FORM-1environmentclearance.nic.in/writereaddata/Online/... · Aqua-Air Environmental Engineers Pvt. Ltd. (Pollution Control Consultants & Engineers) Reg. Office: 403, Centre Point,

FORM-1

for

PROPOSED EXPANSION OF SPECIALTY CHEMICALS (ORGANIC

CHEMICALS) IN EXISTING PREMISES

of

M/s. PRAGNA LIFE SCIENCE PVT. LTD.

Plot No. 409/B/2, GIDC Industrial Estate,

Panoli-394 116, Tal: Ankleshwar,

Dist: Bharuch, Gujarat

Prepared by:

Aqua-Air Environmental Engineers Pvt. Ltd.

(Pollution Control Consultants & Engineers)

Reg. Office: 403, Centre Point, Nr. Kadiwala School, Ring Road,

Surat – 395 002, Gujarat, India Fax: +91 261 2707273 / 3987273

Tel: + 91 261 3048586 / 2460854 / 2461241 E-mail: [email protected] Visit us at: www.aqua-air.co.in

APPENDIX I

(See paragraph - 6)

FORM 1

Sr.

No.

Item Details

1. Name of the project/s M/s. Pragna Life Science Pvt. Ltd. 2. S. No. in the schedule 5 (f)

3. Proposed capacity/area/length/tonnage to

be handled/command area/lease

area/number of wells to be drilled

Proposed Capacity: 187.5 MT/Month

For detail Please refer Annexure – I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. Existing capacity = 13.25 MT/Month

Plot area = 3,500 m2

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

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

please specify.

Yes. Located within 5 km of critically polluted

area (Ankleshwar).

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

please specify.

No

9. Location

Plot/Survey/Khasra No. Plot No. 409/B/2

Village GIDC Industrial Estate, Panoli

Tehsil Ankleshwar

District Bharuch

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Railway Station: Ankleshwar (4.5 km)

Airport: Surat (60 km)

11. Nearest Town, city, District Headquarters

along with distance in kms.

Panoli Village (1.75 km)

Bharuch (18.0 km)

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Panoli Village, Taluka: Ankleshwar, Dist: Bharuch

(Gujarat)

13. Name of the applicant M/s. Pragna Life Science Pvt. Ltd.

14. Registered Address Plot No. 409/B/2, GIDC Industrial Estate, Panoli,

Tal: Ankleshwar, Dist: Bharuch-394116 (Guj.)

15. Address for correspondence:

Name Mr. Jignesh Patel

Designation (Owner/Partner/CEO) Director

Address Plot No. 409/B/2, GIDC Industrial Estate, Panoli,

Tal: Ankleshwar, Dist: Bharuch-394116 (Guj.)

Pin Code 394116

E-mail [email protected]

Telephone No. +919723812606

Fax No. --

Mobile No. +919723812606

16. Details of Alternative Sites examined, if any.

Location of these sites should be shown on a

topo sheet.

NA

17. Interlinked Projects NA

18. Whether separate application of interlinked

project has been submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

21. Whether the proposal involves

approval/clearance under: if yes, details of

the same and their status to be given.

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

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

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

No

22. Whether there is any Government

Order/Policy relevant/relating to the site?

No

23. Forest land involved (hectares) NA

24. Whether there is any litigation pending

against the project and/or land in which the

project is propose to be set up?

(a) Name of the Court

(b) Case No.

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

its relevance with the proposed project.

NA

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,

mining lease area and production capacity for mineral production, area for mineral exploration,

length for linear transport infrastructure, generation capacity for power generation etc.,)

(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 expansion project is within

the Panoli GIDC Industrial Estate.

1.2 Clearance of existing land, vegetation and

Buildings?

Yes Minor site clearance activities shall be

carried out to clear shrubs and weed.

1.3 Creation of new land uses?

No The project site is located on level

ground, which does not require any

major land filling for area grading

work.

1.4 Pre-construction investigations e.g. bore

Houses, soil testing?

No

1.5 Construction works?

Yes 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 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 Please refer Annexure –III.

1.14 Facilities for storage of goods or materials?

Yes Proposed expansion is within the

existing premises. Existing goods or

materials are stored in existing

storage facilities. For Proposed

Expansion, additional raw materials &

finished products storage area will be

developed.

1.15 Facilities for treatment or disposal of solid

waste or liquid effluents?

Yes For Facilities for treatment or disposal

of liquid effluents is given as Annexure-

V.

For Hazardous waste details please

refer 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?

Yes Addition of very few trucks per day.

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

Pipelines?

No

1.21 Impoundment, damming, culverting,

realignment or other changes to the hydrology

of watercourses or aquifers?

No

1.22 Stream crossings? No

1.23 Abstraction or transfers of water form ground

or surface waters?

Yes Water requirement will be met

through Panoli 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 Transportation of personnel or raw

materials and products will be

primarily by road only.

1.26 Long-term dismantling or decommissioning

or restoration works?

No

1.27 Ongoing activity during decommissioning

which could have an impact on the

environment?

No

1.28 Influx of people to an area either

temporarily or permanently?

No

1.29 Introduction of alien species? No

1.30 Loss of native species or genetic diversity? No

1.31 Any other actions? No

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 thereof (with approximate

quantities /rates, wherever possible) with

source of information data

2.1 Land especially undeveloped or agricultural

land (ha)

No Proposed expansion project will be within

GIDC Industrial Estate, Panoli, Dist:

Bharuch.

2.2 Water (expected source & competing users)

unit: KLD

Yes Water Source: Panoli GIDC Water Supply

For details please refer Annexure – IV.

2.3 Minerals (MT) No

2.4 Construction material - stone, aggregates,

and / soil (expected source - MT)

Yes Small quantity of construction materials

will be required for expansion and

addition of few equipments. 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 Please refer Annexure – VII.

2.7 Any other natural resources (use appropriate

standard units)

No

Use, storage, transport, handling or production of substances or materials, which could be harmful

to human health or the environment or raise concerns about actual or perceived risks to

human health.

Sr.

No.

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

quantities/rates, wherever possible) with


3.1 Use of substances or materials, which are

hazardous (as per MSIHC rules) to human

health or the environment (flora, fauna, and

water supplies)

Yes 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

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

Sr.

No.

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

quantities/rates, wherever possible)


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

4.5 Surplus product No

4.6 Sewage sludge or other sludge from effluent

treatment

No

4.7 Construction or demolition wastes No

4.8 Redundant machinery or equipment No

4.9 Contaminated soils or other materials No

4.10 Agricultural wastes No

4.11 Other solid wastes Yes

Please refer Annexure – VI.

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

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



5.1 Emissions from combustion of fossil fuels

from stationary or mobile sources

Yes Please refer Annexure – VII.

5.2 Emissions from production processes Yes Please refer 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 odours from handling of materials

including construction materials, sewage and

waste

No

5.6 Emissions from incineration of waste No

5.7 Emissions from burning of waste in open air

e.g. slash materials, construction debris) No

5.8 Emissions from any other sources Yes Please refer Annexure – VII.

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



source of information data with source of

information data

6.1 From operation of equipment e.g. engines,

ventilation plant, crushers

Yes The Noise level will be within the prescribed

limit. At noisy areas 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:




7.1 From handling, storage, use or spillage of

hazardous materials

Yes Please refer Annexure – VIII.

7.2 From discharge of sewage or other effluents

to water or the land (expected mode and

place of discharge)

Yes For details please refer Annexure – V.

7.3 By deposition of pollutants emitted to air into

the and or into water

No

7.4 From any other sources No

7.5 Is there a risk of long term build up of

pollutants in the environment from these

sources?

No

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

health or the environment

S.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 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. utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.

• Supporting infrastructure (roads, power

supply, waste or waste water treatment, etc.)

• housing development

• extractive industry

• supply industry

• other

Yes 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

(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

NA Proposed expansion project site is within the

GIDC Industrial Estate, Panoli.

2 Areas which important for are or sensitive Ecol

logical reasons - Wetlands, watercourses or

other water bodies, coastal zone, biospheres,

mountains, forests

NA

3 Area used by protected, important or sensitive

Species of flora or fauna for breeding, nesting,

foraging, resting, over wintering, migration

NA No protected area or sensitive species within 5

km from the proposed project boundary.

4 Inland, coastal, marine or underground waters NA No inland, costal or marine within 5 km from

the project.

5 State, National boundaries NA N.A.

6 Routes or facilities used by the public for access

to recreation or other tourist, pilgrim areas

Yes Public transportation

7 Defense installations NA

8 Densely populated or built-up area Ankleshwar Ankleshwar City around 4.5 km from the project

site.

9 Area occupied by sensitive man-made land uses

Hospitals, schools, places of worship,

community facilities)

No

10 Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture,

fisheries, tourism, minerals)

No

11 Areas already subjected to pollution

environmental damage. (those where existing

legal environmental standards are exceeded)or

No NA

12 Areas 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)

NO NA

IV). Proposed Terms of Reference for EIA studies: Please refer Annexure - X

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products and Raw materials along with their Production Capacity

II Layout Map of the Plant

III Brief Manufacturing Process Description

IV Details of water consumption & waste water generation

V Details of Effluent Treatment Scheme

VI Details of Hazardous Waste Generation and Disposal

VII Details of Stacks and Vents, Fuel & Energy Requirements

VIII Details of Hazardous Chemicals Storage & Handling

IX Socio-economic Impacts

X Proposed Terms of Reference

ANNEXURE-I

_______________________________________________________________________

LIST OF PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY WITH RAW MATERIALS

Sr.

No. Product

CAS No. EXISTING

CAPACITY

ADDITIONAL

CAPACITY

TOTAL

CAPACITY

MT/MONTH MT/MONTH MT/MONTH

1. N-Ethyl 2 Pyridone 29097-12-9 3.25 0 3.25

2. Di-Ethyl Malonate 105-53-3 2 0 2

3. Ethyl Cyano Acetate 105-56-6 8 0 8

4. 2,5 DiChloro Para Phenylene Diamine 20103-09-7 0 29.16 29.16

5. 2 Nitro 4 Methoxy Aniline 96-96-8

6. 2,5 Dimethyl-P-Phenylenediamine 6393-01-7

7. 2-Mercapto 5-Methoxy Benzimedazole 27231-36-3

8.

3-[4-chloro-5-(cyclopentyloxy)-2-

fluorophenyl]-5-(propan-2-ylidene)-1,3-

oxazolidin-4-one. (PIK)

9. Sodium/Potessium { 2-[ 2,6 Dichloro

Phenyl] Amino} Phenyl} Acetate

0 41.66 41.66

10. 2 Chlor PPD

11. 2 –{ 2[ 2-{2, 6 dichloro phenyl } Amino ]

Phenyl Acetyl ] Oxyacetic Acid

12. 2-Chloro 1-Phenoxy Benzene

13. 2,3 Xylil Anthranilic Acid 0 33.33 33.33

14. 2 Chloro 5 Methyl PPD

15. 5 Amino Ortho Toludine

16. 4-Bromo Anisole

17. 2 Chloro 4 Flouro 5 Nitro Benzyl Chloride

18. 3 Amino 4 Methoxy Acetanilide 0 83.33 83.33

19. Para Anisidine

20. Para Amino Salicylic Acid

21. Nitro to amino conversion by catalytic

hydrogenation

22. Aldehyde to alcohol conversion by

catalytic hydrogenation

TOTAL 13.25 187.5 200.75

RAW MATERIAL CONSUMPTION

EXISTING PRODUCT RAW MATERIAL LIST

SR

NO PRODUCT NAME

PROPOSED

PRODUCTION

PER YEAR

NAME OF RAW

MATERIAL

CONSUMPTION

KG/KG OF PRODUCT

1 N-ETHYL 2 PYRIDONE 39

ECA 0.663716814

MEA 1.384

MAA 1.384

SUL ACID 1.667692308

soda 1.021538462

solvent 1.230769231

catalyst 0.04

2 DIETHYL MALONATE 24

MCAA 1.17

SODA ASH 0.74

SOD CYNIDE 0.5876

ETHANOL 2.1185

BENZENE 0.494

SULPHURIC ACID 1.6679

CAUSTIC 0.6

3 ETHYL CYANO

ACETATE 96

MCAA 1.17

SODA ASH 0.375

SOD CYNIDE 0.5876

ETHANOL 3.04525

BENZENE 0.494

SULPHURIC ACID 1.667925

caustic 0.125

PROPOSED RAW MATERIAL DATA SHEET

Group

Name Product Name

Production

capacity

MT/YEAR

NAME OF RAW MATERIAL

CONSUMPTION

KG/KG OF

PRODUCT

MT PER

YEAR

GROUP-

01

2,5 DiChloro Para

Phenylene Diamine

350

acetic anhydride 0.67 234.50

2,5-dichloro aniline 1.00 350.00

sulphuric acid-48% 2.40 840.00

con. Nitric acid 0.39 136.50

hydrochloric acid 3.99 1396.50

iron powder 0.90 315.00

sodium carbonate 0.06 21.00

9.41 3293.50

2 Nitro 4 Methoxy

Aniline

para anicidine 0.83 290.50


nitric acid 0.43 150.50

MDC 2.50 875.00

soda 0.17 59.50

caustic 1.17 409.50

5.83 2040.50

2,5 Dimethyl-P-

Phenylenediamine

2,5 xylidine 1.25 437.50

sod carbonate 0.55 192.50

BSC 1.83 640.50

toluene 2.50 875.00


sulphuric acid 1.25 437.50

acetic acid 0.13 45.50

iron powder 0.68 238.00

8.84 3094.00

2-Mercapto 5-

Methoxy

Benzimedazole

4-methoxy nitro aniline 0.95 332.50

NaHS 2.10 735.00

CS2 0.43 150.50

NaOH 0.23 79.10

DMF 2.40 840.00

carbon 0.03 8.75

6.13 2145.85

3-[4-chloro-5-

(cyclopentyloxy)-2-

fluorophenyl]-5-

(propan-2-ylidene)-

1,3-oxazolidin-4-

one. (PIK)

PICK3 0.96 337.05

TOLUENE 0.26 89.71

ECF 0.67 235.55

40%NAOH 2.05 718.55

CPB 1.15 403.20

CAT-2 0.20 70.00

ETHANOL 0.27 93.10

CAT-3 0.02 5.85

CAT-4 0.07 25.97

ECG 0.89 311.15

CHARCOAL 0.01 3.22

SILICA GEL 0.01 3.22

6.56 2296.56

GROUP-

02

Sodium/Potessium {

2-[ 2,6 Dichloro

Phenyl] Amino}

Phenyl} Acetate

500

indolinone 1.00 500.00

caustic flacks 0.14 70.00

1.14 570.00

2 Chlor PPD

2chloro para nitro aniline 1.27 635.00

methanol 2.55 1275.00

h2 0.05 25.00

3.87 1935.00

2 –{ 2[ 2-{2, 6

dichloro phenyl }

Amino ] Phenyl

Acetyl ] Oxyacetic

Acid

tba 0.26 130.00

MCAA 0.33 165.00

(2-((2,6,DICHLORO

PHENYL)AMINO)PHENYL)AC

ETATE

1.11

555.00

FORMIC ACID 1.93 965.00

3.63 1815.00

2-Chloro 1-Phenoxy

Benzene

phenol 0.65 323.80

ODCB 2.02 1011.65

KOH 0.39 192.65

3.06 1528.10

GROUP-

03

2,3 Xylil Anthranilic

Acid

400

ocba 0.83 332.00

2,3 xylidine 0.71 284.00

caustic 0.19 76.00

so. Bicarbonate 0.53 212.00

hcl 0.88 352.00

3.14 1256.00

2 Chloro 5 Methyl

PPD

soda 0.40 160.00

BSC 1.50 600.00

5-chloro methyl aniline 1.20 480.00

toluene 1.80 720.00



hydrogen gas 0.05 20.00

6.49 2596.00

5 Amino Ortho

Toludene

O T 1.25 500.00

sod bicarbonate 0.62 248.00

BSC 2.06 824.00


toluene 2.50 1000.00


methanol 2.50 1000.00

h2 gas 0.06 24.00

10.99 4396.00

4-Bromo Anisole

phenole 0.54 215.38

DMS 0.51 202.15

NaOH 0.95 381.54

EDC 1.73 693.54

Bromine 0.92 366.77

NaHCO3 0.12 49.54

4.77 1908.92

2 Chloro 4 Flouro 5

Nitro Benzyl

Chloride

2 chloro 4-floro -1-

(trichloromethyl)benzene 1.05

420.00

oleum 23% 1.80 720.00


sodium carbonate 0.91 364.00

methanol 1.40 560.00

6.00 2400.00

GROUP-

04

3 Amino 4 Methoxy

Acetanilide

1000

methanol 1.31 1310.00

dinitrochloro benzene 1.25 1250.00

caustic 0.31 310.00



hydrogen 0.08 80.00

3.79 3790.00

Para Anisidine

pncb 1.33 1330.00

methanol 1.28 1280.00


caustic 0.35 350.00

h2 0.05 50.00

3.29 3290.00

Para Amino Salicylic

Acid

para nitro salicylic acid 1.25 1250.00

methanol 1.50 1500.00

h2 0.04 40.00

2.79 2790.00

Amino derivatives

nitro compound 1.36 1363.63

solvent 2.73 2727.27

catalyst 0.05 45.45

h2 gas 0.11 109.09

carbon 0.05 45.45

4.29 4290.89

Alcohol derivatives

aldehyde compound 1.00 1000.00

solvent 2.00 2000.00

catalyst 0.03 33.33

h2 gas 0.08 80.00

carbon 0.03 33.33

3.15 3146.66

ANNEXURE-II

_______________________________________________________________________

LAYOUTOF MAP OF THE PLANT

ANNEXURE-III

MANUFACTURING PROCESS, CHEMICAL REACTION & MASS BALANCE

EXISTING:

1) PRODUCT NAME : N-ETHYL 2-PYRIDONE.

Brief process :

Ethyl CyanoAcetate is mixed with Mono Ethyl Amine and Methyl Aceto Acetate. The

reactants are heated to reflux for few hours to form an intermediate by condensation and

ring closer reaction. The reacted mass is draw into water and acidified with acid to

precipicate the intermediate product which is isolated by filtration.

The intermediate product is charged in to an another reactor and mixed with concentrated

Sulfuric Acid and stirred for few hours. The reaction and mass is drawn in ice cold water

when N-Ethyl Pyridone is precipitated which is filtered on centrifuged and dried to obtain

the finished product.

Reaction:

Material Balance:

Sr

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

1 Ethyl cyano acetate 215 Product 325

2 Mono ethyl amine 450 Sodium Sulfate 122

3 Methyl aceto acetate 450 Water to be recycled 4122

4 Catalyst 13 Effluent to ETP 2575

5 H2SO4 542 Toluene Recover 1045

6 Soda Ash 332 Toluene Loss 52

7 Toluene 1100 Dist. Residue 3

8 Water 5150

Total 8252 Total 8252

2. PRODUCT NAME: ETHYL CYANO ACETATE

BRIEF PROCESS:

Monochloro Acetic Acid is dissolved in water and neutralized with soda Ash, reacted with

Sodium Cyanide is detoxicated sodium hypochlorite. Reacted solution is acidified with

Hydrochloric Acid to form Cyano Acetic Acid, Water is then removed by vacuum distillation

of condensate is recycle in the next batch for the dissolution of Monochloro Acetic Acid

Ethyl alcohol is added to the residue and mass is filtered to isolate Sodium Chloride as bye

product. The filtrate and Alcohol solution of Cyano Acetic Acid is esterified in presence of

Benzene and a Catalyst. Reactants are neutralized by Soda Ash Solution and a little quantity

of aqueous solution is separated.

From the organic layer, first Benzene is recovered by distillation and reused in the

subsequent batch. Finally Ethyl Cyano Aceto Acid is obtained by vacuum distillation as pure

finished Product.

CHEMICAL REACTION:

Cl

O

OH

+ NA2CO

3+ 2NaCN

Na

O

O

N

+ 2Nacl + OH2 + Co22

Na

O

O

N

+

2(94.5) 106 2(49) 2(107) 2(58.5) 18 44

2(107) 2(46) 2(113)

O

O

N

CH3

CH3

OH + Na OH2

2(40)

2

22 2

ETHYL CYNO ACETATE

Material Balance:

Sr

No. Material INPUT Qty(in kg) Material OUTPUT

Qty(in

kg)

1 MCA 468 Product 400

2 Soda Ash 150 CO2 Gas 109

3 Sodium Cyanide 235 Water to be recycled 5375

4 Benzene 1396 Sodium Chloride to TSDF 151

5 Ethanol 1218 Effluent to ETP 3043

6 H2SO4 667 Benzene recover 1340

7 Water 6340 Benzene Loss 50

8 Dist. Residue 6


3. PRODUCT NAME: DIETHYL MALONATE

BRIEF PROCESS:

Monochloro Acetic Acid is dissolved in water and neutralized with Soda Ash. It is than

reacted with Sodium Cyanide to from Sodium Cyano Acetate. Caustic Soda is then added

reactant are heated to reflux when Malonic Acid Disodium Salt is Form, Which on

acidification with Acid is converted to Malonic Acid. Water is removed from the reacted

solution. The condensate is recycled for the dissolution of Monochloro Acetic Acid in the

next batch , the residual mass and Ethyl Alcohol is added and mass is filtered to remove

Sodium Chloride as bye product. Filtrate containing Alcoholic Solution of Malonic Acid

Esterified in presence of Solvent and a Catalyst. Reactants are neutralized by Soda Ash

solution to get final product.

Reaction:

Material Balance:

Sr


Qty(in

kg)

1 MCA 292.5 Product 250

2 Soda Ash 185 Water to be recycled 3331

3 Sodium Cyanide 146.9 Sodium Chloride to TSDF 94

4 Benzene 1173.6 Effluent to ETP 1859

5 Ethanol 529.0 Benzene recover 1132

6 H2SO4 417 Benzene Loss 35

7 Water 3962 Dist. Residue 5


PROPOSED

1. PRODUCT NAME:2, 5 Dichloro Para Phenylene Diamine

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.

CHEMCAL REACTON:

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

CH311

O12

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

STEP-IV REDUCTION

NH2

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

Material Balance:

Sr


Qty(in

kg)

1 Acetic Anhydride 335 Acetic Acid 625

2 2:5 DCA 210 H2SO4 (70%) 1554

3 H2SO4 1200 Effluent 2817

4 Nitric Acid 194 Iron Sludge 407

5 Caustic Lye 1040 Product 500

6 Soda Ash 30

7 Iron Powder 344

8 HCl 2250

9 Ice 300


2. PRODUCT NAME: 2,5 Dimethyl PPD (Tosil Route)

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.

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

Material Balance:

Sr No. Material INPUT Qty(in kg) Material 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


3. PRODUCT NAME: 2-{2[2-[ 2,6 dichlorophenyl)amino]

Phenyl]acetyl]oxyacetic Acid]

Brief Process of

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

and 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.

REACTION :

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

Material 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

7 Drying Loss 90

8 Spent Carbon 10


4.PRODUCT NAME: 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

Material Balance:


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


5. PRODUCT NAME: 3-[4-chloro-5-(cyclopentyloxy)-2-fluorophenyl]-5-(propan-2-ylidene)-

1,3-oxazolidin-4-one. (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.

Reaction Scheme: 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-

3ClF

H5C2OOCHN O

M.W : 301.74

+

ClF

O

O

N

CH3

CH3

O

M.W : 353.77

COOC 2H5

OHCH3

O

M.W : 144.16

PICK4

PIK

ethyl 2-hydroxy-3-oxobutanoate

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

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

Material Balance:


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

9 Water to be recycled 500



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


6. PRODUCT NAME: 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.

ChemicalReaction:

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

Material Balance:


1 Indolinone 1000 Product 1000

2 Caustic Flake 250 Effluent 1250

3 Water 1000


7. PRODUCT NAME : 2 Chloro PPD

Brief Process

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

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

REACTION:

Material 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


8.PRODUCT NAME : 2 Nitro 4 Methoxy Aniline

BRIEF PROCESS: Check reactor 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.

Reaction:

Material Balance:


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


9.PRODUCT NAME : 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

Material Balance:


1 Phenol 1000 Product 1544

2 ODCB 3124 Recovered ODCB 1824

3 KOH 595 Dist. Residue 30

4 KOH 792

5 Effluent 529


10. PROPOSED NEW PRODUCT NAME: 2,3 Xylyl Anthranilic Acid

Brief Process:

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

,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 .

Reaction

Material 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


11. PRODUCT NAME: 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

Reactions

Material Balance:


1 BSC 750 Product 500

2 Soda Ash 200 Recovered Toluene 870

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


5 Nitric Acid 270 Dil. Sulfuric Acid 1480

6 Sulfuric Acid 500 Effluent 2365

7 Hydrogen Gas 25

8 Water 2000


12. PRODUCT NAME : 5 Amino Ortho Toluedene

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

REACTION :

Material Balance:


1 Ortho Toluene 500 Product 400

2 Soda Ash 247 Recovered Toluene 950

3 BSC 824 Toluene Loss 40


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


13. PRODUCT NAME: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:

Material 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


14. PRODUCT NAME: 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.

Reaction Scheme:

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

Material 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


15. PRODUCT NAME: 3 Amino 4 Methoxy Acetanilide

Manufacturing 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.

Chemicals Reactions:

Material 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


16. PRODUCT NAME: 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.

Reactions

Material 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

5 NaCl 550


17. PRODUCT NAME : 2 chlor 4 fluoro 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

REACTION :

Material 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


18. PRODUCT NAME: Amino Product from nitro compound 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:

Material 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


19. PRODUCT NAME: ALCOHOL Product from aldehyde compound 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:

Material 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


Annexure -4

Details of Water Consumption and Wastewater generation

Water Consumption

S. No. Particulars

Water Consumption (KLD)

Existing Additional Total

1. Domestic 10.0

-- 10.0

2. Gardening 2.0 0.5 2.5

3. Industrial 4. Process 7.0 11.38 18.38 5. Boiler 1.0 1.0 2.0

6. Cooling (Make-up) 1.0 1.0 2.0

7. Washing 0.0 0.5 0.5

8. Sub-Total: Industrial 9.0 13.38 22.38

9. Grand Total 21.0 13.88 34.88

Wastewater generation

S. No. Particulars Waste Water Generation (KLD)

Existing Additional Total

1. Domestic 6.0 -- 6.0

2. Gardening -- -- --

3. Industrial 4. Process 3.5 12.30 15.80 5. Boiler (Blow down) 0.25 0.25 0.5 6. Cooling (Blow down) 0.25 0.25 0.5 7. Washing -- 0.5 0.5

8. Sub-Total: Industrial 4.0 13.30 17.30

9. Grand Total 10.0 13.30 23.30

Water Balance (After Proposed Expansion):

3.33 KL/Day �

PETL: Spray Dryer

for disposal

Raw Water 34.88 KL/Day

Domestic 10.0 KL/Day

Industrial 22.38 KL/Day

Gardening 2.5 KL/Day

Process – 18.38 KL/Day

Boiler- 2 KL/Day

Cooling - 2 KL/Day

6 KL Septic Tank/ Soak Pit

System

15.80 KL/Day

0.5 KL/Day

20.0 KL/Day ETP (Primary treatment & Secondary Treatment)

0.5 KL/Day

CETP for further treatment and

disposal

Washing -0.5 KL/Day

0.5 KL/Day

Annexure -5:

Details of ETP

M/s. PRAGNA LIFE SCIENCE PVT. LTD. shall have an Effluent treatment plant consisting of primary

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

PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)

The treatment scheme is given below:

The waste water from unit will be brought to the treatment plant via a series of

underground pipelines. The waste water will be collected in the collection cum equalization

tank. Two numbers of tanks are proposed. One will in filling mode for equalization of waste

water while the other will be in pumping mode. The equalized wastewater is pumped to the

flash mixer for addition of chemicals like lime. From the flash mixer the waste water flows

into the flocculator where chemical flocs are formed by coagulation and flocculation by

addition of Alum/Ferrous sulphate and polyelectrolyte. These flocs are removed in the

primary settling tank. The underflow (sludge) from the primary settling tank is taken to

sludge dewatering unit (Sludge Drying Bed). Neutralized effluent will be sent to aeration

tank. Treated effluent will be sent to CETP, Panoli for further treatment.

The Domestic wastewater is disposed of through septic tank & soak pit.

Effluent Treatment Plant (Dimension):

Sr. No. Name of the Unit Dimension Volume (m3) MOC

1. Collection cum

Neutralization Tank (1

Nos.)

3.86 m x 3.86 m x

2.3 m

34.27 m3 RCC

2. Aeration Tank (1 Nos.) 4.56 m x 3.5 m x

3.4 m

34.27 m3 RCC

3. Settling Tank 3.35 (m) x 3.5(m) x

2.35 (m)

27.55 m3 RCC

Flow Diagram:

EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT

Sr.

No.

Parameter

Characteristics (mg/L) CETP Inlet Norms

(mg/L)

Untreated Treated

1. pH 6.5 - 8.5 7-8 5-9

2. SS 600 200 600

3. COD 7,000 – 10,000 2,000 – 3,000 3,200

4. BOD3 600 – 1,000 <100 1,000

5. Ammonical Nitrogen 10-20 10-20 50

Stream-2: High COD & High TDS:

High COD & High TDS effluent will be neutralized in neutralization tank and neutralized effluent will

be sent to common spray dryer of M/s. PETL, Panoli for further treatment and disposal.

Raw

Effluent

Collection cum

Neutralization

Tank

Settling Tank

Settling Tank Final Collection

Tank

CETP for

further

Treatment

DST FMT Floc.

Aeration Tank

Annexure -6

Details of hazardous waste generation, storage & disposal

Sr.

No. Type of waste

Categ

ory

Qty. (MT/Month) Mode of Treatment &

Disposal Existing Additional Total

1 E.T.P. Sludge 35.3 5 25 30 Collection, Storage,

Transportation and

disposal at TSDF of BEIL or

PSWMCL 2 Inorganic salts 35.3 0 75 75

3 Used Oil 5.1 0.001 0.10 0.101

Collection, Storage,

Transportation & disposal

by Selling to registered re-

refiners

4

Discarded

Containers

33.1

180 Nos 500 Nos 680 Nos Collection, Storage,

Transportation,

Decontamination and

Sale to GPCB authorized

vendor

bags/liners 2400

Nos 550 Nos

2950

Nos.

5 Incinerable Waste

(Residue) 20.3 0 54 54


Transportation and co-

processing in cement

industries or sent to

common incineration

facility

6

Incinerable Waste

(Spent Charcoal &

Hyflow)

28.3 0 7 7

7

Date expired &

Off-specification

material

28.4 0 0.4 0.4

8 Spent Catalyst 28.2 0 2 2


Transportation and return

back to supplier

9 Spent Sulfuric Acid D2 0 280 280


Transportation and Sale

to end user

10 Spent Formic Acid -- 0 100 100

11 Acetic Acid -- 0 10 10

12 Dilute HCl D2 0 50 50

13 NaBr solution -- 0 180 180

14 NaHs solution -- 0 50 50

Annexure -7

Details of flue gas & proposed pollution control equipment

Particulars Fuel Fuel Quantity Stack

height

Emission

Norms

APCM

Existing scenario

Steam Boiler

(600 kg/hr.)

Natural Gas 80 SCM/day 11 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

--

Steam Boiler

(600 kg/hr.) –

Stand by

Natural Gas 80 SCM/day 11 m --

TFH (4 lakh

kcal/hr.)

Natural Gas 440 SCM/day 11 m --

D.G.Set (125

KVA)

Diesel 10 lit/hr 11 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

--

Proposed (Flue Gas Emission)

Steam Boiler

(800 kg/hr.)

Agro

Waste/Coal

3 MT/Day 30 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

Cyclone

Separator

with bag

filter

Steam Boiler

(800 kg/hr.) –

Stand by

LDO/FO 2.4 MT/Day 30 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

Scrubber

TFH (6 lakh

kcal/hr.)

Natural Gas 1000

SCM/day

12 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

--

TFH (4 lakh

kcal/hr.)

Natural Gas 800 SCM/day 12 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

--

D.G.Set (500

KVA)

Diesel 50 lit/hr 11 m PM<150 mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

--

Annexure -8

Storage Details of Hazardous Chemicals

List of Hazardous chemicals

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 10 KL

2 hydrochloric acid CORROSIVE STORAGE TANK 10 KL

3 CON.NITRIC ACID CORROSIVE STORAGE TANK 10 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 10 KL

8 NAHS TOXIC STORAGE TANK 10 KL

9 CS2 FLAMMABLE DRUM 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 0.2 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 10 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 10 MT

33 methanol FLAMMABLE STORAGE TANK 10 KL

34 EDC FLAMMABLE DRUM 10 MT

35 toluene FLAMMABLE STORAGE TANK 10 KL

36 nitro compound TOXIC DRUM/BAG 10 MT

37 aldehyde compound TOXIC DRUM/BAG 10 MT

38 ethanol FLAMMABLE STORAGE TANK 10 MT

Annexure – 9

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 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 there will be no adverse impact on sanitation,

communication and community health, as sufficient measures have been proposed to be

taken under the EMP. The proposed scenario is not expected to make any significant change

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

Annexure-10

__________________________________________________________________________

Proposed Terms of Reference for EIA Studies

1. Project Description

• Justification of project.

• Promoters and their back ground

• Project site location along with site map of 5 km area and site details providing various

industries, surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Existing infrastructure facilities

• Water source and utilization including proposed water balance.

• List of Products & their capacity

• Details of manufacturing process of proposed products

• 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 5 km area.

• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project

site.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

• Existing socio-economic status, land use pattern and infrastructure facilities available in

the study area were surveyed.

4. Impacts Identification And Mitigatory Measures

• Identification of impacting activities from the proposed 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.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

6. Risk Assessment

• Objectives, Philosophy 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

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Information on Rain Water Harvesting

9. Green Belt Development plan

Documents

FORM-1environmentclearance.nic.in/writereaddata/Online/... · Aqua-Air Environmental Engineers Pvt. Ltd. (Pollution Control Consultants & Engineers) Reg. Office: 403, Centre Point,