ Na Cl
M.WT.: 330.85
+
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
p-Chloro Benzhydryl
Piperazine
435.00 Kgs P-Chloro Benzhydryl
Piperazine
500.0 Kgs
2-Chloro Ethanol 260.0 Kgs Toluene 1520.0 Lts
Toluene 1600.0 Lts TEA reuse in Next Batch 380.0 Kgs
Tri Ethyl Amine 400.0 Lts Water 1345.0 Kgs
Sodium Hydroxide 50.0 Kgs
Water 1000.0 Lts
Total 3745.0 Kgs Total 3745.0 Kgs
39
1-(3-CHLOROPROPYL)-1,3-DIHYDRO-2H- BENZIMIDAZOL-2-ONE
Process Description
In SSR charge o-Xylene and OPDA at RT. Then heat the mass up to 120º. Slowly add Methyl
Aceto Acetate in to the reactor then stir the mass for 6 hrs. and cool up to RT and Centrifuge
the mass spine dry and unload it .
In other SSR charge water, KOH, Bromo Chloro Propane and wet cake from previous stage at
RT. Then heat the mass up to 45ºc and stir for 6hrs there after charge HCl in to the mass and
heat up to 60º and stir for 2hr. then cool the mass up to RT and centrifuge the mass .
Chemical Reaction
Stage-1
N
NH
O
CH3
CH2
O-Xylene + CH3 OH OH2+NH2
NH2
+
CH3 O
CH3
O O
M.Wt.: 108.14 M.Wt.: 116.12 M.Wt.: 174.2 M.Wt.: 32.04 M.Wt.: 18.02
Stage-2
BrCl
N
NH
O
CH3
CH2
+ + KOH
N
N
O
CH3
CH2
Cl
+ K Br + OH2
N
N
O
CH3
CH2
Cl
+ ClHMeOH
NH
N
OCl
+Cl
CH3
CH2
M.Wt.: 157.44 M.Wt.: 56.12 M.Wt.: 250.72 M.Wt.: 119.00
M.Wt.: 36.46M.Wt.: 210.66 M.Wt.: 76.52
M.Wt.: 174.2 M.Wt.: 18.02
M.Wt.: 250.72
40
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product & waste QTY
Stage-1 Stage-1 110.0 Kgs
O-Phenylene Diamine 88.0 Kgs O-Xylene 380.0 Lts
Methyl Aceto Acetate 96.0 Lts Water + Methanol From
Reaction
41.0 Lts
O-Xylene 400.0 Lts Water 138.0 Kgs
Water 100.0 Lts Residue 15.0 Kgs
Total 684.0 Kgs Total 684.0 Kgs
Stage-2
Stage-1 110.0 Kgs Stage-2 1-(3-Chloropropyl)-1,3-
Dihydro-2H- Benzimidazol-2-
One
100.0 Kgs
1-Bromo-3-Chloro Propane 128.0 Kgs Methanol 270.0 Kgs
Methanol 300.0 Lts KBr Sol 275.0 Kgs
KOH 68.0 Kgs Water 556.0 Kgs
HCL 100.0 Kgs Residue 5.0 Kgs
Water 500.0 Lts
Total 1206 Kgs Total 1206 Kgs
41
N
OO
NH
CH3
Cl
O2N
M.Wt.: 327.76
+ 3H2Toluene
Raney Nickel
N
OO
NH
CH3
Cl
NH2
2H2O+
M.Wt.: 6.04
M.Wt.: 297.78
M.Wt.: 36.03
N
OO
NH2
CH3
M.Wt.: 172.22
+Cl NO2
Cl
M.Wt.: 192.00
1/2Na2CO3 Methanol NaCl
M.Wt.: 58.44
+ 1/2H2O
M.Wt.: 9.0
1/2CO2+
M.Wt.: 22.00
+
M.Wt.: 53.0
N
OO
NH
CH3
NO 2
Cl
M.Wt.: 327.76
+
5-CHLORO-1-(4-PIPERIDINYL)-2-BENZIMIDAZOLIDINONE
Process Description
Stage-1- N-carbethoxy-4-piperidone is reacted with Hydrogen and Ammonia in the presence
of Raney nickel as catalyst and Methanol as solvent media to give stage-1 as product.
Stage-2-Stage-1 reacts with 2, 5-Dichloro nitrobenzene & Sodium Carbonate in presence of
Methanol as a solvent media to give Stage-2 as product.
Stage-3-Stage-2 reacts with Hydrogen in presence of Raney Nickel as catalyst and Toluene as
solvent media to give Stage-3 as product.
Stage-4-Stage-3 reacts with Urea in the presence of Sodium Hydroxide and there after
hydrolysis with Sodium Hydroxide to give 5-Chloro-1-(4-Piperidinyl)-2-Benzimidazolidinone
which is purified in methanol gives pure product
Chemical Reaction
Stage-1
N
OO
O
CH3
+ H2 + NH
3
N
OO
NH2
CH3
+ OH2Raney Nickel
M.Wt.: 171.19
M.Wt.: 2.02
M.Wt.: 17.03
M.Wt.: 172.22
M.Wt.: 18.02
Stage-2
Stage-3
42
NH
N
NH
O
Cl
M.Wt.: 251.77
NH
N
NH
O
Cl
M.Wt.: 251.77
Methanol
N
OO
NH
CH3
Cl
NH2
N
OO
N
CH3
NH
O
Cl
M.Wt.: 297.78
+ NH2NH2
O
+ 2NH3
M.Wt.: 60.03
M.Wt.: 323.77
M.Wt.: 34.06
NaOH
M.Wt.: 40.00+
NH
N
NH
O
Cl
OCH3 Na + CO2
M.Wt.: 251.77
M.Wt.: 68.05M.Wt.: 44.00
Stage-4
Stage-5
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product & waste QTY
Stage-1
N-Carbethoxy-4-piperidone 180.0 Kgs Stage-1 160.0 Kgs
Ammonia gas 63.0 Kgs Methanol Recovery 640.0 Kgs
Methanol 675.0 Kgs Methanol Loss 35.0 Kgs
Raney Nickel 45.0 Kgs Raney Nickel reuse 45.0 Kgs
Hydrogen 11.25 Kgs Residue 40.0 Kgs
Process Emission( Ammonia +
Hydrogen)
54.25 Kgs
Total 974.25 Kgs Total 974.25 Kgs
Stage-2
Stage-1 160.0 Kgs Stage-2 215.0 Kgs
2,5-Dichloro Nitrobenzene 178.0 Kgs Methanol Recovery 1100.0 Kgs
Sodium Carbonate 70.0 Kgs Methanol Loss 50.0 Kgs
Methanol 1150.0 Kgs Water 583.0 Kgs
Water 450.0 Kgs Process Emission (CO2) 20.0 Kgs
Residue 40.0 Kgs
Total 2008.0 Kgs Total 2008.0 Kgs
43
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product & waste QTY
Stage-3
Stage-2 215.0 Kgs Stage-3 170.0 Kgs
Hydrogen 11.3 Kgs Toluene Recovery 760.0 Kgs
Raney Nickel 22.6 Kgs Toluene Loss 40.0 Kgs
Toluene 800.0 Kgs Raney Nickel reuse 22.6 Kgs
Water 450.0 Kgs Residue 20.0 Kgs
Process Emission(Hydrogen) 7.5 Kgs
Water 478.8 Kgs
Total 1498.90 Kgs Total 1498.90 Kgs
Stage-4
Stage-3 170.0 Kgs Stage-4 105.0 Kgs
Urea 45.0 Kgs Process Emission (ammonia) 19.0 Kgs
Sodium Hydroxide 80.0 Kgs Water 1371.0 Kgs
Water 1200.0 Kgs
Total 1495.0 Kgs Total 1495.0 Kgs
Stage-5
Stage-4 105.0 Kgs 5-Chloro-1-(4-Piperidinyl)-2-
Benzimidazolidinone
100.0 Kgs
Methanol 800.0 Lts Methanol Recovery 760.0 Kgs
Activated carbon 15.0 Kgs Methanol Loss 40.0 Kgs
Spent carbon 15.0 Kgs
Residue 5.0 Kgs
Total 920.0 Kgs Total 920.0 Kgs
44
NOSYL CHLORIDE
Process Description
Para Nitro aniline reacts with sodium nitrite & Aq. HCl at below 10˚C temp. This gives
diazonium compound, which on reaction with Sodium Bisulfite in Aq. HCl in presence of
Copper Sulfate gives Nosyl Chloride which on purification in Xylene and Acetic Acid gives
Pale yellow Crystalline Powder of Nosyl Chloride
Chemical Reaction
NO2
NH2
+ Na NO2+ ClH
M.Wt.: 72.92M.Wt.: 69.00
NO2
N2+
Cl-
NaHSO 3+ + ClH
M.Wt.: 36.46M.Wt.: 104.06
2 + NaCl H2O+ 2
M.Wt.: 36.02M.Wt.: 58.44
M.Wt.: 138.12 M.Wt.: 185.58
NO2
N2+
Cl-
M.Wt.: 185.58
CuSO4
M.Wt.: 159.60
NO2
SO2Cl
M.Wt.: 221.62
+
M.Wt.: 53.49
NH4Cl H2O+ Na NO2
M.Wt.: 69.00 M.Wt.: 18.02
++ 2
M.Wt.: 36.02
H2O
NO2
SO2Cl
M.Wt.: 221.62
Toluene
Acetic Acid
NO2
SO2Cl
M.Wt.: 221.62
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
P-Nitro Aniline 100.0 Kgs Nosyl Chloride 100.0 Kgs
Sodium Nitrite 56.0 Kgs Xylene 280.0 Lts
Sodium Bisulfite 143.0 Kgs Acetic acid 80.0 Lts
Copper Sulphate 27.0 Kgs Residue 20.0 Kgs
O-Xylene 300.0 Lts Water 2896.0 Lts
Acetic Acid 100.0 Lts
HCL 950.0 Kgs
NaOH Lye 100.0 Kgs
Water 1600.0 Lts
Total 3376.0 Kgs Total 3376.0 Kgs
45
ANNEXURE-IV
TREATMENT PROCESS
Details of Effluent Treatment Plant along with flow diagram
Stream I (Low COD & TDS Stream) = 11.83 KL/Day
First all non-toxic and biodegradable streams (low & medium COD & TDS) of wastewater
shall pass through Screen Chamber where floating material shall be removed with help of
Screen. Then effluent shall be passed through Oil & Grease Removal Tank. Automatic
mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and grease
from the wastewater to Oil & Grease Collection Tank. Then effluent shall be collected in
Collection cum Equalization tank-1. Pipe grid is provided at bottom of the CET-01 to keep all
suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1W+1
stand-by) shall supply air through to pipe grid.
Then after, equalized wastewater shall be pumped to Neutralization Tank-1 where the
continuous addition and stirring of Caustic solution is done to maintain neutral pH of
wastewater from Caustic Dosing Tanks as per requirement by gravity. Then after,
neutralized wastewater shall go to Flash Mixer-1 by gravity. Alum and Polyelectrolyte shall
be dosed from Alum Dosing Tank and Polyelectrolyte Dosing Tank respectively by gravity
into FM-1 to carry out coagulation by using a Flash Mixer. Then after, coagulated
wastewater shall be settled in Primary Clarifier. Treated effluent will be sent to CETP of
PETL, Panoli for further treatment.
Stream II (High COD & TDS Stream) = 1.67 KL/Day
High COD effluent shall be passed through collection cum neutralization tank where the
continuous addition and stirring of Caustic solution is done to maintain neutral pH of
wastewater from Caustic Dosing Tanks as per requirement by gravity. Treated neutral
effluent will be sent to Common Spray Dryer facility of PETL, Panoli for further treatment.
46
FLOW DIAGRAM OF ETP:
Screen Chamber Oil & Grease
Trap
Collection cum
Equalization
Tank
Neutralization
Tank
Primary Settling
Tank
CETP of PETL,
Panoli
Common
Spray Dryer
of PETL,
Panoli
Raw Effluent
Low COD
Collection cum
Neutralization
Tank
High COD
47
SIZE OF TANKS
S.N. Name of unit Size (m x m x m) No. MOC/ Remark
Stream I (Low COD & TDS Stream) 11.83 KL/Day
1 Screen Chamber 2.5 x 1.0 x (0.05 +0.3 FB) 1 RCC M25+A/A Bk.
Lining
2 Collection cum Equalization
Tank-1
3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
3 Neutralization Tank 3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
4 Flash Mixer-1 0.8 x 0.8 x (1.5 LD +0.5 FB) 1 RCC M25
5 Primary Clarifier 2.0 x 1.2 x (2.0 LD + 0.75
HB+ 0.5 FB)
1 RCC M25
6 Aeration Tank-1 7.0 x 5.2x (3.5 LD +0.5FB) 1 RCC M25
7 Secondary Clarifier-1 2.0 x 1.2 x (2.0 LD + 0.75
HB+ 0.5 FB)
1 RCC M25
Stream II (High COD & TDS Stream) 1.67 KL/Day
1 Collection cum
Neutralization Tank-1
3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)
PCC = PLAIN CEMENT CONCRETE
PP = POLYPROPELENE
MSEP = MILD STEEL EPOXY PAINTED
SS = STAINLESS STEEL
48
EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-I)
Sr.
No.
Category of Wastewater Before Treatment After Treatment
1 pH 3.5-6.5 6.5-8.0
2 COD (mg/L) 5500 1000
3 BOD3 (mg/L) 1700 300
4 TDS (mg/L) 3500 3250
5 Ammonical Nitrogen (mg/L) 30 20
EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-II)
Sr.
No.
Category of Wastewater Before Treatment
1 pH 2-10
2 COD (mg/L) 55000
3 BOD3 (mg/L) 12000
4 TDS (mg/L) 40000
5 Ammonical Nitrogen (mg/L) 300
49
ANNEXURE-V
HAZARDOUS WASTE GENERATION AND DISPOSAL
Generation Sr.
No
Type of Waste Category
Existing Total
Proposed
Mode of Treatment & Disposal
1. ETP Sludge 35.3 - 0.8
MT/Month
Collection, Storage, Transportation &
Sent to TSDF site of M/s. PSWML,
Panoli or M/s. BEIL, Ankleshwar
2. Used Oil 5.1 0.01
MT/Month
0.5
Lit/Month
Collection, Storage, Transportation &
Sale to registered re-processor or
used for lubrication within premises
3. Spent Carbon 28.3 - 3.8
MT/Month
Collection, Storage, Transportation &
co-processing in cement industries or
Send to M/s. BEIL, Ankleshwar for
incineration
4. Discarded Containers
/Barrels/Liners
33.1 0.5
MT/Month
500
Nos/Month
Collection, Storage, Transportation,
Decontamination & sold to
registered vendor
5. Distillation Residue 36.1 - 10
MT/Month
Collection, Storage, Transportation &
Sent to Common Incineration of M/s.
BEIL, Ankleshwar or for Co-
Processing in Cement Industries
6. Hydrobromic Acid - - 65
MT/Month
7. Aluminium Chloride
Soln.
- - 80
MT/Month
8. Potassium Bromide
Soln.
- - 40
MT/Month
Collection, Storage & Sold to re-
processors or end users
50
ANNEXURE-VI
_______________________________________________________________________
WATER, FUEL & ENERGY REQUIREMENT
WATER CONSUMPTION AND WASTEWATER GENERATION
Water Consumption
(KL/Day)
Waste Water
Generation (KL/Day)
Sr.
No.
Category
EXISTING TOTAL
PROPOSED
EXISTING TOTAL
PROPOSED
1. Domestic 8 10 7.5 9
2. Other (Gardening) NIL 1 NIL NIL
3. Industrial
Process 2 15 NIL 13.5
Boiler NIL 0.7 NIL 0.03
Cooling NIL 0.4 NIL 0.2
Washing NIL 1.4 NIL 1.4
Total Industrial 2 17.5 0 15.13
Grand Total 10 28.5 7.5 24.13
51
WATER BALANCE DIAGRAM (EXISTING)
Domestic
8
Water Consumption
10
Domestic
7.5
Wastewater
7.5
Septic Tank/Soak Pit
Process
2
Process
0
All Figures in KLD
52
WATER BALANCE DIAGRAM (TOTAL PROPOSED)
All Figures in KLD
Domestic
10
Boiler
0.7
Washing
1.4
Water Consumption
28.5
Domestic
9
Cooling
0.4
Wastewater
13.46
Boiler
0.03
Washing
1.4
Cooling
0.2
ETP
Process
15
Sent to PETL, Panoli
Process
13.5
Gardening
1
High COD &
High TDS �
1.67
Common Spray
Dryer of PETL,
Panoli for further
treatment
Septic Tank/Soak Pit
53
TOTAL POWER REQUIREMENT & SOURCE OF POWER
Power requirement will be 75 HP (Existing) + 50 HP (Additional Proposed) = 125 HP which
will be taken from DGVCL. 1 No. of 62 KVA DG Set will be kept for emergency power back
up.
FUEL REQUIREMENT
SR.
NO.
NAME OF FUEL QUANTITY
1 Natural Gas 600 Sm3/day
2 LDO 500 Lit/day
54
ANNEXURE-VII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
Quantity Sr.
No.
Name of Hazardous
Substances Max.
That can be
stored (MT)
State &
Operating
Pressure &
Temp.
Type of
Hazard
Possible
(Fire, Explosion etc.)
Remarks
1 Ethyl Chloro Formate 250.0 kgs NTP Corrosive HDPE DRUM
2 Toluene 1000.0 kgs NTP Flammable MSDRUM
3 Ammonia Anhydrous 200.0 kgs NTP Harmful CYLINDER
4 Hydrogen Gas. 100.0 kgs NTP Highly Flammable CYLINDER
5 2,5,Dichloro Nitrobenzene 200.0 kgs NTP Flammable HDPE DRUM
6 Isopropyl Alcohol 500.0 kgs NTP Flammable MS DRUM
7 HCl 500.0 kgs NTP Corrosive CARBOY
8 Soda Ash 500.0 kgs NTP Corrosive BAGS
9 Dimethyl Formamide 500.0 kgs NTP Harmful MS DRUM
10 Raney Nickel 100.0 kgs NTP Flammable CARBOY
11 Ethyl Acrylate 250.0 kgs NTP Harmful CARBOY
12 Benzene 1000.0 kgs NTP Flammable MS DRUM
13 Sodium Methoxide 200.0 kgs NTP Corrosive CARBOY
14 Thionyl Chloride 300.0 kgs NTP Corrosive, Harmful GAL.DRUM
15 Methylene Dichloride 500.0 kgs NTP Harmful HDPE DRUM
16 Sodium Hydroxide 300.0 kgs NTP Corrosive BAGS
17 Monochlorobenzene 750.0 kgs NTP Irritant MS DRUM
18 Benzoyl Chloride 250.0 kgs NTP Corrosive, Irritant HDPE DRUM
19 Aluminium Chloride 500.0 kgs NTP Corrosive, Harmful BAGS
20 Sodium Borohydride 50.0 kgs NTP Corrosive, Flammable MS CARBOY
21 1-Naphthol 500.0 kgs NTP Harmful BAGS
22 O-Dichloro Benzene 500.0 kgs NTP Flammable MS DRUM
23 Phenol 500.0 kgs NTP Corrosive ,Harmful MS DRUM
24 Carbon Tetrachloride 750.0 kgs NTP Harmful MS DRUM
25 Liq. Bromine 500.0 kgs NTP Corrosive CARRET PACK.
26 Ethylene Dichloride 500.0 kgs NTP Flammable HDPE DRUM
27 Zinc Chloride 200.0 kgs NTP Harmful ,Corrosive FIBER DRUM
55
ANNEXURE-VIII
_______________________________________________________________________
DETAILS OF STACKS & VENTS
Details of Flue Gas Emissions
Sr. No. Source of
Emission
Type of
Emission
Stack Height
(meter)
Stack
Diameter
(meter)
Pollution Control
Equipment
1 Boiler SPM, SO2,
NOx
15 0.5 -
2 DG Sets SPM, SO2,
NOx
8 0.2 -
2 Process Vent-1 SO2,
HCl, HBr
15 0.3 Scrubber
3 Process Vent-1 NH3 15 0.3 Scrubber
56
ANNEXURE-IX
_______________________________________________________________________
EXPECTED 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 equipments 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
EXPECTED NOISE LEVELS:
SR.
NO.
SOURCE OF NOISE PERMISSIBLE LIMIT
(DAY/NIGHT)
dB (A)
EXPECTED NOISE
LEVEL dB (A)
1. Near Security Gate 75/70 60
2. Near Administration Building 75/70 60
3. Near Boiler & Utility Block 75/70 65
4. Near ETP 75/70 65
5. Near Process Plant 75/70 65
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.
57
ANNEXURE-X
_______________________________________________________________________
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 new factory will have 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.
58
ANNEXURE-XI
_______________________________________________________________________
PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various
industries, surface water bodies, forests etc.
• Project cost
• Regulatory framework
• Project location and Plant layout.
• Existing infrastructure facilities
• Water source and utilization including proposed water balance.
• Product spectrum (proposed products along with production capacity) and process
• List of hazardous chemicals with their toxicity levels.
• Mass balance of each product along with the batch size
• Storage and Transportation of raw materials and products.
• Existing environmental scenario
2. Description of the Environment and Baseline Data Collection
• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall
in 5 km area.
• Study of Data from secondary sources.
• Other industries in the impact area
• Prevailing environment quality standards
• Existing environmental status vis a vis air, water, noise, soil in 5 km area from the project
site. For SPM, RSPM, SO2, NOx.
• Ground water quality at 5 locations within 5 km.
• Complete water balance
3. Socio Economic Data
• Existing socio-economic status, land use pattern and infrastructure facilities available in
the study area were surveyed.
4. Impacts Identification and Mitigatory Measures.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
• Control of fugitive emissions
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
59
6. Risk Assessment
• Objectives, Philosophy and methodology of risk assessment
• Details on storage facilities
• Identification of hazards
• Consequence analysis through occurrence & evaluation of incidents
• Recommendations on the basis of risk assessment done
• Disaster Management Plan.
• Safety precautions for the storage of Chemicals and vapour condensation.
7. Information for Control of Fugitive Emissions
8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Occupational Health and Safety Program for the Project.
10. Information on Rain Water Harvesting
11. Green Belt Development Plan
60
ANNEXURE-XII
_______________________________________________________________________
GIDC LETTER FOR WATER CONSUMPTION
61
ANNEXURE-XIII
_______________________________________________________________________
PETL MEMBERSHIP LETTER
62
63
ANNEXURE-XIV
_______________________________________________________________________
BEIL MEMBERSHIP LETTER