M/s. ADARSH DYE CHEM (UNIT-II)environmentclearance.nic.in/writereaddata/FormB/TOR/Proposed_TOR... · 3 Address M/s. Adarsh Dye Chem (Unit-II) Plot No. A-1/3621, Opp. ETL, GIDC Estate,

1

FORM-I

for

PROPOSED EXPANSION OF BULK DRUGS AND

BULK DRUG INTERMEDIATES IN

EXISTING UNIT

of

M/s. ADARSH DYE CHEM (UNIT-II)

PLOT NO. A-1/3621, OPP. ETL, GIDC ESTATE,

ANKLESHWAR-393002, DISTRICT: BHARUCH, GUJARAT.

Consultant

2

APPENDIX I

FORM 1

(I) Basic Information

Sr.

No.

Item Details

1. Name of the Project/s M/s. Adarsh Dye Chem (Unit-II)

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

For details Refer to Annexure: 2

4. New/Expansion/Modernization Expansion

5. Existing capacity/area etc. Existing capacity: 23 MT/Month

For detail Refer to Annexure: 2

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

7. Does it attract the general condition?

If yes, please specify.

8. Does it attract the specific condition?

If yes, please specify.

Not applicable

9. Location

Plot/Survey/Khasra No. A-1/3621

Village GIDC, Estate

Tehsil Ankleshwar

District Bharuch

State Gujarat

10. Nearest railway station/airport along

with distance in kms.

Nearest Railway Station: Ankleshwar: 2.8 km

Nearest Airport: Surat: 60.0 km

11. Nearest Town, city, District

Headquarters along with distance in

kms.

Nearest town: Ankleshwar: 1.2 km

12. Village Panchayats, zilla parishad,

Municipal corporation, Local body

(Complete postal addresses with

telephone nos. to be given)

Notified Area Authority, Ankleshwar

13. Name of the applicant M/s. Adarsh Dye Chem (Unit-II)

14. Registered address Plot No. A-1/3621, Opp. ETL, GIDC Estate,

Ankleshwar-393 002, District: Bharuch, Gujarat.

Address for correspondence:

Name Mr. Sureshbhai Dobaria

15.

Designation (Owner/Partner/CEO) Partner

3

Address M/s. Adarsh Dye Chem (Unit-II)

Plot No. A-1/3621, Opp. ETL, GIDC Estate,

Ankleshwar-393 002, District: Bharuch, Gujarat

Pin Code 393 002

E-Mail [email protected];

[email protected]

Telephone No. +919904163130

Fax No. 91-2646-253392

16. Details of Alternative Sites examined,

if any location of these sites should be

shown on a topo sheet.

No

17. Interlinked Projects No

18. Whether separate application of

interlinked project has been

submitted?

No

19. If Yes, date of submission Not applicable

20. If no., reason Not applicable

21. Whether the proposal involves

approval/clearance under: If yes,

details of the same and their status to

be given.

(a) The Forest (Conservation) Act,

1980?

(b) The Wildlife (Protection) Act,

1972?

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

No

22. Whether there is any Government

order/policy relevant/relating to the

site?

No

23. Forest land involved (hectares) No

24. Whether there is any litigation

pending against the project and/or

land in which the project is propose to

be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court,

if any and its relevance with the

proposed project.

No

4

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which will cause

physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes

/No?

Details thereof (with approximate

quantities / rates, wherever possible) with

source of information data

1.1 Permanent or temporary change in

land use, land cover or topography

including increase in intensity of land

use (with respect to local land use

plan)

No Proposed expansion is within Existing

Premises.

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 --

1.4 Pre-construction investigations e.g.

bore houses, soil testing?

No --

1.5 Construction works? Yes Plant layout is attached as Annexure: 1.

1.6 Demolition works? No --

1.7

Temporary sites used for construction

workers or housing of construction

workers?

No --

1.8 Above ground buildings, structures or

Earthworks including linear structures,

cut and fill or excavations

Yes Plant layout is attached as Annexure: 1.

1.9

Underground works including mining

or tunneling?

No --

1.10 Reclamation works? No --

1.11 Dredging? No --

1.12 Offshore structures? No --

1.13 Production and manufacturing Yes List of Products & their capacity is attached

as Annexure: 2 and manufacturing process

is attached as Annexure: 3.

1.14 Facilities for storage of goods or

materials?

Yes Dedicated storage area for storage of Raw

Materials, finished products, solvents, etc.

shall be provided.

1.15

Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes Details of proposed Effluent Treatment

Plant are attached as Annexure: 5.

Details of Hazardous waste generation and

disposal is attached as Annexure: 6.

1.16

Facilities for long term housing of

operational workers?

No --

1.17 New road, rail or sea traffic during

construction or operation?

No --

5

1.18 New road, rail, air waterborne or

other 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, converting,

realignment or other changes to the

hydrology of watercourses or

aquifers?

No --

1.22 Stream crossings? No --

1.23

Abstraction or transfers or the water

form ground or surface waters?

No --

1.24

Changes in water bodies or the land

surface affecting drainage or run-off?

No --

1.25

Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel, raw material

and products will be primarily by road only.

1.26 Long-term dismantling or

decommissioning or restoration

works?

No --

1.27 Ongoing activity during

decommissioning which could have

an impact on the environment?

No --

1.28

Influx of people to an area in either

temporarily or permanently?

Yes Direct/Indirect employment shall be

generated after proposed expansion.

1.29 Introduction of alien species? No --

1.30 Loss of native species of genetic

diversity?

No --

1.31 Any other actions? No --

2. Use of Natural resources for construction or operation of the Project (such as land, water,

materials or energy, especially any resources which are non-renewable or in short supply):

Sr.

No.

Information/checklist confirmation Yes/

No?

Details there of (with approximate

quantities/rates, wherever possible) with


2.1 Land especially undeveloped or

agriculture land (ha)

No --

2.2 Water (expected source & competing

users) unit: KLD

Yes Water requirement will be met through the

GIDC Water supply.

A detail of water balance is given as

Annexure – 4.

2.3 Minerals (MT) No --

2.4 Construction material -stone, Yes Company shall use Sand, stone, Cement and

6

aggregates, sand / soil (expected

source MT)

Structural Steel for Construction as

required.

2.5 Forests and timber (source - MT) No --

2.6

Energy including electricity and fuels

source, competing users Unit: fuel

(MT), energy (MW)

Yes Power Requirement:

Existing:

Power required from DGVCL is 100 KVA.

Proposed:

Power required from DGVCL will be 250

KVA.

1 DG Set = 100 KVA (for Emergency only)

Fuel Requirement:

Existing: No fuel

Proposed:

Agrowaste = 5 MT/Day

Diesel = 5 Lit./Hr (Only for emergency).

2.7 Any other natural resources (use

appropriates standard units)

No --

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

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

to human health.

Sr.

No.

Information / Checklist confirmation Yes/

No?


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: 8

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?


quantities / rates, wherever possible)

with source of information data

7

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: 6

4.4 Other industrial process wastes Yes Please refer Annexure: 6

4.5 Surplus product No --

4.6

Sewage sludge or other sludge from

effluent treatment


4.7 Construction or demolition wastes Yes Construction waste shall be utilized for

leveling, land filling in the premises.

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: 6

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

Sr.

No.


No


quantities/rates, wherever possible) with


5.1 Emissions from combustion of fossil

fuels from stationary or mobile sources


5.2 Emissions from production processes Yes Please refer Annexure: 7

5.3 Emissions from materials handling

storage or transport

Yes All liquid raw materials shall be procured

in tankers and shall be transferred through a

closed circuit pipe lines.

Solid raw materials shall be charged

through close pipeline into reactors and the

dust collection hopper shall be connected

to a bag filter and ID fan.

Also all hazardous chemicals storage tanks

will be provided with flame arrestors &

breather valves for safety.

5.4 Emissions from construction activities

including plant and equipment

Yes During construction work, only dust

contamination will be there & water

sprinklers shall be utilized whenever

necessary.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Dust from drying will be collected in to dust

collector through cyclone separator &

recovered powder will be recycled back to

process. Air Handling Unit will be provided

where ever applicable.

8

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: 7

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

Sr.

No.


No?


Quantities /rates, wherever possible) With

source of source of information data

6.1

From operation of equipment e.g.

engines, ventilation plant, crushers

Yes There are few activities due to which noise

would be generated. The equipments

resulting in noise generation are machinery

of plant and Diesel generator. Adequate

noise control measures will be provided

whenever required.

Proper and timely oiling, lubrication and

preventive maintenance will be carried out

for the machineries & equipments to reduce

noise generation.

Use of PPEs like ear plugs and ear muffs will

be made compulsory near the high noise

generating machines.

Noise monitoring shall be done regularly in

plant area.

The D.G. Set will be installed in a closed

room and provided with acoustic enclosure.

The unit will increase the plantation species

in the proposed greenbelt within the

premises which will prevent the noise

pollution in surrounding area.

6.2 From industrial or similar processes Yes All machinery / equipment shall be well

maintained, shall have proper foundation

with anti vibrating pads wherever applicable

to keep noise levels within permissible

limits.

Acoustic enclosures shall be provided for DG

set.

6.3 From construction or demolition No --

6.4 From blasting or piling No --

6.5 From construction or operational

traffic No

--

9

6.6 From lighting or cooling systems No --

6.7 From any other sources No --

7. Risks of contamination of land or water from releases of pollutants into the ground or into

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

Sr.

No


No?




7.1

From handling, storage, use or

spillage of hazardous materials

Yes All the raw material shall be stored

separately in designated storage area with

safety. Bund walls shall be provided around

raw materials storage tanks for containing

any liquid spillage.

Please refer Annexure: 8.

7.2

From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes Sewage shall be treated in Septic Tank &

Soak Pit.

7.3

By deposition of pollutants emitted

to air into the land or into water

No --

7.4 From any other sources No --

7.5 Is there a risk of long term build up

of pollution in the environment from

these sources?

No --

8. Risks of accident during construction or operation of the Project, which could affect human

health or the environment:

Sr.

No.

Information/Checklist confirmation

Yes/

No?




8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances


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

10

activities in the locality

Sr.

No.


No?




9.1 Lead to development of supporting.

laities, 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 industries

• supply industries

• other

No Site is having the entire required

infrastructure.

Existing road infrastructure & power supply

are to be utilized.

Local people will be employed and no

housing is required.

Please refer Annexure: 9.

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

--

*(III) Environmental Sensitivity

Sr.

No.

Information/Checklist confirmation Name /

Identity

Aerial distance (within 5 km) Proposed

Project Location Boundary.

1 Areas protected under international

conventions national or local

legislation for their ecological,

landscape, cultural or other related

value

No Proposed expansion project site is within

the GIDC, Ankleshwar.

2 Areas which are important or sensitive

for Ecological reasons - Wetlands,

watercourses or other water bodies,

coastal zone, biospheres, mountains,

forests

No Proposed expansion project site is within

the GIDC, Ankleshwar.

3 Areas used by protected, important or

sensitive species of flora or fauna for

breeding, nesting, foraging, resting,

over wintering, migration

No --

4 Inland, coastal, marine or underground

waters

Yes River Narmada = 7.6 kms

11

5 State, National boundaries No --

6 Routes or facilities used by the public

for to recreation or other tourist,

pilgrim areas.

Yes Public transportation

7 Defense installations No --

8 Densely populated or built-up area Yes Ankleshwar City around 1.2 km from the

proposed expansion project site.

9 Areas occupied by sensitive man-made

land community facilities)

No --

10 Areas containing important, high

quality or scarce resources (ground

water resources, surface resources,

forestry, agriculture, fisheries, tourism,

tourism, minerals)

No

--

11 Areas already subjected to pollution or

environmental damage. (those where

existing legal environmental standards

are exceeded)

Yes Ankleshwar

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 --

IV). Proposed Terms of Reference for EIA studies: Please refer Annexure: 10.

12

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

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

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

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

and cost.

Date: Nov 06, 2017

Place: GIDC, Ankleshwar

For Adarsh Dye Chem (Unit-II)

Authorized Signatory

NOTE:

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

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

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

the State Coastal Zone Management Authority (at the stage of EC). Simultaneous action shall

also be taken to obtain the requisite clearance under the provisions of the C.R.Z. Notification,

1991 for the activities to be located in the CRZ.

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

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

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

location and the recommendations or comments of the Chief Wildlife Warden thereon (at the

stage of EC).

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

application for TOR/Environmental Clearance, subsequent clarifications, as may be required

from time to time, participation in the EAC Meeting on behalf of the project proponent shall

be made by the authorized signatory only. The authorized signatory should also submit a

document in support of his claim of being an authorized signatory for the specific project.

13

ANNEXURES

1 PLANT LAYOUT

2 LIST OF PRODUCTS WITH PRODUCTION CAPACITY AND RAW MATERIALS

3 BRIEF MANUFACTURING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH

FLOW DIAGRAM

4 WATER CONSUMPTION AND EFFLUENT GENERATION

5 DETAILS OF PROPOSED EFFLUENT TREATMENT PLANT

6 DETAILS OF INHOUSE MEE

7 DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL

8 DETAILS OF STACK & VENTS

9 DETAILS HAZARDOUS CHEMICAL STORAGE FACILITY

10 SOCIO - ECONOMIC IMPACTS

11 PROPOSED TERMS OF REFERENCES

12 GIDC PLOT ALLOTMENT LETTER

13 GIDC WATER SUPPLY LETTER

14 TSDF & CHWIF MEMBERSHIP

15 TOPOSHEET

16 Copy of CCA

17 Copy of EC

14

ANNEXURE: 1

PLANT LAYOUT

15

ANNEXURE: 2

LIST OF PRODUCTS WITH PRODUCTION CAPACITY

Sr

No Existing Product Cas No.

Existing

Capacity

(MT/

Month)

Additional

Capacity

(MT/

Month)

Total

Capacity

(MT/

Month)

End Use

1. 2-Chloro Ethyl Amine

Hydrochloride 0000870-24-6

7.0 --

2. N,N-Bis [(2-Chloro Ethyl)

Amine] Hydrochloride

0000821-48-7

4.0 --

3. 1-(4-Hydroxy Phenyl)

Piperazine Hydrochloride

0056621-48-8

12.0 --

23.0 Pharma

TOTAL ( EXISTING PRODUCTS) 23.0 -- 23.0

Proposed Product

1. Ketoconazole and its intermediates

65277-42-1

a. Cis-Tosylate 154003-23-3

b. Para-Hydroxylphenyl-n-

acetyl piperazine 67914-60-7

c. Cis-Bromobenzoate 61397-56-6

2. Itraconazole and its intermediates

84625-61-6

a. Triazole alcohol --

b. Cis-mesylate 67914-86-7

3. 2-Chloroacetamide 79-07-2

4. Fluconazole and its intermediates

86386-73-4

86404-63-9 a.

1-(2,4-Difluorophenyl)-1-

(1H-1,2,4- triazole-1yl)-

ethanone (DFTA)

b.

2-(2,4-Difluorophenyl)-1-

(1H-1,2,4-triazole-1yl)

2,3Epoxy propane-

Methane sulphonate

(EPOXY MESYLATE)

86386-77-8

5. Trazodone 19794-93-5

a. 1-(3-

chlorophenyl)piperazine 6640-24-0

b.

1-(3-chlorophenyl)-4-(3-

chloropropyl)piperazine

hydrochloride

52605-52-4

6. Aripiprazole 129722-12-9

-- 20.0 20.0 Pharma

16

a. 1-(2,3- Dichlorophenyl)

piperazine hydrochloride 119532-26-2

b. 7-(4-bromobutoxy)-3 4-

dihydro-2(1h)-quinolinone 129722-34-5

7.

1-[2-(2-

Hydroxyethoxy)ethyl]pipe

razine

13349-82-1

TOTAL (PROPOSED PRODUCTS) -- 20.0 20.0

TOTAL ( EXISTING + PROPOSED PRODUCTS) 23.0 20.0 43.0

17

List of Raw Material

Existing Products:

Sr. No. Raw Material Quantity

(MT/MONTH)

Cas No.

1. 1-(4-Hydroxy Phenyl) Piperazine Hydrochloride

Di Ethanol amine 22.6 111-42-2

EDC 14.1 107-06-2

Thionyl Chloride 3.5 7719-09-7

Caustic Lye (40% solution) 42.4 1310-73-2

Methanol 13.6 67-56-1

Acetic Anhydride 21.9 108-24-7

Toluene 7.1 108-88-3

2. 2-Chloro Ethyl Amine Hydrochloride

Monoethanolamine 4.4 141-43-5

Thionyl chloride 9.6 7719-09-7

NaOH 1.1 1310-73-2

EDC 13.1 107-06-2

3. N,N- Bis (2-Chloro Ethyl) Amine Hydrochloride

DiEthanolamine 2.5 111-42-2


NaOH 0.625 1310-73-2

EDC 7.5 107-06-2

Proposed Products:

Sr. No. Raw Materials Quantity

(MT/MONTH)

Cas No.

1. KETOCONAZOLE AND ITS INTERMEDIATES

Cis Bromo benzoate 30.6 61397-56-6

Imidazole 13.0 288-32-4

DMF 1.4 68-12-2

Sodium Bicarbonate 5.8 144-55-8

P-toluene sulfonyl chloride 18.2 98-59-9

Methylenechloride 7.6 70110-03-1

18

Sodium carbonate- anhydrous

Monohydrate

decahydrate

12.0

497-19-8

5968-11-6

6132-02-1

Carbon 1.0 7440-44-0

Vacuum salt 0.2 7647-14-5

Sodium hydroxide 6.6 1310-73-2

Hydrochloric acid 6.6 7647-01-0

Acetone 1.6 67-64-1

Toluene 2.6 108-88-3

Sodium methoxide powder 2.8 124-41-4

Dimethyl sulfoxide 2.6 67-68-5.

Para hydroxyl phenyl N-acetyl piperazine 11.2 67914-60-7

Ethyl acetate 7.8 141-78-6

Methanol 2.8 67-56-1

PARA-HYDROXYLPHENYL-N-ACETYL PIPERAZINE

Bis(2-chloroethyl)amine HCL 28.0 821-48-7

Para amino phenol 20.0 123-30-8

Acetic anhydride 20.0 203-564-8


Carbon 0.4 7440-44-0


CIS-BROMO BENZOATE 61397-56-6

2,4-Dichloroacetophenone 13.3 937-20-2

Benzoyl Chloride 12.4 98-88-4

Bromine 12.5 7726-95-6

CS Flakes 4.8 1310-73-2

Glycerin 7.2 56-81-5

Liq. Ammonia 10.0 1336-21-6

Methanol 57.9 67-56-1

N- Butanol 4.0 71-36-3

PTSA ( p-Toluenesulfonic acid)

0.4 104-15-4 6192-52-5

(monohydrate)

Sodium Bicarbonate 0.8 144-55-8

TEBAC 0.3 80904-15-0

19

2. ITRACONAZOLE AND ITS INTERMEDIATES

1-(4-Methoxy) piperidine 20.4 4045-24-3

1H,1,2,4-Triazole 16.6 63598-71-0

2-Bromo butane 7.8 78-76-2

Acetone 1.3 67-64-1

Carbon 1.8 7440-44-0

Cis-Bromobenzoate 26.2 61397-56-6

Dimethyl formamide 10.5 68-12-2

Ethyl acetate 2.8 141-78-6

Formamidine acetate 15.0 3473-63-0

Hydragin hydrate 15.3 7803-57-8

Hydrobromic acid 6.2 10035-10-6


Hydrogen gas 2.4 1333-74-0

Hyflow supercell 1.6 68855-54-9

Methane sulfonyl chloride 9.0 124-63-0


Methylene chloride 3.0 70110-03-1

n-Butanol 0.6 71-36-3

Palladium carbon 0.0 7440-05-3

Paranitro chlorobenzene 16.8 100-00-5

Phenyl chloroformate 18.5 1885-14-9

Potassium carbonate 55.0 584-08-7

Potassium hydroxide 12.2 1310-58-3

Soda ash 20.4 497-19-8

Sodium bicarbonate 16.7 144-55-8


Toluene 2.1 108-88-3

Triethyl amine 9.5 121-44-8

3. 2-CHLOROACETAMIDE

Ammonia solution 48.3 1336-21-6

Methyl 2-chloroacetate

25.0 4755-81-1

20

4. FLUCONAZOLE AND ITS INTERMEDIATES

1,2,4-Triazole 13.2 288-88-0

1,3-Difluorobenzene 16.0 372-18-9

4-Amino-1,2,4-Triazole 13.0 584-13-4

Aluminium Chloride 19.2 7446-70-0

Ammonia Solution 67.2 1336-21-6

Carbon 1.2 7440-44-0

Chloroacetyl chloride 16.8 79-04-9

Citric acid 1.2 77-92-9


Hyflow supercell 1.0 68855-54-9

IPA 63.2 67-63-0

Methylene chloride 96.0 70110-03-1

Potassium Hydroxide 18.8 1310-58-3

Sodium bicarbonate 1.2 144-55-8

Sodium Nitrite 9.4 7632-00-0

Toluene 168.0 108-88-3

Trimethyl sulphoxonium Iodide 26.4 1774-47-6

5. Trazodone Hydrochloride

Diethanolamine 10.3 111-42-2

Ethylene di chloride 21.3 107-06-2

Meta -chloroaniline 12.1 108-42-9


toluene 7.9 108-88-3

IPA- HCl 14.3 7647-01-0

1-bromo-3-chloropropane 8.3 109-70-6

2-chloropyridine 12.9 109-09-1

1, 2, 4-triazolo [4,3-a] pyridine -3-(2H)-one 22.2 6969-71-7

acetone 60.0 67-64-1

Thionyl chloride

23.8

7719-09-7

21

6. Aripiprazole

Diethanolamine 10.3 111-42-2

Ethylene di chloride 21.3 107-06-2

2.3 -Dichloroaniline 15.5 Not available


Xylene 23.7 1330-20-7

DMF 31.7 68-12-2

1,4-dibromo butane 9.9 110-52-1

Tryethylamine 12.9 121-44-8

7-(4-bromobutoxy)-3,4-dihydroquinolin-2(1H)-one 9.9 129722-34-5

Acetone 23.7 67-64-1


7. 1-[2-(2-Hydroxyethoxy)ethyl]piperazine

Piperazine 14.3 110-85-0

2- (2-chloroethoxy) ethanol 7.0 628-89-7

Methanol 15.5 67-56-1


22

ANNEXURE: 3

BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH FLOW

DIAGRAM

Existing Products: [1] 1-(4-Hydroxy Phenyl) Piperazine Hydrochloride

Manufacturing Process:

The mixture of Bis-(2-chloro ethylamine) hydrochloride para amino phenol ,Methanol was heated

to reflux (70-850C) & progress of the reaction was monitored by TLC.On completion the reaction

mass was cooled to 300C and further chilled to 0-5

oC when product crystallizes asoff white crystals

this product taken in reactor with water and methanol than slowly cooled 100C to 15

0C than slowly

addition acetc anhydride and progress of the reaction was monitored by TLC.On completion the

above solid was then dissolved in 30% sodium hydroxide sol. (100 ml) & warmed to 400C when a

clear sol. Was obtained.The sol. was then slowly cooled to 00C when product crystallizes as sodium

salt & thick slurry was obtained.The sodium salt of the product was isolated by filtration and

washed with chilled (00C,200ml) prior to drying at 70

0C under reduced pressure (10mm/Hg) for 12

hrs.

Chemical Reaction:

Cl

N

H

Cl

+

NH

2

HO

+

C

C

CH

3

O

O

O

H

3

C

EDC+Methanol

Bis(2-chloroethyl)amine para amino phenol acetic anydride

C

4

H

9

Cl

2

N .HCl C

6

H

10

NO C

4

H

6

O

3

(178.49) (109.12) (102.09)

N N

HO

CH

3

O

Toluene + Methanol

Sodium hydroxide

NaOH (39.99)

NH

N

+

O

H

3

C

ONa

OH

Para hydroxylphenyl-n-acetyl piperazine 1-(4-hydroxyphenyl) Sodium acetate

piperazine

C

12

H

16

N

2

O

2 (220.12)

C

10

H

14

N

2

O CH

3

COONa

(178.23) (82.03)

23

Mass balance:

INPUT QTY (kg) OUTPUT QTY (kg)

Bis HCL 160 Finish Product 85

PAP 100 Methanol Recovery 275

NaOH 25 Methanol Loss 25

EDC 300 Toluene Recover 45

Acetic anhydride 96 Toluene Loss 5

Methanol 155 Sodium Acetate 451

Toluene 50

TOTAL 886 TOTAL 886

24

[2] 2-Chloro Ethyl Amine Hydrochloride


In a dry GL fitted with a sealed mechanicals stirrer, an efficient reflux condenser, and addition flask

is placed of Thionyl Chloride and Ethylene Dichloride. Throughout, the entire period of operation,

as the reaction is very exothermic. Monoethanol amine is added through the flask and slow

addition.The cooled mass over a period of an hour, during which time there is a copious evolution

of sulfur dioxide. After all the Diethanol amine has been added, the cooling is stop and the reaction

mixture.

Chemical Reaction:

OH-CH2- CH2-NH2 + SOCl2 Cl-CH2- CH2-NH2.HCl + SO2

Monoethanolamine Thionyl Chloride 2-Chloro ethyl amine HCl Sulphur oxide

Or

NH2

OH

NaOH

EDCMONO ETHANOL AMINE

Cl

NH2

ClH

2-CHLOROETHYLAMINEHCL

+ T C

+NaSO4

2-chloroethanamine

Mass balance:

INPUT QTY (kg) OUTPUT QTY (kg)

Monoethanolamine 100 Finish Product 160

Thionyl chloride 220 EDC Recovery 275

NaOH 25 EDC Loss 25

EDC 300 NaSO4 40

HCl 25 % 145

TOTAL 645 TOTAL 645

EDC (Media)

25

[3] N,N, Bis (2-Chloro Ethyl) Amine Hydrochloride


In a dry GL fitted with a sealed mechanicals stirrer, an efficient reflux condenser, and addition flask

is placed of Thionyl Chloride and Ethylene Dichloride. Throughout the entire period of operation

the reaction is very exothermic. Diethanol amine is added through the flask and slow addition. The

cooled mass over a period of an hour, during which time there is a copious evolution of sulfur

dioxide after all the Diethanol amine has been added, the cooling is stop and the reaction mixture.

Chemical Reaction:

2(OH-CH2- CH2)NH2 + 2SOCl2 2(Cl- CH2- CH2)NH2 .HCl + SO2

Di Ethanol amine Thionyl Chloride Bis(2-Chloro ethyl)amine HCl Sulphur

oxide

Or

NH

OH

OH

NaOH

EDCDI ETHANOL AMINE

Cl

NH

Cl

ClH

N,N-BIS (2

-CHLOROETHYL)AMINEHCL

+ T C

Mass Balance:

INPUT QTY (kg) OUTPUT QTY

(kg)

DiEthanolamine 100 Finish Product 160

Thionyl chloride 220 EDC Recovery 275

NaOH 25 EDC Loss 25

EDC 300 NaSO4 40

HCl 25 % 145

TOTAL 645 TOTAL 645

EDC (Media)

26

Proposed:

1. Ketoconazole And Its Intermediates:

Manufacturing Process and Chemical Reaction:

KT-I: CBB is reacted with IMD in the presence of DMF as solvent. The reaction mass is quenched in

sodium bicarbonate solution and the product is extracted with toluene. The aqueous layer is

kept for IMD recovery. The organic layer containing the product is reacted with sodim hydroxide

solution. After completion of the reaction, the pH of the mass is adjusted with hydrochloric acid.

The mass is diluted with water and centrifuged. The wet cake is dissolved in ethyl acetate and

treated with carbon. The mass is filtered and the ethyl acetate is distilled off. The residue is

cooled and centrifuged. The mass is dried to produce KT-I

KT-II

KT-I is reacted with PTSC in the presence of sodium carbonate and methylene chloride as

solvent. The reaction mass is diluted and the organic layer separated. Methylene chloride is

distilled off completely from the organic layer and the residue is diluted with methanol and

water. The mass is centrifuges and washed with methanol and water mixture. The mass is dried

to produce Cis-Tosylate (KT-II).

27

KT-III

Cis-Tosylate (KT-II) is reacted with Para hydroxyl phenyl N-acetyl piperazine and sodium

methoxide in the presence of dimethyl sulfoxide as solvent. After completion of the reaction,

sodium hydroxide solution is charged into the reactor and maintained. The mass is centrifuged.

The wet cake is treated with water and further by acetone. The wet cake is taken for next stage.

KT-IV

The wet cake is dissolved in ethyl acetate and methanol, and treated with carbon. The mass is

filtered and the solution distilled off. The residue is cooled and centrifuged. The material is dried

to produce Ketoconazol

28

Flow Diagram:

29

30

31

Mass Balance:

Ketoconazole

Stage-I

Input Output

CBB 780.0 450.0

IMD 693.0

DMF 37.2 IMD (Rec) 360.0

Toluene 2275.5 Toluene (Rec) 2207.0

Sodium Bicarbonate 148.2 Ethyle acetate (Rec) 1620.0

Sodium hydroxide 120.0 Process loss 254.9

Water 1205.0 Aq. Effluent 2099.4

HCL 156.0 Spent carbon 12.0

Ethyl acetate 1706.4 Residue 130.0

Carbon 6.0

Vacuum salt 6.0

Total 7133.3 Total 7133.3

Stage-II

Input Output

KT-I 450.0 KT-II (Cis-tosylate) 600.0

Methylenechloride 3217.5 Methylenechloride (Rec) 3024.0

P-toluene sulfonyl chloride 465.0 Methanol (Rec) 1375.0

Sodium carbonate 307.5 Aq. Effluent 1278.0

Hydrochloric acid 12.0 Residue 120.0

Methanol 1425.0 Process loss 400.0

water 920.0


Stage-III

Input Output

Cis-tosylate (kt-II) 600.0 KT-III 650.0

Para hydroxyl phenyl n- 285.0

acetyl piperazine

Dimethyl sulfoxide 847.0 Dimethyl sulphoxide (Rec) 779.0

Sodium methoxide powder 70.0 Acetone (Rec) 300.0

Sodium hydroxide 50.0 Aq. Effluent 908.0

Acetone 340.0 Residue 59.0


Water 565.0


32

Stage-IV

Input Output

KT-III 650.0 Ketoconazole 510.0

Ethyl acetate 2220.0 Ethyl acetate + Methanol (Rec) 2550.0


Carbon 20.0 Spent carbon 40.0

Residue 80.0


33

a. Para-Hydroxylphenyl-n-acetyl piperazine


The mixture of bis - (2-chloroethylamine) hydrochloride Para Aminophenol ,Water ,Methanol

was heated to reflux (70-85oC) and progress of the reaction was monitored by TLC. On

completion the reaction mass was cooled to 30oC and further chilled to 0-5oC when product

crystallizes asoff-white crystals.

this product taken in reacter with water and methanol than slowly cooled 10oC to 15

oC than

slowly addition acetic anhydride and progress of the reaction was monitored by TLC. On

completion The above solid was then dissolved in 30 % sodium hydroxide solution (100 mL)

and warmed to 40oC when a clear solution was obtained. The solution was then slowly cooled

to 0oC when product crystallizes as sodium salt and thick slurry was obtained. The sodium salt

of the product was isolated by filtration and washed with chilled water (0oC, 200 mL) prior to

drying at 70oC under reduced pressure (10 mm/Hg) for 12 hours.

Flow Diagram:

34

Mass Balance:

Input Quantity Output Quantity

Para amino phenol 260

BISCEA HCl 364 AHPP 285

Acetic anhydride 260 Waste water 1251

Sodium hydroxide 332 Methanol (Rec) 80

Water 300.5 Spent carbon 8

Methanol 100.5

Carbon 7

TOTAL 1624 1624

35

b. CIS-BROMO BENZOATE:


Stage-I:

Charge toluene, 2,4-dichloroacetophenone and glycerin onto a stainless steel reactor. Charge

PTSA and water into the reactor, and heat the mass to reflux. Maintain the mass at reflux for 24

hours. After completion of the reaction, cool the mass below 35°C and transfer the mass to a

glass lined reactor. Charge n-butanol in the reactor containing the mass and cool below 15°C.

Slowly add bromine into the reactor and maintain the mass below 15°C. After completion of

the reaction, adjust the pH of the mass to 8 with liquor ammonia. Charge water into the

reactor, stir and settle. Separate the organic layer and wash with water. Meanwhile, charge

water and sodium hydroxide into a stainless steel reactor. Transfer the organic layer from GL

reactor into the SS reactor. Cool the mass and

charge TEBAC. Add benzoyl chloride slowly into the reactor below 20°C and maintain. After

completion of the reaction, settle the mass. Separate the organic layer and wash with sodium

bicarbonate solution followed by water. Distill off toluene completely and dilute the residue

with methanol. Cool the mass and centrifuge. Dry the material at 60 – 65°C to produce Cis-

bromo benzoate.

36

Flow Diagram:

Stage-1:

37

Mass Balance:

Stage-I

Input Quantity Output Quantity

2,4-DCAP 500 Cis-Bromo benzoate 750

Benzoyl Chloride 464

Bromine 468 Methanol (Rec) 1868

Glycerin 271 Aq. HBR (HBR Rec) 1000

Liq. Ammonia 374.5 Spent solvent 465

Methanol 2172.5 Aqueous effluent 1622

N- Butanol 150 Residue 25

PTSA 13.5 Process loss 111

Sodium Bicarbonate 30

TEBAC 9.5

Toluene 1720

Water 1035

Total 7389 Total 7389

38

2. ITRACONAZOLE AND ITS INTERMEDIATES:

Manufacturing Process and Chemical ReactionITR-INT-A

Stage-I:

Charge dimethyl formamide, cis-2[bromomethyl-2-(2,4 dichlorophenyl)1,3 dioxalane-4-yl)methyl

benzoate and 1H-1,2,4 triazole into a reactor. Charge sodium hydroxide solution into the reactor.

Heat to reflux and maintain for 8 hours. After completion of reaction, cool the mass below 35°C

and charge potassium carbonate. Stir the mass for 30 minutes and filter. Charge the filtrate and

distill off DMF completely. Charge water and toluene into the reactor and stir for 30 minutes.

Discard the bottom aqueous layer to ETP. Cool the organic layer to 10-15°C. Centrifuge the material

and wasn with toluene. Dry the material at 60-65°C to produce Cis-[2-(2,4-dichlorophenyl)-2-

(1H,1,2,4-triazol-1yl methyl)1,3 dioxolan-4yl]methanol.

Stage-II:

Charge methylene dichloride, Step-I compound and triethyl amine into a reactor. Slowly add

methane sulfonyl chloride into the reactor at 10-15°C. After completion of the reaction, charge

water and stir for 30 minutes. Separate the layers. Charge organic layer in to the reactor and

charge carbon. Stir for 30 minutes and filter the mass into another reactor. Add hydrochloric acid

into the reactor at 25-30°C. Cool the mass to 10-15°C. Centrifuge and wash with methylene

dichloride. Dry the material at 45-50°C to produce Cis-[2-(2, 4 - dichlorophenyl) - 2 - (1H,1, 2, 4 -

triazol - 1yl- methyl) 1,3-dioxolan-4yl]-methyl methane sulfonate (ITR-INT-A).

39

ITR-INT-B

Stage-I:

Charge dimethyl formamide, potassium carbonate and 1-(4-Methyxy) piperadine into a reactor.

Heat the mass to 60-65°C. Add paranitro chlorobenzene for 3-4 hours at same temperature. After

completion of the reaction distill off the dimethyl formamide completely. Cool the mass and charge

methanol ad carbon into the reactor. Maintain the mass for 30 minutes at 50-55°C and filter into

another reactor. Cool the filtrate to 10-15°C and centrifuge. Wash the material in water. Slurry

wash the cake with acetone to produce 1-(4-Methoxyphenyl)-1-(4-nitrophenyl) piperazine.

Stage-II:

Charge DMF, palladium carbon and 1-(4-Methoxyphenyl)-1-(4-nitrophenyl) piperazine into the

reactor. Heat the mass to 50-55°C. Pass hydrogen gas for 18 hours. After completion of the

reaction, cool the mass below 35°C and filter the mass. Cool the filtrate to 0-5°C and maintain.

Centrifuge the mass to produce 1-(4-Methoxyphenyl)-1-(4-aminophenyl) piperazine.

Stage-III + IV:

Charge Methylene chloride and 1-(4-Methoxyphenyl)-1-(4-aminophenyl) piperazine compound into

a reactor. Heat the mass to 35-45°C. Add phenyl chloroformate for 5-6 hours at same temperature.

After completion of the reaction, charge water into the reactor. Separate the layers. Discard

aqueous layer and charge organic layer. Distill off Methylene chloride completely and charge n-

butanol into the reactor. Heat the mass to 55-60°C. Add hydrazine hydrate into the reactor.

maintain for 4 hours at same temperature and cool the mass. Centrifuge the mass and wash with n-

40

butanol to produce 2,4-Dihydro-4-[4-[(4-methoxyphenyl)-1-piperazinyl] phenyl hydrazine

carboxamide.

Stage-V:

Charge DMF and carboxamide compound into the reactor and heat to 70-75°C. Add formanidine

acetate into the reactor slowly. After completion of the reaction, cool the mass and centrifuge, to

produce 2,4-Dihydro-4-[4-[(4-methoxyphenyl)-1-piperazinyl phenyl]-3H-1,2,4-triazole-3

Stage-VI:

Charge 2-bromobutane, potassium carbonate and triazole compound into a reactor. Heat to reflux

and maintain for 8 hours. After completion of reaction filter the mass and distill off 2-bromebutane

completely. Charge DMF into the reactor and acedify the mass with hydrochloric acid. Centrifuge

the material and wash with DMF to produce 2,4-Dihydro-4-[4-[(4-methoxyphenyl)-1-piperazinyl

phenyl]-2-(1-methylpropyl)-3H-1,2,4-triazole-3-one

41

Stage-VII: Charge hydrobromic acid and stage-VI compound into a reactor and heat the mass to reflux. After

completion of the reaction, distill off HBr completely and charge water into the reactor. Neutralize

the mass with soda ash. Centrifuge the mass and wash with water to produce 2,4-Dihydro-4-[4-[(4-

hydroxyphenyl)-1-piperazinyl] phenyl]-2-(1-methylpropyl)-3H-1,2,4-triazole-3-one (ITR-INT-B)

ITRA-Stage-I/II/III Charge water, potassium hydroxide, Cis-(2-(2,4-dichlorophenyl)-2-(1H-1,2,4-triazol-1-yl-methyl)-

1,3-dioxalane-4-yl) methyl methane sulfonate and 2,4-Dihydro-4-[4-[(4-hydroxyphenyl)-1-

piperazinyl] phenyl]-2-(1-methylpropyl)-3H-1,2,4-triazole-3-one into the reactor. Heat the mass to

80-85°C and maintain for 6 hours. Cool the mass below 35°C and centrifuge. Charge the cake and

DMF into a reactor and maintain for 1 hour ar room temperature. Centrifuge the mass and wash

with DMF to produce Itraconazole Crude. The crude is treated with toluene, methanol and ethyl

acetate and carbon to produce Itraconazole pure.

42

43

44

45

46

47

48

49

50

Mass Balance:

ITR-INT-A Stage-I

INPUT Quantity OUTPUT Quantity

Cis-Bromobenzoate 111.3 Triazole derivative 95.8

1H,1,2,4-Triazole 70.4 Solvent rec (DMF) 181.7

Potassium carbonate 105.7 Solvent rec (Tol) 153.3

Dimethyl formamide 186.7 Aq. Effluent 324.3

Sodium hydroxide 10.6 Residue 64.5

Toluene 157.4

Water 186.7 Solvent loss 9.1


Stage-II


Triazole derivative 95.8 ITR-INT-A 101.5

Triethyl amine 40.2 Solvent rec (MDC) 187.0

Methane sulfonyl chloride 38.3

Methylene chloride 193.8 Aq.effluent 192.0

Carbon 3.8 Spent carbon 7.7

Sodium hydroxide 6.9 Residue 56.2

51



ITR-INT-B

Stage-I


1-(4-Methyxy) piperadine 86.9 Stage-I 132.4

Paranitro chlorobenzene 71.2 Solvent Rec (Methanol) 198.9

Potassium carbonate 77.1 Solvent Rec (Acetone) 200.2

Dimethyl formamide 101.5 Solvent Rec (DMF) 98.1

Methanol 203.3 Aq. Effluent 176.5

Acetone 205.7 Spent carbon 3.5

Carbon 1.7 Residue 54.8



Stage-II


Stage-I 132.4 Stage-II 118.3

Dimethyl formamide 238.4 Solvent Rec (DMF) 231.4

Palladium carbon 0.1 Gas loss 5.0

Hydrogen gas 10 Residue 19.2

Solvent loss 7.0


Stage-III+IV


Stage-II 118.3 Stage-IV 136.0

Phenyl chloroformate 78.6 Solvent Rec (MDC) 240.0

Sodium bicarbonate 71.0 Solvent Rec (Butanol) 145.2

Methylene chloride 246.0 Aq. Effluent 450.8

Hydragin hydrate 65.0 Residue 41.8

n-Butanol 147.8



Stage-V


Stage-IV 136.0 Stage-V 121.2

Formamidine acetate 63.6 Solvent Rec (DMF) 380.3

Dimethyl formamide 390.0 Residue 78.3

Solvent loss 9.7


52

Stage-VI


Stage-V 121.2 Stage-VI 92.9

2-Bromo butane 125.2 Solvent Rec (DMF) 349.7

Potassium carbonate 51.0 Solvent Rec (2-BB) 92.0

Dimethyl formamide 357.0 Residue 148.8

Hydrochloric acid 38.3 Solvent loss 9.4


Stage-VII


Stage-VI 92.9 ITR-INT-B 78.0

Hydrobromic acid 961.9 Hydrobromic acid rec 935.5

Soda ash 86.7 Aq. Effluent 476.6



Itraconazole

Stage-I


ITR-INT-B 78 IT-I 125

ITR-INT-A 101.5 Solv. Recovery (DMF) 578

Water 287.5 Aq. Effluent 380.5

N,N-Dimethyl formamide 590 Residue 13.5

Potassium hydroxide 52 Solvent loss 12


Stage-II


Stage IT-I 125 Itraconazole 85

Toluene 165 Solv. Recovery (Tol) 160

Ethyl acetate 432 Solv. Recovery (EA) 420

Methanol 695.9 Solv. Recovery (Me) 675

Carbon 2.3 Residue 34.1

Hyflow supercell 6.7 Spent Carbon 4.6

Spent hyflow 10.3

Solv. Loss 37.9


53

3. 2-CHLOROACETAMIDE


Stage-I:

Charge Ammonia solution into the reactor and cool to 0°C. Add Methyl 2-chloroacetate slowly in

the reactor below 10°C. Maintain and centrifuge the mass. Wash the material with water and dry

to produce 2-Chloroacetamide.

Chemical Reaction:

Flowchart:

54

Mass Balance:

55

4. FLUCONAZOLE AND ITS INTERMEDIATES Manufacturing Process and Chemical Reaction:

Stage-I Charge Methylene dichloride and aluminium chloride into the reactor. Cool the mass to below

5°C. charge 1,3-Difluorobenzene into the reactor. Add slowly chloroacetyl chloride into the

reactor for 4 to 5 hours below 10°C. Charge water into another reactor and cool below 5°C.

Charge the reaction mass to ice and hydrochloric acid, slowly maintaining the temperature

below 10°C. Stir the reaction mass for 4 hours and separate the layers. Wash the organic layer

with sodium bicarbonate solution. Distill off MDC completely below 50°C. Charge isopropyl

alcohol and 4-amino-1,2,4-triazole into the reactor and maintain for 6 hours at 45-50°C. Cool

the reaction mass to 10°C and centrifuge the material and dry to produce 2-(1H-1,2,4-triazole-

1-yl)-2’,4’-difluoroacetophenone salt.

Stage-II 1-(2,4-difluorophenyl)-2-(1H,1,2,4-Triazol-1-yl) ethanone.

Charge water, sodium nitrite and 2-(1H-1,2,4-triazole-1-yl)-2’,4’-difluoroacetophenone into the

reactor and heat to 50-60°C. Slowly add hydrochloric acid at 50-60°C and maintain for 12

hours. Cool the mass below 20°C and neutralize the reaction mass with ammonia solution.

Centrifuge the mass and wash with water. Dry the material to produce 1-(2,4-difluorophenyl)-

2-(1H,1,2,4-Triazol-1-yl) ethanone.

56

Stage-III & IV Charge Toluene, 1-(2,4-difluorophenyl)- 2-(1H,1,2,4-Triazol-1-yl) ethanone, potassium hydroxide,

1,2,4,-Triazole and Trimethyl sulphoxinium iodide into the reactor. Heat to reflux and maintain for

12 hours. Distill off Toluene completely. Cool the reaction mass and charge water into the reactor.

Charge toluene into the reactor and stir for 30 minutes. Settle the mass for 30 minutes. Separate

the layers. Discard the bottom aqueous layer. Cool the mass to 10°C and centrifuge. Dry the

material to produce Flucnazole crude.

Charge water, crude and ammonia solution into the reactor. Check complete dissolution and charge

carbon. Stir for 30 minutes and filter over hyflow bed. Charge toluene and citric acid. Neutralize the

mass with hydrochloric acid. Stir for 30 minutes and settle for 30 minutes. Separate the layers and

discard aqueous layer. Cool the mass. Centrifuge the mass and wash with toluene. Dry the material

to produce Fluconazole pharma.

57

Flowchart:

58

59

60

Mass Balance:

Stage-I

Input Output

1,3-Difluorobenzene 200 Stage-I Compound 480

Aluminium Chloride 240 Solvent Recovery (MDC) 1050

Methylene chloride 1200 Solvent Recovery (IPA) 740

Chloroacetyl chloride 210 Solvent loss 202

4-Amino-1,2,4-Triazole 162 AlCl3 gel for Rec. 1100

IPA 790 Aq. Effluent 490

Sodium bicarbonate 15 Residue 30

Hydrochloric acid 75

Ice & Water 1200


Stage-II

Input Output

Stage-I Compound 480 Stager-II 370

Sodium Nitrite 118

Hydrochloric acid 250

Water 1100 Aq. Effluent 1778

Ammonia Solution 200


Stage-III

Input Output

Stage-II 370 Stage-III 370

Trimethyl sulphoxonium Iodide 330

1,2,4-Triazole 165 Solvent recovery (Toluene) 550

Potassium Hydroxide 235 Aq. Effluent 1170

Toluene 600 Residue 50

Water 500 Solvent loss 60


61

Stage-IV

Input Output

Stage-III Material 370 Fluconazole 250

Toluene 1500 Solvent rec (Tol) 1428

Carbon 15 Aq. Effluent 1478

Citric acid 15 Spent carbon 30

Ammonia solution 640 Spent hyflow 24

Hydrochloric acid (CP) 180 Residue 50

Hyflow supercell 12

Water 600 Solvent loss 72


62

5. Trazodone Hydrochloride


TH- I

In first part of the process bis-(2-chloroethylamine) hydrochloride (Compound P) is prepared by

chlorination of diethanolamine with thionyl chloride in ethylene di chloride which is then

temperature 65 to 70 C which is then condensed with 3-chloro aniline to get 1-(3-

chlorophenyl)-piperazine hydrochloride

STAGE –II (1-(3-chlorophenyl)-4-(3-chloropropyl) piperazine)

1-(3-chlorophenyl)-piperazine hydrochloride intermediate (Compound Q). This is reacted with

3-bromo-3-chloropropane in alkaline aqueous acetone (50 %) gave various 1-(3-

chlorophenyl)-4-(3-chloropropyl) piperazine intermediate (Compound R)

63

Stage – III

In second part of the process, 1-(3-chlorophenyl)-4-(3-chloropropyl) piperazine is condensed with sodium salt of 1, 2, 4-triazolo [4, 3-a] pyridine-3- (2H)-one (Compound S) 1-(3-chlorophenyl)-4-(3-chloropropyl) piperazine (R) and of Trazodone Hydrochloride (T) reported in the literature and observed in the lab are 84-85%, 72-73%, 84-85% respectively. The intermediate 1, 2, 4-triazolo [4, 3-a] pyridine-3- (2H)-one (S) is obtained in >90 % yield and in desired purity. But the process involves long reaction hours (>12) and elevated temperature (145-150

0C).

64

Flowchart:

Mass Balance:

Stage-I

Input Output

Diethanolamine 262

Stage-I Compound 308

Ethylene dichloride 540 Solvent Recovery (EDC) 430

Thionyl chloride 604

Sodium hydroxide 305 Sodium sulpate + water 1581

water 562 Residue 60

3-Chloroaniline 308

Solvent loss 202


65

Stage-II

Input Output

Stage-I Compound 308 Stage-II Compound 361

3-bromo-3-chloropropane 209 Solvent Recovery (Acetone) 530

Acetone 604 Sodium bromide + water 136

Sodium hydroxide 205 Sodium chloride + water 557


Solvent loss 74


Stage-III

Input Output

Stage-II Compound 361 Stage-III Compound 507

1, 2, 4-triazolo 568 Solvent Recovery (Acetone) 730

Acetone 904 IPA 203


IPAHCL 362 Residue 80

Solvent loss 174


66

6. Aripiprazole


STAGE – I (1-(2,3-Dichlorophenyl)piperazine hydrochloride)

In first part of the process bis-(2-chloroethylamine) hydrochloride (Compound A) is prepared by

chlorination of diethanolamine with thionyl chloride in xylene, which is then condensed with

2,3-dichloro aniline to get 1-(2,3-dichlorophenyl)-piperazine hydrochloride intermediate

STAGE – II (7-(4-bromobutoxy)-3 4-dihydro-2(1h)-quinolinone)

The intermediate, 7-(4- bromobutoxy)-3, 4-dihydro-2(1H)-quinolinone (D) is prepared by

condensation of 7-hydroxy-3, 4-dihydro-2(1H)-quinolinone (Compound C) with dibromobutane

in DMF using potassium carbonate as base.

67

STAGE –III

The yields of 1-(2, 3- dichlorophenyl)-piperazine hydrochloride (B), 7-(4- bromobutoxy)-3,4-

dihydro-2(1H)- quinolinone (D) WITH TRA and NaOH after tempature Aripiprazole

68

Flowchart:

69

PMass Balance:

Stage-I

Input Output

Diethanolamine 262 Stage-I Compound 392

Ethylene dichloride 540 Solvent Recovery (EDC) 430

Tionyl chloride 604

Sodium hydroxide 305 Sodium sulpate + water 1581

Xylene 562 Residue 60

2,3-diChloroaniline 392

Solvent loss 202


Stage-II

Input Output

7-(4-bromobutoxy)-3,4-

dihydroquinolin-2(1H)-one 250 Stage-II Compound 361

1-bromo-3-bromopropane 392 Solvent Recovery (DMF) 730

DMF 804 Sodium bromide + water 236

Potasuim carbonate 205


Solvent loss 74


Stage-III

Input Output

Stage-I Compound 392 Stage-III Compound 507

Stage-II Compound 361 Solvent Recovery (TEA) 830

Tryethylamine 904


Residue 80

Solvent loss 174


70

7. 1-[2-(2-Hydroxyethoxy)ethyl]piperazine


Piperazine monohydrochloride prepared with 2- (2-chloroethoxy) ethanol in was added the

reaction solvent, wherein the piperazine monohydrochloride and 2- (2- The molar ratio of

added-chloroethoxy) ethanol was (piperazine 2- (2-chloroethoxy) ethanolthe use of a polar

solvent such as ethanol solvent; and an amount of ethanol is added, in a weight ratio of g / g

operator, is 2- (2-chloroethoxy) ethanol added in an amount of 2.4 times; stirring warmed to 40

° C; in at this temperature for 2 hours. 3) After completion of the reaction, distillation under

reduced pressure below 600C to remove about half of the ethanol 30 g, cooled to 15

0C, filtered ,

and the filter cake was washed with a small amount of ethanol is piperazine dihydrochloride,

500C

7 hours drying after recyclabe. 4) Step 3) The filtrate was filtered slowly heated to 90 ° C,

the0020methanol was removed in vacuo and the residue was distilled under reduced pressure

after the high purity piperazine 1- [2- (2_-hydroxyethoxy) ethyl] piperazine (HEEP) crude. 5)

Step 4) to give 1- [2- (2_-hydroxyethoxy) ethyl] piperazine (HEEP) crude vacuum distillation in

vacuum,

Chemical Reaction:

NH

NH

+Cl

OOH

N

NH

OOH

Na OH

water

piperazine

M.F.= C4H10N2

M.W = 86.13

2-(2-chloroethoxy)ethanol

M.F = C4H9ClO2

M.W.= 124.56

2-[2-(piperazin-1-yl)ethoxy]ethanol

M.F.= C8H18N2O2

M.W.= 174.24

M.W.= 39.99

+ Na Cl + OH2

M.W= 58.44

71

Flow diagram:

Mass Balance:

Stage-I

Input Output

Piperazine 392

1- [2- (2_-hydroxyethoxy) ethyl]

piperazine 507

2- (2-chloroethoxy) ethanol 195 Solvent Recovery 830

water 350 Waste water 271

Sodium hydroxide 205 Residue 80

Methanol 200 Solvent loss 174


72

ANNEXURE: 4

WATER CONSUMPTION AND WASTEWATER GENERATION

WATER CONSUMPTION

WASTEWATER GENERATION

Wastewater Generation (KL/day) Sr.

No.

Usage

Existing Additional Total

1. Industrial

Process Nil 16.0 16.0

Boiler Nil 0.5 0.5

Cooling Tower Nil 0.5 0.5

Washing Nil 1.0 1.0

Total (Industrial) Nil 18.0 18.0

2. Gardening -- -- --

3. Domestic 0.5 1.5 2.0

Total 0.5 19.5 20.0

Water Consumption (KL/day) Sr.

No.

Usage

Existing Additional Total

1. Industrial

Process 1.5 18.0 19.5

Boiler 0.5 1.5 2.0

Cooling Tower 0.5 1.5 2.0

Washing 0.0 1.0 1.0

Total (Industrial) 2.5 22.0 24.5

2. Gardening -- 0.5 0.5

3 Domestic 2.0 2.0 4.0

Total 4.5 24.5 29.0

73

WATER BALANCE DIAGRAM (EXISTING)

All figures are in KL/Day.

Raw Water: 4.5

Domestic:

2.0

Process:

1.5

Boiler:

0.5

Cooling

Tower:

0.5

Gardening:

Nil

Septic Tank

& Soak Pit:

0.5

Nil Nil

Washing:

0.0

Nil Nil

74

WATER BALANCE DIAGRAM (TOTAL = EXISTING + PROPOSED)

All figures are in KL/Day.

Raw Water: 29.0

Domestic:

4.0

Process:

19.5

Boiler:

2.0

Cooling

Tower:

2.0

Gardening:

0.5

Septic Tank

& Soak Pit:

2.0

0.5 0.5

ETP: 18.0

Washing:

1.0

1.0

Inhouse MEE

16.0

MEE salt: MEE salt

will be sent to

common TSDF site of

BEIL, Ankleshwar.

MEE condensate: MEE condensate will

be reused in industrial purpose.

75

ANNEXURE: 5

DETAILS OF EFFLUENT TREATMENT PLANT (ETP)

The details of ETP are as follows.

M/s. Adarsh Dye Chem (Unit-II) shall have an Effluent treatment plant consisting of primary

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

First all wastewater streams from plant shall be collected in Equalization cum Neutralization

tank (ENT-01) where the continuous addition and stirring of Caustic solution is done to maintain

neutral pH of wastewater from Caustic Dosing Tank (CDT-01) as per requirement by gravity.

Mixer is provided in the ENT-01 to keep all suspended solids in suspension and for proper

mixing.

Then, neutralized wastewater shall be pumped to Primary Settling Tank (PST-1). Alum and

Polyelectrolyte shall be dosed from Alum Dosing Tank (ADT-01) and Polyelectrolyte Dosing Tank

(PEDT-01) respectively by gravity into PST-01 to carry out coagulation by using a Mixer. Then

Mixer is stopped and effluent is allowed to settle in Primary Settling Tank (PST-01). After

Primary treatment, Clear supernatant from PST-01 shall be collected in MEE Feed Tank (TES-01)

then sent to in house MEE (MEE-01) for further treatment. MEE condensate will be collected in

Condensate Storage Tank (CST-01) before reuse in plant Slurry. Slurry shall be sent to Dryer Unit

(DU-01) for drying of solids. Salt from Dryer will be sent to common TSDF site of BEIL,

Ankleshwar.

Sludge settled in PST-01 shall be collected in Sludge Drying Beds (SDBs-01-A/B) where,

dewatering shall be carried out before storage in HWSA and ultimate disposal to TSDF.

EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT

Characteristics (mg/L) Sr. No. Parameter

Untreated Condensate

1. pH 4-9 6.5-8.5

2. COD < 8000 < 250

3. BOD3 < 2500 < 30

4. TSS < 200 < 30

76

Effluent Treatment Plant (Dimension):

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

/Capacity No. MOC/ Remark

Flow 18.0 KLD

1 Equalization cum Neutralization

Tank (ENT-01)

2.6 m x 2.6 m x

(2.5 m+0.5 FB) 1

MOC = RCC M30+A/A

Bk. Lining

2 Primary Settling Tank (PST-01)

2.8 m x 1.2 m x

(2.0 m + 0.5 HB +0.3

FB)

1 RCC M30

3 MEE Feed Tank (MFT-01) 2.6 m x 2.6 m x

(2.0 m+0.5 FB) 1 RCC M30

4 Sludge Drying Beds (SDBs-01-A/B) 3.0m x 2.0 m 2 Bk. Maso. With RCC

Bedding

5 Caustic Dosing Tank (CDT-01) 1000 Lit 1 HDPE

6 Alum Dosing Tank (ADT-01) 500 Lit 1 HDPE

7 Poly Dosing Tank (PEDT-01) 250 Lit 1 HDPE

8 Multiple Effective Evaporator

(MEE)with Dewatering Unit 20.0 m

3/D 1 SS316

9 Condensate Storage Tank (CST-01) 2.6 m x 2.6 m x

(2.0 m+0.5 FB) 1 RCC M30

RCC M30 = REINFORCED CEMENT CONCRETE (M 30 GRADE)

BK.MAS. = BRICK MASONARY

HDPE = HIGH DENSITY POLY ETHELINE

SS 316 = STAINLESS STEEL 316 GRADE

77

Flow Diagram:

78

ANNEXURE: 6

DETAILS OF INHOUSE MEE

Type: Forced circulation 3 stage waste water evaporator

Capacity: 3000 Litre/hr, total

Pressures: 1st stage: 2 kg/cm2g

2nd stage: atm.

3rd stage: 600 mmhgg

Heating medium: Thermic fluid

MOC: All parts in SS 304

Technical details of MEE including evaporation capacity, steam required for evaporation,

adequacy of the proposed boiler to supply steam for evaporation in addition to the steam

required for the process etc.

� EVAPORATION SYSTEM:

List of Equipment for MVR Plant

Sr.

No. Name of Equipment Qty Tag No

Vessels

1 Liquid vapor Separator 1 V-101

2 Moisture Trap for Vacuum System 1 V-102

Pumps

3 MVR Circulation Pump 2 (1+1) P-101 A/B

4 Feed Pump 2 (1+1) P-102 A/B

5 Condensate Transfer Pump 4 (3+1) P-103 A/B/C

6 Vacuum Pump 2 (1+1) P-104 A/B

Compressor

7 Vapor Compressor 1 C-101

Heat Exchanger

8 Condenser 3 HX-101 A/B/C

9 Feed Preheater 1 HX-102

79

� Specification of Equipment for MVR Plant Vessels

Liquid Vapor Separator (V-101)

S.N. Description Specifications

1 Type Vertical Cylindrical with Dished Top and Hopper Bottom

2 Duty To receive circulating effluent through heat exchanger

and separate liquid and vapor phase.

3 Fluid Flow Inlet Liquid flow: 3000 kg/hr

Outlet Vapor flow: 300 kg/hr

Outlet Liquid flow: 2850 kg/hr

4 Operating Temperature 75 deg C, Max

5 Operating / Design

Pressure

560 / 760 mmhg g

5 Density Liquid Density: 950 kg/M3

Vapor Density: 0.1711 kg/M3

6 Tank Dimension Diameter: 1500 mm

Straight Height: 2500 mm

Hopper Height: 750 mm

7 Quantity 1

8 End Top End: Dished type

Bottom End: Hopper type

9 Inside Attachment Distributor for liquid injection / Perforated pipe type

10 Material of

Construction

Shell: MS: 8/10 mm thk (Thk calculation to be provided

for vacuum condition)

Lining: 38 mm thk, AR Tile lining with Furan based

pointing material.

11 Support Supported on lugs provided from shell of vessel

� Moisture Trap for Vacuum System (V-102)

Sr.

No. Description Specifications

1 Type Vertical Cylindrical with baffle wall arrangement

and Dished Top and Bottom End

2 Duty To Leakage Air from the System and separate

entrained liquid droplets from the system

80

3 Fluid Flow -

4 Operating Temperature 45 deg C, Max

5 Operating / Design Pressure 560 / 760 mmhg g

5 Density Vapor Density: 0.1711 kg/M3

6 Tank Dimension Diameter: 500 mm

Straight Height: 1500 mm

7 Quantity 1

8 End Top End: Dished type

Bottom End: dished type

9 Inside Attachment Baffle wall

10 Material of Construction Shell: MS: 6/8 mm thk (Thk calculation to be

provided for vacuum condition)

Lining: Epoxy Painted

11 Support Supported on lugs provided from shell of vessel

� Pumps

MVR Circulation Pump (P-101 A/B)

S. N. Description Specifications

1 Type Horizontal Centrifugal Pump

2 Quantity 2 ( 1 Operating + 1 Standby)

3 Liquid Details Fluid Name Concentrated Waste Water with

Suspended solids

Fluid Composition

TDS: 20% (consisting of chloride and

sulfates)

Water: 80%

(Suspended Solids will be in range of

0.5 to 1%)

pH: above 7.5

Temperature Operating: 70, Design: 80

Density 1000 kg/m3 (For power calculation)

Viscosity 1.1 CP

Vapour Pressure 205 mmhg a (555 mmhg g)

Corrosive Agent Chloride (pH will be maintained above

81

7.5)

Erosive Agent Suspended solids

4 Operating

Condition Duty Continuous

Capacity 3 M3/hr

Suction Head Flooded

Discharge Head 20 MLC

Differential Head 20 MLC

NPSH A 2.3 M

NPSH R *

Self Priming NA

Foot Valve NA

5 Pump

Specification Type Centrifugal, Low NPSH Pump

Stages *

Installation Horizontal

Location Outdoor

Casing Type *

Impeller Type *

Seal Mechanical Seal

Lubrication *

Cooling *

Rotation *

Coupling Direct Coupling

6 Motor/Drive Type Flame Proof

Process Power 7.63 KW

Pump Efficiency *

Shaft Power *

Motor Rating *

Motor RPM *

Voltage 415 V

Frequency 50 Hz

7 Material of

Construction Casing PTDF lined

82

Impeller PTDF lined / SS316

Shaft *

Shaft Sleeve *

Impeller Wear Ring *

Stuffing Box Cover *

Casing Wear Ring *

Bearing Housing *

Coupling *

Coupling Guard *

Base Frame MS with Epoxy painted

Casing Gasket *

Packing *

Mech Seal St Face *

Mech Seal Rot Face *

Casing Screw *

Inducer *

Throat Bush Screw *

Drip Tray *

� Effluent Feed Pump (P-102 A/B)

Sr. No. Description Specifications

1 Type Horizontal Centrifugal Pump


3 Liquid Details Fluid Name Waste Water

Fluid Composition

TDS: 1-2% (consisting of

chloride and sulfates)

Water: Balance%

(Suspended Solids will be

in range of < 0.1 %)

pH: above 7.5

Temperature Operating: 35, Design: 50

Density 1000 kg/m3 (For power

calculation)

Viscosity 1 CP

83

Vapour Pressure NA

Corrosive Agent Chloride (pH will be

maintained above 7.5)

Erosive Agent Suspended solids

4 Operating Condition Duty Continuous

Capacity 3, M3/hr




NPSH A Flooded

NPSH R *

Self Priming NA

Foot Valve NA

5 Pump Specification Type Centrifugal

Stages *

Installation Horizontal

Location Outdoor

Casing Type *

Impeller Type *


Lubrication *

Cooling *

Rotation *




Pump Efficiency *

Shaft Power *

Motor Rating *

Motor RPM *

Voltage 415 V

Frequency 50 Hz

7 Material of Construction Casing SS316

84

Impeller SS316

Shaft *

Shaft Sleeve *



Casing Wear Ring *

Bearing Housing *

Coupling *

Coupling Guard *

Base Frame MS with Epoxy painted

Casing Gasket *

Packing *

Mech Seal St Face *

Mech Seal Rot Face *

Casing Screw *

Inducer *

Throat Bush Screw *

Drip Tray *

� Condensate Transfer Pump (P-103 A/B)

Sr.


1 Type Pump suitable for transfer of steam condensate generated

from the steam condenser.


3 Liquid Details Fluid Name Steam condensate

Fluid Composition 100% Water with

traces of salts

Temperature Operating: 70,

Design: 80

Density < 1000 kg/m3 (For

power calculation)

Viscosity < 1 CP

Vapour Pressure Equivalent to

85

Temperature

Corrosive Agent Steam condensate

Erosive Agent NIL

4 Operating

Condition Duty Continuous

Capacity 2, M3/hr




NPSH A *

NPSH R *

Self Priming NA

Foot Valve NA

5 Pump Specification Type Suitable for transfer

of steam condensate

Stages *

Installation *

Location Outdoor

Casing Type *

Impeller Type *


Lubrication *

Cooling *

Rotation *




Pump Efficiency *

Shaft Power *

Motor Rating *

Motor RPM *

Voltage 415 V

Frequency 50 Hz

7 Material of Casing *

86

Construction

Impeller *

Shaft *

Shaft Sleeve *



Casing Wear Ring *

� Compressors

Vapor Compressor (C-101)

Sr.


1 Tag number C-101

2 Equipment Name Vapor Compressor

3 Type and arrangement Centrifugal Fan

4 Duty To compress Steam (Vapor)

5 Quantity 1

8 Inlet Gas Pressure -560 mmhgg / -7368 mmwcg (200 mmhga /

2632 mmwc b)

9 Outlet Gas Pressure -500 mmhgg / -6579 mmwcg (260 mmhga /

3421 mmwc b)

10 Differential Head 60 mmhg / 790 mmwc (Design 850 mmwc)

11 Inlet gas temperature Operating: 67

12 Outlet gas temperature * (Calculated 73)

Inlet Gas Details Flow,Nm3/hr

Operating: 1517.30

Design: 1805.57

Flow, Kg/hr Operating: 1218.50

Design: 1450

Flow, Am3 /hr

Operating: 7117.41

Design: 8470

Density, kg/M3 0.1712

Gas Composition 100% Steam / water

87

Mol wt 18 kg/kmol

13 Dust Content < 50 mg/NM3

14 Barometric Pressure *

16 Blower Type Centrifugal

17 Impeller Type *

18 Casing Type *

19 Bearing Type *

20 Seal Mechanical Seal (Zero Air Leakage)

21 Lubricant type *

22 Coupling Directly coupled

23 Casing Position *

24 Suction Connection *

25 Discharge Connection *

26 Base Frame Common for Blower and Motor

27 Location Outdoor, mounted on RCC Footing

� Heat Exchanger

Condenser (HX-101 A/B/C)

Sr.

No. Description Required as per Specifications

1 Type Shell and Tube Type Surface Condenser - 3

Nos in series

2 Duty To condense steam from compressor by

heating circulating waste water in tube side

3 Installation Horizontal

4 Operating Parameters (All

together for 3 nos) Tube Side Shell Side

Fluid Circulating Waste

Water Steam

Fluid Composition Salts: 20%,

Balance Water 100% Water

Flow, kg/hr 3000 300

Inlet Temperature, C 66.44 72.48

Outlet Temperature, C 70.61 72.48

88

Specific Heat, Kcal/kg-C 1 Condensing

Heat Load, Kcal/hr 677328 Kcal/hr

5 MOC Shell MS, 8 mm thk

Tube SS316 Ti

Tube Sheet SS316

Inlet and Outlet

Head SS316

Baffles MS

Baffles MS

Nut/Bolts SS316

Gaskets *

6 Nozzle details Shell side in/out AS per GAD

Tube side in/out As per GAD

Shell drain/vent As per GAD

Tube drain/vent As per GAD

7 Support Lug support (Min 3 for vertical

arrangement)

89

ANNEXURE: 7

DETAILS OF HAZARDOUS WASTE MANAGEMENT AND DISPOSAL

Sr.

No

Category

No.

Type of

waste Existing Additional Total

Disposal Method

1 33.1 Discarded

Containers

Bags: 50

Nos/Month

Drums: 30

Nos/Month

Bags: 125

Nos/Month

Drums: 45

Nos/Month

Bags: 175

Nos/Month

Drums: 75

Nos/Month

Collection, Storage,

Transportation,

Decontamination &

Disposal by selling to

registered recycler

2 5.1

Used/

Spent Oil

1

Lit./Month

1

Lit./Month

2

Lit./Month


Transportation &

Disposal by selling to

registered recycler

3 35.3 ETP Sludge -- 2

MT/Month

2

MT/Month

4 35.3 MEE Salt -- 25

MT/Month

25

MT/Month

5 -- Spent

Hyflow --

0.1

MT/Month

0.1

MT/Month


Transportation and

disposal in common

TSDF site of BEIL,

Ankleshwar.

6 28.1 Residue -- 1

MT/Month

1

MT/Month

7 28.3 Spent

Carbon --

0.1

MT/Month

0.1

MT/Month


Transportation &

sent to cement

industries for co-

processing or

incineration in CHWIF

of BEIL, Ankleshwar.

8 --

Sodium

Sulphate

(30%

Solution)

30

MT/Month --

30

MT/Month


Transportation and

sale to end user or

disposal in common

TSDF site of BEIL,

Ankleshwar.

90

ANNEXURE: 8

Details of Stack & Vents

EXISTING:

1. Details of Flue Gas Stack; Stack Attached To Boiler,

There shall be no use of fuel; hence there shall be no flue gas emission from the

manufacturing process and other ancillary operations.

2. Details of Process Vent

Sr.

No.

Stack attached

to

Stack

Height

Air Pollution

Control System

Parameter & Permissible

Limit

1 Process Vent-1 10 m Alkali & Water

Scrubber

SO2 < 40 mg/Nm3

Chlorine < 9 mg/Nm3

PROPOSED:

(1). Details of Flue Gas Stack; Stack Attached To Steam Boiler

SOURCES OF GASESOUS EMISSIONS STACK

Fuel Used Agrowaste

Capacity 1.5 T/Hr

Type of Emissions SO2 NOx SPM

Permissible Limits 100 ppm 50 ppm 150 mg/Nm3

Stack Height 18 meter

Stack Diameter at the Top 0.3 meter

Air Pollution Control Measures Multicyclone Separator and Bag Filter

91

2. Details of Flue Gas Stack; Stack Attached To D.G. Set

Sources of Gaseous Emissions D.G. Set (100 KVA)

Fuel Used Diesel

Stack Height 11 meter

Stack Diameter at The Top 0.2 meter

Type of Emissions SO2 NOx SPM

Permissible Limits 100 ppm 50 ppm 150 mg/Nm3

(2). Details of Process Vent

Sr.

No.

Stack attached

to

Stack

Height

Air Pollution

Control System

Parameter Permissible

Limit

1 Process Vent - 2 11 m Two Stage Scrubber HCl 20 mg/Nm3

2 Process Vent - 3 11 m Two Stage Scrubber SO2 40 mg/Nm3

3 Process Vent - 4 11 m Two Stage Scrubber NH3 175 mg/Nm3

92

ANNEXURE: 9

DETAILS HAZARDOUS CHEMICAL STORAGE

Sr.

No.

Name of the

Hazardous

Chemicals

Type of

Hazard

No of

Vessels

Vessel

Capacity

Maximum

Storage

(MT)

Type of

Storage &

MOC

1. Toluene Toxic/Flammable 15 200 Lit 3.0 Drums

2. Ethyl Acetate Toxic/Flammable 1 200 Lit 0.2 Drums

3. HCl Corrosive 6 200 Lit 1.2 Drums

4. Bromine Toxic 70 3 kg 0.2 Bottle

5. Hydrogen gas Flammable 1 90 kg 0.09 Cylinder

6. Methanol Flammable 7 200 Lit 1.4 Drums

7. Acetic anhydride Flammable 2 200 Lit 0.4 Drums

8. Dimethyl

Formamide Toxic/Flammable 4 200 Lit 0.8 Drums

9. Acetone Toxic/Flammable 8 200 Lit 1.6 Drums

10. Hydrobromic

Acid Corrosive 2 50 kg 0.10 Carboy

11. Thionyl Chloride Toxic 4 200 Lit 0.8 Drums

12. Liq. Ammonia Toxic 1 200 Lit 0.2 Drums

13. Xylene Toxic/Flammable 2 200 Lit 0.4 Drums

14. Ethylene

dichloride Flammable 4 200 Lit 0.8 Drums

15. Methylene

chloride Toxic 1 200 Lit 0.2 Drums

16. Benzoyl Chloride

Toxic/Flammable 1 200 Lit 0.21 Drums

17. IPA

Toxic/Flammable 5 200 Lit 1.05 Drums

18. Ammonia

solution

Toxic 10 200 Lit 1.93 Drums

93

ANNEXURE: 10

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement for the proposed project is expected to generate some permanent

jobs and secondary jobs for the operation and maintenance of plant. This will increase direct /

indirect employment opportunities and ancillary business development to some extent for the

local population. This phase is expected to create a beneficial impact on the local socio-economic

environment.

2) INDUSTRIES

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 project 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 project is not expected to make any significant change in the

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

94

ANNEXURE: 11

PROPOSED DRAFT TERMS OF REFERENCE

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.

• Water source and utilization including proposed water balance.

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

• List of hazardous chemicals.

• Mass balance of each product

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5 km

area.

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

For SPM, RSPM, SO2, NOx.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

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

area were surveyed.

4. Impacts Identification And Mitigatory Measures

• 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.

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

95

6. Risk Assessment

• Objectives and methodology of risk assessment

• Details on storage facilities

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

be adopted.

• Identification of hazards

• Consequence analysis through occurrence & evaluation of incidents

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

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

9. Information on Rain Water Harvesting

10. Green Belt Development plan

96

Annexure-12

__________________________________________________________________________

GIDC Plot Allotment Letter

97

Annexure-12

__________________________________________________________________________

GIDC Plot Allotment Letter

98

Annexure-13

_______________________________________________________________________

GIDC Water Supply Letter

99

Annexure-14

__________________________________________________________________________

TSDF & CHWIF membership Letter

100

Annexure-15

__________________________________________________________________________

Toposheet

101

Annexure-16

_______________________________________________________________________ ___

Copy of CCA

102

103

Annexure-16

_______________________________________________________________________ ___

Copy of EC

104

105

Documents

M/s. ADARSH DYE CHEM (UNIT-II)environmentclearance.nic.in/writereaddata/FormB/TOR/Proposed_TOR... · 3 Address M/s. Adarsh Dye Chem (Unit-II) Plot No. A-1/3621, Opp. ETL, GIDC Estate,