proposed pesticides intermediates & specialty...

25

FORM-1

for

PROPOSED PESTICIDES INTERMEDIATES &

SPECIALTY CHEMICALS IN EXISTING

INORGANIC CHEMICALS UNIT

of

M/S. PRAGNA PHARMA PVT. LTD.

PLOT NO. D2/CH/224, GIDC INDUSTRIAL ESTATE,

DAHEJ-2, TAL: VAGRA, DIST: BHARUCH-392130

(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:











Prepared By:

26

APPENDIX I

(See paragraph - 6)

FORM 1

(I) Basic Information

Sr.

No.

Item Details

1. Name of the project/s M/s. PRAGNA PHARMA PVT. LTD.

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

3. Proposed capacity/area/length/tonnage to

be handled/command area/lease

area/number of wells to be drilled

For detail Please refer Annexure – I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. For detail 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 No. D2/CH/224, GIDC Industrial

Estate, Dahej-2, Taluka: Vagra, Dist:

Bharuch, Gujarat

Plot/Survey/Khasra No. Plot No. D2/CH/224

Village GIDC Industrial Estate, Dahej-2

Tehsil Vagra

District Bharuch

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Nearest Railway Station: Bharuch (45 Km)

Nearest Airport: Vadodara (100 km)

11. Nearest Town, city, District Headquarters

along with distance in kms.

Nearest City: Bharuch (45 Km)

12. Village Panchayats, Zilla Parishad,

Municipal Corporation, local body

(complete postal address with telephone

nos. to be given)

--

13. Name of the applicant M/s. PRAGNA PHARMA PVT. LTD.

14. Registered Address M/s. PRAGNA PHARMA PVT. LTD.

Plot No. D2/CH/224, GIDC Industrial Estate,

Dahej-2, Taluka: Vagra, Dist: Bharuch,

Gujarat

15. Address for correspondence:

Name Mr. Jigneshkumar Kalidas Patel

Designation (Owner/Partner/CEO) Director

Address M/s. PRAGNA PHARMA PVT. LTD.

Plot No. 1210, GIDC, Ankleshwar-393002,

Dist: Bharuch, Gujarat

Pin Code 393002

E-mail [email protected]

27

Telephone No. Mobile: +919723812606

Tel. No: (02646)238106

Fax No. --

16. Details of Alternative Sites examined, if

any.

Location of these sites should be shown on

a topo sheet.

NA

17. Interlinked Projects No

18. Whether separate application of

interlinked project has been submitted?

No

19. If yes, date of submission No

20. If no, reason No

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) 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.,)

(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 will be carried out

within the existing premises.

1.2 Clearance of existing land, vegetation

and Buildings?

Yes Minor site clearance activities shall be

carried out.

1.3 Creation of new land uses?

No

28

1.4 Pre-construction investigations e.g.

bore

Houses, soil testing?

No

1.5 Construction works?

Yes For detail Please refer 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

Yes For detail Please refer 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 List of products attached in Annexure-I

and Manufacturing process is attached in

Annexure –III.

1.14 Facilities for storage of goods or

materials?

Yes Areas for storage of raw materials and

finished products will be developed.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes Details of the Liquid Effluent is given as

Annexure – V and Details of solid waste is

given as Annexure –VI.

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

leading to changes in traffic

movements?

No

1.20 New or diverted transmission lines or No

29

Pipelines?

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?

Yes Water Source: GIDC Water supply

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 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

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

2.2 Water (expected source & competing

users) unit: KLD

Yes Water Source: GIDC Water Supply

Please refer Annexure – IV.

2.3 Minerals (MT) No

30

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.

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel (MT),

energy (MW)

Yes Power required : 1000 KVA

D.G. Set : 500 KVA (during emergency

only)

Source: DGVCL

Fuel Requirement:

Existing :

Natural Gas: 1500 m3/Month

OR

LDO: 120 Ltrs/Hours

Proposed:

Natural Gas: 72000 SCM/Month

LDO/Furnace Oil : 100 Ltrs/Hours

Solid Fuel : 150 MT/Month

Diesel: 60 Lit/Hours

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)


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 – VIII.

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

31

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

Sr.

No.




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 –VI.

4.4 Other industrial process wastes Yes Please refer Annexure- VI.

4.5 Surplus product No

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Please refer Annexure- VI.

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 No

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

Sr.

No.




5.1 Emissions from combustion of fossil fuels

from stationary or mobile sources

Yes Please refer as Annexure – VII.

5.2 Emissions from production processes Yes Please refer as Annexure – VII.

5.3 Emissions from materials handling storage

or transport

No

5.4 Emissions from construction activities

including plant and equipment

No

5.5 Dust or odors from handling of materials

including construction materials, sewage

and waste

No

5.6 Emissions from incineration of waste Yes

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

32

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

Sr.

No.





6.1 From operation of equipment e.g. engines,

ventilation plant, crushers

Yes The Noise level will be within the

prescribed limit. At noisy area,

adequate preventive & control

measures will be taken. No significant

noise, vibration or emission of light &

heat from the unit.

6.2 From industrial or similar processes Yes -do-

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 No

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.




7.1 From handling, storage, use or spillage of

hazardous materials

No All the raw material shall be stored

separately in designated storage area

with safely measures. For detail please

refer Annexure – VIII

7.2 From discharge of sewage or other

effluents to water or the land (expected

mode and place of discharge)

No Sewage shall be disposed of through

specific tank & soak pit.

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

33

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



8.1 From explosions, spillages, fires etc. from

storage, handling, use or production of

hazardous substances

Yes For detail please refer Annexure – VIII.

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



9.1 Lead to development of supporting. lities, 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 – IX.

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

34

(II) 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

- The site is located in Notified

Industrial Area of GIDC Estate, Dahej-

2, Dist: Bharuch, Gujarat.

2 Areas which important for are or sensitive

Ecol logical reasons - Wetlands, watercourses

or other water bodies, coastal zone,

biospheres, mountains, forests

-

3 Area used by protected, important or

sensitive Species of flora or fauna for

breeding, nesting, foraging, resting, over

wintering, migration

-

4 Inland, coastal, marine or underground

waters

- N.A.

5 State, National boundaries

- N.A.

6 Routes or facilities used by the public for

access to recreation or other tourist, pilgrim

areas

- Public Transportation

7 Defense installations - N.A.

8 Densely populated or built-up area Bharuch Bharuch is around 45 km from the

proposed project site.

9 Area occupied by sensitive man-made land

uses Hospitals, schools, places of worship,

community facilities)

- N.A.

10 Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture,

fisheries, tourism, minerals)

- N.A.

11 Areas already subjected to pollution

environmental damage. (those where

existing legal environmental standards are

exceeded)or

- N.A.

12 Are as susceptible to natural hazard which

could cause the project to present

environmental problems (earthquake s,

subsidence ,landslides, flooding erosion, or

extreme or adverse climatic conditions)

- N.A.

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

35

I hereby given undertaking that the data and information given in the application and

enclosures are true to the best of my knowledge and belief and I am aware that if any part of

the data and information submitted is found to be false or misleading at any stage, the

project will be rejected and clearance given, if any to the project will be revoked at our risk

and cost.

Date: May 26, 2017

Place: Ankleshwar

NOTE:

1. The projects involving clearance under Coastal Regulation Zone Notification, 1991 shall submit

with the application a C.R.Z. map duly demarcated by one of the authorized agencies, showing the

project activities, w. r. t. C.R.Z. (at the stage of TOR) and the recommendations of the State Coastal

Zone Management Authority (at the stage of EC). Simultaneous action shall also be taken to obtain

the requisite clearance under the provisions of the C.R.Z. Notification, 1991 for the activities to be

located in the CRZ.

2. 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 thereon (at the stage of EC).

3. All correspondence with the Ministry of Environment & Forests including submission of application

for TOR/Environmental Clearance, subsequent clarifications, as may be required from time to time,

participation in the EAC Meeting on behalf of the project proponent shall be made by the authorized

signatory only. The authorized signatory should also submit a document in support of his claim of

being an authorized signatory for the specific project.

36

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 with Chemical and Mass Balance

IV Details of Water Consumption Wastewater Generation

V Effluent Treatment Scheme

VI Details of Hazardous /Solid Waste Generation, Handling and Disposal

VII Details of Air pollution Control System (Stack & Vent)

VIII Details of Hazardous Chemicals Storage & Handling

IX Socio-economic Impacts

X Proposed Terms of Reference for EIA studies

XI Plot Allotment Letter

XII Water Supply Letter

XIII CETP Membership Certificate

XIV RSPL Membership Certificate

XV TSDF Membership Certificate

XIV Toposheet

37

ANNEXURE – 1

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

LIST OF PRODUCTS

Sr.

No.

NAME OF PRODUCTS CAS

No.

Existing

Quantity

Additional

Quantity

Total

Quantity

after

expansion

(MT/Month)

1 Zinc Sulphate liq. 7733-02-0 1500 -- 1500

2 Zinc Sulphate powder 7733-02-0 1000 -- 1000

3 Zinc Oxide 1314-13-2 400 -- 400

4 Manganese Sulphate liq. 7785-87-7 1500 -- 1500

5 Manganese Sulphate

powder

7785-87-7 500 --- 500

6 Copper sulphate

(CUSO4.5H2O)

7758-98-7 300 -- 300

7 Magnesium Sulphate

powder

7487-88-9 500 -- 500

8 Spray Drying of

chemicals on job work

basis

-- 1000 -- 1000

9 2,5 DiChloro Para

Phenylene Diamine

105-56-6 25.0 25.0

10 2 Nitro 4 Methoxy

Aniline

20103-09-

7

25.0 25.0

11 2,5 Dimethyl-P-

Phenylenediamine

96-96-8 25.0 25.0

12 2-Mercapto 5-Methoxy

Benzimedazole

07-01-

6393

33.3 33.3

13 3-[4-chloro-5-

(cyclopentyloxy)-2-

fluorophenyl]-5-(propan-

2-ylidene)-1,3-oxazolidin-

2,4-dione. (PIK)

37052-78-

1

29.2 29.2

14 Sodium/Potessium { 2-[

2,6 Dichloro Phenyl]

Amino} Phenyl} Acetate

110956-

75-7

41.7 41.7

15 2 Chlor PPD 15307-79-

6

25 25

16 2 –{ 2[ 2-{2, 6 dichloro

phenyl } Amino ] Phenyl

Acetyl ] Oxyacetic Acid

139272-

67-6

41.7 41.7

17 2-Chloro 1-Phenoxy

Benzene

2689-07-8 41.7 41.7

38

18 2,3 Xylil Anthranilic Acid 61-68-7 41.7 41.7

19 2 Chloro 5 Methyl PPD 09-03-

5307

25 25

20 5 Amino Ortho Toludine 95-53-4 25 25

21 4-Bromo Anisole 104-92-7 25 25

22 2 Chloro 4 Flouro 5 Nitro

Benzyl Chloride

120890-

66-6

33.3 33.3

23 3 Amino 4 Methoxy

Acetanilide

6375-47-9 41.7 41.7

24 Para Anisidine 104-94-9 41.7 41.7

25 Para Amino Salicylic Acid 65-49-6 41.7 41.7

26 Nitro to amino

conversion by catalytic

hydrogenation

-- -- 83.3 83.3

Benzyl Alcohol 100-51-6

P-Hydroxy Benzyl Alcohol 623-05-2

P-Chloro Benzyl Alcohol 873-76-7

P-nitro Benzyl Alcohol 619-73-8

2,4 Di Nitro Benzyl

Alcohol etc.

483-66-2

27 Aldehyde to alcohol

conversion by catalytic

hydrogenation

-- -- 83.3 83.3

P-Amino Methyl

Benzoate

619-45-4

5-Amino Salicylic Acid 89-57-6

4-Amino 2-Chloro Aniline 615-66-7

2,5 Di Amino Toluene 95-80-7

Aniline etc.. 62-53-3

28 2-Amino Ethane Thiol

Hydrochloride

156-57-0 83.3 83.3

29 Dimethyl

CyanoCarbodithiomidiate

10191-60-

3

83.3 83.3

30 4-Chloro 3-ethyl-1-

methyl-1H-pyrazole 5-

carboxylic acid (PIC-T1)

127892-

62-0

25 25

31 1-[4-(4-

methylphenoxy)phenyl]

methanamine

Hydrochloride (PIC-T2)

262862-

66-8

25 25

TOTAL 6700 945.9 7645.9

39

LIST OF RAW MATERIALS

SR. NO. Name of Raw Materials CAPACITY

(MT/Month)

Existing

1. Zinc Sulphate liq.

1. Zinc Ingots/Zinc brass/ash 600

2. Sulphuric Acid 98% 630

2.Zinc Sulphate Powder

1. Zinc Ingots/Zinc brass/ash 600


3.Zinc Oxide

1. Zinc Ingots 322

2. Oxygen 80

4.Manganese Sulphate Liq.

1. Manganese oxide powder 300


5.Manganese Sulphate Powder

1. Manganese oxide powder 2585


6.Magnesium Sulphate powder

1. Magnesium oxide powder 300


7.Copper Sulphate (CuSO4.5H2O)

1. Copper metal/Cu ash 180


8. Spray Drying job work

1. Dilute Solutions of solutes to be dried --

Proposed

1. 2,5 DiChloro Para Phenylene Diamine

1. acetic anhydride 0.67

2. 2,5-dichloro aniline 1.00

40

3. sulphuric acid-48% 2.40

4. con. Nitric acid 0.39

5. hydrochloric acid 3.99

6. iron powder 0.90

7. sodium carbonate 0.06

2. 2 Nitro 4 Methoxy Aniline

1. para anicidine 0.83


3. nitric acid 0.43

4. MDC 2.50

5. soda 0.17

6. caustic 1.17

3. 2,5 Dimethyl-P-Phenylenediamine

1. 2,5 xylidine 1.25

2. sod carbonate 0.55

3. BSC 1.83

4. toluene 2.50

5. nitric acid 0.65

6. sulphuric acid 1.25

7. acetic acid 0.13

8. iron powder 0.68

4.2-Mercapto 5-Methoxy Benzimedazole

1. 4-methoxy nitro aniline 0.95

2. NaHS 2.10

3. CS2 0.43

4. NaOH 0.23

5. DMF 2.40

6. carbon 0.03

5. 3-[4-chloro-5-(cyclopentyloxy)-2-fluorophenyl]-5-(propan-2-ylidene)-1,3-oxazolidin-2,4-

dione. (PIK)

1. PICK3 0.96

41

2. TOLUENE 0.26

3. ECF 0.67

4. 40%NAOH 2.05

5. CPB 1.15

6. CAT-2 0.20

7. ETHANOL 0.27

8. CAT-3 0.02

9. CAT-4 0.07

10. ECG 0.89

11. CHARCOAL 0.01

12. SILICA GEL 0.01

6. Sodium/Potessium { 2-[ 2,6 Dichloro Phenyl] Amino} Phenyl} Acetate

1. indolinone 1.00

2. caustic flacks 0.14

7. 2 Chlor PPD

1. 2chloro para nitro aniline 1.27

2. methanol 2.55

3. H2 0.05

8. 2 –{ 2[ 2-{2, 6 dichloro phenyl } Amino ] Phenyl Acetyl ] Oxyacetic Acid

1. tba 0.26

2. MCAA 0.33

3. (2-((2,6,DICHLORO

PHENYL)AMINO)PHENYL)ACETATE 1.11

4. FORMIC ACID 1.93

9. 2-Chloro 1-Phenoxy Benzene

1. phenol 0.65

2. ODCB 2.02

3. KOH 0.39

10. 2,3 Xylil Anthranilic Acid

1. ocba 0.83

2. 2,3 xylidine 0.71

42

3. caustic 0.19

4. So. Bicarbonate 0.53

5. HCL 0.88

11. 2 Chloro 5 Methyl PPD

1. soda 0.40

2. BSC 1.50

3. 5-chloro methyl aniline 1.20

4. toluene 1.80

5. nitric acid 0.54


7. hydrogen gas 0.05

12. 5 Amino Ortho Toludene

1. O T 1.25

2. sod bicarbonate 0.62

3. BSC 2.06

4. nitric acid 0.75

5. toluene 2.50


7. methanol 2.50

8. H2 gas 0.06

13. 4-Bromo Anisole

1. phenole 0.54

2. DMS 0.51

3. NaOH 0.95

4. EDC 1.73

5. Bromine 0.92

6. NaHCO3 0.12

14. 2 Chloro 4 Flouro 5 Nitro Benzyl Chloride

1. 2 chloro 4-floro -1-(trichloromethyl)benzene 1.05

2. oleum 23% 1.80

3. nitric acid 0.84

43

4. sodium carbonate 0.91

5. methanol 1.40

15.3 Amino 4 Methoxy Acetanilide

1. methanol 1.31

2. dinitrochloro benzene 1.25

3. caustic 0.31

4. methanol 0.20


6. hydrogen 0.08

16. Para Anisidine

1. pncb 1.33

2. methanol 1.28

3. methanol 0.28

4. caustic 0.35

5. H2 0.05

17. Para Amino Salicylic Acid

1. para nitro salicylic acid 1.25

2. methanol 1.50

3. H2 0.04

18. amino derivatives

1. nitro compound 1.36

2. solvent 2.73

3. catalyst 0.05

4. h2 gas 0.11

5. carbon 0.05

19. alcohol derivatives

1. aldehyde compound 1.00

2. solvent 2.00

3. catalyst 0.03

4. h2 gas 0.08

5. carbon 0.03

44

20 A. 2-Amino Ethane Thiol Hydrochloride- route-1

1. 2-Aminoethanol 0.75

2. DM Water 3.01

3. C.S.Lye 1.04

4. CS2 0.93

5. Con.Hcl 0.68

6. NaOH solution(30 %) 0.94

7. Methanol 3.29

20 B. 2-Amino Ethane Thiol Hydrochloride- route-2

1. 2-Aminoethanol 0.66

2. THIONYL CHLORIDE 1.32

3. TOLUENE 1.98

4. NaHS (30 %) 2.02

5. IPA HCL 2.44

6. NaOH solution ( 10 % ) 0.62

7. NaOH solution ( 25 % ) 2.13

21. Dimethyl CyanoCarbodithiomidiate

1. Cynamide 0.73

2. CS2 0.60

3. 22.5 % NAOH 2.79

4. DMS 2.03

5. CYCLOHEXANE/Ethanol 5.00

22.4-Chloro 3-ethyl-1-methyl-1H-pyrazole 5-carboxylic acid (PIC-T1)

1. Methyl Ethyl Ketone 0.64

2. Toluene 5.24

3. Sodium Ethoxide 0.73

4. Di Ethyl Oxalate 1.35

5. Hydrochloric Acid-30% 3.35

6. Sodium bi carbonate 0.06

7. G.Acetic Acid 0.27

8. 80% Hydrazine Hydrate 0.77

45

9. Di Methyl Sulphate 1.00

10. C.S Lye (48%) 1.97

11. Chlorine Gas 0.33

12. Methanol 4.00

23. 1-[4-(4-methylphenoxy)phenyl]methanamine Hydrochloride (PIC-T2)

1. DMF 3.30

2. NaH 0.20

3. p-Cresol 0.59

4. p-Chlorobenzonitrile 0.68

5. Toluene 4.00

6. IPA 10.34

7. Raney Ni 0.20

8. Ammonia gas 0.02

9. H2 0.09

10. 16% IPA HCl 1.12

46

ANNEXURE – 2

PLANT LAYOUT

47

ANNEXURE – 3

MANUFACTURING ACTIVITIES

DESCRIPTION OF MANUFACTURING PROCESS WITH FLOW DIAGRAM:

EXISTING :

1) ZINC SULPHATE LIQ.

BRIEF PROCESS: Required quantity of water is taken in reactor and Sulphuric acid is added at controlled rate

with temperature control. Next Zinc Ingots/Zinc Ash are added to the reactor with

temperature control by circulating cooling water in reactor jacket. After the reaction is

complete, the mass is filtered to separate insoluble material as sludge.

The Filtrate is zinc sulphate liquid which is sent for packaging.

Chemical Reaction:

Zn + H2SO4 ZnSO4

65 98 177

Mass Balance:

Sr

No. INPUT Qty(in kg) OUTPUT

Qty(in

kg)

1 Zinc ingots/brass/ash 600 Zinc Sulphate Solution 1500

2 Sulphuric Acid 625 Effluent 100

3 Water 550 Wet cake/sludge 175

Total 1775 Total 1775

2) ZINC SULPHATE (powder)

BRIEF PROCESS:

Stage-1:Preparation of Zinc Sulphate Solution Zinc Sulphate solution is obtained by reaction of zinc Ingots/Zinc Ash with sulphuric acid as

detailed in manufacturing process of Zinc Sulphate solution.

Stage-2: Filtration After completion of the reaction filter the reaction mass. The wet cake/sludge will be

recycling in next batch. Solution will be carry forward for evaporation.

Stage-3: Evaporation The zinc sulphate solution is then evaporated to concentrate it up to Zinc content.

Stage-4: Crystallization & Centrifuging The concentrated solution is then cooled to 150 C to obtain of Zinc Sulphate.

The slurry is then centrifuged to separate crystals and mother liquor. Mother liquor is

recycled in next batch and crystals are sent for drying and packaging.

Stage-5: Spray drying Centrifuged wet cake dried and packed.

Chemical Reaction:

Zn + H2SO4 ZnSO4

65 98 177

Mass Balance:

48

Sr


Qty(in

kg)

1 Zinc ingots/brass/ash 600 Zinc Sulphate (powder) 1000




3) ZINC oxide

BRIEF PROCESS: Zinc oxide is obtained by oxidation of Zinc. Zinc ingots are heated to red hot in furnace and

oxygen gas is passed at controlled rate. Zinc ingots get oxidized and zinc oxide is obtained as

fine white powder. Unreacted material of the zinc ingots come out as zinc scrap.

Chemical Reaction:

2Zn + O2 2ZnO

MW 65 32 81

Zinc oxygen Zinc Oxide

Mass Balance:

Sr


Qty(in

kg)

1 Zinc ingots/brass/ash 600 Zinc Sulphate Solution 1500




4) MANGANESE SULPHATE SOLUTION

BRIEF PROCESS: 70% Sulphuric acid is charged gradually in reaction vessel. Then Manganese Oxide powder

(MnO) is added to the mixture with stirring. The reaction takes place and MnO dissolves in

the solution forming Manganese Sulphate solution.

Chemical Reaction:

MnO + H2SO4 MnSO4 + H2O

71 98 151 18

Manganese oxide Sulphuric

Acid

Manganese

SulphateWater

Mass Balance:

Sr


Qty(in

kg)

1 Manganese oxide powder 517

Manganese Sulphate

Solution 2600

2 Sulphuric Acid 625 Filter Cake 192

3 Water 1650


49

5) MANGANESE SULPHATE POWDER

BRIEF PROCESS:

Stage 1-Preparation of manganese sulphate solution

Manganese sulphate solution is obtained by reaction of manganese oxide with sulphuric acid

as detailed in manufacturing process of manganese sulphate solution.

Stage 2-Filtration After completion of the reaction filter the reaction mass. The wet cake/sludge will be recycle

in next batch. Solution will be carry forward for evaporation.

Stage 3-Evaporation The of manganese sulphate solution is then evaporated to concentrate it up to manganese

content.

Stage 4 – Crystallization & Centrifuging The concentrated solution is then cooled to 15° C to obtain heptahydrate crystals of

manganese sulphate.

The slurry is then centrifuged to separate crystals & mother liquor. Mother liquor is recycle

in next batch & crystal are sent for drying & packaging.

Stage 5 – Spray drying Centrifuged wet cake Dried & packed.

Chemical Reaction:

MnO + H2SO4 MnSO4 + H2O

71 98 151 18

Manganese oxide Sulphuric acid Manganese Sulphate

Water

Mass Balance:

Sr


Qty(in

kg)

1 Manganese oxide powder 517

Manganese Sulphate

Powder 1000


3 Water 550 Wet Cake/Sludge 192


6) COPPER SULPHATE

BRIEF PROCESS:

Stage 1 - Preparation of Copper Sulphate solution Copper Sulphate solution is obtained by reaction of copper ash, brass or copper metallic

content with sulphuric acid.

Stage 2- Filtration After completion of the reaction filter the reaction mass.The wet cake/sludge will be

recycling in next batch. Solution will be carry forward for evaporation and chilling.

Stage 3- Evaporation The of copper sulphate solution is than evaporated to concentrate it up to copper content.

Stage 4 – Crystallization & Centrifuging The concentrated solution is than cooled to 15 ˚C to obtain heptahydrate crystals of copper

sulphate.


recycled in next batch and the crystals are sent for drying and packaging.

50

Stage 5 – Spray drying Centrifuged wet cake dried and packed

Chemical Reaction:

CuO + H2SO4 CuSO4 + H2O

MW 79.5 98 159.5 18

Copper Oxide Sulphuric Acid Copper Sulphate

Mass Balance:

Sr


Qty(in

kg)

1 Copper oxide brass/ash powder 600 Copper Sulphate Powder 1000




7) MAGNESIUM SULPHATE POWDER

BRIEF PROCESS:

Stage 1 – Preparation of Copper Sulphate solution Magnesium Sulphate solution is obtained by reaction of magnesium ash, brass or

magnesium metallic content with sulphuric acid.

Stage 2 –Filtration After completion of the reaction filter the reaction mass. The wet cake/sludge will be

recycling in next batch. Solution will be carry forward for evaporation and chilling.

Stage 3 – Evaporation The of magnesium sulphate solution is then evaporated to concentrate it up to magnesium

content.

Stage 4 – Crystallization & Centrifuging The concentrated solution is then cooled to 15 ˚C to obtain hepta hydrate crystals of

magnesium sulphate.


recycled in next batch and the crystals are sent for drying and packaging.

Stage 5 – Spray drying Centrifuged wet cake dried and packed

Chemical Reaction:

MgO + H2SO4 MgSO4 + H2O

MW 40.3 98 120.4 18

Magnesium Oxide Sulphuric Acid magnesium sulphate

Mass Balance:

Sr


Qty(in

kg)

1

Magnesium oxide brass/ash

powder 600

Magnesium Sulphate

Powder 1000




51

8) SPRAY DRYING PROCESS

BRIEF PROCESS:

Dilute solutions of inorganic and organic chemicals shall be dried in Spray dryer and

packed in HDPE bags.

Flow Diagram:

Aprox.20% or 25% solution

Exhaust air to vent after passing

through wet scrubber with ventury

PRODUC

Hot air

TO Packaging

SPRAY

DRYING

52

PROPOSED:

1) 2,5 DICHLORO PARA PHENYLENE DIAMINE

BRIEF PROCESS: Cheak reactor is clean & dry. Charge acetic anhydride & 2,5 DCA , heat reaction mass to re

flux & maintain. Charge H2SO4 & NH3 for further reaction at RT. Add ice to isolate material.

Take reaction with caustic lye. Take reduction by iron powder add soda to maintain reaction

add HCL in reaction mass maintain for few hour till reaction is complete. Filtration, draying &

pack materials.

Chemical Reaction: STEP –I ACETYLATION

NH21

2

3

4

5

6

7

Cl8

Cl9

+

CH31 2

O3

O4

5

O6

CH37

acetic anhydride

1

NH2

3

4

5

6

7

8

Cl9

Cl10

CH311O

12

N-(2,5-dichlorophenyl)acetamide

+ CH31

2

O3

OH4

102

acetic acid

204 60

2,5-dichloroaniline

162

STEP- II NITRATION

NH

Cl

Cl

CH3O

+ OH N+

O-

O

+ OH S

O

O

OH

NH

Cl

Cl

CH3O

N+

O-

O

N-(2,5-dichloro-4-nitrophenyl)acetamide

sulfuric acidnitric acid

N-(2,5-dichlorophenyl)acetamide

+ OH S

O

O

OH + OH2

watersulfuric acid

204

63 98

249

98

18

STEP-III HYDROLYSIS

NH

Cl

Cl

CH3O

N+

O-

O

N-(2,5-dichloro-4-nitrophenyl)acetamide

249

+ Na OH

NH2

Cl

Cl

N+

O-

O

2,5-dichloro-4-nitroaniline

207

+Na

CH3

O

O

sodium acetate

82

40

53

STEP-IV

REDUCTIONNH2

Cl

Cl

N+

O-

O

+ 2 Fe2+ soda water

NH2

Cl

Cl

NH H

+fe derivatives H

2O+

2,5-DCPPD

177

2,5-dichloro-4-nitroaniline

207

+ 6 Hcl

112 219325 36

M.W 538=538

Mass Balance:

Sr


Qty(in

kg)

1 Acetic Anhydride 335 Product 500

2 2:5 DCA 210 Acetic Acid 625

3 H2SO4 1200 H2SO4 (70%) 1554

4 Nitric Acid 194 Effluent 2817

5 Caustic Lye 1040 Iron Sludge 407

6 Soda Ash 30

7 Iron Powder 344

8 HCl 2250

9 Ice 300


54

2) 2 Nitro 4 Methoxy Aniline

BRIEF PROCESS:

Checkreactor is clean & dry. Charge para anisidine& acetic anhydride, maintain to reflux

&distill acetic acid. Add HNO3 & MDC for further reaction. Filter mass & give watch of soda

water to w/c.Do hydrolysis in another reactor by caustic lye & water. Filter mass dry & pack

product.

Chemical Reaction:

Mass Balance:

Sr

No.

INPUT Qty(in kg) OUTPUT Qty(in kg)

1 PARA ANISIDINE 500 Product 600

2 Acetic Anhydride 435 Recovered MDC 1480

3 Nitric Acid 260 MDC Loss 20

4 MDC 1500 Effluent 2180

5 Caustic Lye (48%) 400 Residue 15

6 Water 1000

7 Soda 200


55

3) 2,5 Dimethyl-P-Phenylenediamine

BRIEF PROCESS:

Cheak reactor is clean & dry. Charge water Na2CO3 & 2, 5 xylidine .Do addition of

BSC. Maintain reaction filter mass. Take mass in another reactor. Charge toluene.

Addition of HNO3. Maintain reaction mass. Filter mass & add into other reactor. Add

H2SO4 dump mass in water. Filter the mass. Do reduction with iron powder. Acetic

acid in water media. Filter mass & draying of product and pack materials.

Chemical Reaction:

NH2

CH3

CH3

N+

O-

O

2,5-dimethyl-4-nitroaniline

166

Fe2+

56/240

NH2

CH3

CH3

NH2

+ OH2

2,5-dimethylbenzene-1,4-diamine

2

36

136

4 CH3COOH

+ Fe derivative

290

M.W 462=462

NH2

CH3

CH3

+ 1/2 Na2co3

S

O

O Cl

2,5-dimethylaniline

121

53

176.5

benzenesulfonyl chloride

S

O

O

NH

CH3

CH3

+

+

+

Nacl

58.5

1/2 H2O

9

22

N-(2,5-dimethylphenyl)benzenesulfonamide

261

S

O

O

NH

CH3

CH3

N-(2,5-dimethylphenyl)benzenesulfonamide

261

HNO3 Nitration

63

S

O

O

NH

CH3

CH3

N+

O-

O

+ OH2

18

S

O

O

NH

CH3

CH3

N+

O-

O

N-(2,5-dimethyl-4-nitrophenyl)benzenesulfonamide

306

Hydrolysis H2SO4 Media

OH2

306

18

NH2

CH3

CH3

N+

O-

O

+

SO O

OH

2,5-dimethyl-4-nitroaniline

benzenesulfonic acid

166

158

1/2 CO2

56

Mass Balance:

Stage-I:

Sr No. INPUT Qty(in kg) OUTPUT Qty(in kg)

1 2,5xylidine 500 Product 400

2 Sodium Carbonate 219 Dil. H2SO4 1695

3 BSC 730 Effluent 2521

4 Toluene 1000 Iron Sludge 350

5 Nitric Acid 260 Toluene Recover 960

6 H2SO4 500 Toluene Loss 35

7 Acetic Acid 50 Dist. Residue 5

8 Iron 231

9 Water 2476


57

4) 2-Mercapto 5-Methoxy Benzimedazole

BRIEF PROCESS:

Take 30% NaHs in S.S.Reactor and add 4 Methoxy Nitro Aniline slowly slowly on room

temperature. After addition maintain for two hour than rising the temperature slowly up to

85- 90° C. Than cool the mass up to 15 to 20° C and filter through C.F. and after filtration take

wet cake in S.S.Reactor in pressure of water + NaOH and add CS2 slowly slowly at room

temperature. After addition CS2 rise the temperature up to 105 – 110° C and maintain up to 4

hour after than make a cooling and isolate the product than filter through C.F. and give wash

of chilled water 5° c ,purify wet cake by solvent using carbon and dry the wet cake through

try Dryer or RVD.

Chemical Reaction:

OCH3

NO2

NH2

+ NaHS

4-methoxy-2-nitroaniline

M.W - 168

M.W - 56

OCH3

NH2

NH2

M.W - 138

CS2

N

NH

H3CO

SH

2-marcapto 5-methoxy benzimedazole

M.W- 180

+M.W-76

H2S

M.W- 34+ Na2S + SO2

M.W-78 M.W-64

4-methoxy benzene-1,2-diamine

Mass Balance:

Sr

No. INPUT Qty(in kg) OUTPUT Qty(in kg)

1 4 Methoxy Nitro Aniline 950 Product 1000

2 NaHS (30%) 2100 NaHS – recycled to next batch 1406

3 CS2 430 DMF Recover 2328

4 Caustic Flakes 226 DMF Loss 65

5 DMF 2400 Dis. Residue 7

6 Carbon 25 Spent Carbon 15

7 Water 1500 Effluent to ETP 2710

8 Drying Loss 100


58

5) 3-[4-chloro-5-(cyclopentyloxy)-2-fluorophenyl]-5-(propan-2-ylidene)-1,3-

oxazolidin-2,4-dione. (PIK)

BRIEF PROCESS:

STAGE- 1& 2 First Take PICK3 Organic & Toluene in GLR than add ECF and after ECF add 40 % NaOH. Than

Sample it after Sample Clearance transfer the material in S.S.Reactor and add CPB & Cat-2

than add 40 % NaOH after addition maintain two hour and add water and after settling below

aqueous layer is NaBr and upper organic layer is for Toluene Recovery and than add Ethanol

for Crystallization after Crystallization Filter it.

STAGE – 3 First Take Wet Cake and than add Cat-3 and Cat-4 and add ECG than heat the mass and

Sample it. After than add Toluene and Charcoal & Silica Gel than Filter the Charcoal than

Recover Toluene and Than add Ethanol for Crystallization and than filter it and wash it Wet

Cake again than dry the Wet Cake to get final dry product.

Chemical Reaction:

STAGE- 1 &2 ClF

NH2 OOC2H5

O

5-amino-2-chloro-4-fluorophenyl ethyl carbonate

M.W : 233.62

ClCOOC 2H5

40% NaOH

TOLUENE

M.W : 108.52ClF

H5C2OOCHN OOC2H5

O

2-chloro-5-[(ethoxycarbonyl)amino]-4-fluorophenyl ethyl carbonate

M.W : 305.68

Bu4NBr

cyclo pentyl bromide

40% NaOH

ClF

H5C2OOCHN O

ethyl [4-chloro-5-(cyclopentyloxy)-2-fluorophenyl]carbamate

M.W : 301.74

PICK4

PICK3EPF

STAGE-3 ClF

H5C2OOCHN O

M.W : 301.74

+

ClF

O

O

N

CH3

CH3

O

O

M.W : 353.77

COOC 2H5

OHCH3

O

M.W : 144.16

PICK4

PIK

ethyl 2-hydroxy-3-methylbut3-enoate

ethyl [4-chloro-5-(cyclopentyloxy)-2-fluorophenyl]carbamate

3-[4-chloro-5-(cyclopentyloxy)-2-fluorophenyl]-5-(1-methylethylidene)-1,3-oxazolidine-2,4-dione

FeCl3

(Bu)3N

59

Mass Balance:

Stage-I & II:


Step-1 & 2

1 Toluene 2141 Step -1&2 1200

2 PICK3 963 Toluene Recover 2066

3 ECF 673 Toluene Loss 65

4 40% NaOH 2053 Ethanol Recover 1517

5 CPB 1152 Ethanol Loss 70

6 CAT-2 IN WATER 200 Dist. Residue 10

7 Ethanol 1597 NaBR (By-Product) 1012

8 Water 1833 Effluent to ETP 3499

Water to be recycled 500


STEP-III:


Step-3

1 Step -1&2 1200 Product 1000

2 Cat-3 17 Process Waste 56

3 Cat-4 74 Spent Catalyst 20

4 ECG 889 Spent Charcoal 22

5 Toluene 1660 Toluene Recover 1610

6 Charcoal 9 Toluene Loss 45

7 Silica gel 9 Ethanol Recover 2145

8 Ethanol 2247 Ethanol Loss 95

9 Dist. Residue 12

Recover ECG 1100


60

6) Sodium/Potassium { 2-[ (2,6 dichloro phenyl)amino] Phenyl} Acetate

BRIEF PROCESS:

In SSR, charge C. S. Lye solution ,Charge indolinine ,Maintain for 10 hours 45-55 ⁰C temp,

Check TLC ,Filter it, collect w/c ,Dry Material in FBD/Tray Dyer & Pack.

Chemical Reaction:

NHCl

Cl

O

OH

296

NaOH/KOH

40/56

NaNH

Cl

Cl

O

O /K

{2-[(2,6-dichlorophenyl)amino]phenyl}acetic acid

sodium/potessium{2-[(2,6-dichlorophenyl)amino]phenyl}acetate

318/324

18

+ OH2

sodium/potessium{2-[(2,6-dichlorophenyl)amino]phenyl}acetate

Mass Balance:

Sr

No.


1 Indolinone 1000 Product 1000

2 Caustic Flake 250 Effluent 1250

3 Water 1000


61

7) 2 Chlor PPD

BRIEF PROCESS:

Reduction of 2 chloroparanitro aniline with hydrogen is done. Filtration of the product is

carried out with CF or ANF, Drying and Packing is done.

Chemical Reaction:

Mass Balance:


1 2 chlro para nitro Aniline 700 Product 550

2 Hydrogen 25 Recovered Methanol 1372

3 Methanol 1400 Methanol Loss 28

4 Drying Loss 140

5 Disti. Residue 10


62

74 150.5

+

NaNH

Cl

Cl

O

O

318

+

+

Cl

O

OH

chloroacetic acid

94.5

CH3

CH3

CH3OH

BUTANOLTBCA

18

OH2

150.5

TBCA

Cl

O

O

CH3

CH3

CH3

Cl

O

O

CH3

CH3

CH3

NHCl

Cl

O

OO

O

CH3

CH3

CH3

ESTER

410

NHCl

Cl

O

OO

O

CH3

CH3

CH3

ESTER

410

+ 3HCHO

NHCl

Cl

O

OO

OH

CH3

CH3

CH3OH

+

+

OH24

74

72

90

FORMIC ACID

ACECLOFENAC

354

+NaCl

58.5

8) 2 –{ 2[ 2-{2, 6 dichloro phenyl } Amino ] Phenyl Acetyl ] Oxyacetic Acid

BRIEF PROCESS:

4-(2-Methoxy ethyl) phenol reacted with epichlorhydrin in presence of caustic soda flakes

solution at 42 0C to produce Epoxide or 3-[4-(2-methoxyehtyl) phenoxy]-1,2-epoxypropane.

Dry and clean GLR ,Charge TBA in GLRUnder stirring, charge Mono chloro Acetic AcidCooland

than chill up to -5⁰CMaintain 4 hours 0-5⁰CSettle the mass and collect TBCA upper layer.

Check GLR, dry and cleanCollect TBCA and start heating.

Charge Sodium{ 2-[ (2,6 dichloro phenyl)amino] Phenyl} Acetate under stirring at room temp

in 4 hours,Maintain 6 hours at temp 80-85⁰C. Check TLC ,If condensation is okay, cool the

mass up to 50⁰C,Now charge formic acid, add in 2 hours at temp 50-55⁰C,Maintain 60-65⁰C

for 10 to 12 hours,Check TLC, if ok, cool the mass up to 20-20 ⁰C, Filter through C/F and

collect w/c, purify wet cake by solvent using carbon and dry the material in ANFD.

Chemical Reaction:

Mass Balance:


1 MCA 223 Product 675

2 TBA 174 Dil. Formic Acid 900

3

sodium {2-[2,6

dichlorophenyl)amino]phenyl}

Acetate 750 Effluent to ETP 797

4 Formic Acid 1300 Toluene Recover 1920

5 Toluene 2000 Toluene Loss 70

6 Carbon 25 Dist. Residue 10

Drying Loss 90

Spent Carbon 10


63

9) 2-Chloro 1-Phenoxy Benzene

BRIEF PROCESS:

Take ODCB in S.S. Reactor than add molten phenol. Then add KOH flakes than heat up to 140°

C temperatures, and maintain reaction mass and filter the salt and do the fractional

distillation of filtrate ML and collect the product.

Chemical Reaction:

OH

+

Cl

ClKOH / NaOH

O

Cl

PhenolOrtho Dichloro Benzene

2-Chloro 1 Phenoxy Benzene

+ + H2O

F. W :94.11 F. W: 147.00 F. W:204.65

KCl

F.W:74.55 F. W: 18.01

Mass Balance:

Sr

No.


1 Phenol 1000 Product 1544

2 ODCB 3124 Recovered ODCB 1824

3 KOH 595 Dist. Residue 30

4 KOH 792

5 Effluent 529


64

10) 2,3 Xylil Anthranilic Acid

BRIEF PROCESS:

Take 1000 liters water and add NaOH and OCBA, maintain for 1 hour at room temperature,

Addition of Xylidine in 60 minutes ,Rise temperature up to reflux (95-98⁰C) ,Maintain it for 5

to 6 hours, dump in to HCl ,Decrease temp. up to 30 ⁰C and then filter it though C/F ,purify

wet cake by using dmf and carbon and Dry the wet cake and go for packing .

Chemical Reaction:

Mass Balance:


1 OCBA 500 Product 600

2 2:3 xylidine 425 Recovered DMF 1455

3 NaOH 115 DMF Loss 35

4 Sod bicarbonate 320 Dist. Residue 10

5 HCL 530 Spent Carbon 15

6 DMF 1500 Effluent 2390

7 Activated Carbon 20 Drying Loss 155

8 Water 1250


65

11) 2 Chloro 5 Methyl PPD

BRIEF PROCESS:

Check reactor is clean & dry. Take water, soda ash, 2-chloro 5-methyl aniline. Start addition of

BSC at specific temperature. Maintain reaction for few hours. Filter the mass & charge in

other reactor. Add toluene & start addition of HNO3 at specific temperature condition to

complete nitration reaction. Filter mass & charge in reactor. Add H2SO4 &water, maintain

and filter mass. Charge wet cake in reactor. Add water and pass H2 gas at specific

temperature & pressure condition. Filter mass, dry & pack materials

Chemical Reaction:

66

Mass Balance:


1 BSC 750 Product 500

2 Soda Ash 200 Recovered Toluene 870

3 2-chloro 5-methyl Aniline 600 Toluene Loss 25

4 Toluene 900 Dist. Residue 5

5 Nitric Acid 270 Dil. Sulfuric Acid 1480

6 Sulfuric Acid 500 Effluent 2365

7 Hydrogen Gas 25

8 Water 2000


67

12) 5 Amino Ortho Toludine

BRIEF PROCESS: Cheak reactor is clean & dry. Charge water, OT base, soda. Start charging BSC under specific

condition & maintain. Filter mass and charge w/c in another reactor, charge toluene & start

addition of HNO3, maintain reaction and filter mass, do hydrolysis by sulphuric acid and

dump mass in water& filter mass. Charge in other reactor. Add methanol and pass H2 gas at

specific temperature and pressure to complete reaction, dry,& pack materials

Chemical Reaction:

Mass Balance:


1 Ortho Toluene 500 Product 400

2 Soda Ash 247 Recovered Toluene 950

3 BSC 824 Toluene Loss 40

4 Toluene 1000 Dist. Residue 20

5 Nitric Acid 300 Dil. Sulfuric Acid 1900

6 Sulfuric Acid 500 Effluent 1495

7 Hydrogen Gas 25 Recovered Methanol 950

8 Water 1400 Methanol Loss 40

9 Methanol 1000


68

13) 4-Bromo Anisole

BRIEF PROCESS:

Phenol reacts with dimethyl sulphate in presence of sodium hydroxide to get anisole. Anisole

react with bromine to get crude 4-bromo anisole. Crude 4-bromo anisole take for fractional

distillation to get pure 4-bromo anisole.

Chemical Reaction:

4-Bromo Anisole

OCH3 OCH3

Br

Br2 + HBr

Anisole 4-Bromo Anisole

M.W : 108.14 M.W : 187.04

M.W : 80.91M.W ; 159.81

OH

Phenol

M.W : 94.11

C.S Lye (48%)

S OCH3

O

O

H3CO

M.W : 126.13

Di Methyl sulphate

+ Na2SO4

M.W.: 142

M.W: 40

Mass Balance:


1 Phenol 700 Product 1300

2 DMS 657 Recovered EDC 2190

3 Caustic Lye 1240 EDC Loss 50

4 EDC 2254 Dist. Residue 14

5 Bromine 1192 NaBr Sol. 1225

6 NaHCO3 1610 Effluent 4974

7 Water 2100


69

14) 2 Chloro 4 Flouro 5 Nitro Benzyl Chloride

BRIEF PROCESS: Cheak reactor is clean & dry. Charge 2 chloro 4 fluoro toluene, pass chlorine gas at specific

temp. & pressure of UV light. Transfer mass in other reactor. Start addition mixture off oleum

& nitric acid. Maintain to complete reaction & check result. Dump mass in water and filter the

mass. Charge wet cake in other reactor, add water & give wash of Na2Co3 & filter mass. Take

methanol in other reactor. Charge w/c .heat mass to reflux & chill mass & filter, dry & pack

material.

Chemical Reaction:

Mass Balance:


1 2 chlro 4 floro Toluene 1050 Product 1712

2 chlorine gas 1550 Recovered Methanol 2330

3 Oleum 23% 3075 Methanol Loss 50

4 Nitric Acid 1474 Dist. Residue 20

5 Hydrogen Peroxide 630 HCl (30%) 2513

6 Na2CO3 150 Dil. H2SO4 6486

7 Methanol 2400 Effluent 1578

8 Water 4360


70

15) 3 Amino 4 Methoxy Acetanilide

BRIEF PROCESS:

Check reactor is clean and dry, add 2,4 DNCD and caustic lye slowly after reaction is over.

Then proceed for filteration of mass with centrifuge.Transfer the ml for ME distillation.Charge

the methoxy mass in reactor. Add methanol and then add slowly iron powder and acetic acid,

cool the mass and add MGO and acetic anhydride Filter the mass by centrifuge, dry and pack.

Chemical Reaction:

Mass Balance:


1 2:4 DNCB 1000 Product 800

2 DMS 657 Recovered Methanol 1010

3 Caustic Flake 250 Methanol Loss 30

4 Methanol 1210 Dist. Residue 10

5 Hydrogen 60 NaCl 300

6 Acetic Anhydride 515 Effluent to Reuse 1542


71

16) Para Anisidine

BRIEF PROCESS:

Cheak reactor is clean & dry. charge PNBC, methanol, charge methoxide prepared by MEOH

& NAOH, maintain to complete reaction. Pass H2 gas to do hydrogenation, filter mass to

separate salt. Take distillation of methanol. The high vacuum distillation of product &

materials.

Chemical Reaction:

Mass Balance:


1 PNCB 1000 Product 750

2 Caustic Flake 260 Recovered Methanol 1130

3 Methanol 1170 Methanol Loss 30

4 Hydrogen 40 Dist. Residue 10

NaCl 550


72

17) Para Amino Salicylic Acid

BRIEF PROCESS: Cheak reactor is clean & dry& ready for batch charging. Charge PNSA & methanol. Start H2

gas passing at specific temperature & pressure to complete reaction. Filter mass & dry wet

cake & pack finish materials.

Chemical Reaction:

Mass Balance:


1 PNSA 1250 Product 1000

2 Methanol 1500 Recovered Methanol 1450

3 Hydrogen Gas 42 Methanol Loss 40

4 Dist. Residue 10

5 Drying Loss 292


73

18) NITRO TO AMINO CONVERSION BY CATALYTIC HYDROGENATION

BRIEF PROCESS: Charge solvent in hydrogenation reactor and add nitro compound and catalyst, mix well heat

up to boiling point of solvent and start purging of H2 gas, as reaction completed filter the

catalyst and purify product by charcolisation then isolate and filter the product and dry to get

final AMINO product.

Chemical Reaction:

Mass Balance:


1 Nitro Compound 750 Product 550

2 Solvent 1500 Recovered Solvent 1470

3 Catalyst 25 Solvent Loss 20


5 Hydrogen 60 Spent Catalyst 27

Spent Carbon 30

Effluent 253


74

19) ALDEHYDE TO ALCOHOL CONVERSION BY CATALYTIC HYDROGENATION

BRIEF PROCESS:

Charge solvent in hydrogenation reactor and add aldehyde compound and catalyst, mix well

heat up to boiling point of solvent and start purging of H2 gas, as reaction completed filter

the catalyst and purify product by charcolisation then isolate and filter the product and dry to

get final ALCOHOL product.

Chemical Reaction:

Mass Balance:


1 Aldehyde Compound 750 Product 550

2 Solvent 1500 Recovered Solvent 1470

3 Catalyst 25 Solvent Loss 20


5 Hydrogen 60 Spent Catalyst 27

Spent Carbon 30

Effluent 253


75

20) 2-Amino Ethane Thiol Hydrochloride

BRIEF PROCESS:

Route -1

2-aminoethanol react with carbon disulphide to get 2-aminoethanthiol. 2-aminoethanthiol

react with hydrochloric acid to get 2-aminoethane thiolhydrochloride.

Chemical Reaction:

OH

NH2

2-aminoethanol

F.W : 61.08

CS2

NaOH

F.W : 76.14

F.W : 39.99

SH

NH2

2-aminoethanethiol

F.W : 77.15

+ NaHS + CO2

F.W: 56.06 F.W: 44.01

2HCl

SH

NH2 HCl

2-aminoethanethiol hydrochloride

F.W: 113.61

F.W: 36.5

+ H2S + NaCl

F.W: 34 F.W: 58.5

Mass Balance:

Sr


Qty(in

kg)

1 2-Aminoethanol 752 Product 1000

2 DM Water 3008 FILTRATE ML( TO ETP/MEE) 5451

3 C.S.Lye 1038 NaHS -30% SOLUTION 1414

4 CS2 932

DRYINGCONDENSATE(INCINERABLE

WASTE) 359

5 Con.Hcl 677 DISTILLED METHANOL 3167

6 Water 752

7 NaOH solution(30 %) 944

8 Methanol 3289


76

21) 2-aminoethane thiolhydrochloride

BRIEF PROCESS:

Route -2 2-aminoethanol react with thionyl chloride to get 2-chloroethanthiol hydochlorider. 2-

chloroethanthiol hydochlorider react with NaHS to get 2-aminoethane thiolhydrochloride.

Chemical Reaction:

OH

NH2

2-aminoethanol

SOCl2

F.W:61.08

F.W: 119Cl

NH2 HCl + SO2

F.W: 116

F.W: 64

NaHS

F.W: 56

HClSH

NH2 + NaCl

F.W: 58.5

2-chloroethanolamine hydrochloride

2-aminorthanethiol hydrochloride

F.W: 113.5 Mass Balance:

Sr No. Material INPUT Qty(in kg) Material OUTPUT

Qty(in

kg)

1 2-Aminoethanol 661 Product 1000

2 THIONYL CHLORIDE 1322 HCL - 30 % 1364

3 TOLUENE 1983 NaOH SOLUTION(10 %) 648

4 NaHS (30 %) 2023 Na2SO4 SOLUTION (25 %) 2843

5 IPA HCL 2438

FILTRATE ML 1 & 2( TO

ETP/MEE) 3279

6 Water 2231 DISTILLED TOLUENE 1942

7 NaOH solution ( 10 % ) 620 DISTILLED IPA 1983

8 NaOH solution ( 25 % ) 2132 RESIDUE 353

Total 13412 13412

77

22) Dimethyl CyanoCarbodithiomidiate

BRIEF PROCESS Cyanamide and carbon disulphide react with sodium hydroxide to produce disodium cyano

carbodithioimidiate. Disodiumcyanocarbodithioimidiate react with dimethyl sulphate to get

dimethyl cyano carbodithioimidate

Chemical Reaction:

CS2 +NH2

N

F.W : 76.14

Carbon disulphide cyanamide

F.W : 42.04

2NaOH

F.W : 40

N S-Na

+

S-Na

+N

F.W : 162.14

Di sodium cyano carbonodithioimidiate

+ 2H2O

F.W : 36.03

Di Methyl Sulphate

F.W. 126.13

N

N

SCH3

SCH3

+

S

O

O

OCH3H3CO

F. W : 142.04F.W:146.23

Dimethyl cyanocarbonodithioimidateSodium Sulphate

Na2SO4

Mass Balance:

Sr


1 Cynamide 660 Product 900

2 WATER 1572 FILTRATE ML 5588

3 CS2 538 Distilled cyclohexane/Ethanol 4275

4 22.5 % NAOH 2515 Incinerable waste 845

5 DMS 1823

6 CYCLOHEXANE/Ethanol 4500


78

23) 4-Chloro 3-ethyl-1-methyl-1H-pyrazole 5-carboxylic acid (PIC-T1)

BRIEF PROCESS:

Methyl ethyl ketone and di ethyl oxalate react in presence of sodium ethoxide to get

ethyl 2,4 dioxohexanoate. Ethyl 2,4 dioxohexanoate cyclise with hydrazine hydrate to

get 1-93-ethyl-1H-pyrazol-5-yl)propan-1-one further react with di methyl sulphate to

get 1-(3-ethyl-1-methyl-1H-pyrazol-5-yl)propan-1-one react with chlorine gas and

sodium hydroxide to get 4-chloro-3-ethyl-1-methyl-1H-pyrazole-5-carboxylic acid.

Chemical Reaction:

CH3

CH3

O

Methyl Ethyl Ketone

+

OC2H5

OC2H5

O

O

Di ethyl Oxalate

F.W: 146.14

NaoC2H5

F.W: 68

CH3

O

O

O

O

CH3

ethyl 2,4-dioxohexanoate

F.W:172.18

+ 2C2H5OH

F.W: 92.14

NH2NH2 H2O

F.W: 50.06

NNH

CH3

O

CH3

1-(3-ethyl-1H-pyrazol-5-yl)propan-1-one

F.W : 152.19

1/2 Di Methyl sulphate

F.W: 126.13N

NCH3

O

CH3

CH3

1-(3-ethyl-1-methyl-1H-pyrazol-5-yl)propan-1-one

NN

CH3

OH

O

CH3

Cl

4-chloro-3-ethyl-1-methyl-1H-pyrazole-5-carboxylic acid

F.W : 166.22

F.W : 188.61

Chlorine gas

Sodium Hydroxide

HCl F.W: 36.5

+ NaCl

F.W: 58.5

+ 3H2O

F.W : 54+H2SO4

F.W: 98

H2O

+ CH3OH + NaOH

F.W : 40F.W : 32

F.W : 35.5

F.W : 40

F.W : 18

F.W: 72

Mass Balance:

79

Sr.

No

INPUT Quantity (in

Kg)

OUTPUT Quantity

(in Kg)

1 Methyl Ethyl Ketone 636 Product 1000

2 Toluene 5241 distilled Toluene 4716

3 Sodium Ethoxide 726 NaCL 543

4 Di Ethyl Oxalate 1351 Filtrate ml to ETP/MEE 25334

5 Hydrochloric Acid-30% 3347 HCL -30% 689

6 Sodium bi carbonate 55 HYPO (14 % solution) 216

7 DM Water 16640 Condensate of drying 275

8 G.Acetic Acid 266 Distilled methanol 3561

9 80% Hydrazine Hydrate 774

10 Di Methyl Sulphate 1002

11 C.S Lye (48%) 1970

12 Chlorine Gas 326

13 Methanol 4000


80

24) 1-[4-(4-methylphenoxy)phenyl]methanamine Hydrochloride (PIC-T2)

BRIEF PROCESS:

P-Cresol react with 4-chlorobenzonitrile in presence of sodium hydride to get 4-(4-

methylphenoxy)benzonitrile. Hydrogenation of 4-(4-methylphenoxy)benzonitrile to

get 1-[4-(4-methylphenoxy)phenyl]methanamine react with IPA Hcl to get 1-[4-(4-

methylphenoxy)phenyl]methanamine hydrochloride.

Chemical Reaction: CH3

OH

CN

Cl

+

P Cresol

F. W : 108.14

4-chlorobenzonitrile

F. W: 137.57

O

CH3CN

4-(4-methylphenoxy)benzonitrile

F.W: 209.24

O

CH3CH2NH2

1-[4-(4-methylphenoxy)phenyl]methanamine Hydrochloride

HCL

F.W : 249.77

Sodium Hydride

F. W : 24+ NaCl

F.W: 58.5

Hydrogenation

Raney Ni

+ H2

2H2

Mass Balance:

Sr


1 DMF 2640 Product 800

2 NaH 158 Distill DMF 2627

3 p-Cresol 473 FILTRATE ML ( TO ETP) 2155

4 p-Chlorobenzonitrile 542 Distill Toluene 3190

5 Toluene 3196 Recycle Raney Ni 162

6 DM Water 1595 Distill IPA 8220

7 IPA 8270 H2 GAS 13

8 Raney Ni 162

FILTRATE ML-

2(INCINERABLE WASTE) 806

9 Ammonia gas 15

DRYING CONDENSATE

(INCINERABLE WASTE) 46

10 H2 72

11 16% IPA HCl 896


81

ANNEXURE - IV

WATER CONSUMPTION AND WASTEWATER GENERATION

WATER CONSUMPTION

SR.

No.

WATER

CONSUMPTION

QUANTITY (KL/DAY)

Existing Additional Total after proposed

expansion

1. Domestic 4.0 2.0 6.0

2. Process 100.0 43.0 143.0

3. Boiler 20.0 50.0 70.0

4. Cooling 10.0 20.0 30.0

5. Washing 11.0 5.0 16.0

5. Other (Gardening) 5.0 1.0 6.0

TOTAL (Industrial) 141.0 118.0 259.0

TOTAL (Domestic +Industrial) 150.0 121.0 271.0

WASTE WATER GENERATION

SR.

No.

WASTE WATER GENERATION

QUANTITY (KL/DAY)

Existing Additional Total after proposed

expansion

1. Domestic 2.5 2.0 4.5

2. Process 33.0 62.0 95.0

3. Boiler 5.5 12.0 17.5

4. Cooling 3.5 7.0 10.5

5. Washing 2.5 5.0 7.5

6. Other (Gardening) 0.0 0.0 0.0

TOTAL (Industrial) 44.5 86.0 130.5

TOTAL (Domestic +Industrial) 47.0 88.0 135.0

82

Water Balance Diagram (Existing):

(Unit-KL/Day)

Water –150 KL/Day

Domestic- 4.00 Gardening- 5.00 Industrial –141.00

2.5 KL/Day �

Specific

tank/soak pit

system Process- 100 Washing- 11 Boiler- 20

Cooling- 10

Process- 33 Washing- 2.5 Boiler- 5.5 Cooling- 3.5

ETP

M/S. GIDC, Dahej (discharged to underground

pipline) for further treatment & disposal = 44.5

KLD

83

Water Balance Diagram (Proposed):

(Unit-KL/Day)

Water –121 KL/Day

Domestic- 2 Gardening- 1 Industrial –118

2.0 KL/Day �

Specific

tank/soak pit


Cooling- 20

Process- 62 Washing- 5 Boiler- 12 Cooling- 7

ETP (56 KL/Day Low COD Effluent + 35 KL/Day-MEE Condensate)

)

81 KL/Day

Reuse/Recycle

30 KL/Day – High COD

Effluent + 10 KL/Day RO

Reject � MEE

5 KL/Day �

MEE

35 KL/Day �

MEE

Condensate

91 KL/Day � RO

84

Water Balance Diagram (Total):

(Unit-KL/Day)

Water –271 KL/Day

Domestic- 6 Gardening- 6 Industrial –259

4.5 KL/Day �

Specific

tank/soak pit


Cooling- 30

Process- 95 Washing- 7.5 Boiler- 17.5 Cooling- 10.5

ETP (100.5 KL/Day Low COD Effluent + 35 KL/Day-MEE Condensate)

)

81 KL/Day

Reuse/Recycle

30 KL/Day – High COD

Effluent + 10 KL/Day RO

Reject � MEE

5 KL/Day �

MEE

35 KL/Day �

MEE

Condensate

91 KL/Day � RO M/S. GIDC, Dahej (discharged to underground

pipline) for further treatment & disposal = 44.5

KLD

85

ANNEXURE - V

EFFLUENT TREATMENT PLANT

PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)

EXISTING:

For Low COD and TDS Stream I (44.5 KLD)

M/s. Pragna Pharma P. Ltd. shall have an Effluent treatment plant consisting of primary,

secondary, tertiary and advanced treatment units. The effluent confirming to inlet standards

of GIDC drain shall be discharged in to underground drainage line. The details of ETP are as

follows.

First all non-toxic and biodegradable streams (low & medium COD) of wastewater shall pass

through Screen Chamber (SC) where floating material shall be removed with help of Screen

(S-01). Then effluent shall be collected in Collection cum Equalization tank-1 (CET-1). Pipe

grid is provided at bottom of the CET-1 to keep all suspended solids in suspension and to

provide proper mixing by mixer.

Then after, equalized wastewater shall be pumped to Neutralization Tank-1 (NT-1) where

the continuous addition and stirring of caustic solution is done to maintain neutral pH of

wastewater from Caustic Dosing Tanks (CDT) as per requirement by gravity. Then after,

neutralized wastewater shall go to Flash Mixer-1 (FM-1) by gravity. Alum and Polyelectrolyte

shall be dosed from Flocculants Dosing Tank (FLDT) and Polyelectrolyte Dosing Tank (PEDT)

respectively by gravity into FM-1 to carry out coagulation by using a Flash Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler-1 (PTS-1). Clear

supernatant from PTS-1 shall be passed in Aeration Tank (AT-1) here, biodegradation of

organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the

AT-1 and for that oxygen shall be supplied by 2 nos. of air blowers (B-02) through diffusers.

Air blowers also keep MLSS in suspension.

Then after, wastewater shall go to Secondary Settling Tank-1 (SST-1) from AT. Here, the

suspended solids shall be settled. Sludge shall be removed from bottom of SST-1 and

pumped to AT to maintain MLSS and excess activated sludge shall be sent to Sludge Sump

(SS). Clear supernatant from SST-1 shall go to Aeration Tank-2 (AT-2). Here biodegradation

of left out organic matter of the wastewater shall be carried out by bacteria (suspended

growth) and for that oxygen shall be supplied by two nos. of blowers (B-03) with help of

diffusers. Then after, wastewater shall go to Secondary Tube Settler-2 (SST-2) from AT-2.

Here, the suspended solids shall be settled. Activated sludge shall be removed from bottom

of SST-2 and pumped to AT-2 to maintain MLSS and remaining will be sent to SS. Nutrients

will be added from NDTs to Aeration Tank-2 for growth of Bacteria. Clear effluent is the

collected in of Intermediate Sump (IS) by gravity.

Thereafter, the wastewater shall be passed through Pressure Sand Filter (PSF) to remove left

out TSS and Activated Carbon Filter (ACF) and collected in Treated Effluent Sump. Clear

supernatant from SST shall be collected in Treated Effluent Sump before sent to GIDC drain

for deep sea disposal.

86

Sludge settled in PTS-1&2 and excess sludge from SST-1&2 shall be collected in Sludge Sump

then sludge shall be pumped to Filter Press where, dewatering shall be carried out before

storage in HWSA and ultimate disposal to TSDF. Leachate from FP shall be sent back to CET-

1 for further treatment.

Effluent treatment Plant (Dimension):

S.N. Name of unit Size (m x m x m)

L x B x (LD+FB) No. MOC/ Remark

Stream I (Low COD & TDS Stream) 44.5 m3/D

1 Screen Chamber (SC-01) 1.0 m x 0.7 m

(0.05 m+0.3 FB) 1

RCC M25+A/A

Bk. Lining

2

Collection cum

Equalization Tank-1 (CET-

01)

3.0 m x2.5 m x

(2.0 m+0.5 FB) 1

RCC M25+A/A

Bk. Lining

3 Neutralization Tank-1 (NT-

01)

1.0 m x 1.0 m x

(2.0 m +0.5 FB) 1

RCC M25+A/A

Bk. Lining

4 Flash Mixer-1 (FM-01) 1.0 m x1.0 m x

(1.8 m +0.7 FB) 1 RCC M25

5 Primary Tube Settler-1

(PTS-01)

2.5 m x 2.0 m x

(1.5 m + 0.75HB+0.5

FB)

1 RCC M25

6 Aeration Tank-1 (AT-01) 8.0 m x 3.5 m x

(4.0 m+0.5 m) 1 RCC M25

7 Secondary Settling Tank-1

(SST-01)

3.0 m x 2.0 m x

(2.0 m + 0.75 HB+0.5

FB)

1 RCC M25

8 Aeration Tank-2 (AT-02) 4.0 m x 3.5 m x

(4.0 m+0.5 m) 1 RCC M25


(SST-02)

3.0 m x 2.0 m x

(2.0 m + 0.75 HB+0.5

FB)

1 RCC M25

10 Intermediate Sump (IS-01) 2.0 x 1.5 x (2.5 m+0.5) 1 RCC M25

11 Pressure Sand Filter (PSF-

01) 2.22 m3/hr 1 FRP

12 Activated Carbon Filter

(ACF-01) 2.22 m3/hr 1 FRP

13 Treated effluent Sump 4.0 m x 3.0 m x

(2.5 m + 0.5) RCC M25

14 Sludge Sump(SS-01) 2.0 x 1.5 x (2.5 m+0.5) 1 RCC M25

15 Filter Press(FP-01) 9 m3

/ batch 1 PP

87

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PCC = PLAIN CEMENT CONCREAT

SS = STAINLESS STEEL

PP = POPYPROPELINE

Flow Diagram:

Mode of Disposal:

MODE OF DISPOSAL

INDUSTRIAL

Generation Quantity Mode of Disposal

Existing: 44.5 KL/Day

Treated effluent is disposed off into deep sea through GIDC

Drainage line.

DOMESTIC 2.5 KL/Day

MODE OF DISPOSAL Discharged in to Septic Tank & Soak Pit.

88

PROPOSED: For Low COD and TDS Stream I (56 KLD)

M/s. Pragna Pharma P. Ltd. shall have a Effluent treatment plant consisting of primary,

secondary, tertiary and advanced treatment units. The details of ETP are as follows.

First all non-toxic and biodegradable streams (low & medium COD) of wastewater shall

collected in Equalization cum Neutralisation Tank-1 (ENT-1) where caustic solution is done

to maintain neutral pH of wastewater from Caustic Dosing Tanks (CDT-01) as per

requirement by gravity. .Mixer is provided in ENT-02 to keep all suspended solids in

suspension and to provide proper mixing.

Then after, neutralized wastewater shall go to Flash Mixer-1 (FM-01) by gravity. Alum and

Polyelectrolyte shall be dosed from Flocculants Dosing Tank (FDT-01) and Polyelectrolyte

Dosing Tank (PEDT-01) respectively by gravity into FM-1 to carry out coagulation by using a

Flash Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler-1 (PTS-01). Clear

supernatant from PTS-1 shall be passed in Aeration Tank (AT-01) here, biodegradation of

organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the

AT-01 and for that oxygen shall be supplied by 2 nos. of air blowers (B-02) through diffusers.

Air blowers also keep MLSS in suspension.

Then after, wastewater shall go to Secondary Settling Tank-1 (SST-01) from AT-1. Here, the

suspended solids shall be settled. Sludge shall be removed from bottom of SST-01 and

pumped to AT-02 to maintain MLSS and excess activated sludge shall be sent to Sludge

Sump (SS-01). Clear supernatant from SST-01 shall go to Aeration Tank-2 (AT-02).

Here biodegradation of left out organic matter of the wastewater shall be carried out by

bacteria (suspended growth) and for that oxygen shall be supplied by two nos. of blowers

(B-03) with help of diffusers. Then after, wastewater shall go to Secondary Tube Settler-2

(SST-02) from AT-2. Here, the suspended solids shall be settled. Activated sludge shall be

removed from bottom of SST-2 and pumped to AT-2 to maintain MLSS and remaining will be

sent to SS. Nutrients will be added from Nutrient Dosing Tank (NDT-01) to Aeration Tank-2

for growth of Bacteria. Clear effluent is the collected in of Intermediate Sump (IS-01) by

gravity.

Thereafter, the wastewater shall be passed through Multi Gain Filter (MGF-01) to remove

left out TSS and Activated Carbon Filter (ACF-01) and collected in Treated Effluent Sump.

From TWS-01 water shall be sent to RO for further treatment. RO reject shall be mixed with

effluent in ME Feed Tank. RO permeate shall be reuse in plant.

Sludge settled in PTS-01 & 02 and excess sludge from SST-01 & 02 shall be collected in

Sludge Sump then sludge shall be pumped to Filter Press where, dewatering shall be carried

out before storage in HWSA and ultimate disposal to TSDF. Leachate from FP-01 shall be

sent back to ENT-01 for further treatment.

89

For High TDS Stream II (40 KLD) - 30 KLD (High COD) + 10 KLD (RO Reject)

All High COD & TDS streams of wastewater shall be collected in Equalization cum

Neutralization Tank-2 (CET-02) where caustic shall be added from Caustic Dosing tank to

maintain neutral pH of waste water. Mixer is provided in ENT-02 to keep all suspended

solids in suspension and to provide proper mixing.

Then after, neutralized wastewater shall be pumped to Flash Mixer-2 (FM-02) where Alum

and poly shall be added from Flocculant Dosing Tank (FDT-01) and Poly Dosing Tank (PEDT-

01) respectively. Then after, coagulated wastewater shall be settled in Primary Tube Settler-

2 (PTS-02). Sludge settles in PTS-02 shall be sent to Sludge sump (SS-01).

Clear effluent from PTS-01 shall be collected in Holding Tank (HT-01) before pumped to

strippers. Effluent from stripper shall be then collected in MEE Feed Tank(MFT-01) here RO

Reject shall be mixed with it. Then before it will be pumped to Multiple Effect Evaporator for

further treatment. Condensate from MEE will be treated in ETP and it will be

reused/recycled in existing premises. And thick liquid shall be sent to Agitated Thin Film

Dryer (ATFD-01) for drying. Solids from ATFD-01 shall be collected and stored in HWSA for

disposal in TSDF.

90

Effluent Treatment Plant (Dimension):

S.

N. Name of unit

Size (m x m x m)

L x B x (LD+FB) No. MOC/ Remark

Stream I (Low COD Stream) 56 KLD + 35 KLD MEE Condensate

1 Equalization cum

Neutralisation Tank (ENT-01) 5.25 m x4.0 m x

(3.0 m+0.5 FB)

2 RCC M25+A/A Bk.

Lining

2 Flash Mixer-1 (FM-01) 1.3 m x1.3 m x

(2.5 m +0.5 FB)

1 RCC M25

3 Primary Tube Settler-1(PTS-

01) 4.0 m x 2.5 m x

(2.0 m + 0.75HB+0.5 FB)

1 RCC M25

4 Aeration Tank-1 (AT-01) 10 m x 6.0 m x

(4.5 m+0.5 m)

1 RCC M25


(SST-01) 4.0 m x 3.3 m x

(2.5 m + 0.75 HB+0.5 FB)

1 RCC M25

6 Aeration Tank-2 (AT-02) 10 m x 6.0 m x

(4.5 m+0.5 m)

1 RCC M25


(SST-02) 4.0 m x 3.0 m x

(2.5 m + 0.75 HB+0.5 FB)

1 RCC M25

8 Intermediate Sump (IS-01) 3.0 x 2.0 x (3.0 m+0.5)

1 RCC M25

9 Multi Grain Filter (MGF-01) 6.0 m3/hr 1 FRP/MSEP

10 Activated Carbon Filter (ACF-

01) 6.0 m3/hr

1 FRP/MSEP

11 Treated effluent Sump 5.25 m x4.0 m x

(3.0 m+0.5 FB)

1 RCC M25

12 RO Units (RO-01) 100 KLD 1 STD.

13 Sludge Sump(SS-01) 2.0 x 2,0 x (2.5 m+0.5) 1 RCC M25

15 Filter Press(FP-01) 30 m3/D 1 PP

Stream II High COD Stream (40 KLD) -30 KLD (High COD) + 10 KLD (RO Reject)

1 Equalization cum

Neutralisation Tank-2 (ENT-

02)

3.5 x 3.5 x (3.0LD+0.5 FB) 1 RCC M25+A/A

Bk. Lining

3 Flash Mixer-2(FM-02) 1.0 x 1.0 x (1.5LD+0.5 FB) 1 RCC M25

4 Primary Tube Settler-02

Tank (PTS-02)

2.5 x 1.5 x (2.0LD+0.5 FB) 1 RCC M25

5 Holding Tank (HT-01) 3.5 x 3.5 x (3.0 LD+0.5 FB) 1 RCC M25

6 Strippers (ST-01) 34 m3/day 1 SS316L

7 MEE Feed Tank (MFT-01) 5.0 x 3.5 x (3.0 LD+0.5 FB) 1 RCC M25

91

8 Four Stages Multiple Effect

Evaporators with Agitated

Thin Film Dryer (MEE-01,

ATFD-01)

34 m3/day 1 SS316L

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PCC = PLAIN CEMENT CONCREAT

SS = STAINLESS STEEL

PP = POPYPROPELINE

Flow Diagram:

Mode of Disposal:

MODE OF DISPOSAL

INDUSTRIAL

Generation Quantity Mode of Disposal

Proposed Total: 86.0 KL/Day

30 KL/Day

(Concentrated Stream)

Shall be subjected to MEE and treated in ETP and it will be

reused/recycled in Plant premises.

56 KL/Day

(Dilute Stream)

Treated effluent will be reused/recycled in plant premises.

DOMESTIC 2.0 KL/Day

MODE OF DISPOSAL Discharged in to Septic Tank & Soak Pit.

92

ANNEXURE-VI

DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL

CAT.

NO. HAZARDOUS WASTE

Existing

Quantity

Additional

Quantity

Total

Quantity METHOD OF DISPOSAL

33.1 Discarded

Containers/Bags

/liner

Bags = 167

Nos. /Month

Drums = 42

Nos. /Month

Bags = 4,167

Nos./Month

Drums =

1,250

Nos./Month

Bags = 4,334

Nos./Year

Drums =

1,292

Nos./Month

Collection, Storage,

Decontamination,

Transportation & Sale to

registered recycler or

reuse within premises.

5.1 Used Oil 0.167

Kg/Month

12.50

Kg/Month

12.50

Kg/Month Collection, Storage,

Transportation & Sale to

GPCB authorized re-

processor.

-- Zinc Sludge (Sludge

generation during Zinc

Salts production)

175

MT/Month

-- 175

MT/Month


Transportation & send to

TSDF Site

-- MnSO4 (Sludge

generation during

Manganese Sulphate

production)

112.5

MT/Month

- 112.5

MT/Month


Transportation and send

to TSDF Site

35.3 ETP Sludge 3

MT/Month

41.67

MT/Month 44.67

MT/Month


Transportation & sent to

TSDF Site

29.1 Solid Waste (Inorganic

Waste)

-- 45

MT/Month

45

MT/Month Collection, Storage,

Transportation and

Disposal at TSDF site

-- MEE Salt -- 150

MT/Month

150


Transportation and

Disposal at TSDF site

20.3 Distillation Residues -- 220

MT/Month

220


Transportation and Co-

processing in Cement

Industries or incineration

at Common Incineration

facility

29.5 Spent Catalyst -- 10

MT/Month

10


Transportation and send

to recycler

29.6 Spent Acid -- 550

MT/Month

550


Transportation and Sale

to end user

93

-- Sodium Hydro sulfide -- 170

MT/Month

170



to end user

- Hydrochloric Acid -- 180

MT/Month

180



to end user

- Formic Acid -- 100

MT/Month

100



to end user

- Acetic Acid -- 10

MT/Month

10



to end user

- Sodium Bromide

Solution

-- 170

MT/Month

170



to end user

28.1 Inorganic Salt -- 60

MT/Month

60


Transportation and Send

to TSDF site

- NaOH (10%) -- 60

MT/Month

60



to end user

- Na2SO4 (25%) -- 250

MT/Month

250



to end user

- HYPO -- 10

MT/Month

10



to end user

- Potassium Chloride

Salt

-- 25

MT/Month

25


Ttransportation and Sale

to end user

29.3 Date expired & Off-

Specification Material

-- 2

MT/Month

2


Transportation and sent

for co-processing in

cement industries or

incineration in common

incineration facility

DETAILS OF DISPOSAL OF SOLID WASTES

Industry is a member of TSDF site of M/s. BEIL (Bharuch Enviro Infrastructure Ltd) for suitable

treatment & disposal of hazardous wastes from time to time.

Industry is a member of M/s. RSPL & M/s. SEPPL for Co-processing & common Incineration facility

respectively.

94

ANNEXURE-VII

DETAILS OF AIR POLLUTION CONTROL SYSTEM

DETAILS OF FUELCONSUMPTION

SR. NO. NAME OF FUEL QUANTITY

EXISTING ADDITIONAL

1. Natural Gas

OR

LDO

1500 m3/Month

OR

120 Lit/Hr

72,000

SCM/Month

2. LDO/Furnace Oil -- 100 Lit/Hr

3. Soild Fuel -- 150 MT/Month

4. Diesel -- 60 Lit/Hr

DETAILS OF PROCESS VENT AND BOILER STACK

• EXISTING (FLUE GAS EMISSION THROUGH STACK)

Sr.

No.

Stack

Attached to

Stack Height in

meter

Air Pollution

Control Measure

Parameter Permissible Limit

1.

Boiler

(Capacity = 600

Kg/Hr)

11 --- SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

2. Hot Air Generator

(3 Nos.)

11 --- SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

3. Furnace (5 Unit) 20 Cyclone

Separator

SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

• EXISTING (PROCESS GAS EMISSION THROUGH STACK)

Sr.

No.

Stack

Attached to

Stack Height in

meter

Air Pollution

Control Measure


1.

Spray Dryer (3 Nos.) 12 Wet Scrubber

with ventury

SPM

150 mg/Nm3

95

• PROPOSED (FLUE GAS EMISSION THROUGH STACK)

Sr.

No.

Stack

Attached to

Stack Height in

meter

Air Pollution

Control Measure


1.

Steam Boiler

(800 Kgs/Hr-1 Nos.)

(Fuel –Natural Gas)

15 -- SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

2. Steam Boiler

(2000 Kgs/Hr-1

Nos.)

(Fuel-Solid Fuel like

Agro Waste, Coal)

30 Multi Cyclone

Separator with

Bag Filter

SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

3. Steam Boiler

(600 Kgs/Hr)

(Fuel-Natural Gas)

Stand by

15 -- SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

4. Steam Boiler

(800 Kgs/Hr-1 Nos.)

(Fuel –LDO/Furnace

Oil)

Stand by

30 Multi Cyclone

Separator with

Bag Filter

SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

5. Thermic Fluid

Heater

(4.0 LAC K.CAL/Hr)

(Fuel-Natural Gas)

15 -- SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

6. Thermic Fluid

Heater

(6.0 LAC K.CAL/Hr)

(Fuel-Solid Fuel)

30 Multi Cyclone

Separator with

Bag Filter

SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

7. Thermic Fluid

Heater

(4.0 LAC K.CAL/Hr)

(Fuel-LDO/Furnace

Oil)

Stand By

30 Multi Cyclone

Separator with

Bag Filter

SPM

SOX

NOX

150 mg/Nm3

100 ppm

50 ppm

96

ANNEXURE-VIII

DETAILS OF HAZARDOUS CHEMICALS STORAGE & HANDLING

Sr No. Name of chemical POTENTIAL

HAZARD

Mode of storage

(in drums /carboys

/bags/ storage tank )

MAX

STORAGE

QTY.

1 SULPHURIC ACID CORROSIVE STORAGE TANK 20 KL

2 Hydrochloric acid CORROSIVE STORAGE TANK 20 KL

3 CON.NITRIC ACID CORROSIVE STORAGE TANK 20 KL

4 ACETIC ACID CORROSIVE DRUM 10 KL

5 ACETIC ANHYDRIDE CORROSIVE DRUM 10 KL

6 FORMIC ACID CORROSIVE DRUM 10 KL

7 OLEUM 23% CORROSIVE STORAGE TANK 20 KL

8 NAHS TOXIC STORAGE TANK 10 KL

9 CS2 FLAMMABLE DRUM/ STORAGE TANK 5 MT

10 Bromine CORROSIVE BOTTAL 1 MT

11 Phenol CORROSIVE DRUM 10 MT

12 ODCB TOXIC DRUM 10 MT

13 DMS TOXIC DRUM 5 MT

14 Hydrogen gas FLAMMABLE CYLINDER 0.8 MT

15 2chloro para nitro aniline TOXIC BAG 5 MT

16 5-chloro methyl aniline TOXIC BAG 5 MT

17 ORTHO TOLUDINE FLAMMABLE DRUM 5 MT

18 Para nitro salicylic acid TOXIC BAG 5 MT

19 2,5 dichloro aniline TOXIC DRUM/BAG 5 MT

20 TBA FLAMMABLE DRUM 5 MT

21 MCAA TOXIC DRUM/BAG 5 MT

22 DNCB TOXIC BAG 5 MT

23 2,5 xylidine FLAMMABLE DRUM 5 MT

24 BSC TOXIC DRUM 5 MT

25 4-Methoxy nitro aniline TOXIC DRUM/BAG 5 MT

26 OCBA TOXIC BAG 20 MT

27 2,3 xylidine FLAMMABLE DRUM 10 MT

28 Dinitrochloro benzene TOXIC DRUM/BAG 5 MT

29 2 Chloro 4-floro -1-

(trichloromethyl)benzene CORROSIVE DRUM 10 MT

30 PNCB TOXIC DRUM/BAG 5 MT

31 MDC TOXIC DRUM 10 MT

32 DMF FLAMMABLE DRUM 20 KL

33 Methanol FLAMMABLE STORAGE TANK 20 KL

34 EDC FLAMMABLE DRUM 10 MT

35 Toluene FLAMMABLE STORAGE TANK 20 KL

36 Nitro compound TOXIC DRUM/BAG 10 MT

97

37 Aldehyde compound TOXIC DRUM/BAG 10 MT

38 Ethanol FLAMMABLE STORAGE TANK 20 KL

39 2-Aminoethanol FLAMMABLE DRUM/ STORAGE TANK 20 MT

40 THIONYL CHLORIDE FLAMMABLE DRUM 10 MT

41 Cynamide TOXIC DRUM/ STORAGE TANK 20 MT

42 Sodium Ethoxide FLAMMABLE DRUM 20 MT

43 Di Ethyl Oxalate FLAMMABLE DRUM/BAG 20 MT

44 80% Hydrazine Hydrate FLAMMABLE DRUM 10 MT

45 Ammonia gas CORROSIVE CYLINDER 10 MT

46 NaH FLAMMABLE DRUM/BAG 10 MT

47 Chlorine Gas CORROSIVE CYLINDER 10 MT

48 Raney Ni FLAMMABLE DRUM/BAG 5 MT

98

ANNEXURE – IX

SOCIO - ECONOMIC IMPACTS

1) Employment Opportunities

The manpower requirement for the proposed Expansion project is being 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

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 economical status of the

locality, to some extent.

3) Public Health

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 have been taken and

proposed expansion 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 proposed

expansion project there will be no adverse impact on sanitation, communication and community

health, as sufficient measures have been proposed expansion to be taken under the EMP. The

proposed expansion project is not expected to make any significant change in the existing status of

the socio -economic environment of this region.

99

ANNEXURE-X

______________________________________________________________________

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 10 km area and site details providing various

industries, surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Water source and utilization including proposed water balance.

• Product spectrum (proposed products along with production capacity) and process

• List of hazardous chemicals.

• Mass balance of each product

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 10 km

area.

• Existing environmental status Vis a Vis air, water, noise, soil in 10 km area from the project site.

For SPM, RSPM, SO2, NOx.

• Ground water quality at 8 locations within 10 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

• Identification of impacting activities from the proposed expansion project during construction

and operational phase.

• 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.

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

6. Risk Assessment

• Objectives and methodology of risk assessment

• Details on storage facilities

• Process safety, transportation, fire fighting systems, safety features and emergency capabilities to

be adopted.

• Identification of hazards

• Consequence analysis through occurrence & evaluation of incidents

• Disaster Management Plan.

100

7. Information for Control of Fugitive Emissions

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.

9. Information on Rain Water Harvesting

10. Green Belt Development plan

101

ANNEXURE-XI

______________________________________________________________________

PLOT ALLOTMENT LETTER

104

ANNEXURE-XII

______________________________________________________________________

WATER SUPPLY LETTER

105

ANNEXURE-XIII

______________________________________________________________________

Waste water discharge document

106

ANNEXURE-XIV

______________________________________________________________________

RSPL MEMBERSHIP CERTIFICATE

107

ANNEXURE-XV

______________________________________________________________________

TSDF MEMBERSHIP CERTIFICATE

108

ANNEXURE-XVI

______________________________________________________________________

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