M/s. PAUSHAK LTD. PLOT NO.: 135, 136, 145, 146, 147, 229

Pre-Monsoon, 2017

M/s. PAUSHAK LTD.PLOT NO.: 135, 136, 145, 146, 147, 229 & 230, VILL.: PANELAV, PO: TAJPURA, TAL.: HALOL,DIST. PANCHMAHAL – 389 350 (GUJ.)

DRAFT ENVIRONMENTAL IMPACT & RISK ASSESMENT REPORT

FOR PROPOSED EXPANSION OF SPECIALTY CHEMICALS IN

EXISTING UNIT

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat – 395002 (Guj.)

Prepared By:

DRAFT ENVIRONMENTAL IMPACT & RISK

ASSESSMENT REPORT

CLIENT

PROJECT TITLE

PROJECT NO.

:

:

:

M/s. PAUSHAK LTD.

PLOT NO.: 135, 136, 145, 146, 147, 229 & 230,

VILL.: PANELAV, PO: TAJPURA, TAL.: HALOL,

DIST. PANCHMAHAL – 389 350 (GUJ.)

DRAFT ENVIRONMENTAL IMPACT & RISK ASSESMENT REPORT FOR

PROPOSED EXPANSION OF SPECIALTY CHEMICALS IN EXISTING UNIT

520000





Road, Surat - 395002

Prepared By:











Prepared By:

M/s. PAUSHAK LTD. ENVIRONMENTAL IMPACT & RISK ASSESSMENT REPORT

Prepared By: Aqua-Air Environmental Engineers Pvt. Ltd., Surat I- 1

INDEX

SR. NO. TITLE PAGE NO.

1 CHAPTER 1: INTRODUCTION

1.1 JUSTIFICATION & BACKGROUND 1

1.1.1 IDENTIFICATION OF THE PROJECT PROPONENT 2

1.1.2 REGULATORY FRAMEWORK 2

1.2 PROJECT SETTING 14

1.2.1 KEY INFRASTRUCTURAL FEATURES AND SETTLEMENTS 15

1.2.1.1 METHOD OF DATA PREPARATION 15

1.2.1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE 15

1.2.1.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 15

1.3 PURPOSE OF EIA 17

1.4 OBJECTIVES OF EIA 17

1.5 METHODOLOGY FOR EIA 17

1.5.1 BASE LINE ENVIRONMENTAL CONDITION 17

1.5.2 IDENTIFICATION OF POLLUTION SOURCE 19

1.5.3 EVALUATION OF POLLUTION CONTROL AND ENVIRONMENTAL

MANAGEMENT SYSTEM

19

1.5.4 EVALUATION OF IMPACT 19

1.5.5 PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN 19

1.6 STRUCTURE OF REPORT 19

2 CHAPTER 2: PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND 22

2.2 MANUFACTURING ACTIVITIES 22

2.3 RAW MATERIAL CONSUMPTION, STORAGE AND HANDLING 104

2.4 INFRASTRUCTURE FACILITIES 117

2.4.1 LAND 117

2.4.2 TRANSPORTATION FACILITIES 117

2.4.3 WATER AND WASTEWATER 117

2.4.3.1 TREATMENT PROCESS 121

2.4.4 AIR POLLUTION AND CONTROL SYSTEM 129

2.4.5 NOISE LEVEL AND CONTROL SYSTEM 134

2.4.6 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM 134

2.5 DETAILS OF UTILITIES 136

2.6 ELECTRICITY REQUIREMENT & FUEL REEQUIREMENT 137

3 CHAPTER 3: BASELINE ENVIRONMENTAL STATUS

3.1 MICRO-METEOROLOGY OF THE AREA 138

3.1.1 TEMPERATURE DETAILS 139

3.1.2 RELATIVE HUMIDITY (RH) 140

3.1.3 RAINFALL 141

3.1.4 WIND SPEED 142

3.2 AIR ENVIRONMENT 146

3.2.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY MONITORING

LOCATIONS

146

3.2.2 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING 147



3.3 NOISE ENVIRONMENT 153

3.3.1 METHODOLOGY FOR NOISE MONITORING 153

3.4 WATER ENVIRONMENT 159

3.4.1 RECONNAISSANCE 159

3.4.2 METHODOLOGY FOR WATER QUALITY MONITORING 159

3.5 LAND ENVIRONMENT 164

3.5.1 METHODOLOGY FOR SOIL MONITORING 164

3.5.2 SOIL CLASSIFICATIONS 167

3.6 GEOLOGICAL DATA 170

3.6.1 METHOD OF PREPARATION 170

3.6.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA UNDER DIFFERENT

FORMATIONS

170

3.6.3 GEOLOGICAL MAP 170

3.7 LAND USE PATTERN 172

3.7.1 METHOD OF DATA PREPARATION 172

3.8 ECOLOGICAL INFORMATION 177

3.8.1 PHYSIOGRAPHY 177

3.8.2 FOREST 178

3.8.3 METHOD OF PREPARATION 178

3.8.4 AREA UNDER DIFFERENT VEGETATION CLASSIFICATION 178

3.8.5 AREA UNDER FORESTS AND SANCTUARY 178

3.8.6 FLORA 181

3.8.7 FAUNA 182

3.9 SOCIO-ECONOMIC ENVIRONMENT 182

3.9.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN 183

3.9.1.1 METHOD OF DATA PREPARATION 183

3.9.1.2 DEMOGRAPHIC DATA WITHIN THE REGION 183

3.9.1.3 LITERACY RATE 187

3.9.2 OCCUPATIONAL STRUCTURE 191

3.9.3 AMENITIES 193

4 CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 IDENTIFICATION OF IMPACTS 196

4.2 PREDICTIONS AND EVALUATION OF IMPACTS 203

4.2.1 WATER ENVIRONMENT 203

4.2.2 AIR ENVIRONMENT 204

4.2.3 NOISE ENVIRONMENT 216

4.2.4 HAZARDOUS WASTE DETAILS 216

4.2.5 INFRASTRUCTURE AND SERVICES 217

4.2.6 ENVIRONMENTAL HAZARDS 217

4.2.7 HOUSING 217

4.2.8 ECOLOGY 217

4.3 MATRIX REPRESENTATION 222

4.3.1 CUMULATIVE IMPACT CHART 222

5 CHAPTER 5: ENVIRONMENTAL MONITORING PLAN

5.1 PROJECT ENVIRONMENT MONITORING PLAN 228

5.1.1 LABORATORY FACILITIES 230

5.1.2 DOCUMETATION & RECORDS 230



6 CHAPTER 6: RISK ASSESSMENT & DMP

6.1 RISK ASSESSMENT 231

6.1.1 INTRODUCTION 231

6.1.2 APPROACH TO THE STUDY 231

6.1.3 METHODOLOGY 232

6.1.4 HAZARD IDENTIFICATION 234

6.1.5 CONSEQUENCE ANALYSIS 251

6.1.6 RISK ASSESSMENT SUMMARY 298

6.1.7 OTHER RISK REDUCTION OPPORTUNITIES 301

6.1.8 RECOMMENDATIONS FOR ALARP 301

6.1.9 FIRE FIGHTING SYSTEM 302

6.2 DISASTER MANAGEMENT PLAN 305

6.2.1 DEFINING THE NATURE OF EMERGENCY 305

6.2.2 OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM 306

6.2.3 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM 307

6.3 COMMMUNICATION SYSTEM 329

6.3.1 RAISING THE ALARM 329

6.3.2 DECLARING THE MAJOR EMERGENCY 331

6.3.3 TELEPHONE MESSAGES 335

6.3.4 COMMUNICATION OF EMERGENCY & STATUTORY INFORMATION 335

6.4 ACTION ON SITE 339

6.4.1 PRE-EMERGENCY ACTIVITIES 339

6.4.2 POST EMERGENCY ACTIVITIES 346

6.4.3 EMERGENCY TIME ACTIVITIES 346

6.4.4 EVACUATION & TRANSPORTATION 348

6.4.5 SAFE CLOSE-DOWN 349

6.4.6 USE OF MUTUAL AID 349

6.4.7 HELP OF EXTERNAL AUTHORIES 349

6.4.8 MEDICAL TREATMENT 349

6.4.9 ACCOUNTING FOR PERSONNEL 349

6.4.10 ACCESS TO RECORDS 350

6.4.11 PUBLIC RELATIONS 350

6.4.12 REHABILITATION 350

6.5 OFF – SITE EMERGENCY PLAN 350

6.5.1 NEED OF THE OFF – SITE EMERGENCY PLAN 350

6.5.2 STRUCTURE OF THE OFF-SITE EMERGENCY PLAN 351

6.5.3 ROLE OF FACTORY MANAGEMENT 352

6.5.4 ROLE OF EMERGENCY CO-ORDINATION OFFICER (ECO) 352

6.5.5 ROLE OF THE FIRE AUTHORITIES 352

6.5.6 ROLE OF THE HEALTH AUTHORITIES 353

6.5.7 ROLE OF TELEPHONE DEPARTMENT 353

6.5.8 ROLE OF POLICE AND EVACUATION AUTHORITIES 353

6.5.9 ROLE OF THE MUTUAL-AID AGENCIES 354

6.6 OCCUPATIONAL HEALTH AND SAFETY 355

6.6.1 OCCUPATIONAL HEALTH 355

6.6.2 SAFETY PLAN 362

6.6.3 SAFETY ORGANIZATION 363



6.6.4 SAFETY CIRCLE 364

6.6.5 SAFETY TRAINING 364

6.6.6 HEALTH AND SAFETY MONITORING PLAN 364

6.7 TRAINING, REHERASAL & RECORDS 365

6.7.1 NEED OF TRAINNING & REHEARASAL 365

6.7.2 SOME CHECK POINTS 365

6.7.3 RECORDS AND UPDATING THE PLAN 366

6.8 HAZOP STUDY 366

6.8.1 OBJECTIVE 366

6.8.2 PURPOSE OF HAZOP 367

6.8.3 FEATURES OF HAZOP STUDY 367

6.8.4 HAZOP STUDY PROCEDURE 368

6.8.5 PROCESS HAZARD AND ITS CONTROL 371

6.8.6 PLANNING FOR HAZOP 371

7 CHAPTER 7: ENVIRONMENTAL MANAGEMENT PLAN

7.1 BACKGROUND 372

7.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN 372

7.3 ENVIRONMENTAL MANAGEMENT CELL 373

7.3.1 ENVIRONMENT POLICY 375

7.3.2 CORPORATE ENVIRONMENT RESPONSIBILITY 378

7.3.3 MANAGEMENT RESPONSIBILITY 378

7.4 ENVIRONMENTAL MANAGEMENT PLAN 380

7.4.1 CONSTRUCTION PHASE 380

7.4.2 WATER ENVIRONMENT 383

7.4.3 AIR ENVIRONMENT 384

7.4.4 NOISE ENVIRONMENT 388

7.4.5 LAND ENVIRONMENT 390

7.4.5.1 HAZARDOUS WASTE MANAGEMENT 390

7.4.5.2 IDENTIFICATION OF RECYCLE/REUSE, CLEANER PRODUCTION AND CO-

PROCESSING OPTION OF HAZARDOUS WASTE

391

7.5 GREEN BELT DEVELOPMENT 392

7.6 OCCUPATIONAL HEALTH AND SAFETY 395

7.7 INFORMATION FOR RAIN WATER HARVESTING 396

7.8 MEASURES FOR CONSERVATION OF ENERGY 397

7.9 NATURAL RESOURCES CONSERVATION 398

7.10 SKILLED AND TRAINED MANPOWER 399

7.11 SOCIO ECONOMIC DEVELOPMENT ACTIVITIES 399

7.12 SOLVENT RECOVERY PLAN 407

7.13 METHODOLOGY OF DE-CONTAMINATION AND DISPOSAL OF DISCARDED

CONTAINERS AND ITS RECORD KEEPING

409

7.14 TRAFFIC STUDY 410

7.15 ACTION PLAN FOR TRANSPORTATION OF RAW MATERIALS AND PRODUCTS 413

7.16 CAPITAL COST FOR ENVIRONMENTAL MANGEMENT 414

8 CHAPTER 8: EXECUTIVE SUMMARY OF PROJECT

8.1 PROJECT DESCRIPTION 415

8.2 DESCRIPTION OF THE ENVIRONMENT 418

8.3 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES 420



8.4 ENVIRONMENTAL MONITORING PROGRAMME 423

8.5 ADDITIONAL STUDIES 424

8.6 PROJECT BENEFITS 425

8.7 ENVIRONMENT MANAGEMENT PLAN 425

8.8 CONCLUSION 426

9 CHAPTER 9: DISCLOSURE OF CONSULTANTS ENGAGED 427



LIST OF TABLES

TABLE

NO.

TITLE PAGE NO.

1.1 BREAK UP OF PROJECT COST 3

1.2 LAND BREAKUP 4

1.3 LIST OF PRODUCTS ALONGWITH PRODUCTION CAPACITY 10-13

1.4 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE 15

2.1 RAW MATERIAL REQUIREMENT 104-116

2.2 WATER CONSUMPTION & WASTE WATER GENERATION 118

2.3 HAZARDOUS & SOILD WASTE GENERATION QUANTITY, PHYSICAL

CHARACTERISTICS AND MODE OF DISPOSAL

135

3.1 TEMPERATURE DETAILS 139

3.2 RELATIVE HUMIDITY DETAILS 140

3.3 RAINFALL DETAILS 141

3.4 WIND SPEED DETAILS 142

3.5 SITE SPECIFIC METEOROLOGICAL DATA 143

3.6 DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS 148

3.7 AMBIENT AIR QUALITY STATUS 150-152

3.8A DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS 154

3.8B BACKGROUND NOISE LEVELS 156

3.9 NOISE LEVELS DUE TO TRANSPORTATION & INDUSTRIAL NOISE LEVELS 157

3.10 SAMPLING LOCATIONS FOR MONITORING SURFACE WATER AND GROUND

WATER QUALITY

160

3.11 WATER QUALITY- PHYSICAL PARAMETERS 162

3.12 SAMPLING LOCATIONS: SOIL QUALITY 164

3.13 PHYSICO-CHEMICAL CHARACTERISTICS OF SOIL 166

3.14 SOIL CHARACTERISTICS UNDER PROJECT AREA 168

3.15 GEOLOGICAL FEATURES 170

3.16 AREAS UNDER DIFFERENT LANDUSE 174

3.17 FLORA 181

3.18 FAUNA 182

3.19 DEMOGRAPHIC DATA 183

3.20 POPULATION DENSITY 185

3.21 LITERACY RATE 187

3.22 OCCUPATIONAL STRUCTURE 191

3.23 DETAILS OF AMENITIES AVAILABLE IN THE STUDY AREA 194

4.1 DETAILS OF EMISSION FROM STACKS 205

4.2 SUMMARY OF ISCST3 MODEL OUTPUT 211 & 215

4.3 PREDICTED AMBIENT AIR QUALITY 216

4.4 IMPACT IDENTIFICATION MATRIX 223

4.5 CONSTRUCTION & OPERATION STAGE POTENTIAL IMPACTS & MITIGATIVE

MEASURES

225

4.6 ENVIRONMENTAL IMPACT MATRIX 226

4.7 CUMULATIVE IMPACT CHART 227

5.1 PROJECT ENVIRONMENT MONITORING PLAN 229

6.1 STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS 237

6.2 OTHER HAZARDS AND CONTROL 238

6.3 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL

HAZARD AND ANTIDOTES

239-240



6.4 POSSIBLE ACCIDENT SCENARIOS 262

6.5 FACILITIES FOR FIRE FIGHTING 303-304

7.1 ENVIRONMENT MANAGEMENT PLAN 382

LIST OF FIGURES

FIGURE

NO.

TITLE PAGE NO.

1.1 LOCATION OF THE PROJECT SITE 5-7

1.2 PLANT LAYOUT 8

1.3 PHOTOGRAPHS OF PLANT 9

1.4 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 16

1.5 ACTIVITIES, SOURCES OF INFORMATION AND CONTENTS OF EIA

REPORT

21

3.1 WIND ROSE DIAGRAM & STABILITY CLASS DISTRIBUTION 144-145

3.2 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS 149

3.3 LOCATION OF NOISE LEVEL MONITORING STATIONS 155

3.4 LOCATIONS OF WATER SAMPLING STATIONS 161

3.5 LOCATIONS OF SOIL SAMPLING STATIONS 165

3.6 SOIL CHARACTERISTICS MAP 169

3.7 MAJOR GEOLOGICAL FEATURES 171

3.8 LAND USE/ LAND COVER 175

3.9 LANDUSE / LANDCOVER WITH VILLAGE LOCATIONS 176

3.10 FOREST MAP 179

3.11 VEGETATION DENSITY MAP WITH VILLAGE LOCATION 180

3.12 POPULATION DENSITY 186

3.13 LITERACY DATA 190

4.1 IMPACT NETWORK 197-202

4.2 ISOPLETHS 206-210

212-214

6.1 QRA METHODOLOGY 232

6.2 FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT 233

6.3 HAZARDOUS CHEMICAL STORAGE AREA 235-236

7.1 ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 374



COPY OF TORs FROM MoEFCC, NEW DELHI





Annexure-I

GENERIC TERMS OF REFERENCE (TOR) IN RESPECT OF INDUSTRY SECTOR

1. Executive Summary

2. Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3. Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether adequate

land is available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their management.

vii. Requirement of water, power, with source of supply, status of approval, water balance

diagram, man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow sheet

(quantities) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

a. Copy of all the Environmental Clearance(s) including Amendments thereto obtained for

the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the

latest Monitoring Report of the Regional Office of the Ministry of Environment and

Forests as per circular dated 30th May, 2012 on the status of compliance of conditions

stipulated in all the existing environmental clearances including Amendments shall be

provided. In addition, status of compliance of Consent to Operate for the ongoing I

existing operation of the project from SPCB shall be attached with the EIA-EMP report.

b. In case the existing project has not obtained environmental clearance, reasons for not

taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006

shall be provided. Copies of Consent to Establish/No Objection Certificate and Consent

to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY

2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to

the conditions of consents from the SPCB shall be submitted.

4. Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State, Justification for

selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale

on an A3/A2 sheet. (Including all eco-sensitive areas and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant

area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout

of Industrial Area indicating location of unit within the Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show

photographs of plantation/greenbelt, in particular.



viii. Landuse break-up of total land of the project site (identified and acquired),

government/private - agricultural, forest, wasteland, water bodies, settlements, etc shall be

included. (Not required for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall be

incorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km

radius of any major river, peak and lean season river discharge as well as flood occurrence

frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the

project site and maximum Flood Level of the river shall also be provided. (Mega green field

projects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process

and expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy

5. Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, and

recommendations of the State Forest Department. (if applicable)

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site

delineating the forestland (in case of projects involving forest land more than 40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest

status shall be submitted.

iv. 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 there on

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State

Government for conservation of Schedule I fauna, if any exists in the study area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the

Standing Committee of the National Board for Wildlife

6. Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific

micrometeorological data using temperature, relative humidity, hourly wind speed and

direction and rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other

parameters relevant to the project shall be collected. The monitoring stations shall be based

CPCB guidelines and take into account the pre-dominant wind direction, population zone

and sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the

NAQQM Notification of Nov. 2009 along with – min., max., average and 98% values for each

of the AAQ parameters from data of all AAQ stations should be provided as an annexure to

the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point)

and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if

yes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.



ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of

materials, additional traffic due to proposed project, parking arrangement etc.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area

shall be given with special reference to rare, endemic and endangered species. If Schedule-I

fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and

furnished.

xi. Socio-economic status of the study area.

7. Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based on

site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP

Modelling shall be done using inputs of the specific terrain characteristics for determining

the potential impacts of the project on the AAQ. Cumulative impact of all sources of

emissions (including transportation) on the AAQ of the area shall be assessed. Details of the

model used and the input data used for modelling shall also be provided. The air quality

contours shall be plotted on a location map showing the location of project site, habitation

nearby, sensitive receptors, if any.

ii. Water Quality Modelling – in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding

environment shall be assessed and provided. In this regard, options for transport of raw

materials and finished products and wastes (large quantities) by rail or rail-cum road

transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled and

reused for different purposes shall be included. Complete scheme of effluent treatment.

Characteristics of untreated and treated effluent to meet the prescribed standards of

discharge under E (P) Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and management.

Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also

be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover

techniques, Energy conservation, and natural resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan

of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than

1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall

be included. The green belt shall be around the project boundary and a scheme for greening

of the roads used for the project shall also be incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest

rainwater from the roof tops and storm water drains to recharge the ground water and also

to use for the various activities at the project site to conserve fresh water and reduce the

water requirement from other sources.

xi. Total capital cost and recurring cost/annum for environmental pollution control measures

shall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency

Management Plan including Risk Assessment and damage control. Disaster management

plan should be linked with District Disaster Management Plan.



8. Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract and casual

workers

ii. Details of exposure specific health status evaluation of worker. If the workers’ health is being

evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far

& Near vision, Colour vision and any other ocular defect) ECG, during pre placement and

periodical examinations give the details of the same. Details regarding last month analyzed

data of above mentioned parameters as per age, sex, duration of exposure and department

wise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards

and whether they are within Permissible Exposure level (PEL)? If these are not within PEL,

what measures the company has adopted to keep them within PEL so that health of the

workers can be preserved

iv. Annual report of heath status of workers with special reference to Occupational Health and

Safety.

9. Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its Board of

Directors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process / procedures to bring

into focus any infringement / deviation / violation of the environmental or forest norms /

conditions? If so, it may be detailed in the EIA.

iii. What is the hierarchical system or Administrative order of the company to deal with the

environmental issues and for ensuring compliance with the environmental clearance

conditions? Details of this system may be given.

iv. Does the company have system of reporting of non compliances / violations of

environmental norms to the Board of Directors of the company and / or shareholders or

stakeholders at large? This reporting mechanism shall be detailed in the EIA report

10. Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to

the labour force during construction as well as to the casual workers including truck drivers during

operation phase.

11. Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the

Enterprise Social Commitment based on Public Hearing issues and item-wise details along

with time bound action plan shall be included. Socio-economic development activities need

to be elaborated upon.

12. Any litigation pending against the project and/or any direction/order passed by any Court of Law

against the project, if so, details thereof shall also be included. Has the unit received any notice

under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water

Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13. ‘A tabular chart with index for point wise compliance of above TORs.

14. The TORs prescribed shall be valid for a period of three years for submission of the EIA-EMP

reports.

The following general points shall be noted:

i. All documents shall be properly indexed, page numbered.

ii. Period/date of data collection shall be clearly indicated.

iii. Authenticated English translation of all material in Regional languages shall be provided.

iv. The letter/application for environmental clearance shall quote the MOEF file No. and also

attach a copy of the letter.



v. The copy of the letter received from the Ministry shall be also attached as an annexure to

the final EIA-EMP Report.

vi. The index of the final EIA-EMP report must indicate the specific chapter and page no. of the

EIAEMP Report

vii. While preparing the EIA report, the instructions for the proponents and instructions for the

consultants issued by MOEF vide O.M. No. J-11013/41/2006-IA.II (I) dated 4th August, 2009,

which are available on the website of this Ministry shall also be followed.

viii. The consultants involved in the preparation of EIA-EMP report after accreditation with

Quality Council of India (QCl) /National Accreditation Board of Education and Training

(NABET) would need to include a certificate in this regard in the EIA-EMP reports prepared

by them and data provided by other organization/Laboratories including their status of

approvals etc. Name of the Consultant and the Accreditation details shall be posted on the

EIA-EMP Report as well as on the cover of the Hard Copy of the Presentation material for EC

presentation.

TORs’ prescribed by the Expert Appraisal Committee (Industry) shall be considered for preparation

of EIA-EMP report for the project in addition to all the relevant information as per the ‘Generic

Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006. Where the documents

provided are in a language other than English, an English translation shall be provided. The draft EIA-

EMP report shall be submitted to the State Pollution Control Board of the concerned State for

conduct of Public Hearing. The SPCB shall conduct the Public Hearing/public consultation, district-

wise, as per the provisions of EIA notification, 2006. The Public Hearing shall be chaired by an Officer

not below the rank of Additional District Magistrate. The issues raised in the Public Hearing and

during the consultation process and the commitments made by the project proponent on the same

shall be included separately in EIA-EMP Report in a separate chapter and summarized in a tabular

chart with financial budget (capital and revenue) along with time-schedule of implementation for

complying with the commitments made. The final EIA report shall be submitted to the Ministry for

obtaining environmental clearance.



COMPLIANCE OF TERMS OF REFERENCES (TORs)

Sr.

No.

TOR Point Compliance Status

A. Additional TORs

i No storage of phosgene and isocynate shall be done in plant.

Limit of phosgene centre to be fixed at 0.1 ppm

Refer Annexure - 14, Page No. 541

ii A plan for 24x7 online monitoring of air and water shall be

submitted

Waste Water: Environment monitoring lab is provided with

analysis facilities to analyzed COD, BOD, TDS, pH, NH3-N, etc.,

however online pH and Flow Meter is provided at the guard

pond and we are not directly discharging our effluent in the

environment. Our treated effluent is sent to CETP for further

treatment and final discharge.

Air: Online detector is provided in the process stack vent for

monitoring of HCl & Cl2.

Refer Chapter – 5, Page No. 229

iii GCMS monitoring shall be done for phosgene and isocynate Refer Annexure - 11, , Page No. 537 to 538

iv Public Hearing shall be conducted as per provision of the EIA

Notification, 2006

It shall be incorporated in Final EIA Report

v Layout plan with 10m wide greenbelt of perennial trees like

neem, seas am, teak etc around plant periphery to be

submitted

Refer Chapter – 1 Page No. 8

vi Certified compliance report of existing EC from RO, MoEF&CC to

be submitted

It shall be incorporated in Final EIA Report

vii A plan for implementation for Zero Liquid Discharge (ZLD) shall

be submitted

Zero Liquid Discharge shall be envisaged in future but as of

now we shall discharge our Final treated effluent to CETP of

M/s. Enviro Infrastructure Co. Ltd., Umraya, Dist: Vadodara.

Refer Chapter – 2, Page No. 120 & Refer Annexure - 8, Page

No. 480 to 481

Generic TORs

1 Executive Summary Refer Chapter-8, Refer Page No. 415 to 426

2 Introduction

i Details of the EIA Consultant including NABET accreditation Refer Chapter-9, Page No. 427 to 435 & Annexure – 16, Page

No. 604 to 608

ii Information about the project proponent Refer Chapter-1, Page No. 1 & 2

iii Importance and benefits of the project Refer Chapter-1, Page No. 1 & 2

3 Project Description

i Cost of project and time of completion Refer Chapter-1, Page No. 3

ii Products with capacities for the proposed project Refer Chapter-1, Page No. 10 to 13

iii If expansion project, details of existing products with capacities

and whether adequate land is available for expansion,

reference of earlier EC if any

Refer Chapter-1, Page No. 10 to 13

Refer Annexure – 9, Page No. 486 to 521

iv List of raw materials required and their source along with mode

of transportation


v Other chemicals and materials required with quantities and

storage capacities

Refer Chapter-6, Page No. 237

vi Details of Emission, effluents, hazardous waste generation and

their management


vii Requirement of water, power, with source of supply, status of

approval, water balance diagram, man-power requirement

(regular and contract)


Refer Chapter-4, Page No. 217 & 218

Refer Annexure - 7, Page No. 447 to 479

viii Process description along with major equipments and

machineries, process flow sheet (quantities) from raw material

to products to be provided




ix Hazard identification and details of proposed safety systems Refer Chapter – 6, Page No. 234 to 251,

298 to 302

x Expansion/modernization proposals Expansion

a Copy of all the Environmental Clearance(s) including Amendments

thereto obtained for the project from MoEF/SEIAA shall be attached as

an Annexure. A certified copy of the latest Monitoring Report of the

Regional Office of the Ministry of Environment and Forests as per

circular dated 30th

May, 2012 on the status of compliance of conditions

stipulated in all the existing environmental clearances including

Amendments shall be provided. In addition, status of compliance of

Consent to Operate for the ongoing Existing operation of the project

from SPCB shall be attached with the EIA-EMP report

Refer Annexure – 9, Page No. 486 to 521 for EC

Letter & its Compliance

Refer Annexure – 10, Page No. 522 to 536 for Valid

CCA & its Compliance

Refer Annexure – 12, Page No. 539 for Certified RO

Report

b In case the existing project has not obtained environmental clearance,

reasons for not taking EC under the provisions of the EIA Notification

1994 and/or EIA Notification 2006 shall be provided. Copies of Consent

to Establish/No Objection Certificate and Consent to Operate (in case of

units operating prior to EIA Notification 2006, CTE and CTO of FY 2005-

2006) obtained from the SPCB shall be submitted. Further, compliance

report to the conditions of consents from the SPCB shall be submitted.

Not Applicable, as Company has obtained

environmental clearance, under the provisions of

the EIA Notification 1994 and/or EIA Notification

2006.

4 Site Details

i Location of the project site covering village, Taluka/Tehsil, District and

State, Justification for selecting the site, whether other sites were

considered

M/s. Paushak Ltd. proposes expansion of Specialty

Chemicals in Existing Unit at Plot No.: 135, 136, 145,

146, 147, 229 & 230, Vill. Panelav, PO: Tajpura, Tal.

Halol, Dist. Panchmahal – 389 350, Gujarat.

Proposed Expansion is within the existing premises

Refer Chapter-1, Page No. 1 & 5 to 7

ii A toposheet of the study area of radius of 10km and site location on

1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive

areas and environmentally sensitive places)


iii Details w.r.t. option analysis for selection of site Proposed Expansion is within the existing premises,


iv Co-ordinates (lat-long) of all four corners of the site Longitude 73°28'30.55"E, Latitude 22°27'23.77"N,


v Google map-Earth downloaded of the project site Refer Chapter-1, Page No. 5 to 7

vi Layout maps indicating existing unit as well as proposed unit indicating

storage area, plant area, greenbelt area, utilities etc. If located within

an Industrial area/Estate/Complex, layout of Industrial Area indicating

location of unit within the Industrial area/Estate


vii Photographs of the proposed and existing (if applicable) plant site. If

existing, show photographs of plantation/greenbelt, in particular


viii Landuse break-up of total land of the project site (identified and

acquired), government/private - agricultural, forest, wasteland, water

bodies, settlements, etc shall be included. (not required for industrial

area)


ix A list of major industries with name and type within study area (10km

radius) shall be incorporated. Land use details of the study area



x Geological features and Geo-hydrological status of the study area shall

be included


xi Details of Drainage of the project upto 5km radius of study area. If the

site is within 1 km radius of any major river, peak and lean season river

discharge as well as flood occurrence frequency based on peak rainfall

data of the past 30 years. Details of Flood Level of the project site and

maximum Flood Level of the river shall also be provided. (mega green

field projects)




xii Status of acquisition of land. If acquisition is not complete, stage of

the acquisition process and expected time of complete possession

of the land

Proposed Expansion is within the existing premises, Refer

Chapter-1, Page No. 1

xiii R&R details in respect of land in line with State Government policy Proposed Expansion is within the existing premises, Refer

Chapter-1, Page No. 1

5 Forest and wildlife related issues (if applicable) Not Applicable

6 Environmental Status

i Determination of atmospheric inversion level at the project site

and site-specific micrometeorological data using temperature,

relative humidity, hourly wind speed and direction and rainfall.


ii AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2,

NOx, CO and other parameters relevant to the project shall be

collected. The monitoring stations shall be based CPCB guidelines

and take into account the pre-dominant wind direction, population

zone and sensitive receptors including reserved forests.


iii Raw data of all AAQ measurement for 12 weeks of all stations as

per frequency given in the NAQQM Notification of Nov. 2009 along

with – min., max., average and 98% values for each of the AAQ

parameters from data of all AAQ stations should be provided as an

annexure to the EIA Report


iv Surface water quality of nearby River (100m upstream and

downstream of discharge point) and other surface drains at eight

locations as per CPCB/MoEF&CC guidelines


v Whether the site falls near to polluted stretch of river identified by

the CPCB/MoEF&CC, if yes give details

Not Applicable

vi Ground water monitoring at minimum at 8 locations shall be

included


vii Noise levels monitoring at 8 locations within the study area Refer Chapter-3, Page No. 153 to 158

viii Soil Characteristic as per CPCB guidelines Refer Chapter-3, Page No. 164 to 167

ix Traffic study of the area, type of vehicles, frequency of vehicles for

transportation of materials, additional traffic due to proposed

project, parking arrangement etc


x Detailed description of flora and fauna (terrestrial and aquatic)

existing in the study area shall be given with special reference to

rare, endemic and endangered species. If Schedule-I fauna are

found within the study area, a Wildlife Conservation Plan shall be

prepared and furnished.


xi Socio-economic status of the study area Refer Chapter-3, Page No. 182 to 190

7 Impact and Environment Management Plan

i Assessment of ground level concentration of pollutants from the

stack emission based on site-specific meteorological features. In

case the project is located on a hilly terrain, the AQIP Modelling

shall be done using inputs of the specific terrain characteristics for

determining the potential impacts of the project on the AAQ.

Cumulative impact of all sources of emissions (including

transportation) on the AAQ of the area shall be assessed. Details of

the model used and the input data used for modeling shall also be

provided. The air quality contours shall be plotted on a location

map showing the location of project site, habitation nearby,

sensitive receptors, if any


ii Water Quality modeling – in case of discharge in water body Refer Chapter-4, Page No. 204 to 216



iii Impact of the transport of the raw materials and end products on

the surrounding environment shall be assessed and provided. In

this regard, options for transport of raw materials and finished

products and wastes (large quantities) by rail or rail-cum road

transport or conveyor-cum-rail transport shall be examined


iv A note on treatment of wastewater from different plant

operations, extent recycled and reused for different purposes shall

be included. Complete scheme of effluent treatment.

Characteristics of untreated and treated effluent to meet the

prescribed standards of discharge under E(P) Rules


v Details of stack emission and action plan for control of emissions to

meet standards



vi Measures for fugitive emission control Refer Chapter-7, Page No. 386 to 387

vii Details of hazardous waste generation and their storage, utilization

and management. Copies of MOU regarding utilization of solid and

hazardous waste in cement plant shall also be included. EMP shall

include the concept of waste-minimization, recycle/reuse/recover

techniques, Energy conservation, and natural resource

conservation.


Refer Chapter-7, Page No. 382, 390, 391, 396 to 399

viii Proper utilization of fly ash shall be ensured as per Fly Ash

Notification, 2009. A detailed plan of action shall be provided

Not Applicable, as there is no generation of fly ash.

ix Action plan for the green belt development plan in 33 % area i.e.

land with not less than 1,500 trees per ha. Giving details of species,

width of plantation, planning schedule etc. shall be included. The

green belt shall be around the project boundary and a scheme for

greening of the roads used for the project shall also be

incorporated


x Action plan for rainwater harvesting measures at plant site shall be

submitted to harvest rainwater from the roof tops and storm water

drains to recharge the ground water and also to use for the various

activities at the project site to conserve fresh water and reduce the

water requirement from other sources


xi Total capital cost and recurring cost/annum for environmental

pollution control measures shall be included


xii Action plan for post-project environmental monitoring shall be

submitted


xiii Onsite and Offsite Disaster (natural and Man-made) Preparedness

and Emergency Management Plan including Risk Assessment and

damage control. Disaster management plan should be linked with

District Disaster Management Plan

Refer Chapter – 6, Risk Assessment & Disaster

Management Plan, Page No. 231 to 371

Refer Chapter – 6, Page No. 305 to 354

8 Occupational health

i Plan and fund allocation to ensure the occupational health & safety

of all contract and casual workers


ii Details of exposure specific health status evaluation of worker. If

the workers’ health is being evaluated by pre designed format,

chest x rays, Audiometry, Spirometry, Vision testing (Far & Near

vision, Colour vision and any other ocular defect) ECG, during pre

placement and periodical examinations give the details of the

same. Details regarding last month analyzed data of above

mentioned parameters as per age, sex, duration of exposure and

department wise




iii Details of existing Occupational & Safety Hazards. What are the

exposure levels of hazards and whether they are within Permissible

Exposure level (PEL). If these are not within PEL, what measures

the company has adopted to keep them within PEL so that health

of the workers can be preserved

Refer Chapter – 6, Risk Assessment & Disaster

Management Plan, Page No. 231 to 371


iv Annual report of heath status of workers with special reference to

Occupational Health and Safety.

Heath status of workers with special reference to

Occupational Health and Safety is done regularly and

records maintained, Refer Chapter – 6, Page No. 355 to

362

9 Corporate Environment Policy

i Does the company have a well laid down Environment Policy

approved by its Board of Directors? If so, it may be detailed in the

EIA report


ii Does the Environment Policy prescribe for standard operating

process / procedures to bring into focus any infringement /

deviation / violation of the environmental or forest norms /

conditions? If so, it may be detailed in the EIA


iii What is the hierarchical system or Administrative order of the

company to deal with the environmental issues and for ensuring

compliance with the environmental clearance conditions? Details

of this system may be given.


iv Does the company have system of reporting of non compliances /

violations of environmental norms to the Board of Directors of the

company and / or shareholders or stakeholders at large? This

reporting mechanism shall be detailed in the EIA report


10 Details regarding infrastructure facilities such as sanitation, fuel,

restroom etc. to be provided to the labour force during

construction as well as to the casual workers including truck drivers

during operation phase.

Proposed Expansion is within the existing premises

11 Enterprise Social Commitment (ESC)

i Adequate funds (at least 2.5 % of the project cost) shall be

earmarked towards the Enterprise Social Commitment based on

Public Hearing issues and item-wise details along with time bound

action plan shall be included. Socio-economic development

activities need to be elaborated upon

Refer Chapter – 7 Page No. 399 to 406

12 Any litigation pending against the project and/or any

direction/order passed by any Court of Law against the project, if

so, details thereof shall also be included. Has the unit received any

notice under the Section 5 of Environment (Protection) Act, 1986

or relevant Sections of Air and Water Acts? If so, details thereof

and compliance/ATR to the notice(s) and present status of the

case.

Not Applicable

13 A tabular chart with index for point wise compliance of above

TORs.

As Above

14 The TORs prescribed shall be valid for a period of three years for

submission of the EIA-EMP reports.

Shall be Complied










Prepared By: Aqua-Air Environmental Engineers Pvt. Ltd., Surat 1

CHAPTER - 1

___________________________________________________________________________

INTRODUCTION

1.1 JUSTIFICATION AND BACKGROUND

M/s. Paushak Ltd. proposes expansion of Specialty Chemicals in Existing Unit at Plot No.:

135, 136, 145, 146, 147, 229 & 230, Vill. Panelav, PO: Tajpura, Tal. Halol, Dist.: Panchmahal –

389 350, Gujarat.

M/s. Paushak Ltd., is a member of Alembic group (government recognized "Export House"),

manufacturers & exporters of specialty chemicals.

Alembic, founded in 1907, is committed to excellence in pharmaceutical healthcare through

the development of indigenous technologies, with a mission to give access to the best

healthcare products at affordable prices to everyone, anywhere in the world. Alembic is one

of India's most experienced manufacturers of bulk drugs and pharmaceutical formulations in

human and animal healthcare, as well as a respected export house. The leadership position

that Alembic's products enjoy in their respective categories speak aloud of the quality and

service standards set by the company. Six of Alembic's brands feature among the top 300

brands in the country today.

Alembic was a pioneer in the basic manufacture of penicillin. It is a world leader in

Macrolides and has the distinction of producing Cephalosporin – C for the first time in the

country. Alembic's brand, Althrocin, is India's 3rd largest antibiotic. The major therapeutic

segments where Alembic has a strong presence are antibiotics and antibacterials, cough and

cold remedies, analgesic and anti-inflammatory medications, nutraceupticals and anti-

diabetics. Alembic unveils the country's first zero calorie sugar substitute and Alembic is the

first company in India to introduce sucralose. Alembic is a certified WHO-GMP and USFDA

company with manufacturing practices and facilities that conform to WHO-GMP guidelines.



1.1.1 PROMOTERS AND THEIR BACK GROUND

M/s. Paushak Ltd. is a Limited company, having Six Directors. The detail of project

proponent is as below:

1.1.2 REGULATORY FRAMEWORK

For proposed expansion project; following assumptions has been considered:

a. Capacity of Plant 2490 MT/Month

b. Total working days in a year 330

c. Raw material storage facility for one month

d. Finished product storage for 50 tons

e. Solvent Storage facility for 30 days

Sr. Name of Director Address

1. Mr. Chirayu Ramanbhai Amin F 10/195, Race Course Circle, Gorti Road,

Vadodara- 390 007

2. Mr. Atul Haribhai Patel 1-2, Akshwan Housing Complex, Gotri-Sevasi Road,

Vadodara - 391 101

3. Mr. Udit Chirayu Amin F 10/195, Race Course Circle, Gorti Road,

Vadodara- 390 007

4. Mr. Amit Mohandas Goradia 12 Kesarbaugh, Vasna Road, Vadodara- 390 015.

5. Mr. Abhijit Achyut Joshi D-701, Kunj Plaza, Nr-Polo Club, Lalbaug, Vadodara

- 390001

6. Mr. Vijaybhai Harkishandas Gandhi 11, Dhanushya Society-Ii, Near Jyoti Park Society,

Sama Road, Vadodara- 390 008



TABLE 1.1

BREAK-UP OF PROJECT COST

Total cost of the Existing Project is Rs 70 Crores. The Existing Capital cost for air & water

pollution control system and environmental monitoring equipments is Rs 10 Crores. O&M cost

of pollution control system is Rs. 1.10 Crores per annum.

Total Cost for Proposed Expansion Project is Rs. 70 Crores.

Sr. Particulars Amount

(Rs. In Crores)

1 Plant Up gradation / Modification 50

2 ETP & Pollution Control System 10

3 Utilities & Contingency 10

Total 70



TABLE 1.2

BREAK UP OF DIFFERENT LAND USE OF FACTORY

Area (m2) Sr.

No.

Land Use

EXISTING TOTAL AFTER

PROPOSED EXPANSION

1 Plant Facilities 6344.12 12688.24

2 Engineering / Utility Services 1745.94 3491.88

3 Admin & Office Building 383.61 767.22

4 R & D , PD Lab Building 616 1232

5 U.G. Solvent Tank Yard Area 1445 2890

6 Warehouse (Storage of Raw material, Packing

Material & Finished Goods)

2668.45 5336.9

7 Storage Tank Area ( DMA, LDO, FO) 246.81 493.62

8 Fire Water Storage Area 270 540

9 Effluent Treatment Plant Area 491.62 983.24

10 Green Belt Area 32654.45 65308.9

11 Approach Road & Others Area 7750 15500

12 Parking Area 4928 9856

13 Security Area 10 20

Total 59,554 1,19,108



FIGURE - 1.1

LOCATION OF THE PROJECT SITE

Project Site

•Panelav







FIGURE - 1.2

LAYOUT OF THE PLANT



FIGURE - 1.3

PLANT PHOTOGRAPHS (EXISTING)



TABLE 1.3

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

Quantity (MT/Month) LD50 LC50 Sr.

No. Name of the Product

Existing Additional Total CAS No.

mg/kg ppm

1 Phosgene 400 800 1200 75-44-5 -- 96

2 3,4,4 – Trichlorocarbanilide 50 -50 0 101-20-2 >34600 --

Carbamyl Chloride -- -- --

Dimethyl Carbamoyl Chloride 79-44-7 1000 180

Diphenyl Carbamoyl Chloride 83-01-2 1500

Diethyl Carbamoyl Chloride 88-10-8 750

N Ethyl N Methyl Carbamoyl

Chloride

42252-34-6 -- --

N Methyl Piperazine

Carbamoyl Chloride

55112-42-0 -- --

N, N Bis 2 Chloroethyl

Carbamoyl Chloride

2998-56-3 >1540

Morpholine Carbamoyl

Chloride

15159-40-7 -- --

3

Any Other Carbamoyl Chloride

40 -12 28

-- -- --

Chloroformates -- -- --

Benzyl Chloroformate 501-53-1 3000 590

Isobutyl Chloroformate 543-27-1 -- --

N Pentyl Chloroformate 638-41-5 -- --

N Hexyl Chloroformate 6092-54-2 -- --

Phenyl Chloroformate 1885-14-9 44 800

Methyl Chloroformate 79-22-1 40 0.06

2 Ethyl Hexyl Chloroformate 24468-13-1 -- --

Cetyl Chloroformate 26272-90-2 -- --

Myristyl Chloroformate 56677-60-2 5000 --

Tert-Butyl Cyclohexyl

Chloroformate

42125-46-2 2000 0.72

Sec Butyl Chloroformate 17462-58-7 -- --

1 Chloro2 Methyl Propyl

Chloroformate

92600-11-8 -- --

Propyl Chloroformate 109-61-5 650 --

Isopropyl Chloroformate 543-27-1 -- --

Ethyl Chloroformate 541-41-3 270 0.64

4

Any Other Chloroformates

250 150 400

-- -- --

Vinyl Chloroformates 5130-24-5 -- -- 5

Isopropenyl chloroformate

1 0 1

6 4 Nitrophenyl Chloroformate 10 -5 5 7693-46-1 -- --

Urea -- -- -- 7

Diuron

10 190 200

330-54-1 1017 5.05






mg/kg ppm

3,4,4 Trichloro Carbanilide 101-20-2 >34600 --

1,3 Diethyl Urea 96-31-1 4000 --

Tetramethyl Urea 632-22-4 794 --

Tetrabutyl Urea 4559-86-8 1700 700

Any Other Urea -- -- --

Isocyanates -- -- --

Trans 4 Methyl Cyclohexyl

Isocyanate

32175-00-1 -- --

2 Phenyl Ethyl Isocyanate 1943-82-4 -- --

Cyclohexyl Isocyanate 3173-53-3 13 --

2 Chloroethyl Isocyanate 1943-83-5 -- --

Isopropyl Isocyanate (75% in

Toluene)

1795-48-8 -- --

4 Chloro -3 -(Trifluoromethyl)

Phenyl Isocyanate

16588-69-5 -- --

Phenyl Isocyanate 103-71-9 800 0.02

Tert Butyl Isocyanate 1609-86-5 360 0.06

3,4 Dichlorophenyl Isocyanate 102-36-3 91 2.7

3,5 Dichlorophenyl Isocyanate 34893-92-0 7000 --

4 Chloro Phenyl Isocyanate 104-12-1 138 0.11

P - Toluene Sulfonyl

Isocyanate

4083-64-1 2234 --

Stearyl Isocyanate 112-96-9 100 --

3 Chlorophenyl Isocyanate 2909-38-8 4200 --

4 Isobutoxybenzyl Isocyanate

8

Any Other Isocyanate

50 250 300

-- -- --

Carbonates -- -- --

Chloromethyl Isopropyl

Carbonate

35180-01-9 -- --

Bis 4 Nitro Phenyl Carbonate 5070-13-3 -- --

4,5-Dimethyl-1,3-Dioxolen-2-

One

37830-90-3 -- --

4-Chloromethyl-5-Methyl-1,3-

Dioxol-2-One

80841-78-7 -- --

4-(Hydroxy Methyl)-5-Methyl-

1,3-Dioxol-2-One

91526-18-0 -- --

2-Methyl Cryloxy Ethyl Vinyl

Carbonate

145497-35-4 -- --

Dimethyl Carbonate 616-38-6 5000 5.36

Diphenyl Carbonate 102-09-0 1500 --

9

Any Other Carbonate

20 20 40

-- -- --

Benzimidazol -- -- -- 10

2 Benzimidazol

2 -2 0

51-17-2 2910 --






mg/kg ppm

Any Other Benzimidazol -- -- --

11 Forskoline Carbonate 0.5 -0.5 0 81826-81-5 -- --

Chlorides/Acid Chlorides -- -- --

3 Chloropropionyl Chloride - 3

CPC

625-36-5 1200 1

Isobutyryl Chloride 79-30-1 -- --

5 - Chlorovaleroyl Chloride 1575-61-7 320 --

Pivaloyl Chloride 3282-30-2 638 1.4

Chloroacetyl Chloride 79-04-9 220 660

12

Other Chlorides/Acid

Chlorides

22.5 17.5 40

-- -- --

Carbamates -- -- --

N Butyl Propargyl Carbamate 76114-73-3 -- --

2-Methyl-2-Propyl-1,3-

Propanediol Dichlocarbamate

(90% in Toluene)

80471-57-4 -- --

Benzyl Carbamate 621-84-1 -- --

3 Iodo 2 Propynyl N Butyl

Carbamate

55406-53-6 -- --

13

Other Carbamates

22.5 17.5 40

-- -- --

Carbodiimides -- -- --

Dicyclohexyl Carbodiimide -

DCC

538-75-0 400 0.16

14

Other Carbodiimides

10 -5 5

-- -- --

Protected Amino Acids -- -- --

CBZ Valine 1149-26-4 -- --

15

Other Amino Acids

3 -3 0

-- -- --

Nitriles -- -- --

Ethyl 2-(Hydroxylmino)

Cyanoacetate

3849-21-6 -- --

Acetonitrile 75-05-8 1320 3587

2 Cyano Phenol 611-20-1 -- --

16

Other Nitriles

5 -4 1

-- -- --

17 FTMA 1 -1 0 535-52-4 -- --

Polymers -- -- --

Polyquat 75345-27-6 -- --

18

Other Polymers

0.5 0.5 1

-- -- --

Thiadiazole -- -- -- 19

5-Methoxy-1, 3, 4-Thiadiazol-

2(3H)-One

0 20 20

17605-27-5 -- --

Esters -- -- --

Methyl 3-Aminocrotonate 14205-39-1 1760 0.02

20

Phenyl Benzoate

0 209 209

93-99-2 1225 --






mg/kg ppm

Ethylene Glycol Dibenzoate 120-55-8 4190 200

Benzyl Carbazate 5331-43-1 -- --

Tert Butyl Carbazate 870-46-2 -- --

Total 898 1592 2490

By-Products List

Quantity (MT/Month) Sr. Name of By-Product

Existing Additional Total

CAS No. LD50

mg/kg

LC50

Ppm

1 Hydrochloric Acid (30 %) 500 1000 1500 7647-01-0 -- --

2 FeCl2 6 12 18 7705-08-0 1300 --

3 Recovered Mercury 3.6 3.6 7.2 7439-97-6 -- 0.03

4 Recovered Mercury

Chloride

3.6 3.6 7.2 7487-94-7 -- --

Total 513.2 1019.2 1532.4



1.2 PROJECT SETTING

M/s. Paushak Ltd. located at longitude 73°28'30.55" E and latitude 22°27'23.77" N. Detailed

Layout map of the plant is shown in Figure – 1.2.

Project site, where M/s. Paushak Ltd. is located, comes under Panch Mahal District, is 40 km

from Nandesari GIDC an important industrial estate of Gujarat and India. In addition, it is a

major centre of the pharmaceutical and glass industry in India; the basic chemical industry is

also a growing one. Halol city is about 5.5 km away and has population of around 2,37,959.

The city is well connected by road and rail to rest of India. Development of Communication

systems is good in the region due to proximity to Vadodara. Sources of water in the region

include river and ground water resources. The river Vishwamitri is flowing 3.2 km distance in

the west direction of the project site. "Champaner", world heritage place is located about 8

km aerial distance from the project site but "Champaner" is located in NE direction of

"Pavagadh" mountain while the project is located in SW of "Pavagadh" mountain. Secured

land fill site and Common Incineration facility operated by M/s Nandesari Environment

Control Ltd. is located in Nandesari, GIDC Estate, about 40 km away from the project site.

The salient features of the site are as under:

1. Minimum distances:

a) From City : Halol (5.5 km)

(Population – 2,37,959 as per 2011 census data)

b) Historical Site : Champaner (World Heritage Palace) (8 km)

c) Sanctuaries : Jambughoda Wildlife Sanctuary (29 km)

d) Highway : National Highway No. 8 (41 km West),

State Highway SH 194 (1.37 km West)

e) Railway Line : 5.59 km North-East

2. Use of forest land : None

3. Use of prime agricultural land: None

4. Planned submergence : None

5. Displacement of population : None



1.2.1 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

1.2.1.1 METHOD OF DATA PREPARATION

Key infrastructure features have been extracted from Survey of India (SoI) topographical

maps of 1:50,000 scale. The features have been updated using satellite data and have been

verified with ancillary information derived from TTK maps and guide maps. The locations of

the settlement have been extracted from Census of India (CoI) maps and verified by using SoI

topographical maps and satellite data.

1.2.1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

The distance of railways and National and State highways are presented in Table 1.4 below.

TABLE 1.4

___________________________________________________________________________

DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

1.2.1.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

A map depicting administrative boundaries up to Taluka level, showing locations of towns

and villages along with National and State highways, major and medium roads and railways

is presented as Figure 1.4. The map also shows the water bodies for better understanding of

project area. The map marks the area within 10 km with the project site as the center.

Sr.

No.

Nearest Infrastructure Feature Distance from Project Site

1. National Highway NH 8 41 km West

2. State Highway SH 194 1.37 km West

3. Railway Line 5.59 km North-East

4. Halol Railway Station 5.80 km North-East

5. River

Pratappura Talav 8.67 km North West

Dhanora Talav 11.27 km North East

Sayaji Sarovar 10.84 km South West

Karod Nadi 14.51 km North East

6. Reserve Forest

Reserve Forest 1.32 km East

Gutal Reserve Forest 8.22 km South

Reserve Forest 12.30 km South East



7. Vadodara Airport 23.23 km South-West



FIGURE – 1.4

KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS



1.3 PURPOSE OF EIA

The EIA study is carried out to assess the pollution potential and evaluate the adequacy and

efficiency of existing and proposed Pollution Control & Environmental Management System.

1.4 OBJECTIVES OF EIA

The main objectives of the study are

1) To assess the background environmental status,

2) To identify potential sources of pollution,

3) To predict and evaluate the impact on environment along with pollution control

measures taken and

4) To prepare a comprehensive Environment Management Plan and Disaster

Management Plan.

1.5 METHODOLOGIES FOR EIA

Taking into consideration proposed expansion project activities and guidelines, an area of 10

km radius from the center of the project has been selected and is designated as the study

area for the purpose of EIA studies.

1.5.1 Base Line Condition

The samples of ambient air, ground and surface water and soil are collected and analyzed as

per the standard methods for establishing the baseline data and to determine the impact of

proposed expansion activity on the same.

1.5.1.1 Ambient Air Environment

The air environment around the plant was studied by setting up eight locations within the

study area of 10 km radius from the project site and collection and monitoring the site

specific meteorological data, viz. wind speed, wind direction, humidity, rainfall and ambient

temperature was carried out. Design of network for ambient air quality monitoring locations

is based on guidelines provided by CPCB. The ambient air samples were collected and

analyzed for SPM, PM10, PM2.5, SO2, NOX, HCl, Cl2, O3, Pb, CO, NH3, C6H6, Benzo (a) Pyrene

(BaP), Arsenic (As), Nickel (Ni) & VOCs for identification, prediction, evaluation and

assessment of potential impact on ambient air environment.



1.5.1.2 Ground And Surface Water Environment

The water required for domestic and industrial use is being made available from surface

water. Hence, to assess the physico-chemical quality of the water, a number of water

samples were collected and analyzed for pollution parameters viz., pH, TDS, Turbidity, BOD3,

COD, Fluorides, Chlorides, Sulphates, Nitrates, Ammonical Nitrogen, Hardness, Alkalinity, Oil

& Grease and some heavy metals in order to find out the contamination, if any.

1.5.1.3 Noise Environment

Noise pollution survey was conducted in the study zone. The anticipated noise sources were

industrial activities, which are likely to be increased due to proposed expansion activity.

Noise levels were also recorded in surrounding villages for evaluating general scenario of

the study area. Hourly equivalent sound levels (Leq) were also recorded for calculating Day

and Night noise levels in the surrounding villages.

1.5.1.4 Soil Environment

Soil sampling and analysis was carried out to assess physico-chemical characteristics of the

soils and delineate existing cropping pattern, existing land use and topography, within the

study area.

1.5.1.5 Biological Environment

Keeping in view, the importance of biological component of total environment due to the

proposed expansion project, biological characterization of terrestrial and aquatic

environments, changes in species diversity of flora and fauna in terrestrial as well as aquatic

systems were studied for impact analysis due to proposed expansion project activity, if any.

1.5.1.6 Socio-economic Environment

Demographic and related socio-economic data was collected from census handbook to

assess socio-economic status of the study area. Assessment of impact on significant

historical, cultural, and archeological sites/places in the area and economic and employment

benefit arisen out from the project is given special attention.



1.5.2 Identification of Pollution Source

Detailed study of manufacturing process for proposed expansion scenario is carried out

along with input and output of materials, water, and wastewater as well as infrastructure

facilities available.

1.5.3 Evaluation of Pollution Control and Environmental Management System

The qualitative and quantitative analysis of various pollution sources as well as evaluation of

pollution control system is carried out.

1.5.4 Evaluation of Impact

A comprehensive evaluation of environmental impact with reference to proposed expansion

activities is carried out.

1.5.5 Preparation of Environmental Management Plan

A comprehensive Environmental Management Plan has been prepared covering all the

aspects of pollution prevention measures, Air and Water Pollution Control measures,

Hazardous Waste Management, Environmental Surveillance and Environmental

Management Plan.

The present report is an EIA conducted during Pre-Monsoon, 2017 (March, 2017 to May,

2017). The baseline environmental conditions have been established through field

monitoring and literature survey. The contents of EIA report, details of data collection and

source of secondary data are presented in Figure 1.5.

1.6 STRUCTURE OF REPORT

The objective of the EIA study is preparation of Environment Impact Assessment (EIA) report

based on the guidelines of the Ministry of Environment and Forests (MoEF), CPCB and GPCB.

It incorporates the following.

• Chapter 1 is an Introduction to the Industry, their premises and surrounding areas. It

also expresses the basic objectives and methodologies for EIA studies and work to be

covered under each Environmental component.



• Chapter 2 presents a Description of Project and Infrastructure facilities including all

industrial and environmental aspects of M/s. Paushak Ltd. as well as manufacturing

process details. This chapter also gives information about raw material storage and

handling, water and wastewater quantitative details, air pollution and control

system, Hazardous Waste generation, storage facility and disposal and utilities for

proposed expansion plant capacity. It also provides information about proposed

expansion Environmental Management Facilities available at the project site.

• Chapter 3 covers Baseline Environmental Status including meteorological details,

Identification of baseline status of Environmental components of the surrounding

area covering air, water and land environment. Also presents a study of land use

pattern, Biological Environment & Socio-Economic Environment giving details about

District Panchmahal, Taluka Halol and the study area in terms of land use pattern,

biological environment, and socio-economic environment.

• Chapter 4 deals with Anticipated Environmental Impacts & Mitigation Measures,

which provides quantification of significant impacts of the proposed expansion

activities of plant on various environmental components. Evaluation of the proposed

expansion pollution control facilities has been presented.

• Chapter 5 deals with Environmental Monitoring Plan.

• Chapter 6 describes Risk assessment and Disaster management plan that shall be

adopted by the company.

• Chapter 7 describes Environment Management Plan (EMP) to be adopted for

mitigation of anticipated adverse impacts if any and to ensure acceptable impacts.

• Chapter 8 describes Executive Summary of the Project.

• Chapter 9 describes Details of Consultants Engaged.



FIGURE 1.5

____________________________________________________________________________________________________________________

ACTIVITIES, SOURCES OF INFORMATION AND CONTENTS OF EIA REPORT

RECONNAISSANCE SURVEY OF PLANT ANNUAL REPORT

MARKET ASSESSMENT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS

DATA ON METEOROLOGY, SOCIO-ECONOMIC STATUS &

BASIC AMENITIES

SITE VISITS AND INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS OF INDIA

INDIAN METEOROLOGICAL DEPT

ENVIRONMETAL INFORMATION CENTRE

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

EXISTING &

PROPOSED

PLANT

FACILITY DESCRIPTION IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE

MANAGEMENT, GREEN BELT DEVELOPMENT

MONITORING PROGRAM

CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

RISK ASSESSMENT

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR



CHAPTER - 2

PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND

M/s. Paushak Ltd. proposes expansion of Specialty Chemicals in Existing Unit at Plot No.: 135,

136, 145, 146, 147, 229 & 230, Vill. Panelav, PO: Tajpura, Tal. Halol, Dist. Panchmahal – 389 350,

Gujarat.

2.2 MANUFACTURING ACTIVITIES

Manufacturing activities in the project include various processes. The activities shall also

include operation of various utilities. The manufacturing process is described in details in

following sections. The list of products and their capacity is given in Table 1.1.

PROCESS DESCRIPTION

PHOSGENE

Process Description

Carbon Monoxide Gas is manufactured by incomplete combustion of coal in presence of Carbon

Dioxide. The Carbon Monoxide thus manufactured is further condensed with Chlorine in

presence of Activated Charcoal to produced Phosgene. The excess Carbon Monoxide is

recycling in the system, while the excess of gas being scrubbed suitably.

Chemical Reaction

3C + CO2 + O2 + 4Cl2 4COCl2

Material Balance

Input (kg) Output (kg)

CO2 Gas 0.086 Phosgene 1.00

Chlorine Gas 0.75 Off Gases 0.073

Oxygen 0.108

Petroleum Coke 0.125

Caustic Soda Lye 0.004

Total 1.073 Total 1.073



3, 4, 4’ TIRCHLOROCARBANILIDE (TO BE DISCONTINUED)

Process Description

4 Chloro Phenyl Isocyanate / 3,4 Di Chloro Phenyl Isocyanate react with 3,4 Di Chloroaniline /

P- Chloro Aniline in solvent (Toluene / Mono Chloro Benzene) media at controlled

temperature to forms 3,4,4’ Trichlorocarbanilide. Afterwards the slurry is filter to separate the

solvent, and then material is dried at controlled temperature in rotary vacuum drier followed

by milling in air jet mill.

Chemical Reaction

C l

N O

4- Chlorophenylisocyanate

+

3 ,4 -d ich lo roan il ine

N H 2

C l

C l

NH N H

O

C l C l

C l

3, 4, 4' - TRICHLOROCARBANILIDE

Material Balance


4 CPI 0.502 TCC 1.00

3, 4 DCA 0.528 MCB 0.93

MCB 0.94 Tar 0.042

Nitrogen Gas 0.001

DMF 0.001




CARBAMYL CHLORIDE GROUP

DIMETHYL CARBAMOYL CHLORIDE

Process Description

Aromatic / Aliphatic primary or secondary amines are reacted with Phosgene in suitable solvent

under control condition of temperature and pressure, the resultant mass is degassed to

remove free HCl & free Phosgene through scrubber. The crude product is distilled to get pure

product.

Chemical Reaction

R R

NH + COCl2 NCOCl + HCl

R1 R1

Material Balance


Dimethyl Amine 0.47 DMCC 1.00

Phosgene Gas 1.27 Tar 0.04

Solvent 0.10 HCl 30% 1.94

Nitrogen 0.03

NaOH 0.07

Water 1.04




DIPHENYL CARBAMOYL CHLORIDE

Process Description

Diphenyl amine is reacted with Phosgene in suitable solvent under control condition of

temperature and pressure, the resultant mass is degassed to remove free HCl & free Phosgene

through scrubber. The crude product is distilled to get pure product.

Chemical Reaction

Material Balance


DPA 0.85 DPCC 1.00

Phosgene 1.20 Residue 0.12

Toluene 3.63 Toluene 3.45

NaOH 0.03 Toluene Loss 0.18

HCl 0.91

NaCl 0.05


NH N

OCl

COCl2+ + HCl

Formula Weight = 169.22244 Formula Weight = 231.6776FW - 99 FW - 36.5



DIETHYL CARBAMOYL CHLORIDE

Process Description

Diethyl Amine is reacted with Phosgene in suitable solvent under control condition of



Chemical Reaction

Material Balance


DEA 0.56 DECC 1.00


NaOH 0.01 HCl 0.61

NaCl 0.02


CH3

NH

CH3

CH3

N

CH3 Cl

O

+ +COCl 2 HCl




N ETHYL N METHYL CARBAMOYL CHLORIDE

Process Description

Ethyl Methyl Amine is reacted with Phosgene in suitable solvent under control condition of



Chemical Reaction

Material Balance


EMA 0.78 EMCC 1.00




HCl 1.17

NaCl 0.06


H5C2

NH

CH3

N

H5C2

CH3 O

Cl

COCl2 HCl++

FW - 36.5FW - 99 Formula Weight = 121.56542Formula Weight = 59.11026



N METHYL PIPERAZINE CARBAMOYL CHLORIDE

Process Description

NMPCC HCl is reacted with Phosgene in suitable solvent under control condition of



Chemical Reaction

Material Balance


NMPCC HCl 0.56 NMPCC 1.00


Chloroform 10.71 Chloroform 10.07

NaOH 0.02 Chloroform Loss 0.64

HCl 0.56

NaCl 0.03


NHNCH3 NNCH3

Cl

O

COCl2H Cl

+

Formula Weight = 100.16218 FW - 99 Formula Weight = 199.07828



N, N BIS 2 CHLOROETHYL CARBAMOYL CHLORIDE

Process Description

2CEA HCl is reacted with Phosgene in suitable solvent under control condition of temperature

and pressure, the resultant mass is degassed to remove free HCl & free Phosgene through

scrubber. The crude product is distilled to get pure product.

Chemical Reaction

Material Balance


2CEA HCl 1.02 BCC 1.00


NaOH 0.01 HCl 0.60

NaCl 0.02


N

Cl

Cl

O

ClNH

Cl

Cl

H ClCOCl2+ 2HCl+

Formula Weight = 178.4879Formula Weight = 204.48212

FW - 99 FW - 73



MORPHOLINE CARBAMOYL CHLORIDE

Process Description

Morpholine is reacted with Phosgene in suitable solvent under control condition of



Chemical Reaction

Material Balance


Morpholine 0.74 MOCC 1.00

Phosgene 1.68 Toluene 0.89

Toluene (85 % recovery) 0.89 HCl 1.30

Nitrogen gas 0.30 NaCl 0.46

Caustic lye 0.07 Residue 0.03


O

NH

+

morpholine

[87.08]

COCl2

Phosgene

[99]

O

N

O Cl

morpholine-4-carbonyl chloride

[149.58]

+ HCl

[36.5]



CHLOROFORMATE GROUP

BENZYL CHLOROFORMATE

Process Description

Aromatic/Aliphatic primary or secondary amines are reacted with Phosgene in suitable solvent

under control condition of temperature and pressure, the resultant mass is degassed to remove

free HCl & free Phosgene through scrubber. The crude product is distilled under vacuum to get

pure product.

Chemical Reaction

ROH + COCl2 ROCOCl + HCl

Material Balance


Benzyl Alcohol 0.672 Benzyl Chloroformate 1.00

Phosgene Gas 0.98 HCl 30% 1.45

Nitrogen 0.03 NaCl 0.035

Water 0.843 Tar 0.07

NaOH 0.03




ISOBUTYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


IBA 0.60 IBCF 1.00


NaOH 0.01 HCl 0.59

NaCl 0.02


CH3

CH3 O

O

ClCH3

CH3 OH

FW - 36.5FW - 99

COCl2 HCl+ +

Formula Weight = 74.1216 Formula Weight = 136.57676



N PENTYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


n-Pentanol 0.74 PTCF 1.00


NaOH 0.02 HCl 0.67

NaCl 0.02


CH3

OHCH3

Cl

O

COCl2HCl+ +

Formula Weight = 88.14818 Formula Weight = 148.63052 FW - 36.5FW - 99



N HEXYL CHLOROFORMATE

Process Description

n-Hexanol is reacted with phosgene, the reactions is completed and then quench the reaction

mass in to the water for removed excess phosgene & HCl and to give pure n-Hexyl

Chloroformate.

Chemical Reaction

OHCH3

O

O ClCH3COCl2+ + HCL

Material Balance


Hexanol 0.71 HCF 1.00

Phosgene 1.43 Anhy. Sodium Sulfate 0.01

Caustic 0.07 Residue 0.01

Soda Ash 0.01 HCl 0.91

Anhy. Sodium Sulfate 0.01 NaCl 0.30

Nitrogen gas 0.03 Nitrogen 0.03




PHENYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


Phenol 0.78 PCF 1.00


NaOH 0.02 HCl 0.63

NaCl 0.04


OHO

O

Cl

COCl2++ HCl


FW - 99 FW - 36.5



METHYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


Methanol 0.59 MCF 1.00


NaOH 0.03 HCl 1.21

NaCl 0.04


CH3OH COCl2 + HCl+

FW - 99 FW - 36.5

CH3O Cl

O




2 ETHYL HEXYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


EHA 0.69 EHCF 1.00


NaOH 0.01 HCl 0.47

NaCl 0.02


CH3 OH

CH3

CH3 O Cl

O

CH3

COCl2 + HCl+

Formula Weight = 130.22792 Formula Weight = 192.68308FW - 99FW - 36.5



CETYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


Cetyl alcohol 0.85 CETCF 1.00

Phosgene 0.51 HCl 0.36


OH

COCl2

O Cl

O

Cetyl alcohol

Cetyl chloroformate



MYRISTYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


Myristyl alcohol 0.82 CETCF 1.00


Caustic for scrubber 0.15 NaCl 0.09


OH+

O Cl

O

Cl Cl

O

Myristyl alcoholPhosgene

Myristyl chloroformate

+ ClH

[214.3][99]

[276.8]



TERT-BUTYL CYCLOHEXYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


4-tert-Butylcyclohexanol 0.79 TBCHCF 1.00


Caustic for scrubber 0.16 NaCl 0.20


OH COCl2O

ClO

4-tert Butylcyclohexanol

MW:- 156.26

4-tert Butylcyclohexyl chloroformate

MW:- 218.72



SEC BUTYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


Sec-Butanol 0.57 SBUCF 1.00


NaOH HCl 1.14

NaCl 0.15


OH

+

O

Cl Cl

O

O

Cl

+ ClH

Sec-ButanolPhosgene

Sec-Butylchloroformate MW :-74 MW :-99

MW :-136.5



1 CHLORO 2 METHYL PROPYL CHLOROFORMATE

Process Description




pure product.

Chemical Reaction

Material Balance


Isobutyraldehyde 1.05 CMPCF 1.00

Phosgene 1.38 MDC 2.11

MDC 2.11 Pyridine 0.32

Pyridine 0.32 Residue 1.43

Sodium Sulphate 0.05 Nitrogen 0.42


Caustic lye 0.10


CH3

CH3

O

+

O

Cl

Cl

CH3

CH3

O

Cl O

Cl

Isobutylaldehyde Phosgene

1-Chloro2

-Methyl propyl chloroformate

M.W.-72M.W.-99

M.W.-171



PROPYL CHLOROFORMATE

Process Description

n-Propyl alcohol (1-Propanol) is reacted with phosgene. After completion of reaction, water

wash is given for removal of phosgene and HCl & dry with sodium sulphate and soda ash to get

product.

Chemical Reaction:

+O

Cl Cl

+ ClH

CH3

OH

n-Propylalcohol

CH3

O

Cl

O

n-Propyl ChloroformatePhosgene

Material Balance:

In put (kg) Out put (kg)

n-Propyl Alcohol 200 n-Propyl Chloroformate(PrCF) 370

Phosgene 659 Aq. Layer 620

Water 600 Soda Ash cake (wet) 10

Sodium Sulphate 2.5 Loss (as HCl) 121

Soda ash 2.5 Excess Phosgene loss 329

Other loss(sampling and

handling)

14

Total 1464 Total 1464



ISOPROPYL CHLOROFORMATE

Process Description

Iso - Propyl alcohol is reacted with phosgene. After completion of reaction, water wash is given

for removal of phosgene and HCl & dry with Sodium Sulphate and soda ash to get product.

Chemical Reaction:

+O

Cl Cl

+ ClH

Iso propyl alcohol Iso Propyl ChloroformatePhosgene

OH

CH3

CH3O

CH3

CH3

ClO

Material Balance:


Iso Propanol 200 Finished Product (IPCF) 352

Phosgene 659 Aq. Layer 638

Water 600 Soda Ash cake (wet) 8

Sodium Sulphate 2.5 Loss (as HCl) 121

Soda ash 2.5 Excess Phosgene loss 329

Other loss(sampling and handling) 16




ETHYL CHLOROFORMATE

Process Description

Ethanol (Ethyl alcohol) is reacted with phosgene under control condition of temperature &

pressure. The resultant mass is degassed to remove free HCl & free Phosgene through scrubber.

The crude product is distilled under vacuum to get pure product.

Chemical Reaction:

CH3 OHCH3 O Cl

O

Ethyl chloroformateEthanol Phosgene

O

Cl Cl

++ ClH

[46] [99] [108.5][36.5]

Material Balance:


Ethanol 0.59 Ethyl Chloroformate 1.00


NaOH 0.05 HCl 1.10

NaCl 0.08




VINYL CHLOROFORMATE GROUP

VINYL CHLOROFORMATE

Process Description

Vinyl Acetate reacts with Mercuric Chloride mix together to form Chloro Mercuric

Acetaldehyde; this Chloro Mercuric Acetaldehyde is reacted with Phosgene in solvent media to

form Crude Vinyl Chloroformate and residual Mercuric Salts. Crude Vinyl Chloroformate is

distilled out to get pure product and mercuric salt is/are react with Iron to produce metal

Mercury.

Chemical Reaction

CH2 O

O

CH3

HgCl2 Phosgene

OHg

Cl

H

CH2O

O

ClNitrobenzeneCaCO3

Material Balance


Caustic Soda Lye 10.0 Vinyl Chloroformate 1.00

Vinyl Acetate 3.49 Mercury 3.10

CaCO3 1.57 Ferric Chloride 3.92

Mercuric Chloride 8.41 Mercuric Chloride 4.20

Acetone 3.33 Acetone 3.00

Nitrogen Gas 1.25 Water 53.00

Water 63.0 Nitrobenzene 8.00

Nitro Benzene 8.1 HCl 30% 25.90

Phosgene 4.00 NaCl 1.03




ISOPROPENYL CHLOROFORMATE

Process Description

STAGE: - 1

Isopropenyl Acetate is reacted with a mercuric chloride in the presence of water and an acid

acceptor preferably mercuric oxide to produce chloro-mercuricacetone.

STAGE: - 2

Phosgene is reacted with chloro-mercuricacetone in the presence of a solvent preferably nitro

benzene to produce Isopropenyl chloroformate (IPECF).

Chemical Reaction

CH2

CH3

O O

CH3

+ Hg

Cl

Cl

+ + OH2+

CH3

O

OH

+ OH2

Isopropenyl Acetate Mercuric chloride Mercuric oxide Chloromercuric Acetone Acetic acid

Stage - 1 (Chloro mercuric Acetone )

Cl

Hg

O

CH3

Hg

O

Cl

Hg

CH3

O

+ O

Cl

Cl

CH2

CH3 O O

Cl

+Hg

Cl

Cl

Chloro mercuric Acetone Phosgene Isopropenyl chloroformate Mercuric chloride

Stage-2 Isopropenyl chloroformate

Material Balance

STAGE: - 1

Input Quantity

(Kg)

Output Quantity

(Kg)

Isopropenyl Acetate 3.850 Chloro-Mercuric acetone 7.000

Mercuric chloride 4.025 Filtrate ML 14.91

Mercuric oxide 3.234 Loss 1.029

Process water for reaction 11.830

Total 22.939 22.939

STAGE: - 2

Input Quantity

(Kg)

Output Quantity

(Kg)

Chloro-Mercuric acetone 7.00 Isopropenyl chloroformate 1.000

Nitro benzene 18.000 Residual mass 24.400

Phosgene 4.300 Loss 3.900

Total 29.300 29.300



4-NITROPHENYL CHLOROFORMATE

Process Description

In the solution of 4-Nitrophenol & Toluene, Phosgene is purged and Diethyl Aniline is added to

it. After reaction completion Dil. HCl and Water are added to the reaction mass and after layer

separation toluene is distilled under vacuum. Residue is cooled and Hexane is added to

crystallize the product. Product is filtered and dried under Vacuum.

Chemical Reaction

Phosgene

O2N

OH

4-nitrophenol

O2N

O Cl

O

4 - Nitro phenylchloroformate

NNDEA

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

4-Nitro Phenol 0.86 4-Nitrophenyl Chloroformate (4-NPCF) 1.00

Phosgene (COCl2) 0.80 DPCO 0.19

N,N Diethyl Aniline (NNDEA) 1.21 Dil. Hydrochloric Acid (HCl) 1.56

Dil. Hydrochloric Acid (HCl) 1.27 Water (H2O) 2.34

Sodium Hydroxide (NaOH) 0.41 N,N Diethyl Aniline (NNDEA) 1.21

Water (H2O) 2.46 Sodium Chloride (NaCl) 0.60

Toluene 7.27 Carbon Dioxide (CO2) 0.11

Hexane 12.07 Residue 2.15

Toluene 6.33

Hexane 10.86

Total 26.35 26.35



UREA GRUOUP

1, 3-DIETHYL UREA

Process Description

Two moles of Amine is reacted with Phosgene at controlled temperature in solvent media to

form Urea. The solvent is then separated out suitably and recycled. The Off gas (HCl) generated

is scrubbed out in scrubber. The scrubbed material (HCl 30%) is sold out.

Chemical Reaction

NH2CH3

CH3 NH NH CH3

O

+ COCl2

ethanamine 1,3-diethylureaPhosgene

Material Balance

Input Quantity (Kg) Output Quantity (Kg)

Ethylamine 0.86 DEU 1.00

Phosgene (COCl2) 0.95 HCl 0.7


Residue 0.37

Total 6.12 6.12



3-(3, 4-DICHLOROPHENYL)-1, 1-DIMETHYL UREA (DIURON)

Process Description

3, 4 Dichloro Phenyl Isocyanate is reacted with Dimethyl Amine to produce 3-(3, 4-

Dichlorophenyl)-1, 1-Dimethyl Urea. (Diuron/DCMU)

Chemical Reaction

Cl

Cl

N

O

+ NHCH3

CH3

Cl

Cl

NH

O

NCH3

CH3

3,4 Dichlorophenyl isocyanate

Dimethyl Amine3_(3,4 dichlorophenyl)-1,1 dimethylurea

Material Balance

In put Out put Sr.

Name Qty. in Kg Name Qty. in Kg

1 3,4 Dichloro Phenyl Isocyanate 0.862 Diuron 1.0

2 Dimethyl Amine 0.259 Filtrate 4.71

3 Toluene 5.232 Loss 0.643

TOTAL 6.353 TOTAL 6.353



3, 4, 4 TRICHLORO CARBANILIDE

Process Description

Two moles of Amine is reacted with Phosgene at controlled temperature in solvent media to

form Urea. The solvent is then separated out suitably and recycled. The Off gas (HCl) generated

is scrubbed out in scrubber. The scrubbed material (HCl 30%) is sold out.

Chemical Reaction

C l

N O

4- Chlorophenylisocyanate

+

3 ,4 -d ich lo roan il ine

N H 2

C l

C l

NH N H

O

C l C l

C l

3, 4, 4' - TRICHLOROCARBANILIDE

Material Balance


4 CPI 0.502 TCC 1.00

3, 4 DCA 0.528 MCB 0.93

MCB 0.94 Tar 0.042

Nitrogen Gas 0.001

DMF 0.001




TETRAMETHYL UREA

Process Description

Dimethyl amine is reacted with phosgene in the presence of Base to get crude product Tetra

methyl urea, extracted in MDC and then distilled out to get Liquid product Tetra methyl urea

[TMU] .

Chemical Reaction:

2 NH

CH3

CH3

+O

ClCl

NCH3

CH3

O

NCH3

CH3

+ 2HCl

Dimethyl amine Phosgene Tetra methyl ureaHydrochloric acid

Material Balance:


Di methyl amine (40 % solution) 2.375 Tetra methyl urea (TMU) 1.000

Phosgene 1.625 Sodium chloride soln. (NaCl) 9.535

Caustic lye (48%) 1.735 Distilled Dichloromethane (MDC) 5.200

Process water for reaction 3.75 Residue /(Loss) 1.500

Process water for washing 1.250

Dichloro methane (MDC) 6.500

Total 17.235 17.235



TETRABUTYL UREA

Process Description

Di-n-butyl amine is reacted with phosgene in presence of Soda ash solution. After completion of

reaction, layers are separated. Organic layer is collected as Tetrabutylurea and purified if

required.

Chemical Reaction:

CH3

NH

CH3

+O

Cl Cl

CH3

N

CH3

O

N

CH3

CH3

2 + ClH2

Material Balance:

Input (kg) Out put (kg)

Di n-butyl amine 515 Tetra butyl urea 525

Water 3450 Water layer (total) 4182

Phosgene 255

Degassing Loss & sampling

loss 22

Soda ash 451 --- ---

HCl (Conc.) 58 --- ---

T O T A L 4729 T O T A L 4729



ISOCYANATE GROUP

CYCLOHEXYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

RNH2 + COCl2 RNCO + 2HCl

Material Balance


Cyclo Hexyl Amine 0.98 Cyclohexyl Isocyanate 1.00

Phosgene Gas 1.725 Tar 0.237

Solvent 0.1 HCl 30% 4.514

Nitrogen 0.001 NaCl 0.073

Water 2.968

NaOH 0.05




TRANS 4 METHYL CYCLOHEXYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


T4CHA 1.18 T4MCHI 1.00




HCl 1.27

NaCl 0.05


CH3 NH2

H Cl

CH3 N

O

COCl2 + 3HCl+




2 PHENYL ETHYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


PEA 1.14 2PEI 1.00




HCl 1.92

NaCl 0.06


NH2 NCO

+ COCl2 2HCl+


FW - 73FW - 99



2 CHLOROETHYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


CEA 1.20 2CEI 1.00


EDC 6.19 EDC 5.88

NaOH 0.04 EDC loss 0.31

HCl 2.08

NaCl 0.06


ClNH2

H Cl

ClN O

+ COCl23HCl+


FW - 99 FW - 109.5



ISOPROPYL ISOCYANATE (75% IN TOLUENE)

Process Description




pure product.

Chemical Reaction

Material Balance


IPAM 0.93 IPIC 1.00


NaOH 0.07 HCl 2.50

NaCl 0.10


NH2

CH3

CH3

N

CH3

CH3

O

FW - 73FW - 99

2HClCOCl2+ +

Formula Weight = 59.11026 Formula Weight = 85.10448



4 CHLORO -3 - (TRIFLUOROMETHYL) PHENYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


4-Chloro-3-

(trifluoromethyl) Aniline

1.26 CTPIC 1.00

Toluene 5.42 Recovered Toluene 5.15

Phosgene 0.95 Toluene Loss 0.27

Residue 0.07

HCl 1.05

NaCl 0.09


NH2

Cl

F

FF

+O

Cl Cl

N

Cl

O

F

FF

+ 2HCl



PHENYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


Aniline 1.05 PI 1.00




HCl 1.37

NaCl 0.04


NH2 N O

+ +COCl22HCl

Formula Weight = 99.17412 Formula Weight = 125.16834 FW - 73FW - 99



TERT BUTYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

COCl2+ + HCL

N

CH3

CH3

CH3

O

NH2

CH3

CH3

CH3

Toluene

Material Balance


TBA 0.89 TBI 1.00


Caustic 2.09 ODCB 0.8

Sodium Sulfate 0.18 HCl 0.98

Soda Ash 0.18 NaCl 3.03

OCDB (92% Rec.) 0.8




3, 4 DICHLOROPHENYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


DCA 0.88 DCPI 1.00


MCB 4.74 MCB 4.62

NaOH 0.03 MCB Loss 0.12

HCl 1.05

NaCl 0.05


NH2

Cl

Cl

N O

Cl

Cl

+ COCl2 + 2HCl

FW - 99 FW - 73Formula Weight = 162.0166 Formula Weight = 188.01082



3,5 DICHLOROPHENYL ISOCYANATE

Process Description

3, 5-DCA reacts with phosgene in presence of solvent and catalyst. The solution is then

evaporated to give crude product which is distilled off under high vacuum to get pure distilled

product.

Chemical Reaction:

NH2

ClCl+ COCl 2 + 2. HCl

3,5-Dichloroaniline

[3,5-DCA]

3,5-Dichlorophenyl Isocyanate

[3,5-DCPI]

Phosgene

[catalyst]

solvent

N

ClCl

CO

Material Balance:


3,5-DCA 500 3,5-DCPI 534

Toluene for 3,5-DCA 867 3,5-DCPI loss 46

DMF 1.5 Toluene recovery [76%] 1985

Toluene for phosgene 1734 Toluene loss 616

Phosgene 621 Hydrochloric acid 225

Phosgene loss 288

Residue 30

Total 3724 Total Output 3724



4 CHLORO PHENYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


PCA 0.91 4CPI 1.00


NaOH 0.02 MCB Recovery 4.70

MCB 4.82 MCB Loss 0.12

HCl 1.05

NaCl 0.03


NH2

Cl

N O

Cl

+ COCl2 + 2HCl

Formula Weight = 127.57154 Formula Weight = 153.56576FW - 99 FW - 73



p - TOLUENE SULFONYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

Material Balance


P- Toluene Sulfonamide 1.24 PTSI 1.00

Phosgene 1.43 MCB 0.93

MCB (85 % recovery) 0.93 CHI 0.09

CHI 0.09 HCl 1.54


Caustic lye 0.12


CH3

SO O

NH2

+

Cl Cl

O

CH3

S

O

O

N

C

O

+

Para -toluenesulfonamide

M.Wt. = 171.21

Phosgene

M.Wt. = 98.92

Para-Toluenesulfonyl isocyanate

M.Wt. = 197.21

2. HCl

Hydrochloric acid

M.Wt. = 36.5 x 2 = 73



STEARYL ISOCYANATE

Process Description




pure product.

Chemical Reaction

R-NH2 + COCl2 → R-N=C=O + 2 HCl

Material Balance


Stearyl palmityl amine 1.06 SICPIC 1.00

Toluene 0.95 Residue 0.02

Phosgene 1.06 Toluene 0.95

Nitrogen gas 0.43 Nitrogen 0.43

Caustic lye 0.09 HCl 1.04

NaCl 0.15




3 CHLOROPHENYL ISOCYANATE

Process Description

3-Chloroaniline [3-CA] reacts with phosgene in presence of solvent and catalyst. The solution is

then evaporated to give crude product which is distilled off under high vacuum to get pure

distilled product.

Chemical Reaction:

NH2

Cl+ COCl 2 + 2. HCl

3-Chloroaniline [3-CA] 3-Chlorophenyl Isocyanate [3-CPHI]Phosgene

[catalyst]

solvent

N

Cl

CO

Material Balance:

Input (kg) Out put (kg)

3-CA 500 3-CPHI 482

Toluene for 3-CA 867 3-CPHI loss 120

DMF 1.5 Toluene recovery [76%] 1985

Toluene for phosgene 1734 Toluene loss 616


Phosgene loss 189

Residue 25




4 ISOBUTOXYBENZYL ISOCYANATE

Process Description

Basification of 4-isobutoxybenyl amine acetate gives 4-Isobutoxybenzyl Amine, and then it

reacts with phosgene in presence of solvent and catalyst. The solution is then evaporated to

give crude product which was distilled off under high vacuum to get pure distilled product.

Chemical Reaction:

CH3

CH3

O

NH2

AcOH

NaOH / H2O

4-Isobutoxybenzylamine acetate

[IBBAC]

4-Isobutoxybenzylamine [IBBA]

CH3

CH3

O

N C O

CH3

CH3

O

NH2

4-Isobutoxybenzyl Isocyanate

[IBBIC]

COCl2, HCl

Tolune Tolune

Material Balance:


IBBAC 1.00 Aq. layer 2.98

Water 1.60 Sodium acetate 0.34

30% Aq. NaOH solution 1.20 Toluene recovery-I 2.77

Toluene 3.47 Toluene recovery-II 2.77

Water for back wash 0.88 HCl gas liberated 0.46

Toluene 3.47 IBBIC product pure 0.79

Dry HCl gas 0.20 IBBIC product loss 0.02

Phosgene gas 0.62 Residue + toluene + Phosgene

loss 2.11




CARBONATES GROUP

DIMETHYL CARBONATE

Process Description

Methanol is reacted with Phosgene to give Crude Dimethyl Carbonate, which is further distilled

to give pure Dimethyl Carbonate.

Chemical Reaction

CH3OO

CH3

O

dimethyl carbonate

CH3 OH + COCl 2

methanol Phosgene

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

Methanol 0.79 Dimethyl Carbonate (DMC) 1.00

Phosgene 1.34 2 Hydrochloric Acid (2HCl) 0.90

MCF 0.23

Total 2.13 2.13



CHLOROMETHYL ISOPROPYL CARBONATE

Process Description

Chloromethyl Chloroformate is reacted with Isopropyl Amine to give Crude Chloromethyl

Isopropyl Carbonate, which is further distilled to give pure Chloromethyl Isopropyl Carbonate.

Chemical Reaction

O

CH3Cl

O

Methyl Chloroformate

Cl2

Cl O Cl

O

Chloromethyl Chloroformate

IPA / Pyridine

OCl O CH3

CH3O

Chloromethyl isopropyl carbonate

- HCL - HCL

Material Balance


CMCF 1.11 CMIC 1.00

Isopropyl Alcohol 0.48 Pyridine 0.00

Sodium Sulfate 0.00 HCl 0.53

Caustic Soda Lye 0.15 NaCl 0.21

Pyridine 0.00




BIS 4 NITRO PHENYL CARBONATE

Process Description

4 Nitro Phenol is reacted with Phosgene to give crude Bis 4 Nitrophenyl Carbonate, which is

further distilled to give pure Bis 4 Nitrophenyl Carbonate.

Chemical Reaction

Material Balance


4 Nitro Phenol 1.04 BNPCO 1.00

Toluene loss (20%) 1.56 Toluene 1.56

Phosgene 1.21 TEA 0.04

Caustic Lye 1.38 NaCl 2.63

TEA 0.04


OHO2N

4-nitrophenol

+Cl Cl

O

OO2N O

O

NO2+2

Phosgene

2 HCl

bis(4-nitrophenyl) carbonate2 x [139.1] [99] [304.21] 2 x [36.5]



4, 5-DIMETHYL-1, 3-DIOXOLEN-2-ONE

Process Description

Acetone is reacts with Phosgene in presence of N, N Diethyl Aniline to get crude 4, 5-DIMETHYL-

1, 3-DIOXOLEN-2-ONE, which is further distilled to give pure Bis 4 Nitrophenyl Carbonate.

Chemical Reaction

Material Balance


Acetone 1.25 DMDO 1.00


N,NDEA 2.49 N,N DEA 2.49

NaOH 0.04 Aq HCl 3.00

HCl (28%) 3.00 MDC Recovery 9.91

MDC 10.77 MDC Loss 0.86

Toluene 1.77 Toluene Revcovery 1.68

Toluene Loss 0.09

HCl 1.56

NaCl 0.06


O O

CH3 CH3

O

O OH

CH3 CH3

COCl2+ ++N

C2H5H5C2 NC2H5H5C2

HCl

FW - 88.10 FW - 149.23FW - 99 FW - 114.09

HCl+

FW - 185.69 FW - 36.5



4-CHLOROMETHYL-5-METHYL-1, 3-DIOXOL-2-ONE

Process Description

4 Dimethyl 5 Methyl 1, 3 Dioxolen One is reacts with Chlorine in solvent to get crude 4, 5-

DIMETHYL-1, 3-DIOXOLEN-2-ONE, which is further distilled to give pure 4 Chloromethyl 5

Methyl 1, 3 Dioxolen One.

Chemical Reaction

Material Balance


DMDO 1.30 DMDOCl 1.00

MDC 1.45 MDC 1.45

Chlorine Gas 0.86 ODCB 0.35

Caustic 100% 0.27 HCl 0.52

ODCB 0.34 NaCl 0.90


OO

CH3CH3

O

+ Cl ClOO

CH3

O

Cl

+ H Cl



4-(HYDROXY METHYL)-5-METHYL-1, 3-DIOXOL-2-ONE

Process Description

4 Dichloromehtyl 5 Methyl 1,3 Dioxol 2 One is reacts with Formic Acid in presence of Triethyl

Amine to get 4 Hydroxy Methyl 5 Methyl 1,3 Dioxol 2 One & Triethyl Amine Hydrochloride.

Chemical Reaction

Material Balance


DMDOCl 1.64 HMMDO 1.00

Chloroform 6.81 Chloroform 6.81

TEA 2.03 TEA HCl 3.62

Sodium Sulfate 0.03 Methyl Formate 2.56

Formic Acid 0.92 Sodium Sulfate 0.03

Methanol 2.56 Nitrogen 0.12

HCl 0.03

Nitrogen 0.12


O

O

O

CH3

ClO

O

O

CH3

O O

H

TEA

HCOOH + TEA.HCl+



CH2

O

CH3

O

OHCH2O

O

Cl

+

2-Hydroxyethyl 2-methacrylate Vinyl chloroformate 2-Methacryloxyethyl vinyl carbonate

CH2

O

CH3

O

O CH2O

O

+ ClH

[130.1] [106.5] [200.19] [36.5]

2-METHYL CRYLOXY ETHYL VINYL CARBONATE

Process Description

2 Hydroxyethyl 2 Methacrylate reacts with Vinyl Chloroformate to get crude 2 Methyl Cryloxy

Ethyl Vinyl Carbonate and Hydrochloric Acid.

Chemical Reaction

Material Balance


HEMA 1.10 HEMAVC 1.00

VCF 1.33 Pyridine HCl 5.28

Pyridine 0.82 MDC 13.43

HCl 3.04 Silica Gel 1.10

NaCl 3.39 2,5 Dimethyl-p-Benzoquenone 0.00

NaOH 1.06 1,1'-Bis 2 Naphthol 0.00

MDC 13.43 Residue 0.01

Cuprous Chloride 0.00 Cuprous Chloride 0

Sodium Sulfate 0.17 Sodium Sulfate 0.17

2,5 Dimethyl-p-Benzoquenone 0.00 NaCl 3.39

Silica Gel 1.10 NaOH 1.06

1,1'-Bis 2 Naphthol 0.00




DIPHENYL CARBONATE

Process Description

Phenol is reacted with phosgene in the presence of Base to get Solid product Diphenyl

carbonate [DPC].

Chemical Reaction:

OH

+ Na OH +

O

Cl

Cl

O

O

O

+ Na Cl +2 2 2 OH22

PhenolPhosgene Diphenyl carbonate Sodium chlorideSodium hydroxide Water

Material Balance:


Phenol 0.915 Di Phenyl Carbonate (DPC) 1.000

Phosgene 0.734 Sodium chloride soln. (NaCl) 9.350

Caustic lye (48%) 1.096 Residue /(Loss) 0.630



Total 10.980 10.980



BENZIMIDAZOL GROUP (TO BE DISCONTINUED)

2 BENZIMIDAZOL

Process Description

2-Aminoaniline is reacted with Phosgene to give Crude Benzimdazolone which is further

purified to give Pure Benzimdazolone.

Chemical Reaction

Phosgene NH

NH

O

1,3-dihydro-2H-benzimidazol-2-one

NH2

NH2

benzene-1,2-diamine

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

2-Amino Aniline 0.96 2-Benzimdazolone 1.00

Phosgene (COCl2) 0.96 2 Hydrochloric Acid (2HCl) 0.71

Water (H2O) 0.02 Carbon Dioxide (CO2) 0.04

Monochlorobenzene (MCB) 4.80 Monochlorobenzene (MCB) 4.80

Residue 0.19

Total 6.74 6.74



FORSKOLINE CARBONATE (TO BE DISCONTINUED)

Process Description

Forskohlin, Pyridine are reacted with Phosgene in MDC solvent. After reaction completion

Pyridine Hydrochloride is removed by Water washing and MDC is distilled to get the Product

Forskohlin Carbonate.

Chemical Reaction

O

CH3 OH

O

OHCH3

OH

CH3

OCH3

CH2

CH3

H

CH3

O O

CH3 OH

CH3

CH3

CH2

CH3

H

O

OO

O

O

CH3

CH3

O1 9

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

Forskohlin 1.18 Forskohlin Carbonate 1.00

Phosgene (CoCl2) 0.31 Pyridine Hydrochloride 0.66

Pyridine 0.50 Dichloromethane (MDC) 5.31

Dichloromethane (MDC) 5.90 Residue 0.93

Water (H2O) 11.80 Water 11.79

Total 19.69 19.69



CHLORIDES/ACID CHLORIDES GROUP

PIVALOYL CHLORIDE

Process Description

Pivalic Acid is reacted with Phosgene in the presence of Phosgene to give Crude Pivaloyl

Chloride which is further distilled under vacuum to give Pivaloyl Chloride.

Chemical Reaction

CH3

CH3

CH3

OH

O

CH3

CH3

CH3

Cl

O

pivalic acid 2,2-dimethylpropanoyl chloride

COCl2

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

Pivalic Acid 0.94 Pivaloyl Chloride (PVCl) 1.00

Phosgene 0.91 Carbon Dioxide (CO2) 0.41

Hydrochloric Acid (HCl) 0.34

Residue 0.10

Total 1.85 1.85



3 CHLOROPROPIONYL CHLORIDE - 3 CPC

Process Description

Phosgene is passed through acrylic acid and water until reaction is completed. 3-

Chloropropionyl chloride is prepared and purified by distillation.

Chemical Reaction

OH

CH2

O

+Cl Cl

O

H2O

DMF Cl

O

Cl

+ HCl DMF CO2+ +

Acrylic acid

MW: 72.06 g/mol

Phosgene

MW: 98.92 g/mol

3-Chloropropionyl chloride

MW: 72.06 g/mol

Material Balance


Acrylic Acid 0.738 3CPC 1.000


DMF 0.004 CO2 0.723

Water 0.112 Residue 0.120

Loss 0.080

Inter Cut 0.080




ISOBUTYRYL CHLORIDE

Process Description

Iso Butyric Acid reacts with Phosgene under control condition of temperature and pressure, the

resultant mass is degassed to remove free HCl & free Phosgene through scrubber to give Iso

Butyryl Chloride.

Chemical Reaction

Material Balance


Isobutyric acid 1.00 Isobutyryl chloride (IBCL) 1.00

D.M.F. 0.01 Carbon dioxide (CO2) 1.00

Phosgene 2.30 Hydrochloric Acid (HCl) 1.29

Nitrogen 0.10 Residue /(Loss) 0.27

Caustic lye for scrubber 0.15


O

OH

+O

Cl Cl O

Cl

+

Iso butyric acid Phosgene Iso butyrylchloride

CO2 + HCl



5 - CHLOROVALEROYL CHLORIDE

Process Description

Delta-Valerolactone is reacted with Phosgene in presence of catalyst at suitable condition to

give 5-Chlorovaleroyl Chloride.

Chemical Reaction

Material Balance


Delta-Valerolactone 1.00 5-Chlorovaleroyl Chloride (5-CVCL) 1.00

D.M.F. 0.04 Carbon dioxide (CO2) 1.10

Phosgene 2.00 Residue /(Loss) 1.14

Nitrogen 0.10

Caustic lye for scrubber 0.10


Cl

O

Cl

O

O

+O

Cl

Cl

+

Delta-Valerolactone Phosgene 5-Chlorovaleroyl chloride Carbon dioxide

CO2



CHLOROACETYL CHLORIDE

Process Description

Chloroacetic acid react with phosgene in presence of DMF gives Chloroacetyl chloride after high

vacuum distillation of crude Chloroacetyl chloride.

Chemical Reaction:

Cl

O

OH

+ Cl

O

ClCl

O

Cl

+ +ClH CO2

Chloroacetic acid Phosgene Chloroacetyl chloride

Catalyst

Material Balance:


Chloroacetyl chloride 100 Chloroacetyl chloride 84

DMF 5 Chloroacetyl chloride loss 35


Carbon dioxide 47

Phosgene loss 75

Residue 13

Total 293 Total 293



CARBAMATES GROUP

BENZYL CARBAMATE

Process Description

Benzyl Chloroformate (in Toluene) is reacted with Liq. Ammonia at suitable condition to give

Benzyl Carbamate as a Product which is further filtered and washed with water. After filtration

product is dried under vacuum to give Benzyl Carbamate.

Chemical Reaction O

O

Cl

benzyl chlorocarbonate

O

O

NH2

benzyl carbamate

Molecular Formula = C8H7ClO2

Formula Weight = 170.59298

Molecular Formula = C8H9NO2

Formula Weight = 151.16256

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

Benzyl Chloroformate (BCF-50%) 2.54 Benzyl Carbamate (BCM) 1.00

Liq. Ammonia (~25%) 1.21 Ammonium Chloride (NH4Cl) 0.39

Toluene 1.19

Residue 0.20

Ammonia solution 0.97

Total 3.75 3.75



N BUTYL PROPARGYL CARBAMATE

Process Description

Propargyl Alcohol is react with Phosgene under control condition of temperature and pressure

to get Propargyl Chloroformate which is to be further n Butyl Amine to get n Butyl Propargyl

Carbamater.

Chemical Reaction

Material Balance


Propargyl alcohol 0.39 PGCF 0.76

BHT 0.00 Aq. layer 0.92

Phosgene 1.02 Residue /(Loss) 0.51

Water wash 0.78



Propargyl chloroformate 0.76 NBPC 1.00

Sodium carbonate 0.38 Aq. layer 3.51

N-Butyl amine 0.48 Residue /(Loss) 0.17

Water for sodium

carbonate

3.06


OH+

O

ClCl+ H Cl

Propargyl alcohol

M.W.-56.06

Phosgene

M.W.-99

Propargyl chloroformate

M.W.-118.52

Hydrochloric acid

M.W.-36.5

O

O

Cl

O

O

Cl+ NH2

O

O

NHPropargyl chloroformate

[118.52]

n-Butylamine

[73]

n-Butyl propargyl carbamate

[155]

+ ClH

[36.5]



2-METHYL-2-PROPYL-1,3-PROPANEDIOL DICHLOCARBAMATE (90% IN TOLUENE)

Process Description

2-Methyl-2-propyl-1,3-propanediol is reacted with Phosgene (in Toluene), in the presence of

Triethylamine to give 2-Methyl-2-propyl-1,3-propanediol dichlorocarbamate (crude, MPPBC)

and Triethylamine hydrochloride (TEA.HCl). TEA.HCl is then removed by water wash. Toluene

layer separated is distilled under vacuum to get the product, 2-Methyl-2-propyl-1, 3-

propanediol dichlorocarbamate.

Chemical Reaction

HOH2C CH2OH

CH3

CH3

2-methyl-2-propylpropane-1,3-diol

O O

CH3

CH3

ClCl

OO

2COCl2+ Toluene

2-{[(chlorocarbonyl)oxy]methyl}-2-methylpentyl chloridocarbonate

or

2 -methyl- 2 -propyl- 1, 3 propanediol dichlorocarbamate

+ +2 N ( C2H5) 3

2 N ( C2H5) 3. HCL

Material

Balance


2 Methyl 2 Propyl 1,3

Propandiol

0.54 MPPBC 1.00

Toluene loss (8%) 0.85 Toluene 0.85

Triethyl Amine 0.83 TEA HCl 2.54

Phosgene 2.38 Anhy. Sodium Sulfate 0.05

Nitrogen 0.07 Nitrogen 0.07

Caustic 0.47 NaCl 0.68

Anhy. Sodium Sulfate 0.05




3 IODO 2 PROPYNYL N BUTYL CARBAMATE

Process Description

This product is prepared by reacting n-Butyl Propargyl Carbamate with iodine in presence of

sodium hypochlorite.

Chemical Reaction:

O

O

NH

n-Butyl propargyl carbamate

+O

O

NH

I

3-Iodo-2-propynyl butylcarbamateIodine

+

+

1/2 I21/2 NaCl

1/2 H2O

NaOCl

Material Balance:


N-Butyl Propargyl carbamate 0.670 3-Iodo-2-propynyl-N-butyl

carbamate

1.000

Iodine 0.602 Filtrate ML (Aq. With methanol) 10.780

Caustic lye (48%) 0.448 Residue /(Loss) 0.780

Sodium Hypochlorite solution 4.550

Methanol 3.10

Acetic acid 0.670

Sodium Bisulfite 0.035






CARBODIIMIDES GROUP

DICYCLOHEXYL CARBADIIMIDES (DCC)

Process Description

CHA is reacted with Phosgene in the presence of Caustic (at below 60°C) to give Dicyclohexyl

Urea (DCU). DCU is reacted with Phosgene at 15°C to give Chloroformamidinium Salt, which is

further reacted with Ammonia at 0 to 5°C gives DCC.

Chemical Reaction

NH2NH NH

O

N NH

Cl

H Cl

COCl2

- CO2

2NH3

- 2NH4Cl

N NCOCl2

DCU DCC

Material Balance

Step –I


Cyclohexylamine (CHA) 1.37 Dicyelohexylurea (DCU) 1.49

Phosgene (COCl2) 0.68 2 Sodium Chloride (2NaCl) 0.81

2 Sodium Hydroxide (NaOH) 0.55 Water (H2O) 0.25

Impurity 0.05

Total 2.6 2.6

Step –II


Dicyelohexylurea (DCU) 1.49 Dicyclohexylcarbadiimide (DCC) 1.00

Phosgene (COCl2) 0.66 EtOAc 11.32

EtOAc 11.92 Hexane 6.71

Ammonia (NH3) 0.23 Carbon Dioxide (CO2) 0.29

Hexane 7.45 Ammonium Chloride (NH4Cl) 0.71

Residue 1.72

Total 21.75 21.75



PROTECTED AMINO ACIDS GROUP (TO BE DISCONTINUED)

CBZ VALINE

Process Description

L-Valine is reacted in controlled temperature with Benzylchloroformate in diluted Sodium

Hydroxide solution. Toluene is added to the reaction mass and Aq. layer is separated. To the

Aq. Layer Hydrochloride acid is added and product is extracted in Ethyl Acetate. Ethyl Acetate

layer is separated and distilled to get crude product. Crude product is crystallized using

Cyclohexane solvent and after filtration dried to get the pure product.

Chemical Reaction

CH3

CH3 NH2

OH

OO

O

Cl

BenzylchloroformateL -Valine

CH3

CH3

NH

OHO

O

O

+

CBZ -L -Valine

NaOH/H 2O

Material Balance

Input Quantity

(Kg)

Output Quantity

(Kg)

L-Valine 0.583 N-Benzyloxy carbonyl CBZ-L -Valine 0.998

Sodium Hydroxide (NaOH) 0.399 Benzyl Alcohol (BzOH) 0.107

Benzyl Chloroformate (BCF -100%) 0.848 Sodium Chloride (NaCl) 1.053

Hydrochloric Acid -30% (HCl) 0.603 Carbon Dioxide (CO2) 0.044

Sodium Chloride (NaCl) 0.470 Water (H2O) 5.884

Water (H2O) 5.300 Valine 0.117

Total 8.203 8.203



NITRILES GROUP

ACETONITRILE

Process Description

To the solution of Nitro Benzene & Acetamide Phosgene is purged till the reaction mass

becomes clear. After reaction is over, reflux is continued to remove the excess Phosgene and

HCl. The reaction mass is further heated to distill the Acetonitrile as a pure product.

Chemical Reaction

CH3

NH2

O

CH3 CN

acetamideacetonitrile

Nitrobenzene/Phosgene

Material Balance


Acetamide 1.69 Acetonitrile (ACN) 1.0

Phosgene 3.40 Carbon Dioxide (CO2) 1.26

Nitrobenzene 6.76 Hydrochloric Acid (HCl) 2.09

Residue 0.37

Phosgene (COCl2) 0.57

Nitrobenzene 6.56

Total 11.85 11.85



ETHYL 2-(HYDROXYLMINO) CYANOACETATE

Process Description

To a mixture of Ethyl Cyanoacetate, sodium nitrite & water, Acetic acid is added at low

temperature. After completion of addition, mass is heated to get clear solution. Cool the mass

& add HCl at low temperature. Chill the mass & filter. Wash the cake with chilled water. Dry the

cake and packed as final product.

Chemical Reaction

CH3

O

O

N

ethyl cyanoacetate

+ + CH3

O

OH

CH3 O

O

N

N

OH

+ CH3

O

ONa

+ H2O

M.W :-113.11M.W :-142.11

Sodium nitrite

[69]

Ethyl 2-(hydroxyimino)cyanoacetate

NaNO2

Material Balance


Ethyl Cyanoacetate 1.05 EHICA 1.00

Acetic Acid 0.42 HCl 0.97

Sodium nitrite 0.66 Sodium Acetate 1.13

Conc.HCl 0.97




2 CYANO PHENOL

Process Description

The Salicylamide reacted with phosgene in presence of catalyst in solvent at high temperature

followed by crystallization, filtration and drying to isolate the product.

Chemical Reaction:

Material Balance:


Salicylamide 1.00 2-Cyanophenol 0.78

THF 0.00227 CO2 0.32


MCB 9.99 THF 0.00227

MCB Recover 9.19

MCB loss 0.8

Impurity 0.16




2-FLUORO-5-(TRIFLUOROMETHOXY) ANILINE (FTMA) (TO BE DISCONTINUED)

Process Description

1-Chloro-4-(Trifluoromethoxy) Benzene is nitrated in the presence of Nitric Acid and Sulphuric

Acid to give Stage-I. Stage-I is further reacted with Potassium Fluoride and 18-Crown-6 to give

Fluorinated Product (Stage-II) which is further reduced with Pd/Carbon in Toluene to give

(Stage-III) Amine Derivative. Amine Derivative is reacted with Phosgene to give Carbamoyl

Chloride as a product.

Chemical Reaction

OCF3

Cl

OCF3

Cl

NO2

F

NO2

OCF3 OCF3

F

NH2

Material Balance

Stage –I


1-Chloro-4-Trifluoromethoxy

Benzene (CTMB)

5.4 1-Chloro-2-nitro 4-

(trifluoromethoxy) Benzene

(FTMA-I)

6.17

Nitric Acid (HNO3) 3.42 Sulphuric Acid (H2SO4) 32.4

Sulphuric Acid (H2SO4) 32.4 Water (H2O) 7.26

Water (H2O) 5.4 Residue 0.79

Dichloromethane (MDC) 5.4 Dichloromethane (MDC) 5.4

Total 52.02 52.02

Stage –II


1-Chloro-2-nitro 4-

(trifluoromethoxy) Benzene

(FTMA-I)

6.17 1-Fluoro-2-Nitro-

4(trifluoro methoxy)

benzene

1.35

Potassium Fluoride (KF) 1.93 Hydrogen Fluoride (HF) 0.51

18-Crown-6 0.19 Carbonyl Difluoride (COF2) 1.68

Potassium Chloride (KCl) 1.904

Isomer 2.846

Total 8.29 8.29



Stage –III

Input Quantity

(Kg)

Output Quantity

(Kg)

FTMA-III 1.35 2-Fluoro -5-(Trifluoromethoxy) Aniline (FTMA) 1.00

Palladium (Pd/C) 0.01 Palladium (Pd/C) 0.01


Hydrogen 0.04 Toluene 4.26

H2O 0.22

Total 5.88 5.93



POLYMERS GROUP

POLYQUAT

Process Description

Dimethylamine is reacted with Trans-1, 4-Dichlorobutene in Toluene solvent. After reaction

completion Caustic and Sodium Chloride is added in it. Aq. layer is separated. In Toluene layer

after drying with Sodium Sulfate, Methanol is added and azeotropic distillation is done. Residue

obtained is distilled under vacuum to give pure product Tetramethyl -1, 4-Diaminobutene

which is further reacted with 1, 4-Dichlorobutene in the presence of Triethanolamine, Caustic &

Hydrochloric Acid to give product Polyquat.

Chemical Reaction

Cl

Cl

+ NH

CH3

CH3

Toluene

65 oC

CH3

NNCH3

CH3

CH3

water

ClCl

N+

OH

OH

OH

N+

CH3

CH3

N+

OH

OH

OH

n

65oC,6 hrs

trans-1, 4-dichlorobuteneDimethyl amine

Polyquat# 1

+

Triethanolamine



Material Balance

Stage -I

Input Quantity

(Kg)

Output Quantity

(Kg)

Trans-1,4-Dichloro Butane 0.34 Step-I 0.17

Dimethyl Amine 2.9 Toluene+Methanol 19.59


Dil. Sodium Hydroxide (NaOH -40%) 0.54 Water (H2O) 2.61

Sodium Chloride (NaCl) 2.27 Sodium Chloride (NaCl) 2.59

Methanol (MeOH) 17.0

Total 25.78 25.78

Stage -II

Input Quantity

(Kg)

Output Quantity

(Kg)

Step –I 0.17 Polyquat (POL) 1.00

Triethanolamine 0.04 Water 0.35

Water (H2O) 0.88

Trans1,4-Dichloro Butane 0.17

Sodium Hydroxide (NaOH) 0.08

Hydrochloric Acid (HCl) 0.01

Total 1.35 1.35



THIADIAZOLE

5-METHOXY-1, 3, 4-THIADIAZOL-2(3)-ONE [METDO]

Process Description

Stage-1: Potassium Hydroxide is reacted with Methanol and Carbon Disulfide followed by

reaction with Hydrazine Hydrate to get O-Methyl Hydrazine Carbothioate.

Stage-2:- O-Methyl Hydrazine Carbothioate is reacted with Phosgene to give product 5-

Methoxy-1, 3, 4-Thiadiazol -2 (3H) – One (METDO).

Chemical Reaction

+ CH 3OHKOH + 2.H 2O

carbon disulfide

NH 2 - NH 2 . H2O

CH3

O NH

S

NH2

Hydrazine Hydrate

O

Cl Cl

+

+ H2S

Hydrogen sulfide

CH3

O NH

S

NH2

5-methoxy-1,3,4-thiadiazol-2(3H)-onePhosgene

+

Potasium Hydroxide+ KCl

S

N NH

O

OCH3

-2HCl

Stage-1:

Stage-2: 5-Methoxy-1,3,4-Thidiazole-2(3H)-one: [METDO]

HCl

+

O-methyl

hydrazinecarbothioate

CS 2

O-methyl

hydrazinecarbothioate

Methanol



Material Balance

Stage 1:

In put

Raw Material

Qty.

Kg Out put

Qty.

Kg

Potassium Hydroxide 1.28 O-Methyl Hydrazine Carbothioate 11.88

Carbon Disulfide 1.58

Methanol 0.63

Water 3

Hydrazine Hydrate 0.97

HCl 4.42

Caustic Flakes 1.58

Water for Caustic Solution 14.17 Scrubber Solution 15.75

Total 27.63 27.63

Stage 2:

In put

Raw Material

Qty.

Kg Out put

Qty.

Kg

O-Methyl Hydrazine Carbothioate 11.88 METDO 1.00

MDC 5.42 Recovered MDC 3.52

Phosgene 3.53 HCl Gas Generated 2.6

Water 3.64 CO2 Gas Generated 0.84

Methanol 2.67 Aq. Layer Crude 10.783

Mother Liquor 6.05

Loss (Solvent & Other) 1.997

Insoluble Salt 0.35

Total 27.14 Total Output 27.14



ESTERS GROUP

METHYL 3-AMINOCROTONATE

Process Description

Methyl Acetoacetate is reacted with Ammonia to give Methyl 3-Aminocrotonate as a Product.

Chemical Reaction

CH3

O O

O

CH3 NH3+ CH3

O

O CH3

NH2

OH2+

Methyl Acetoacetate Ammonia Methyl 3-aminocrotonate Water

Material Balance

Input

Raw material

Quantity

(Kg)

Output Quantity

(Kg)

Methyl Acetoacetate 1.00 Methyl 3-Aminocrotonate (MAC) 0.72

Liq Ammonia (23%) 0.91 Water 1.2

Methanol 0.59 Ammonia in Water 0.20

Water 0.4 Methanol 0.50

Residue /(Loss) 0.28

Total 2.9 2.9



PHENYL BENZOATE

Process Description

Benzoyl Chloride is reacted with Phenol to give Phenyl Benzoate as a Product.

Chemical Reaction

Cl

O

+OH

O

O

phenyl benzoatephenolbenzoyl chloride

+ ClNa

Sodium chloride

Route of synthesis:-

Na OH

+ OH2

Water

Material Balance

Input

Raw material

Quantity

(Kg)

Output Quantity

(Kg)

Phenol 0.500 Phenyl Benzoate (PHB) 1.00

Benzoyl Chloride 0.750 Sodium Chloride Soln. (NaCl) 4.062

Caustic Lye (48 %) 0.460 Residue /(Loss) 0.148

water 3.500

Total 5.21 5.21



ETHYLENE GLYCOL DI BENZOATE

Process Description

Benzoyl Chloride is reacted with Ethylene Glycol to give Ethylene Glycol Dibenzoate as a

Product.

Chemical Reaction

Cl

O

+

benzoyl chloride

+ ClNa

Sodium chloride

Route of synthesis:-

Na OH

+ OH2

Water

OH

OH

Ethylene glycol

O

O

O

O

2

2

2 2

Ethylene glycol dibenzoate

Material Balance

Input

Raw material

Quantity

(Kg)

Output Quantity

(Kg)

Ethylene Glycol 0.316 Ethylene Glycol Dibenzoate (EGDB) 1

Benzoyl Chloride 1.316 Sodium Chloride Soln. (NaCl) 6.029

Caustic Lye (48 %) 0.895 Residue /(Loss) 0.13

Water 4.632

Total 7.159 7.159



BENZYL CARBAZATE

Process Description

Benzyl Chloroformate is reacted with Hydrazine Hydrate to give Benzyl Carbazate as a product.

Chemical Reaction

Material Balance

Input

Raw material

Quantity

(Kg) Output

Quantity

(Kg)

Benzyl Chloroformate (BCF) 1.00 Methylene Dichloride (MDC) (Recovery) 6.43

80% Hydrazine Hydrate 1.44 Aqueous Layer 4.30

Methylene Dichloride (MDC) 7.14 Residue /(Loss) 2.32

Sodium Sulfate 0.10 Benzyl Carbazate (Product) 0.63

Water 4.00

Total 13.68 13.68



TERT-BUTYL CARBAZATE

Process Description

Tert Butyl Alcohol is reacted with Phenol Chloroformate to give Tert Butyl Phenyl Carbonate as

a Stage-1 (In-situ) which is further reacted with Hydrazine Hydrate to give Tert-Butyl Carbazate

as a product.

Chemical Reaction

Material Balance

Input

Raw material

Quantity

(Kg) Output

Quantity

(Kg)

Tert Butyl Alcohol 1.00 Pyridine-HCl Solution 2.56

Pyridine 1.07 Methylene Dichloride (MDC) (Recovery) 2.36

Methylene Dichloride (MDC) 2.62 Sodium Phenoxide Solution 9.70

Phenyl Chloroformate 2.10 Aqueous Layer 2.10

30% Hydrochloric Acid 0.54 Tert-Butylcarbazate (Product) 1.32

Sodium Sulfate 0.30

80% Hydrazine Hydrate Solution 0.49

Sodium Hydroxide Flakes 0.82

Water 9.10

Total 18.04 18.04



2.3 RAW MATERIAL STORAGE AND HANDLING

The raw materials shall be received in M.S. tank, HDPE/fibre drums, Carboys and cylinders as

well as through tankers. All the storage tanks of hazardous flammable substances shall be

located within premises in separate storage area i.e. Tank farm area. They shall be stored in

MS/SS tank with all precautionary process instrumentation and safety appliances. Large area is

covered by well-designed warehouse, which shall be containing store office, raw material store,

finished product store, etc. The personnel protective equipments like hand gloves, safety shoes,

goggles, helmet, clothing, etc. are provided to those handling hazardous chemicals as per

requirement. All the motors and electrical connections are flame proof. List of raw materials

are given in Table-2.1.

TABLE – 2.1

LIST OF RAW MATERIALS

QUANTITY (MT/Month) SR. NAME OF RAW MATERIAL

Existing Proposed Total

Phosgene

CO2 gas 34.4 68.8 103.2

Chlorine gas 300 600 900

Oxygen 43.2 86.4 129.6

Petroleum Coke 50 100 150

1

Caustic Soda Lye 1.6 3.2 4.8

3,4,4 – Trichlorocarbanilide

4 CPI 25.1 -25.1 0

3, 4 DCA 26.4 -26.4 0

MCB 47 -47 0

Nitrogen Gas 0.05 -0.05 0

2

DMF 0.05 -0.05 0

Carbamyl Chloride

Dimethyl Carbamoyl Chloride 18.8 -5.64 13.16

Dimethyl Amine 50.8 -15.24 35.56

Phosgene Gas 4 -1.2 2.8

Solvent 1.2 -0.36 0.84

Nitrogen 2.8 -0.84 1.96

NaOH 41.6 -12.48 29.12

Diphenyl Carbamoyl Chloride

DPA 34 -10.2 23.8

Phosgene 48 -14.4 33.6

Toluene 145.2 -43.56 101.64

3

NaOH 1.2 -0.36 0.84





Diethyl Carbamoyl Chloride

DEA 22.4 -6.72 15.68

Phosgene 43.2 -12.96 30.24

NaOH 0.4 -0.12 0.28

N Ethyl N Methyl Carbamoyl Chloride

EMA 31.2 -9.36 21.84

Phosgene 68 -20.4 47.6

Toluene 126.4 -37.92 88.48

NaOH 1.6 -0.48 1.12

N Methyl Piperazine Carbamoyl Chloride

NMPCC HCl 22.4 -6.72 15.68

Phosgene 42.4 -12.72 29.68

Chloroform 428.4 -128.52 299.88

NaOH 0.8 -0.24 0.56

N, N Bis 2 Chloroethyl Carbamoyl Chloride

2CEA HCl 40.8 -12.24 28.56

Phosgene 29.2 -8.76 20.44

NaOH 0.4 -0.12 0.28

Morpholine Carbamoyl Chloride

Morpholine 29.6 -8.88 20.72

Phosgene 67.2 -20.16 47.04

Toluene (85 % recovery) 35.6 -10.68 24.92

Nitrogen gas 12 -3.6 8.4

Caustic lye 2.8 -0.84 1.96

Chloroformates

Benzyl Chloroformate

Benzyl Alcohol 167.5 100.5 268

Phosgene Gas 245 147 392

Nitrogen 7.5 4.5 12

Water 210 126 336

NaOH 7.5 4.5 12

Isobutyl Chloroformate

IBA 150 90 240

Phosgene 265 159 424

NaOH 2.5 1.5 4

N Pentyl Chloroformate

n-Pentanol 185 111 296

Phosgene 272.5 163.5 436

NaOH 5 3 8

4

N Hexyl Chloroformate





Hexanol 177.5 106.5 284

Phosgene 357.5 214.5 572

Caustic 17.5 10.5 28

Soda Ash 2.5 1.5 4

Anhy. Sodium Sulfate 2.5 1.5 4

Nitrogen gas 7.5 4.5 12

Phenyl Chloroformate

Phenol 195 117 312


NaOH 5 3 8

Methyl Chloroformate

Methanol 147.5 88.5 236


NaOH 7.5 4.5 12

2 Ethyl Hexyl Chloroformate

EHA 172.5 103.5 276


NaOH 2.5 1.5 4

Cetyl Chloroformate

Cetyl alcohol 212.5 127.5 340

Phosgene 127.5 76.5 204

Myristyl Chloroformate

Myristyl alcohol 205 123 328

Phosgene 142.5 85.5 228

Caustic for scrubber 37.5 22.5 60

Tert-Butyl Cyclohexyl Chloroformate

4-tert-Butylcyclohexanol 197.5 118.5 316

Phosgene 197.5 118.5 316

Caustic for scrubber 37.5 22.5 60

Sec Butyl Chloroformate

Sec-Butanol 142.5 85.5 228

Phosgene 432.5 259.5 692

NaOH

1 Chloro2 Methyl Propyl Chloroformate

Isobutyraldehyde 262.5 157.5 420


MDC 527.5 316.5 844

Pyridine 80 48 128

Sodium Sulphate 12.5 7.5 20

Nitrogen gas 105 63 168





Caustic lye 27.5 16.5 44

Propyl Chloroformate

n-Propylalcohol 50 30 80

Phosgene 164.75 98.85 263.6


Soda ash 0.625 0.375 1

Isopropyl Chloroformate

Iso Propanol 50 30 80

Phosgene 164.75 98.85 263.6


Soda ash 0.625 0.375 1

Vinyl Chloroformates

Caustic Soda Lye 10 0 10

Vinyl Acetate 3.49 0 3.49

CaCO3 1.57 0 1.57

Mercuric Chloride 8.41 0 8.41

Acetone 3.33 0 3.33

Nitrogen Gas 1.25 0 1.25

Water 63 0 63

Nitro Benzene 8.1 0 8.1

Phosgene 4 0 4

5

Isopropenyl chloroformate

4 Nitrophenyl Chloroformate

4-Nitro Phenol 8.6 -4.3 4.3

Phosgene (CoCl2) 8 -4 4

N,N Diethylaniline (NNDEA) 12.1 -6.05 6.05

Dil. Hydrochloric Acid (HCl) 12.7 -6.35 6.35

Sodium Hydroxide (NaOH) 4.1 -2.05 2.05

Water (H2O) 24.6 -12.3 12.3

Toluene 72.7 -36.35 36.35

6

Hexane 120.7 -60.35 60.35

Urea

Diuron

3,4Dichloro Phenylisocyanate 8.62 163.78 172.4

Dimethyl amine 2.59 49.21 51.8

Toluene 52.32 994.08 1046.4

3,4,4 Trichloro Carbanilide

4 CPI 5.02 95.38 100.4

3, 4 DCA 5.28 100.32 105.6

7

MCB 9.4 178.6 188





Nitrogen Gas 0.01 0.19 0.2

DMF 0.01 0.19 0.2

1,3 Diethyl Urea

Ethylamine 8.6 163.4 172

Phosgene (COCl2) 9.5 180.5 190

Toluene 43.1 818.9 862

Tetramethyl Urea

Di methyl amine (40 % solution) 23.75 451.25 475

Phosgene 16.25 308.75 325

Caustic lye (48%) 17.35 329.65 347

Process water for reaction 37.5 712.5 750

Process water for washing 12.5 237.5 250

Dichloro methane (MDC) 65 1235 1300

Tetrabutyl Urea

Di n-butyl amine 5.15 97.85 103

Water 34.5 655.5 690

Phosgene 2.55 48.45 51

Soda ash 4.51 85.69 90.2

HCl (Conc.) 0.58 11.02 11.6

Isocyanates

Trans 4 Methyl Cyclohexyl Isocyanate

T4CHA 59 295 354

Phosgene 78.5 392.5 471

Toluene 215 1075 1290

NaOH 2 10 12

2 Phenyl Ethyl Isocyanate

PEA 57 285 342


Toluene 232.5 1162.5 1395

NaOH 3 15 18

Cyclohexyl Isocyanate

Cyclo Hexyl Amine 49 245 294

Phosgene Gas 86.5 432.5 519

Solvent 5 25 30

Nitrogen 0 0 0

NaOH 2.5 12.5 15

2 Chloroethyl Isocyanate

CEA 60 300 360


8

EDC 309.5 1547.5 1857





NaOH 2 10 12

Isopropyl Isocyanate (75% in Toluene)

IPAM 46.5 232.5 279

Phosgene 141.5 707.5 849

NaOH 3.5 17.5 21

4 Chloro -3 -(Trifluoromethyl) Phenyl

Isocyanate

4-Chloro-3-(trifluoromethyl) Aniline 63 315 378

Toluene 271 1355 1626

Phosgene 47.5 237.5 285

Phenyl Isocyanate

Aniline 52.5 262.5 315

Phosgene 80 400 480

Toluene 150 750 900

NaOH 1.5 7.5 9

Tert Butyl Isocyanate

TBA 44.5 222.5 267

Phosgene 84.5 422.5 507

Caustic 104.5 522.5 627

Sodium Sulfate 9 45 54

Soda Ash 9 45 54

OCDB (92% Rec.) 40 200 240

3,4 Dichlorophenyl Isocyanate

DCA 44 220 264

Phosgene 60.5 302.5 363

MCB 237 1185 1422

NaOH 1.5 7.5 9

3,5 Dichlorophenyl Isocyanate

3,5-DCA 25 125 150

Toluene for 3,5-DCA 43.35 216.75 260.1

DMF 0.075 0.375 0.45

Toluene for phosgene 86.7 433.5 520.2

Phosgene 31.05 155.25 186.3

4 Chloro Phenyl Isocyanate

PCA 45.5 227.5 273

Phosgene 61 305 366

NaOH 1 5 6

MCB 241 1205 1446

P - Toluene Sulfonyl Isocyanate

P- toluene sulfonamide 62 310 372





Phosgene 71.5 357.5 429

MCB (85 % recovery) 46.5 232.5 279

CHI 4.5 22.5 27


Caustic lye 6 30 36

Stearyl Isocyanate

Stearyl palmityl amine 53 265 318

Toluene 47.5 237.5 285

Phosgene 53 265 318


Caustic lye 4.5 22.5 27

3 Chlorophenyl Isocyanate

3-CA 25 125 150

Toluene for 3-CA 43.35 216.75 260.1

DMF 0.075 0.375 0.45

Toluene for phosgene 86.7 433.5 520.2

Phosgene 30 150 180

4 Isobutoxybenzyl Isocyanate

IBBAC 50 250 300

Water 80 400 480

30% aq. NaOH solution 60 300 360

Toluene 173.5 867.5 1041

Water for back wash 44 220 264

Toluene 173.5 867.5 1041

Dry HCl gas 10 50 60

Phosgene gas 31 155 186

Carbonates

Chloromethyl Isopropyl Carbonate

CMCF 22.2 22.2 44.4

Isopropyl Alcohol 9.6 9.6 19.2

Sodium Sulfate 0 0 0

Caustic Soda Lye 3 3 6

Pyridine 0 0 0

Bis 4 Nitro Phenyl Carbonate

4 Nitro Phenol 20.8 20.8 41.6

Toluene loss (20%) 31.2 31.2 62.4

Phosgene 24.2 24.2 48.4

Caustic Lye 27.6 27.6 55.2

TEA 0.8 0.8 1.6

9

4,5-Dimethyl-1,3-Dioxolen-2-One





Acetone 25 25 50

Phosgene 36.2 36.2 72.4

N,NDEA 49.8 49.8 99.6

NaOH 0.8 0.8 1.6

HCl (28%) 60 60 120

MDC 215.4 215.4 430.8

Toluene 35.4 35.4 70.8

4-Chloromethyl-5-Methyl-1,3-Dioxol-2-One

DMDO 26 26 52

MDC 29 29 58

Chlorine Gas 17.2 17.2 34.4

Caustic (100%) 5.4 5.4 10.8

ODCB 7 7 14

4-(Hydroxy Methyl)-5-Methyl-1,3-Dioxol-2-

One

DMDOCl 32.8 32.8 65.6

Chloroform 136.2 136.2 272.4

TEA 40.6 40.6 81.2

Sodium Sulfate 0.6 0.6 1.2

Formic Acid 18.4 18.4 36.8

Methanol 51.2 51.2 102.4

HCl 0.6 0.6 1.2

Nitrogen 2.4 2.4 4.8

2-Methyl Cryloxy Ethyl Vinyl Carbonate

HEMA 22 22 44

VCF 26.6 26.6 53.2

Pyridine 16.4 16.4 32.8

HCl 60.8 60.8 121.6

NaCl 67.8 67.8 135.6

NaOH 21.2 21.2 42.4

MDC 268.6 268.6 537.2

Cuprous Chloride 0 0 0

Sodium Sulfate 3.4 3.4 6.8

2,5 Dimethyl-p-Benzoquenone 0 0 0

Silica Gel 22 22 44

1,1'-Bis 2 Naphthol 0 0 0

Dimethyl Carbonate

Methanol 15.8 15.8 31.6

Phosgene 26.8 26.8 53.6

Diphenyl Carbonate





Phenol 18.3 18.3 36.6

Phosgene 14.68 14.68 29.36

Caustic lye (48%) 21.92 21.92 43.84

Benzimidazol

2 Benzimidazol

2-Amino Aniline 1.92 -1.92 0

Phosgene (CoCl2) 1.92 -1.92 0

Water (H2O) 0.04 -0.04 0

10

Monochlorobenzene (MCB) 9.6 -9.6 0

Forskoline Carbonate

Forskohlin 0.59 -0.59 0

Phosgene (CoCl2) 0.155 -0.155 0

Pyridine 0.25 -0.25 0

11

Dichloromethane (MDC) 2.95 -2.95 0

Chlorides/Acid Chlorides

3 Chloropropionyl Chloride - 3 CPC

Acrylic Acid 16.605 12.915 29.52

Phosgene 36.63 28.49 65.12

DMF 0.09 0.07 0.16

Isobutyryl Chloride

Isobutyric acid 22.5 17.5 40

D.M.F. 0.225 0.175 0.4

Phosgene 51.75 40.25 92

Nitrogen 2.25 1.75 4

Caustic lye for scrubber 3.375 2.625 6

5 - Chlorovaleroyl Chloride

Delta-Valerolactone 22.5 17.5 40

D.M.F. 0.9 0.7 1.6

Phosgene 45 35 80

Nitrogen 2.25 1.75 4

Caustic lye for scrubber 2.25 1.75 4

Pivaloyl Chloride

Pivalic Acid 21.15 16.45 37.6

Phosgene 20.475 15.925 36.4

Chloroacetyl Chloride

Chloroacetyl chloride 2.25 1.75 4

DMF 0.1125 0.0875 0.2

12

Phosgene 4.23 3.29 7.52

Carbamates 13

N Butyl Propargyl Carbamate





Propargyl alcohol 8.775 6.825 15.6

BHT 0 0 0

Phosgene 22.95 17.85 40.8

Sodium carbonate 8.55 6.65 15.2

N-Butylamine 10.8 8.4 19.2

2-Methyl-2-Propyl-1,3-Propanediol

Dichlocarbamate (90% in Toluene)

2 Methyl 2 Propyl 1,3 Propandiol 12.15 9.45 21.6

Toluene loss (8%) 19.125 14.875 34

Triethyl Amine 18.675 14.525 33.2

Phosgene 53.55 41.65 95.2

Nitrogen 1.575 1.225 2.8

Caustic 10.575 8.225 18.8

Anhy. Sodium Sulfate 1.125 0.875 2

Benzyl Carbamate

Benzyl Chloroformate 57.15 44.45 101.6

Liq. Ammonia (~25%) 27.225 21.175 48.4

3 Iodo 2 Propynyl N Butyl Carbamate

N-Butyl Propargyl carbamate 15.075 11.725 26.8

Iodine 13.545 10.535 24.08

Caustic lye (48%) 10.08 7.84 17.92

Sodium Hypochlorite solution 102.375 79.625 182

Methanol 69.75 54.25 124

Acetic acid 15.075 11.725 26.8

Sodium bisulfite 0.7875 0.6125 1.4

Carbodiimides

Dicyclohexyl Carbodiimide - DCC

Cyclohexylamine (CHA) 13.7 -6.85 6.85

Phosgene (CoCl2) 6.8 -3.4 3.4

2 Sodium Hydroxide 5.5 -2.75 2.75

Dicyelohexylurea (DCU) 14.9 -7.45 7.45

Phosgene (CoCl2) 6.6 -3.3 3.3

EtOAc 119.2 -59.6 59.6

Ammonia (NH3) 2.3 -1.15 1.15

14

Hexane 74.5 -37.25 37.25

Protected Amino Acids

CBZ Valine

L-Valine 1.749 -1.749 0

Sodium Hydroxide (NaOH) 1.197 -1.197 0

15

Benzyl Chloroformate 2.544 -2.544 0





Hydrochloric Acid -30% (HCl) 1.809 -1.809 0

Sodium Chloride (NaCl) 1.41 -1.41 0

Water (H2O) 15.9 -15.9 0

Nitriles

Ethyl 2-(Hydroxylmino) Cyanoacetate

Ethyl cyanoacetate 5.25 -4.2 1.05

Acetic Acid 2.1 -1.68 0.42

Sodium nitrite 3.3 -2.64 0.66

Conc.HCl 4.85 -3.88 0.97

Acetonitrile

Acetamide 8.45 -6.76 1.69

Phosgene 17 -13.6 3.4

Nitrobenzene 33.8 -27.04 6.76

2 Cyano Phenol

Salicylamide 5 -4 1

THF 0.01135 -0.00908 0.00227

Phosgene 3.95 -3.16 0.79

16

MCB 49.95 -39.96 9.99

FTMA

1-Chloro-4-Trifluoromethoxy Benzene 5.4 -5.4 0

Nitric Acid (HNO3) 3.42 -3.42 0

Sulphuric Acid (H2SO4) 32.4 -32.4 0

Water (H2O) 5.4 -5.4 0

Dichloromethane (MDC) 5.4 -5.4 0

1-Chloro-2-nitro 4-(trifluoromethoxy)

benzene (FTMA-I)

6.17 -6.17 0

Potassium Fluoride (KF) 1.93 -1.93 0

18-Crown-6 0.19 -0.19 0

FTMA-III 1.35 -1.35 0

Palladium (Pd/C) 0.01 -0.01 0

Toluene 4.48 -4.48 0

17

Hydrogen 0.04 -0.04 0

Polymers

Polyquat

Trans-1,4-Dichloro butane 0.17 0.17 0.34

Dimethyl Amine 1.45 1.45 2.9

Toluene 1.365 1.365 2.73

Dil. Sodium Hydroxide 0.27 0.27 0.54

Sodium Chloride (NaCl) 1.135 1.135 2.27

18

Methanol (MeOH) 8.5 8.5 17





Step –I 0.085 0.085 0.17

Triethanolamine 0.02 0.02 0.04

Water (H2O) 0.44 0.44 0.88

Trans1,4-Dichloro butane 0.085 0.085 0.17

Sodium Hydroxide (NaOH) 0.04 0.04 0.08

Hydrochloric Acid (HCl) 0.005 0.005 0.01

Thiadiazole

5-Methoxy-1, 3, 4-Thiadiazol-2(3H)-One

Potassium Hydroxide 0 25.6 25.6

Carbon disulfide 0 31.6 31.6

Methanol 0 12.6 12.6

Hydrazine Hydrate 0 19.4 19.4

HCl 0 88.4 88.4

Caustic flakes 0 31.6 31.6

water for caustic solution 0 283.4 283.4

O-methyl hydrazine carbothioate 0 237.6 237.6

MDC 0 108.4 108.4

Phosgene 0 70.6 70.6

19

Methanol 0 53.4 53.4

Esters

Methyl 3-Aminocrotonate

Methyl Acetoacetate 0 209 209

Liq Ammonia (23%) 0 190.19 190.19

Methanol 0 123.31 123.31

Phenyl Benzoate

Phenol 0 104.5 104.5

Benzoyl chloride 0 156.75 156.75

Caustic lye (48 %) 0 96.14 96.14

Ethylene Glycol Dibenzoate

Ethylene glycol 0 66.044 66.044

Benzoyl chloride 0 275.044 275.044

Caustic lye (48 %) 0 187.055 187.055

Water 0 968.088 968.088

Benzyl Carbazate

Benzyl Chloroformate (BCF) 0 209 209

80% Hydrazine Hydrate 0 300.96 300.96

Methylene Dichloride (MDC) 0 1492.26 1492.26

Sodium sulfate 0 20.9 20.9

Water 0 836 836

20

Tert Butyl Carbazate





Tert Butyl alcohol 0 209 209

Pyridine 0 223.63 223.63

Methylene dichloride (MDC) 0 547.58 547.58

Phenyl chloroformate 0 438.9 438.9

30% Hydrochloric acid 0 112.86 112.86

Sodium sulfate 0 62.7 62.7

80% Hydrazine Hydrate solution 0 102.41 102.41

Sodium hydroxide flakes 0 171.38 171.38

Water 0 1901.9 1901.9



2.4 INFRASTRUCTURE FACILITIES

2.4.1 LAND

Total 1,19,108 m2

land area is available at site; out of this 65,308 m2 (i.e. approx 55 % of total

area) is developed as greenbelt and other forms of greenery.

2.4.2 TRANSPORTATION FACILITIES

Transportation of all the raw material and products shall be primarily by road only.

2.4.3 WATER AND WASTEWATER

Total fresh water requirement will be 344 KL/Day (Existing: 144 KL/Day + Additional: 200

KL/Day) which shall be met through own bore well. The total wastewater generation will be 245

KL/Day (Industrial: 185 KL/Day + Domestic: 60 KL/Day). Industrial wastewater generation will be

185 KL/Day (Existing: 65 KL/Day + Additional: 120 KL/Day) which shall be treated in ETP and

Final treated effluent shall be disposed to CETP of M/s. Enviro Infrastructure Co. Ltd., Umraya,

Dist: Vadodara. Domestic wastewater generation will be 60 KL/Day (Existing: 30 KL/Day +

Additional: 30 KL/Day) which shall be treated in own STP and then shall be used for land

irrigation. Details of water consumption and wastewater generation are given in Table 2.2.



TABLE - 2.2

WATER CONSUMPTION & WASTEWATER GENERATION (EXISTING)

WATER CONSUMPTION

QUANTITY (KL/DAY) SR. USAGE


A DOMESTIC 30 30 60

B INDUSTRIAL

1 Processing 2 33 35

2 Cooling 35 35 70

3 Washing/ Scrubbing 20 40 60

4 Boiler /DM water/ RO Water 42 42 84

Gardening 10 10 20

Others 5 10 15

TOTAL INDUSTRIAL 114 170 284

TOTAL 144 200 344

WASTEWATER GENERATION

QUANTITY (KL/DAY) SR. USAGE


A DOMESTIC 30 30 60

B INDUSTRIAL

1 Processing 2 33 35

2 Cooling 15 15 30

3 Washing/ Scrubbing 12 32 44

4 Boiler /DM water/ RO Water 33 33 66

Gardening 0 0 0

Others 3 7 10

TOTAL INDUSTRIAL 65 120 185

TOTAL 95 150 245



WATER BALANCE DIAGRAM (EXISTING)

Note: Final treated effluent in existing scenario (i.e. 65 KL/day) is disposed to CETP of M/s. Enviro Infrastructure

Co. Ltd., Umraya, Dist: Vadodara.

Domestic

30 KL/day

Boiler/DM Water/

RO Water

42 KL/day

Washing/

Scrubbing

20 KL/day

Gardening

10 KL/day

Water Consumption

144 KL/day

Domestic

30 KL/day

Cooling

35 KL/day

Wastewater

65 KL/day

Boiler/DM Water/

RO Water

33 KL/day

Washing/

Scrubbing

12 KL/day

Cooling

15 KL/day

ETP

STP

Used for Land

Plantation /

Gardening

Purpose

Process

2 KL/day

Others

5 KL/day

Process

2 KL/day

Sent to CETP

Others

3 KL/day



WATER BALANCE DIAGRAM (TOTAL PROPOSED)

Note: Final treated effluent (i.e. 185 KL/day) after proposed expansion shall also be disposed to CETP of M/s.

Enviro Infrastructure Co. Ltd., Umraya, Dist: Vadodara

Others

10 KL/day

Domestic

60 KL/day

Boiler/DM Water

/RO Water

84 KL/day

Washing/

Scrubbing

60 KL/day

Gardening

20 KL/day

Water Consumption

344 KL/day

Domestic

60 KL/day

Cooling

70 KL/day

Wastewater

185 KL/day

Boiler/DM Water

/RO Water

66 KL/day

Washing/

Scrubbing

44 KL/day

Cooling

30 KL/day

ETP

STP

Used for Land

Plantation /

Gardening

Purpose

Process

35 KL/day

Others

15 KL/day

Process

35 KL/day

Sent to CETP



2.4.3.1 TREATMENT PROCESS

PROCESS DESCRIPTION

HIGH TDS EFFLUENT TREATMENT PLANT:

Following start-up and commissioning procedures to be followed:

1.0 EQUALIZATION TANK:

The HTDS effluent from plant and tank farm shall be taken to equalization tank. The effluent

shall be always under mixing through blower operation. When tank is 65 % full with effluent

start transferring the effluent to neutralization tank.

2.0 NEUTRALIZATION TANK:

The effluent from equalization tank shall be taken to neutralization tank I. The effluent shall be

always under mixing through blower operation. When tank is full with effluent switch the

effluent to neutralization tank II for collection. Neutralize the effluent.

3.0 FLASH MIXER:

Prepare alum solution of 30 % in Dosing tank. Put on the Alum Dosing System. Put on the Flash

mixer agitator

4.0 FLOCCULATOR:

Prepare poly solution of 0.5 TO 1 % in Dosing tank. Put on the Poly Dosing System, Put on the

Flocculator agitator

5.0 TUBE SETTLER:

The effluent from Flocculator will come to tube settler through gravity line. The pH at this stage

shall have to be between 8.0 to 8.5. The clarified water shall go to MEE feed tank. Operate the

sludge valve such as to drain settled sludge at every 3 hrs.

6.0 MEE FEED TANK:

The effluent from Tube settler will come to MEE feed tank through gravity line.

7.0 MULTI EFFECT EVAPORATOR:

Remove Total Dissolve Solid in Multi Effect Evaporator.



LOW TDS EFFLUENT TREATMENT PLANT:

Following start-up and commissioning procedures to be followed:

1.0 EQUALIZATION CUM NEUTRALIZATION TANK (SAMPLING POINT-06):

The effluent from plant and utility and filtrate from filter press shall be taken to equalization

tank. The effluent shall be always under mixing through blower operation. When tank is full

with effluent switch the effluent to equalization tank II for collection.

2.0 FLASH MIXER:

Prepare alum solution of 30 % in Dosing tank. Put on the Alum Dosing System. Put on the Flash

mixer agitator.

3.0 FLOCCULATOR:

Prepare poly solution of 0.1 % in Dosing tank. Put on the Poly Dosing System. Put on the

Flocculator agitator.

4.0 TUBE SETTLER:

The effluent from Flocculator will come to tube settler through gravity line.

5.0 TRIKLING FILTER:

Supernatant of aeration tank shall be kept under recycling mode during start up until actual

effluent is received. During commissioning, the clarified overflow shall be taken to the feed

sump, from where it is to be pumped to trickling filter.

6.0 AERATION TANK:

The treated effluent from feed sump shall be pumped to Aeration Tank after ensuring pH

between 7.5 and 8.5. The COD inlet to Aeration Tank shall be always maintained below 5000

mg/l.

7.0 SECONDARY CLARIFIER (SST):

The effluent from Aeration Tank I will come to SST through gravity line.

8.0 HOLDING TANK:

The supernatant from clarifier will come to holding tank through gravity line.

9.0 TERTIARY TUBE SETTLER:

The treated effluent from holding tank shall be pumped to tertiary tube settler.

Note: After Proposed Expansion, Treatment scheme will remain same only volume will be

increased i.e. it will be modification of Existing ETP.



ETP DIAGRAM



DETAILS OF UNITS

MEE Pre-Treatment HTDS

Equipment List for HTDS

Treatment Units

Size (Meter) Sr. Treatment Unit

L W H

Volume

(m3)

No. of

Tanks MOC Remarks

1 Equilisation Tank 3 3 3.3 29.7 1 RCC Tile Lining

2 Neutralization Tank 3.2 3.2 2.8 28.7 2 RCC Tile Lining

3 Flash Mixer 0.5 1 HDPE

4 Flocculator 0.75 1 HDPE

5 MEE Feed Tank 3 3 3.3 29.7 1 RCC

6 Condensate Collection Tank 3 3 3.3 29.7 1 RCC

Equipments

1 Equilisation Tank (3.0 x 3.0 x 3.3 m)

Blower 2 Capacity 25 m3/Hr; 0.4 kg/cm

2

Diffuser 4 Silicon based Coarse bubble diffuser

2 Neutralization Tank (3.3 x 3.3 x 2.8 m)

Blower 2 Capacity 100 m3/Hr; 0.35 kg/cm

2

Diffuser 8 Silicon based Coarse bubble diffuser

3 Feed Pump 2 Cast Iron, 1.5 m3/hr and 14 mlc

4 Flash Mixer 0.5 kl HDPE Tank

Dosing System 1 PDP Head - pp, flow 0-20 LPH

Agitator 1 100 RPM, Watted part MOC - SS316L and MS Epoxy

5 Flocculator 0.750 Kl HDPE Tank

Dosing System 1 PDP Head - SS316L, flow 0-20 LPH

Agitator 1 20 RPM, Watted part MOC - SS316L and MS Epoxy

6 Lamella Settler 1 Size: 1.6 x 1.6 x 3.3; MOC - MS Epoxy

7 Lamella U-Flow Pump 2 SP, MOC - CI, 5 m3/hr and 30 mlc (to be reviewed)

Size (Meter) Sr. Treatment Unit

L W H

Volume

(m3)

No. of

Tanks MOC Remarks

1 Neutralization Tank 3 3 3.3 29.7 2 RCC Tile Lining

2 Flash Mixer 1.1 - 1.225 1 1 HDPE

3 Flocculator 1.35 - 1.265 1.5 1 HDPE

4 Trickling Filter 5 7.5 147 1 RCC

5 Feed Sump 2 2 2.8 10 1 RCC

6 Aeration Tank 6.7 6.7 5 225 1 RCC

7 Secondary Clarifier 2 - 2.8 8.8 1 RCC

8 Holding Tank 2 2 2.8 10 1 RCC

9 Flocculator 1.35 - 1.265 1.5 1 HDPE



10 Final Collection Tank 6 6 3 108 1 RCC

11 Sludge Sump 2 2 2.8 10 1 RCC

Equipments

1 Neutralization Tank (3.0 x 3.0 x 3.3 m)

Pump 2 Cast Iron, 3 m3/hr and 14 mlc

Blower 2 Capacity 50 m3/hr; 0.4 kg/cm

2

Diffuser 4 Silicon Based coarse bubble diffuser

2 Flash Mixer (1.1 ǿ x 1.225 m)

Dosing System 1 PDP Head-PP, Flow 0-20 LPH

Agitator 1 100 RPM, Watted Part MOC - MS Epoxy

3 Flocculator (1.35 m ǿ x 1.265 m)

Dosing System 1 PDP Head-SS316L, Flow 0-20 LPH



5 Lamella Sludge Pump 2 SP, MOC-CI, 3 m3/hr and 30 mlc

6 Trickling Filter Media PVC, Volume - 120 m3 of packing

7 Trickling Filter Mechanism 2 30 m3/hr, hydraulic feed type

8 Trickling Filter Recycle Pump 2 Cast Iron, 30 m3/hr and 25 mlc

9 Aeration Tank Blower 2 Capacity 300 m3/hr; 0.7 kg/cm

2

10 Aeration Tank Diffuser 30 Silicon Based Fine Bubble Diffusers

11 Secondary Clarifier Mechanism 1 0.08 RPM for 2.0 dia (2.5+0.3), MOC-MS Epoxy

12 Holding Tank Transfer Pump 2 Cast Iron, 2.1 m3/hr and 14 mlc

13 Secondary Clarifier U-Flow

Pump 2 SP, MOC-CI, 10 m

3/hr and 30 mlc

14 Flocculator (1.35 m ǿ x 1.265 m)

Dosing System 1 PDP Head-SS316L, Flow 0-20 LPH



16 Filter Press 1 Vendor Package



CHARACTERISTICS OF EFFLUENT

COD

mg/l

TDS

mg/l pH

SS

mg/l Design

Basis Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet

HTDS 50,000 <5,000 1,00,000 5,000 1-9 6-8 5,000 1,000

LTDS 5,000 <2,000 5,000 -- 6-8 6-8 1,000 600

Colour O&G

mg/l

Cl-

mg/l

SO4-2

mg/l

NH4-N

mg/l Design

Basis Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet

HTDS Yellow Pale

Yellow 70 -- 95,000 2,500 1,000 1,000 3,000 500

LTDS Pale

Yellow -- -- -- 2,500 -- 1,000 -- 500 <50



EXISTING STP PROCESS DESCRIPTION

Collection Well

Sewage from factory & colony flow by gravity & is collected in the Collection Well followed by

BOD Well. The sewage is further pumped to Aeration Tank for biological process.

Aeration Tank

Sewage is subject to suspended aerobic biological treatment in the Aeration Tank. The oxygen

& mixing requirement of Mixed Liquor (ML) of the Aeration Tank consisting of aerobic biomass

is sufficed by surface aerator. The aerobic biomass oxidizes the dissolved & particulate

carbonaceous organic matter into simple end products & additional biomass, as represented by

the following equation for aerobic biological oxidation of organic matter.

Organic Matter + O2 + NH3 + PO4 → micro organism

→ New Cell + CO2 + H2O

Oxygen (O2), Ammonia (NH3) & Phosphate (PO4) are the nutrients need for conversion of the

organic matter to simple end products, i.e., Carbon dioxide (CO2) & water (H2O).

Secondary Settling Tank

The ML from Aeration Tank flows to the Secondary Settling Tank. The ML is subjected to

quiescent state in the Settling Tank, the biological sludge settles at the bottom & clear

supernatant overflow to Treated Water Collection Tank. Portion of the settled sludge is

returned back to Aeration Tank to maintain the MLSS concentration & balance is waste to

Sludge Drying Beds for dewatering & drying.

Treated Water Collection Tank

Treated effluent from secondary treatment is collected in Treated Water Collection Tank is

further subjected to tertiary treatment prior to disposal.

Pressure Sand Filter

The treated wastewater is pumped through Pressure Sand Filter to further remove suspended

solids. The Filter is backwashed periodically by water to maintain the filtration rate.

Sludge Drying Beds

The sludge is subjected to dewatering & drying at the Sludge Drying Beds. The dry biological

sludge is collected stored at Waste Storage Shed for its final disposal. The treated sewage is

disposed on land for plantation.



LIST OF STP UNITS (EXISTING)

Sr.

No.

Name of unit No. of

unit

Dimension in

(meter)

Volume Capacity

(KL)

1 Collection Well 1 2.0 x 8.0 25.12

2 Collection Sump 1 2 X 3 X 4 24.0

3 Aeration tank 1 2.8 X 1.24 X 1.5 5.20

4 Tube Settler 1 1.7 X 0.9 X 1.5 2.30

Collection Tank 1 1 X 1.25 X 1.5 1.87

5 Sludge drying bed 3 2 X 2 X 1.1 4.40

6 Sand Filter 2 -- --

7 Treated Effluent 1 3 X 7 21.00

DIAGRAM OF STP



2.4.4 AIR POLLUTION AND CONTROL SYSTEM

DETAILS OF STACKS & VENTS (Existing):

Sr.

No. Source of Emission

Stack

Height

(meter)

Stack

Diameter

(meter)

Pollution Control

Equipment

Air

Pollutant Concentration

SPM < 150 mg/Nm3

SO2 < 100 ppm 1 3 TPH Boiler 30 1 Bag Filter

NOx < 50 ppm

Phosgene ---

HCl 20 mg/ Nm3 Final Caustic Scrubber

2

Central Scrubber (Alkali

Scrubber)

15 0.4 Caustic Scrubber

Cl2 9 mg/ Nm3

DG Set – 625 KVA (Stand by) 3

DG Set – 320 KVA (Stand by) 10 0.3 Silencer

4 DG Set – 125 KVA (Stand by) 5 0.1 Silencer

SPM

SO2

NOx

< 150 mg/ Nm3

< 100 ppm

< 50 ppm

DETAILS OF STACKS & VENTS (Total Proposed):

Sr.

No. Source of Emission

Stack

Height

(meter)

Stack

Diameter

(meter)

Pollution Control

Equipment

Air

Pollutant Concentration

SPM < 150 mg/ Nm3

SO2 < 100 ppm 1 10 TPH Boiler 60 1 Electro Static

Precipitator (ESP) NOx < 50 ppm

SPM < 150 mg/ Nm3

SO2 < 100 ppm 2 3 TPH Boiler (Stand by) 30 1 Bag Filter

NOx < 50 ppm

Phosgene ---

HCl 20 mg/ Nm3 Final Caustic Scrubber

3

Central Scrubber (Alkali

Scrubber)

15 0.4 Caustic Scrubber

Cl2 9 mg/ Nm3

DG Set – 320 KVA (Stand by) 4

DG Set – 625 KVA (Stand by) 10 0.3 Silencer

5 DG Set – 125 KVA (Stand by) 5 0.1 Silencer

6 DG Set - 1000 KVA (Stand by) 15 0.3 Silencer

SPM

SO2

NOx

< 150 mg/ Nm3

< 100 ppm

< 50 ppm



SCRUBBER SYSTEM

At M/s. Paushak Ltd., Phosgene plant has the following Scrubbing system to reduce the

emission;

Procedure - For Unit no 1:

1. Open suction valve of HCl tank and start HCl pump.

2. Open suction red valve of NaOH tank and start pump.

3. Check circulation in both HCl and NaOH Tower.

4. Whenever we stop the scrubbing system, first stop pump of HCl and NaOH pump.

5. Close suction valve of HCl Tank no and NaOH Tank no.

Procedure - For Unit no 2:

1. Open suction valve of HCl tank and start HCl Pump.

2. Open suction white valve of NaOH Tank and start pump.

3. Check circulation in both HCl and NaOH Tower.

4. Whenever we stop the scrubbing system, first stop pump of HCl and NaOH pump.

5. Close suction valve of HCl Tank and NaOH Tank.

6. Mainly before starting of scrubbing systems following check points are being checked.

CHECK POINTS STANDARD CHECKING FREQUENCY

P.H of NaOH soln. Above 8 Once in a hour

% NaOH in soln. Between 1% to 12% Once in a week

Volume of NaOH solution in tank approximately 2500 lit

Volume of Water in HCL tank approximately 2500 lit

% of HCL in HCL tank. Below 25 % Once in a week

If above one of the first two conditions is not being fulfilled then the NaOH solution is being

drained to ETP and new solution is made. When % HCl exceed 25% then it is being transferred

to HCl Tanker and new water 2500 lits filled in the tank.

Scrubbing Fluid:

1. 2500 lits of H2O for HCl scrubbing system.

2. 13% NaOH solution for NaOH scrubbing system

Stack Height:

After scrubbing of phosgene from HCl and NaOH scrubber, the vent gases are passed through

central scrubbing system which has stack height of 15 m.



PHOSGENE PLANT SCRUBBER SYSTEM

Phosgene Gas from System Vent Unit-1,

Safety valve opening vent

Phosgene Gas From

System Vent Unit-2

Central Caustic

Scrubber

NaOH

Scrubber

No: 3

HCl

Scrubber

No: 1

HCl

Scrubber

No: 2

NaOH

Scrubber

No: 4

NaOH

Sol Tank

NaOH

Sol Tank

HCL Tank



SCRUBBING SYSTEM

Vent Coming from Reactors

4 " HDPE line

4" line to steam ejector

4 " line 4 " line

vent connected to central scr.tower

vent connected to central scr. tower vent connected to central scr. tower

2 " line 2 " line

HE

30 % HCl

HDPE tank

10 % HCl

HDPE tank Caustic

HDPE tank

30 %

HCl

T

O

W

E

R

10 %

HCl

T

O

W

E

R

C

A

U

S

T

I

C

T

O

W

E

R



CENTRAL SCRUBBING SYSTEM

steam ejector

2 " line

Vent

released

at ht. of @

15mtr

Vent from All Plants

Caustic

HDPE tank

C

A

U

S

T

I

C

T

O

W

E

R



2.4.5 NOISE LEVEL AND CONTROL SYSTEM

Extensive oiling and lubrication and preventive maintenance shall be carried out to reduce

noise generation at source to the permissible limit. However, at place where noise levels can

exceed the permissible limit, Earplugs and Earmuffs are provided to those working in such area.

2.4.6 HAZARDOUS WASTE GENERATIONS AND DISPOSAL SYSTEM

Existing & total after proposed expansion hazardous waste generation quantity, physical

characteristics and mode of disposal are given in Table-2.3.



TABLE-2.3

DETAILS OF HAZARDOUS WASTE AND ITS MODE OF DISPOSAL

QUANTITY SR.

NO.

NAME OF WASTE CATEGORY

EXISTING TOTAL AFTER

PROPOSED

EXPANSION

MODE OF DISPOSAL

1 Used Oil 5.1 83 Kg/Month 167 Kg/Month Collection, Storage,

Transportation, Disposal by Selling

to Registered Refiner

2 ETP Sludge 35.3 4.16

MT/Month

12.5 MT/Month

3 MEE Salt 37.3 - 20.83

MT/Month

Collection, Storage,

Transportation, Disposal at TSDF of

NECL, Nandesari

33.3

Nos./Month

125 Nos./Month

4

Discarded

Container

(Drums / Bags)

33.1

666.6

Nos./Month

2,000

Nos./Month

Collection, Storage,

Transportation, Decontamination

& given to registered vendors

5 Spent Carbon 28.3 83 Kg/Month 416.6 Kg/Month

6 Residue & Waste

(from VCF Process)

28.1 0.5 MT/Month 1.67 MT/Month

7 Distillation Residue 20.3 1.67

MT/Month

5 MT/Month

8 Distillation Residue

(from

contaminated

organic solvents)

36.1 3.75

MT/Month

11.25

MT/Month

Collection, Storage, Transportation

& given for co-processing in

cement industries/RSPL, Panoli or

disposal at CHWIF of NECL,

Nandesari

9 Toxic Metal

residue (from

water purification

plant)

26.1 416 Kg/Month 833 Kg/Month Collection, Storage, Transportation

& Disposal at TSDF of NECL,

Nandesari/RSPL, Panoli

10 Hydrochloric Acid

(30 %)

- 500

MT/Month

1500

MT/Month

11 FeCl2 - 0.5 MT/Month 1.5 MT/Month

12 Recovered

Mercury

- 3.6 MT/Month 7.2 MT/Month

13 Recovered

Mercury Chloride

- 3.6 MT/Month 7.2 MT/Month

Collection, Storage, Transportation

& Sell to authorized end users



2.5 DETAILS OF UTILITIES

Various utilities required for proper functioning of manufacturing plants. These utilities include

boiler, cooling plant, Cooling tower, DM water plant, Chilling Plant & Brine Unit, Air

compressor, High Vacuum System, etc.

SR.

NO.

NAME OF EUIPMENT TYPE CAPACITY

1 F O Fired IBR Boiler Fire tube Boiler 3 TPH, 10.5 Kg/cm2

2 Solid Fuel Fired IBR Boiler Fire tube Boiler 10 TPH, 10.5 Kg/cm2

3 KC 4 Compressor 1 Reciprocating 30 TR



6 Voltas 04 Chilled Reciprocating 30 TR

7 Voltas 05 Brine Reciprocating 30 TR

8 Air Compressor #1 Reciprocating 670 m3/hr



11 Cooling Tower 1 (For Utility) Forced Draft 250 TR

12 Cooling Tower 2 (For Plant) Forced Draft 250 TR

13 Boiler Feed Water Plant MSRL (Manually) 3.5 m3/hr

14 DG Set (Stand by Arrangement) Piston, LDO (320 + 625) KVA

15 DG Set (Stand by Arrangement) Piston Diesel/LDO 125 KVA

16 DG Set (Stand by Arrangement) Piston Diesel/LDO 1000 KVA



2.6 ELECTRICITY & FUEL REQUIREMENT

TOTAL POWER REQUIREMENT (KW)

Sr. Scenario Total

1 Existing 1,200 KW

2 Total after Proposed Expansion 3,000 KW

SOURCE OF POWER (KW)

Sr. Scenario SEB/Grid DG Set

1 Existing MGVCL 620 KVA, 325 KVA & 125 KVA (used in emergency only)

2 Total after

expansion

MGVCL 1000 KVA + 620 KVA + 325 KVA & 125 KVA (shall be used

in emergency only)

DETAILS ON FUEL & SOURCE (EXISTING + PROPOSED)

Consumption Sr. Fuel


1 Bio Mass (Agro Waste) or FO or Coal (MT/Day) 30 30 60

2 LDO (Lit./Day) 5,400 5,400 10,800

3 Diesel (Lit./Day) 15 15 30

Documents

M/s. PAUSHAK LTD. PLOT NO.: 135, 136, 145, 146, 147, 229