Astec Lifesciences Ltd.environmentclearance.nic.in/writereaddata/Online/TOR/26...about 6.5%). The ever-increasing demand for Pesticides and Intermediated in India and abroad as well

August 2017

Sadekar Enviro Engineers Pvt. Ltd. Page 1

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Astec Lifesciences Ltd.

PPlloott nnoo –– BB--1166,,1177,, 1188,, && BB--2211,, MMIIDDCC MMaahhaadd ,, MMaahhaadd,, RRaaiiggaadd,,MMaahhaarraasshhttrraa.. 440022330099

EIA Consultant

M/s. SADEKAR ENVIRO ENGINEERS PVT. LTD.

QCI – NABET accredited EIA consultancy for schedule 5(b) Cat.-‘A’Certificate No – NABET/EIA/1518/SA 021

NABL Accredited Laboratory, Valid up to 29.06.2018Lab. Recognized by MoEF& CC, GOI, Valid up to 2.01.2019

Certified by ISO 9001:2008 & BS OHSAS 18001:2007

310, Dempo Towers, EDC Patto, Panaji, Goa state, India. PIN: 403001Email :[email protected] / [email protected]

Web site:-www.sadekarenviro.com Telephone :0832-2437048/2437164

August 2017


Table of Content

Sr. Title Page

1 Executive summary 3

2 Introduction of the project 5

3 Description of Project 8

4 Site Analysis 19

5 Planning 22

6 Proposed infrastructure 23

7 Rehabilitation and resettlement 27

8 Project schedule and cost estimation 27

9 Analysis of proposal 27

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1. Executive summary

Salient Features of ProjectName & Address ofCompany

M/s Astec Lifescience Ltd.

Plot no B-16,17, 18, & B-21, MIDC Mahad , Mahad, Raigad, Maharashtra.402309.

Schedule of project asper EIA Notification,2006

5 (b)

Category of Project ‘A’

Area statementExisting, sq. m. Proposed, sq. m. Total, sq. m.

Plot area

B-16,17,18 12150 -- 13950

B-21 1800

Built up area 8544 -- 8544Green belt 3500 1100 4600

Production detailsExisting

(MT/month)

Proposed (MT/month) Total

(MT/month)

Pesticide products 219

(Vide consent no.

Format 1.0/ AS(T)/EIC

No. RD-3108-

15/Amend/CC-3030 dt.

25/07/2016)

562 781

Pesticide Formulation 700

(Vide consent no.

MPCB/ROR/15/11840

dt. 08/09/2015)

-- 700

byproducts -- 1773 1773

Total production 919 2335 3254

Water Requirement Existing, CMD Proposed, CMD Total, CMD

Vide pesticide productionCTO

205.67 94.33 447

Vide pesticide formulationCTO

147

Total 352.67 94.33 447Effluent generation 35.43 164.57 200

136.43 164.57 200

Effluent treatment Existing 36.43 CMD effluent & 15 CMD sewage is treated in 55 CMD ETP.

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The treated effluent is discharged to CETP. Additional 164.5 CMD will betreated by two psychrometric evaporators of 500 TR capacity each. Total 52.5CMD effluent will be recycled to process.

Sewage generation 11 -- 15415 -- 15

Sewage Treatment Sewage is mixed with effluent and treated in aeration tank of ETP.

Utility requirementExisting Proposed Total

Boiler 06 TPHStack : 30m

10 TPHStack : 39 m

1 unit of 6 TPH1 unit of 10 TPH

2.5 TonStack Height :25m

Will be discontinued

850 Kg/hrStack Height :24 m

Will be discontinued

Thermic fluid heater -- 6 lakh kcal/hrStack Height: As perCPCB norms

6 lakh kcal/hrStack Height: As perCPCB norms

-- 2 lakh kcal/hrStack Height: As perCPCB norms

2 lakh kcal/hrStack Height: As perCPCB norms

Electrical powerConnected load 1600 KVA -- 1600 KVA

900 KVA -- 900 KVADG set 250 KVA

Stack height: 3.5 m

500 KVA

Stack height: 4.5 m

1. 250 KVA

Stack height: 3.5 m

2. 500 KVA

Stack height: 4.5 m

125 KVA*2 units

Stack height: 3.5 m

(Will be

discontinued)

FuelCoal for boiler 22 MTPD 35 MTPD 57 MTPD

FO for TFH 125 L/day 6450 L/day 6575 L/day

HSD 110 L/day 2700 L/day 2810 L/dayStack height

Boiler 30 m 39 m 1 stack of 30 m1 stack of 39 m

Thermic fluid heater - As CPCB guidelines 2 stacks as per CPCBguidelines

DG , 125 KVA 3.5 m above roof 125 KVA DG Will be discontinued250 KVA 3.5 m above roof -- 3.5 m above roof500 KVA -- 4.5 above roof 4.5 above roofProcess scrubber 5 m above roof -- 5 m above roof

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Hazardous wasteType Category Existing After expansion Disposal

Used/ spent oil 5.1 50 1000 L/month Sale to Authorised recycler /CHWTSDF

Residues and waste 29.1 204 411MT/m CHWTSDF

Chemical sludge residuefrom herbicides

29.2 2.7 0 CHWTSDF

Discarded containers 33.1 78 1250 nos/M Sale to Authorised recycler /CHWTSDF

Chemical sludge from ETP 35.3 1.12 69 MT/m CHWTSDF

Filter & filter materialhaving organic liquid

36.2 32 500 kg/m CHWTSDF

Spent carbon 36.2 10 200 kg/m CHWTSDF

Asbestos gaskets 15.2 - 100 kg/m CHWTSDF

Spent solvents 29.4 28 MT/m 140 MT/m Sale to Authorised recycler /CHWTSDF

Non hazardous wasteExisting After expansion Disposal

Paper waste (paper boxesand bags)

150 kg/m 5600 kg/m

Sale to registered brickmanufacturer

Plastic waste 50 kg/m 5600 kg/mMetal scrap 100 5000 kg/mWooden pellets 25 1000 nos/mCoal ash 2700 8550 kg/d

Existing Proposed TotalMan power 160 - 160EMP cost, 60 Lakh rupees capital cost. 7.2 lakh rupees operating costProject Cost, 5 Cr. rupees

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2. Introduction of the project

2.1 Identification of Project Proponent:

The objective of this pre-feasibility study is to provide information for the Pesticides and

Chemical Intermediates manufacturing unit of Astec Lifesciences Ltd. at Plot No. B-16, 17,

18 and B-21, MIDC Mahad, District Raigad, Maharashtra.

As per the EIA Notification No S. O. 1533 promulgated on 14th September 2006, proposed

expansion project has covered Pesticides Industry and pesticide specific intermediates as 5 (b) and

need prior environmental clearance. It is stated that 5(b) industries located in a notified

industrial area are classified in category A and would be appraised by Centre Level Expert appraisal

committee. Based on the OM dated 16th May 2014 by Director MoEF, Public Hearing is

exempted for the Industrial Estates / Parks which have taken Environmental Clearance.

Introduction of the Project Proponent

Mr. Ashok Hiremath, Managing Director, Astec LifeSciences, is a Masters of Arts from

University of Oxford and Post Graduate Diploma holder in Chemical Engineering from University

College, University of London. He started his career as Project Engineer in 1978 with GEA Air

exchangers Ltd., London. He returned to India in 1980 and joined Hiremath Chemicals Ltd., a

company promoted by his brother as Technical Manager where he was responsible for

manufacturing and business development. After leaving this company in 1994 from the post of

Technical Manager, he established Astec Lifesciences Ltd. as one of the promoters and since

then he has been actively involved and played a key role in the growth of the Company with his

inputs in strategic planning and business development.

2.2 Nature of project:

The expansion project will be done at Plot No B-16, 17, 18 and B-21 at MIDC Industrial area

Mahad with land admeasuring 13950 Sq Meters. The land is already in demarcated as “Industrial”

in a notified industrial area and is not a prime agricultural land. Thus there is no change in the land

use status.

2.3 Need for the project and its importance to the country and or region:

India's Chemical industry is the third largest in the world in terms of volume. Its rank is 14 in terms

of value. India is also one of the top five active Chemical ingredients producers (with a share of

about 6.5%). The ever-increasing demand for Pesticides and Intermediated in India and abroad as

well as changing market conditions requisite Indian Chemical industries to grow further.

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The company aims to expand its product portfolio further in order to cater to Domestic &

International markets by expanding its production capacities. These products will serve to cut the

supply of imports from foreign countries thus saving currency and at the same time will earn

valuable foreign currency by export of the proposed products.

Astec Lifesciences Limited is a global supplier of Pesticides and chemical intermediate to the other

chemical companies worldwide. Astec Lifesciences Limited aims to expand its product portfolio

further in order to cater to domestic & international markets by expanding its production capacities.

These products will serve to cut the supply of imports from foreign countries thus saving currency

and at the same time will earn valuable foreign currency by export of the proposed products.

2.4 Demand supply gap

Competition in the Indian Chemical market swelled in recent years, with increasing generic

penetration. This had many companies opting out of low-margin segments, as competition resulted

in lower prices. This created a gap between demand and supply. Such unusual price hikes take

place when there is withdrawal of some of the key competitors, which leads to demand override

and as a consequence prices start soaring in a free-pricing market.

2.5 Import Vs. Indigenous production

The proposed products including production of pesticides and chemical intermediate have huge

demand in the domestic as well as export market. Production of these pesticides and chemical

intermediate are domestically reduces the need to import products along with significant scope for

export in these products.

2.6 Export & economic feasibility

The Indian crop protection industry is of USD 4.25 billion in FY14 and is expected to grow at a

CAGR of 12% to reach USD 7.5 billion by FY19. Exports currently constitute almost 50% of

Indian crop protection industry and are expected to grow at a CAGR of 16% to reach USD 4.2

billion by FY19, resulting in 60% share in Indian crop protection industry. Domestic market on the

other hand would grow at 8% CAGR, as it is predominantly monsoon dependent, to reach USD 3.3

billion by FY19. Globally, India is fourth largest producer of crop protection chemicals, after

United States, Japan and China. The crop protection companies in India can be categorized into

three types –Multi-National, Indian including public sector companies and small sector units.

August 2017


Source: Industry Analysis by Tata Strategic

2.7 Domestic/ export markets

The finished goods will be sold in domestic market primarily and it would be exported to the

Regulated International Market as per demand.

2.8 Employment generation:

The activities will be done by industry would produce improvement in the socioeconomic

status of people in the study area in terms of local labor employment and contract basis jobs.

The expansion activity provide employment opportunities services like transportation activity.

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3. Description of Project

3.1 Project type:

Proposed expansion project is to manufacture Pesticides and Chemical Intermediates. Production

capacity of the manufacturing of pesticide and chemical intermediate will be of 781 MT/M and

1773 MT/month of byproducts and 700 MT/m of formulation products.

3.2 Location

Astec Lifesciences Ltd. proposes expansion of existing manufacturing unit located at Plot No B-

16, 17, 18 and B-21, MIDC Mahad, District Raigad, Maharashtra. A total of about 13950 SQMs of

land is acquired for the expansion project. Satellite image of the expansion project is shown

below.

Figure 1: Location of M/s Astec Lifescience Ltd

The project site is well connected by Mumbai- Goa highway (NH 66). The national highway is

approximately 9 km away and can be reached by state road network. The nearest railway station

is Veer which is approximately 18 km away from site. The MIDC map is given in figure 2

showing location of plot in MIDC.

Nearby Industries

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Sr. Direction Industry

1 North Odessy organics Pvt. Ltd.

2 South Tritech catalyst and

intermediates Pvt. Ltd.

3 East Caprolactum chemicals Pvt.

Ltd.

4 West Vinati Organics Pvt. Ltd.

Figure 2: MIDC Mahad map

The plot layout of expansion unit of M/s Astec Lifescience Ltd. is given in figure 3. Total plot

area is 13950 sq. m. the location of plant building, utility building, ware house, internal roads,

parking area is shown in the layout.

M/s. Astec Lifesciences Ltd.Plot no. B-16,17,18 & B-21

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Figure 3 : Plot layout of Astec Lifesciences Ltd.

Area statement of M/s Astec Lifescience Ltd

Sr. Particulars Existing Area (sq. m.) Proposed Area (sq.

m.)

Total Area (sq. m.)

1 Total plot

area

13950 13950 13950

2 Built up area 8544 -- 8544

3 Green belt

area

3500 1100 4600

3.3 Details of alternate sites considered:

This is an expansion project for existing products and new products along with byproducts will be

manufactured on existing plot. There is sufficient area available for expansion and current site is in

approved chemical zone of MIDC and is well connected to get raw material by road / railway and

August 2017


carry on the manufacturing activities. the MIDC have all adequate facilities viz. good road and rail

network, 24 hour electricity, water supply, MIDC roads, CETP etc.

3.4 Size of operation

The production capacity with byproducts is given in following table.

Sr. No.Product

ExistingQty

(MT/M)

Total Quantity(MT/M)

1 Propiconazole 15.00 1652 Hexaconazole 14.00 1003 Tebuconazole 60.00 1504

Dextrinol6.00

2

5 3,4-Chlorostyrene 30.00 256 Metalaxyl 5.00 10

74-Hydroxy 3-Methyl-2-(Propinyl)-2-Cyclopentene-1-Lon

12.00 12

8 Dichloro Benzyl Cyanide/4-Chlorophenyl Ethyl Chloride

5.00 5

9 Bromuconazole 30.00 4010 Cyproconazole 25.00 2511 Prallethrine 12.00 1212 Difenoconazole 5.00 3013 Tricyclazole - 30

14 2-Ethyl 2-Methyl ButanoicAcid

- 10

15 Metconazole - 20

165-Methyl-Α-(2-Propinyl) -5-Furfuryl Alcohol

- 10

17 Myclobutynil - 2518 Dimethoxy Benzoic Acid - 2019 Boscalid - 2020 Prothiconazole - 20

21 Ipconazole - 20

22 4-Trifluromethyl BenzylAlcohol

- 20

23 Fenpyroximate - 10

Total219

781

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List of byproducts

Sr No Name of Byproduct Qty Unit Remarks1 Aliphatic Hydrocarbon 114

2MT/month Sale / Job work

2 Biphenyl3 Dil HCL 49 MT/month Sale / Job Work4 H3PO3 2 MT/month Sale /Job Work5 K2CO3

,K2SO4,KTMI,KBr,KOH,KCL, 805MT/month Sale /Job Work

6 LiOH H2O 3 MT/month Sale /Job Work7 MGCl2, MgBr2,MgSO4 242 MT/month Sale /Job Work8 Na2SO4,Nacl,NaBr,NaOH 536 MT/month Sale /Job Work9 ZnCl2,Zn,Zn(CH3CO)2 21 MT/month Sale /Job Work

Total 1773 MT/month

List of formulation products

S.No.Product Existing

Qty.(MT/M)

ProposedQty.

(MT/M)

Total Quantity(MT/M)

1 Wettable Powder(WP/SP) 150 0 100( 50 MT will bereduced)

2 Granular Products(CG/G) 150 0 1503 Liquid Product EC 200 0 2004 Liquid Product (SC/SL) 200 50 250

Total 700 50 700

3.5 Project description with process detail.

The process details and material balance for Propiconazole Technical is given in following table.

Manufacturing process of other products is given in annexure-1.

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August 2017


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3.6 Raw material details

Raw Materials:

The basic raw material for this key product capacity are submitted herein below and for the

details are

given for all reactants, solvents and work up support chemicals.

Source for Raw Material Procurement: Raw Material is easily available in the local market;

some of the raw materials will be procured from the International Market.

Mode of Transport of Raw Materials: Few of the raw materials will be transported locally

and few will be imported from the International Market.

August 2017


Storage at the site: Raw Materials will be stored in storage yard at the project site. Location of

storage yard is demarcated in Layout Plan. Raw Material list is given in following table.

Table 4: Raw Material List

Sr.No. Product Name of RM1

Hexaconazole

Valeryl ketone2 Dimethyl Sulphide3 Dimethyl Sulphate4 Pottasium Hydroxide5 Valeryl Oxirane6 Dimethyl Acetamide7 Triazole8 Sodium Hydroxide9 Sodium bisulphide10 Sodium thiomethoxide11 Methanol12

Tebuconazole

Pentanone13 Potassium Hydroxide14 Dimeyhyl Sulphide15 Dimethyl Sulphate16 Oxirane17 Dimethyl Formamide18 Triazole19 Potassium Hydroxide20

Metalyxal

2,6 Xylidine21 Methyl chloro propionate22 Sodium Bromide23 Dimethyl formamide24 Cyclohexane25 Sodiumbi carbonate

26T-Butyl AmmoniumBromide

27 Methoxy acetyl chloride28 Ammonia soln29

Benzenepropanenitrile4-chloro-a-phenyl

p-Dichloro Benzene30 Mg31 THF32 Toluene33 Thionyl Chloride

Benzyl nitrileLiNH2

34 Ethylene Oxide35

Dextronil

Crotonic acid36 Butydine37 Isobutidine38 Xylene

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39 Hydrochloric acid40 Potassium Hydroxide41

Propiconazole

Dichloroacetophenone42 1,2 propanediol43 Sulphuric Acid44 Cyclohexane45 Bromine46 Caustic lye47 Dimethyl acetamide48 Triazole49 Sodium Hydroxide50

Cyproconazole

Ketone51 Dimethyl Sulphide52 Dimethyl Sulphate53 Sodium Hydroxide54 SPT Oxirane55 Dimethyl Acetamide56 Triazole57 Sodium Hydoxide58

Difenoconazole

CCP-ll59 Propylene glycole60 Sulphuric acid61 Cyclohexane62 Bromine63 Caustic lye64 CCP-lV65 Dimethyl Acetamide66 Triazole67 Sodium Hydroxide68

Bromoconazole

Trichloro acetophenone69 Magnessium70 Tetrahydrofuron71 Allyl Chloride72 Hydrochloric acid73 Potassium Carbonate74 Dimethylformamide75 Methanol76 Hydrobromic acid77 Dichloromethane78 Sodium Thiosulphate79 Triazole80 Bromine81 Pottasium Hydroxide82

TRICYCLAZOLEHMBT

83 Formic acid84 Pallethrin 2-Methylfuron

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85 Dimethylformamide86 Phosgene87 2,3-Dichloropropane88 Zink89 Acetic acid solution90 Toluene91 DMCC92 Potassium Hydroxide93 Celite94 Triacetonalkamine95

4-HYDROXY-3-METHYL-2-(2-PROPINYL) -2-CYCLOPENTENE-1-ON

2-Methylfurfural96 Tetrahydrofuron97 Magnessium98 Allyl chloride99 HCl100 Acetic acid101

3,4-Chlorostyrene

Chlorobenzaldehyde102 THF103 Methyl chloride104 Magnesium105 HCl 32%106 Sulphuric acid107

Metconazole

Dimethyl Adipate108 Sodium methoxide 28%109 Toluene110 Dimethyl Formamide111 Methyl Bromide112 Sodium methoxide 28%113 Dimethyl Formamide114 P-chloro benzyl chloride115 Toluene116 Ketone M117 Sodium hydride118 Toluene119 Dioxane120 NaOH solution 48%121 Ketone-K122 Dimethyl Sulphide123 Dimethyl Sulphate124 Pottasium Hydroxide125 Oxirane126 Dimethyl Acetamide127 Triazole128 Sodium Hydroxide129

MyclobutynilIntermediate

130 Dimethyl Acetamide

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131 Triazole132 Sodium Hydroxide133

2-Methyl 2-EthylButanoic acid

Methyl Chloride134 Magnesium135 Tetrahydrofuron136 Diethyl Ketone137 HCL (32%)138 DK-2139 Thionyl chloride140 DK-3141 Magnesium142 Tetrahydrofuron143 Toluene144 CO2 gas145 HCL (32%)146

5-METHYL-α-(2-PROPINYL) -5-FURFURYLALCOHOL

Propygil Chloride147 Magnesium148 THF149 Toluene150 Zink chloride151 Methyl Furfuryldehyde152 Biphenyl153 HCL (32%)154

Dimethoxy BenzoicAcid

Dichloro Benzyl nitrile155 Sodium Methoxide156 NaOH Sol. 20%157 Dimethyl sulphoxide158 HCl159

Boscalid

1,4 Dichlorobenzene160 Magnesium161 Toluene162 THF163 Trimethyl Borate164 HCl165 1-chloro-2-nitrobenzene166 Toluene167 Catalyst168 Methanol169 Pd-C170 Acetonitrile171 PCl3172 Sodium Hydroxide173 Cat.174 Cyclohexane175

ProthioconazolePTC-l

176 N-butyl lithium

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177 Hexane178 Sulphur179

Epconazole

Dimethyl adipate180 Sodium methoxide181 2-Bromopropane182 Toluene183 Cat-R184 4-Chlorobenzyl chloride185 Sodium hydrxide

186

Fenpyroximate

Dimethyl 4-chloropyrazole formaldehyde

187 Pottasium Hydroxide188 Phenol189 Toluene190 Distilled DMPF

191Hydroxylaminehydrochloride

192 Methanol193 NaOH194 p-Toluic chloride195 Butanol196 BE197 Bromine198 Chloroform199 5 % NaOH200 BTBE201 DMPO

202

4-trifluoromethylbenzyl alcohol

4-trifluro methyl benzylchloride

203 Bromoethane204 Magnessium205 THF206 Formaldehyde207 HCl

3.7 Resource optimization ( recycle/ reuse):

1. The effluent generated from process and scrubber will be sold as byproduct.

2. The treated domestic sewage will be reused for gardening which will reduce daily fresh water

need for gardening.

3. The company have rooftop rain water harvesting system and the harvested rain water is stored

in dedicated underground water tank. In rainy season the fresh water need will be reduced.

August 2017


4. The high TDS effluent will be treated in MEE and thermo-siphon reboiler system and recycled

back to plant.

3.8 Availability of water, energy fuel:

The water will be supplied by MIDC Mahad. Daily fresh water need for domestic and process

water requirement will be 447 CMD.

A 2.5 MVA capacity transformer is installed to meet the daily power demand of company.

One DG set of capacity 250 KVA and Two DG Sets of 125 KVA will be replaced by 500 KVA to

meet emergency power requirement of the plant.

3.7.3 Fuel Requirement

FuelCoal for boiler 22 MTPD 35 MTPD 57 MTPD

FO for TFH 125 L/day 6450 L/day 6575 L/day

HSD 110 L/day 2700 L/day 2810 L/day

3.9 Quantity of waste to be generated

Trade effluent generated from the expansion project will be 200 CMD. High TDS will be treat in

MEE and thermo siphon reboiler and Low TDS will be treat in 55 CMD ETP plant consisting

primary, secondary and tertiary treatment The sewage generated due to domestic activities will be

treated in aeration tank of ETP and treated water will be reused for gardening.

Parameter Requirement, CMD Losses , CMD Effluent, CMDDomestic Process

Domestic 17 3.4 13.6

Process 34.5 6.4 28.1

Cooling Tower152 144 8

BoilerGardening -- -- -- --Total 203.5 153.8 13.6 49.7

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Proposed water budget after expansion

ParameterRequirement, CMD

Losses ,CMD Effluent, CMD

Domestic ProcessDomestic 20 5 15

Process 32.3 0 -- 36.3Cooling Tower 394 230 164BoilerGardening -- -- --

Total447 235

15+36.3=51.3 CMD is treated in ETP. 46 CMDtreated effluent is discharged to CETP as per

valid CTO.164 CMD blow down will be treated by

psychrometric evaporator. 55 CMD water willbe recycled to plant. 109 CMD losses

3.8.2 Solid waste generation and Disposal

The types of Hazardous wastes generated from the project with method of disposalis shown in below table 3.6.

Table 3.6 : Details of Hazardous Waste Generation

Hazardous wasteType Category Existing After expansion Disposal

Used/ spent oil 5.1 50 1000 L/month Sale to Authorised recycler /CHWTSDF

Residues and waste 29.1 204 411MT/m CHWTSDF

Chemical sludge residuefrom herbicides

29.2 2.7 0 CHWTSDF

Discarded containers 33.1 78 1250 nos/M Sale to Authorised recycler /CHWTSDF

Chemical sludge from ETP 35.3 1.12 69 MT/m CHWTSDF

Filter & filter materialhaving organic liquid

36.2 32 500 kg/m CHWTSDF

Spent carbon 36.2 10 200 kg/m CHWTSDF

Asbestos gaskets 15.2 - 100 kg/m CHWTSDF

Spent solvents 29.4 28 MT/m 140 MT/m Sale to Authorised recycler /CHWTSDF

The non hazardous waste generation after expansion is presented in the table below,

Non hazardous wasteExisting After expansion Disposal

Paper waste (paper boxes 150 kg/m 5600 kg/m Sale to registered brick

August 2017


and bags) manufacturerPlastic waste 50 kg/m 5600 kg/mMetal scrap 100 5000 kg/mWooden pellets 25 1000 nos/mCoal ash 2700 8550 kg/d

August 2017


3.10 schematic representation of feasibility drawing for EIA purpose

PRODUCTION ACTIVITY

RESOURCE CONSUMPTION(WATER)

POWER CONSUMPTION

WASTEGENERATION

FINISHED PRODUCTS

MARKET

ECONOMY

EMPLOYMENT

RAW MATERIAL

POLLUTIONABATEMENT

CLEANENVIRONMENT

August 2017


4. Site Analysis

4.1 Connectivity:

M/s Astec Lifescience Ltd. is located at lot No. B-16, 17, 18 and B-21, MIDC Mahad,

District Raigad, Maharashtra. The nearest city from the site is Mahad at a distance of 8.0 Km.

The nearest railway station is Veer at a distance of 11 Km from the site. National Highway 17 is

near from site which is connected to Mumbai and Goa.

4.2 Land Form, Land use and Land Ownership

The Pesticides and Chemical intermediate manufacturing unit is located in Notified Industrial

Estate –Mahad MIDC having plot area 13950 SQM. The plot no B-16,17,18 & B-21 is owned by

M/s Astec Lifescience Ltd. The land use type is industrial for the manufacturing unit.

4.3 Topography:

The Geographical location of this industry is Latitude: 180 06’03.20” N Longitude: 730 29’ 24.56”

E. with an elevation of 59 ft (18m) above mean sea level MSL.

August 2017


Environmentally sensitive features within 15 km radius of the plant

The environmentally sensitive features exist around 15 km radial distance from the plant is,

1. Reserve Forest near Khaire Village at an approximate aerial distance of 0.4 km towards NE

from the project site.

2. Reserve Forest near Boargaon Village at an approximate aerial distance of 1.8 km towards S


3. Reserve Forest near Kharvali Village at an approximate aerial distance of 2.4 km towards SE


4. Reserve Forest near Kondivae Village at an approximate aerial distance of 3.5 km towards SW

from the project site..

5 Kal River is 750 m away and Savitri River is 2.1 km away from the project site.

6 Meeting point of Kal and Savitri river is 2.52 km away from plant aerially

7 A Bajire dam backwater is 14.8 km away from project site.

8 No national or state boundary is within 15 km.

9 Raigadh fort and Shivathar ghal are approximately 14.8 km away at aerial distance.

10 No defense installations are within 15 km area.

11 Nearest densely populated area -Mahad town is 8 km away.

12 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship,

community facilities) are Present in and around 15 km distance from project site.

13 The expansion project is in Mahad, MIDC area which is not declared as critically polluted area

by CPCB O.M. J-11013/5/2010-IA.II(I) dated 17/09/2013.

4.4 Existing land use pattern

The expansion project is located in the notified industrial area which has been developed for

industrial development. The existing land use pattern in the 10 km radial distance of the project site

comprises of Industrial, human habitations/settlements, small agricultural/ crop lands, quarrying

land use classes.

4.5 Existing infrastructure:

The land is in a recognized MIDC industrial area.

All infrastructures are available.

Air travel is readily available from Mumbai airport.

Water is available from MIDC.

Electricity is available from MSEDCL.

August 2017


4.6 Soil classification:

The soils in the area are formed from the Deccan Trap which is predominating rock formation with

small out crops of Laterite at a few places in the Poladpur taluka. The soils are medium black and

black soil which can be further grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium

and Laterite as per the location and topographical situation.

Climatic data from secondary sources

The climate in area is characterized by hot summer and general dryness throughout the

year except the south west monsoon season.

Climate Classification: Project site features a semi arid climate. In rainy season the climate is very

humid.

Temperature: annual average max. Temperature is 32°C and min. temperature is 17 °C

Rainfall: The analysis of long term rainfall data indicates that normal annual rainfall over the

district ranges from 2200 mm to more than 3000 mm in the plains and it is above 5000 mm in the

hills. The average rainfall around Mahad area is 3360 mm in rainy season.

4.7 Social infrastructure available:

Social infrastructure like schools, road, hospitals, is available near MIDC Mahad.

August 2017


5. Planning Brief

5.1 Planning concept:

The expansion activity will start after acquiring environmental clearance

The MIDC Mahad have road network and water will be provided by MIDC, therefore company

will not be relied on ground water in the MIDC area.

Electricity will be provided by MSEDCL and transformer and substation will be constructed.

The construction material is available locally and it will be transported through road network.

5.2 Population projection:

As per the 2011 census data, the Mahad region have 1,80,191, of which 88,734 are males and

91,457 are females. Total population equal to 19,044 is lied in 0-6 year age group. Area according

to census data total literates are 1,31,981.

The data published by census India 2011, shows that density of Raigad district for 2011 is 368

people per sq. km. It is assumed that due to expansion project minor migration of skilled labour in

the region is expected after commissioning of the project.

5.3 Land use planning:

The expansion of manufacturing unit will be done at existing project site at plot B-16,17, 18 & 21,

MIDC Mahad . The land is acquired by MIDC and the land use will be industrial type. No

cultivated land or forest land will be utilized for the expansion unit.

5.4 Assessment of Infrastructure demand

The major physical infrastructure like road, water supply is provided by MIDC Mahad . The

electricity will be supplied by MSEDCL by means of continuous feeder substation.

The industrial infrastructure will be constructed after grant of EC. The need of social infrastructure

is not presently envisaged.

5.5 Amenities:

Basic amenities like road, electricity, process water will be available at site. The drinking water will

be provided by further purification of process water by RO purification unit. In the plant personal

hygiene facilities will be provided to workers as per the rule.

August 2017


6. Proposed infrastructure:

6.1 Industrial area

Astec Lifescience Ltd proposed an expansion of manufacturing capacity project from 919 MT/M

to 1099.94 MT/M manufacturing of Pesticides and Chemical intermediate and 116.36 MT/month

at the existing project located at plot No. B-16, 17, 18 and B-21 at MIDC Industrial Area Mahad,

Dist: Raigad, State: Maharashtra..

6.2 Residential area

The unit is pesticide manufacturing unit and situated at notified MIDC Mahad therefore there

will be no need of residential infrastructure.

6.3 Green belt

The project is available in MIDC area. Total plot area of project 13950 sq. m. and existing green

belt area is 3500 sq. m. additional 1100 sq. m. greenbelt will be developed in the premise totaling

4600 sq. m. which will be 33% of total plot area. 200 Trees along with some garden variety

shrubs are already available at the site and more 400 no. of new trees and shrubs will be planted at

site to fulfill MoEF norms.

6.4 Social infrastructure:

The project site is approximately 8 km from Mahad city. All basic social infrastructure facilities

are available in the study area.

The basic amenities within the study area include primary schools, dispensaries, water supply,

electric supply, public telephones, hotels, banks, post offices, petrol pumps, bus services, technical

training institute and entertainment etc.

6.5 Connectivity

The site can be accessed by national highway and connecting state highway from Mahad to

Solamkund village. The MIDC Mahad have excellent internal and connecting road network

therefore no additional connectivity infrastructure will be constructed.

6.6 Sewerage system

MIDC Mahad have provided sewerage and storm water drainage network. The effluent generated

is treated in the ETP and transferred to CETP,Mahad by MIDC provided drainage network.

6.7 Industrial waste management

Existing 36.43 CMD effluent & 15 CMD sewage is treated in 55 CMD ETP. The treated effluent

is discharged to CETP. Additional 164.5 CMD will be treated by two psychrometric evaporators

of 500 TR capacity each. Total 52.5 CMD effluent will be recycled to process.

6.8 Solid waste management

August 2017


The hazardous waste will be segregated as per category in schedule I of “Hazardous and Other

Wastes (Management and Trans-boundary Movement) Rules, 2016” and it will be stored in

demarcated area. The hazardous waste will be treated at CHWTSD facility or it will be sold to

MPCB authorized re-processor. The fly ash will be sold to brick manufacturers or authorized

vendours.

6.9 Power requirement/ supply/ source

A 2.5 MVA capacity transformer will be installed in the company for connected load of equal

amount. The power demand will remain same for expansion unit. Electrical power will be supplied

by MSEDCL.

Total 57 T/day foreign grade coal will be required for running boiler. 6575 L/day fuel oil will be

used to run FO run boiler and thermic fluid heater.

Total 2800 L/day HSD will be used for running D.G. sets in case of power failure.

August 2017


7. Rehabilitation and resettlement:

The expansion will be done at existing production unit situated at notified industrial area of

MIDC Mahad. No rehabilitation and resettlement will be incorporated.

8. Project schedule and cost estimation

It is proposed that the project will be commissioned after 24 months from grant of EC.

9. Analysis of proposal

The expansion activity will provide employment to the local residents, resulting financial and

social benefits of the nearby people.

Indirect employment will be generated by the unit like canteen, transportation facilities to

workers.

The export will result in generation of foreign exchange to the country.

August 2017


Annexure A: mass balance

Product Hexaconazole

Reaction

Process Description

Material Balance

Step-I

1 CLS-I 1003.12

R-01Reaction

3480.82 Reaction mass

2 FFB 1705.303 Saturn 4.554 Water 36.475 DMS 731.36

Total 3480.82 3480.82 Total

Reaction mass 3480.82

R-02Quenching

2769.27 Organic Layer

HOT 650.43 2273.77 Aqueous layerWater 911.84

Total 5043.08 5043.05 Total

Organic Layer 2769.27

Recovery

1063.97 CLS-II (Crude)

1637.09 FFB68.21 FFB loss

Total 2769.27 2769.27 Total

August 2017


Aqueous layer 2273.77

Recovery

948.31 Water recover

1008.94 K2SO4185.78 CH3OH104.37 H2O

4.55 Saturn21.93 Residue

Total 2273.77 2273.89 Total

Step-II

1 CLS-II (Crude) 1063.97

R-03 water washand seperation

1040.24 CLS-II pure

2 Water 690.15 713.92 water recover

Total 1754.12 1754.16 Total

Step-III CLS-II pure 1040.24

R-04 Reaction

1426.19 CLS-III crude

DMF 2280.09 2211.69 DMFTMI 299.93 68.40 DMF lossK2CO3 86.02

Total 3706.28 3706.28 Total

Step-IV CLS-III crude 1426.19

R-05 Cystalization

1000.00 CLS-III pureWater 1735.40 877.29 MeOHMethanol 913.84 36.55 MeOH loss

1735.40 Water340.79 Impurity

9.17 K-TMI76.24 K2CO3

Total 4075.43 4075.43 Total

August 2017


Product Tebuconazole

Reaction

Material BalanceStep-l

PCS-II

PCS-II 778

Reaction


Dimethyl sulfide 991 Aqueous layer 1479.95Saturn 3.235Water 25.92DMS 622HOT 553.24Water 323.99

Dimethyl sulfide 413.10Total 3710.6 3710.6


Water Recovery

Water 349.91

K2SO4 858.17CH3OH 158.02Water 88.78

Loss Water 25.06Total 1480.0 1480.0


Recovery

PCS-lll 816.47

Water 486.0 Dimethyl Sulphide 1334.31Dimethyl Sulphide loss 70.23Water (Aqueous Layer) 486.00Water 9.6

Total 2716.7 2716.7

August 2017


Step-II

PCS-III 816.5

Reaction

CMD 6769.2

CMD 7051.277 CMD 281.5TMI 269.0496 PCS-IV crude 1196.5NaOH 110.4192

Total 8247.2 8247.2

PCS-IV crude 1196.5

Washing


Water 1113.368 Aqueous layer 1248.6XP-100 856.9152

Total 3166.8 3166.8

Organic layer 1918.2

Crystallization

Product 1000.0

MLR 918.2

Total 1918.2 1918.2

MLR 918.2

Solvent recovery

XP-100 822.6

XP-100 34.3Residue 61.2

Total 918.2 918.2

Aqueous Layer 1248.6

recovery

Water 1113.4

Residue 135.2

Total 1248.6 1248.6

August 2017


Product : Dextrinol

Material Balance

Crotonic acid 425.0

Reaction

BTD 272.0 486.6 aqueous layer 1Catalyst 20.0 2355.2 Orgnic layerEthyl cyclohexane 1499.83

HCl, 30% 625.0

Total 2841.8 2841.8

Org. lyer 2355.2ReactionTer. Butyl alcohol 372.0 184.7 aqueous layer 2

PTSA 15.0 2649.9 Orgnic layer

NaOH, 5% 92.4Total 2834.6 2834.6

Orgnic layer 2649.9Recovery

1467 Ethyl cyclohexane

1000.0 DTX

145.0 Residue38.0 Loss

Total 2650 2650.0

aqueous 1+2 184.7recovery

159.7 Rec water

25.0 NaCl salt

Total 184.7 184.7

August 2017


Product: Chlorostyrene

Reaction:

Material Balance:

Inputs Qty. kg

Chlorobenzaldehyde 1035

Reaction


Magnessium 176.985 Aqs. Layer 1 2580.255

Tetrahydrofuron 2020.32

Methyl Chloride 367.425

Chlorobenzaldehyde 1035


HCl 32% 828

Water 1324.8Total 6118.92 6117.885


Solvent Recovery

CRB-1 1141.605

Rec THF 2267.685

Loss 119.025

Residue 9.2115

Total 3537.63 3537.527

CRB-1 1141.605

Reaction

Product 1000.328

Sulphuric acid 23.4945 Rec. water 131.445

Residue 33.741

1165.1 1165.514

Aqs. Layer 1 2580.255Water recovery

Rec. water 1324.8

MgCl2 692.415

Cl

O

H + CH3 Cl+ MgCl

O-MgCl

CH3 +HCl

Cl

CH3

OH

+ MgCl2

Cl

CH3

OH

+ H2SO4

Cl

CH2 + H2O H2SO4+

August 2017


HCl 563.04

2580.255 2580.255

Product METALAXYL

Reaction

Material Balance

2,6 Xylidine 783.0

R-02Reaction

MCP 525.0 1138.0 OrganicDMF 20.0 2653.1 AqueousNaHCO3 428.75Water 2034.3

Total 3791.0 3791.0

Distillation

825.0 MXL1Organic 1138.0 286.9 rec. 2,6 Xylidine

26.1 loss

Total 1138.0 1138.0

Aqueous 2653.1 Recovery 2212 Rec water

NH2 +O

Cl

O

NaHCo3,DMFNH

O

O

NH

O

O + OO

ClN

O

OO

O

August 2017


188.6 CO2252.5 NaCl

Total 2653.1 2653.1

MXL-l 825.0Methoxy acetyl chloride 495.0DMF 161.8

Reaction1000.0 Metalaxyl

Cyclohexane 1648.2 1803.0 AqueousCaustic Lye 48% 208.9 1769.5 Filtration MLWater 1234.0Total 4572.8 4572.5

Aqueous 1803.0recovery

1333.0 Rec water150.0 rec DMF320.0 salt

Total 1803.0 1803.0

recovery1615.3 rec Cyclohexane

Filtration ML 1769.5 82.00 Residue72.3 Loss

Product: LOON

Reaction:

Material Balance

Inputs Qty. kg

Allyl chloride 588.5

Reaction


Allyl chloride 588.5 Aqs. Layer 1 1800.81


Magnessium 311.905

2-Methylfurfural 847.44

HCl 394.295

Water 782.705

August 2017


Total 3707.55 3707.55


Solvent Recovery

THF 747.395Intermediate-I 1053.415

Impurity 105.93

Total 1906.74 1906.74

Intermediate-I 1053.415

Reaction


Impurity 105.93

Acetic acid 29.425

Total 1159.345 1936.165


Solvent Recovery

Organic layerLOON 1000.45

THF 711.4965

Loss 35.31

Impurity 158.895

Acetic acid 29.425

Total 1936.165 1935.577

Aqs. Layer 1 1800.81

Water recovery

Water (HCl) 247.17

MgCl2 729.74

Water 782.705

THF loss 41.195

Total 1800.81 1800.81

August 2017


Product: Dichloro Benzyl Cyanide

Reaction:

Material Balance

Inputs Qty. kg2,4-dichlorobenzylchloride 1167

Reaction

Residue(Product) 999.652,4-dichlorobenzylchloride 1167 Water 537.29Sodium cyanide 298.4019 TBAB/Residue 38.51TBAB 38.511 NaCl 349.28Water 537.2868 Impurity 116.47

Total 2041.2 2041.2

August 2017


Product Bromuconazole

Reaction


MDA 958.00

Reaction


All 593.96 Aqueous layer 3360.85Mg 172.44 Rec. All 264.1toluene 3458.38THF 2874.00HCl(32%) 1123.73Water 1916.00

Total 11096.51 11095.80

Water Recovery

Water 2680.77

Aqueous layer 3360.85 MgCl2 672.52loss 7.0892

Total 3360.85 3360.38

Step-ll

Organic layer Step-l 7470.83Reaction

Toluene 3284.98

K2CO3 266.32 Toluene 170.52THF 2759.04

August 2017



Reaction


MDA 958.00

Reaction



Total 11096.51 11095.80

Water Recovery

Water 2680.77


Total 3360.85 3360.38

Step-ll


Toluene 3284.98

K2CO3 266.32 Toluene 170.52THF 2759.04

August 2017



Reaction


MDA 958.00

Reaction



Total 11096.51 11095.80

Water Recovery

Water 2680.77


Total 3360.85 3360.38

Step-ll


Toluene 3284.98

K2CO3 266.32 Toluene 170.52THF 2759.04

August 2017


THF 114.96RM 1287.84Loss 119.75

Total 7737.15 7737.10

RM 1287.84

Filtration

RM 4065.17

DMF 3065.60 KCl 288.26

Total 4353.44 4353.43

Step-lll

RM of Step 2 4065.17

Reaction

Rec DMF 2973.63

TMI 354.46 DMF Loss 91.97KOH 102.79 RM 1456.83

Total 4522.42 4522.43

RM 1456.83Separation


Water 2874.00 Aqueous layer 3054.91

Total 4330.83 4330.76


Water recovery

Water 2874.00

K-TMI 160.45KOH 20.50

Total 3054.91 3054.95


Crystalisation

Water 513.49

MeOH 670.60 MeOH 643.78Water 513.49 MeOH 26.82

Impurity 241.21TAA (Int-3) 1034.64

Total 2459.94 2459.94

Step-lV

TAA (Int-3) 1080.00

Water recovery


MDC 5387.79 Aqueous layer 2016.49Br2 546.06 Loss 56.52HBr 1200.37NaOH 284.05Water 517.32Na2S2O3 14.37

Total 9029.96 8984.99

August 2017



Water Recovery

NaBr 732.58

Water loss 127.99Na2S2O3 14.37Water 1141.46

Total 2016.49 2016.40

Step-V


Reaction


NaOH 198.31 Aqueous layer 1629.85Water 424.09MeOH 754.90

Total 8289.27 8289.44


Recovery

Water 424.01

NaBr 327.64MeOH 754.90Water loss 56.23

NaOH 67.061629.85 1629.85


Recovery

Rec MDC 5173.2

MDC Loss 215.55BRL-lll Crude 1271.27

6951.56 6660.02

BRL-lll Crude 1271.27

Crystalisation

BRL-III 1000.92

MeOH 1080.62 Impurity 271.11Water 586.30 MeOH 1037.5

MeOH 43.2Water 586.3

Total 2938.19 2939.0

August 2017


Product Cyproconazole

Reaction

Material Balance

Step-lMethyl Cyclopropylketone 684.90

Reaction

Organic Layer 5273.73Dimethyl sulfide 4109.40 Aqueous layer 5965.48Dimethyl sulfate 1404.05Pottasium Hydroxide 643.81Sodium Hydroxide 424.64Water 3972.42

Total11239.2

1 11239.2

RecoveryCPMK-l 698.60Dimethyl sulfide 4040.91

Organic Layer 5273.73 Dimethyl sulfide 68.49

August 2017


lossImpurity/Residue 109.58Methanol 356.15

Total 5273.73 5273.73

Water Recovery

Potassium sulfate 999.95Aqueous layer 5965.48 Sodium sulfate 753.39

Water 3972.42Loss water 239.72

Total 5965.48 5965.48

Step-llCPMK oxirane 698.60

ReactionReaction Mass 2095.79

Tetrahydrofuron 1397.20 Catalyst 84.86Catalyst 84.86

Total 2180.65 2180.65

Step-lll

Magnessium 1006.80

recoveryTetrahydrofuron 2075.25 Grignard mass 3780.65P-Dichloro Benzene 1534.18 Magnessium 835.58

Total 4616.23 4616.23

Grignard mass 3780.65CouplingCPMK-ll Reaction Mass 2095.79 Reaction mass 5876.44

Total 5876.44 5876.44

Reaction Mass 5876.44

Quenching

Aqs. Layer 2883.43HCl (32%) 1095.84 Organic Layer 5458.65Water 1369.80Total 8342.08 8342.08


Recovery/Distillation

Rec. THF 3301.22CPMK-lll 1013.65Residue 972.56Loss 171.23

Total 5458.65 5458.65

Aqs. Layer 2883.43 Water recovery Water 2116.34

August 2017


Magnesiumchloride 664.35

Loss water 102.74Total 2883.43 2883.43

Step-lV

CPMK-lll 1013.65

Reaction

Aqs. Layer11643.3

0Toluene 5794.25 Organic Layer 7821.56Sodium Hypochlorite 7095.56NaBr 77.80Sodium bicarbonate 405.67TEMPO 2.88Water 4061.46Toluene 1013.65

Total19464.9

319464.8

6


Recovery

Rec. Toluene 6739.07Loss 68.49Ketone 984.20Impurity 29.79

Total 7821.56 7821.56

Aqs. Layer11643.3

0

Water recovery

Water11086.1

3Sodium chloride 557.17

Total11643.3

011643.3

0

Step-V

Impurity (Carry Over) 29.79

Reaction

Organic Layer 5606.59Ketone 984.20 Aqs. Layer 5040.18Dimethyl sulfide 3212.18Saturn 3.42Dimethyl sulfate 934.14Pottasium Hydroxide 539.98Sodium Hydroxide 138.14Water 3738.18FFB 1068.44Total 10648.4 10646.7

August 2017


8 7


Recovery

Dimethyl sulfide 4216.31Dimethyl sulfideloss 68.49SPT-II 1012.28Impurity 72.19Methanol 237.32

Total 5606.59 5606.59

Aqs. Layer16683.4

8

Water recovery

Water15379.3

6Pottasium sulfate 838.32Sodium sulfate 245.26Loss water 220.54

Total16683.4

816683.4

8

Step-VlSPT-II 1012.28

Reaction

Rec. CMD 2950.89CMD 3034.11 Rec. Toluene 2954.80Triazole 344.09 Aqs. Layer 2220.03Pottasium Carbonate 192.73 SPT-lll Crude 1354.32Water 2027.30 CMD loss 68.49Toluene 3036.16 Toluene loss 68.49Total 9646.7 9617.02

SPT-lll Crude 1354.3

Crystalisation

XP-50 2463.11XP-50 2534.13 XP-50 loss 68.49

SPT-III 1000.43Residue 356.42

Total 3888.45 3888.45

Aqs. Layer 2220.03

Water recovery

Water 2027.30K2CO3 192.73

Total 2220.03 2220.03

August 2017


Product: Prallethrin

Reaction:

Material Balance

Inputs Qty. kg

2-Methylfuran 369.3

Reaction


2-Methylfuran 369.3 Aqs. Layer 1 2152.2

Dimethylformamide 406.2

2,3-Dichloropropane 694.3

Phosgene 491.2

zinc 588.2

Acetic acid solution 1080.5

Toluene 997.1Total 4626.7 4626.5


Solvent Recovery


Dimethylformamide 388.0Dimethylformamideloss 14.8

Toluene 947.3

Toluene loss 52.1

Impurity 205.3

2,3-Dichloropropane 195.1Total 2474.3 2474.2

Water Recovery

Zn(CH3CO)2 825.3

Aqs. Layer 1 2152.2 Water 540.2

HCl 164.2

ZnCl2 613.0

Water loss 9.5

Total 2152.2 2152.2

Step-ll

August 2017


Impurity 205.3


Reaction


DCPC 570.8 Aqueous layer 1771.6

KOH 222.1

Toluene 997.1

Water 1421.8

Total 4088.8 4088.3


Solvent Recovery

Product 1000.1

Toluene 947.3

Toluene loss 49.9

Impurity 319.0

Total 2316.6 2316.2

Aqs. Layer 1 1771.6

Water recovery

Water 1421.8

KCl 268.3

Water 64.8

Water loss 16.8

Total 1771.6 1771.6

Documents

Astec Lifesciences Ltd.environmentclearance.nic.in/writereaddata/Online/TOR/26...about 6.5%). The ever-increasing demand for Pesticides and Intermediated in India and abroad as well