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1
FORM-1
for
PROPOSED API & API INTERMEDIATES IN
EXISTING PIGMENT UNIT
of
M/s. AMAR PIGMENTS
PLOT NO. 3012-3013, PHASE – III, GIDC PANOLI,
DIST: BHARUCH-394116 (GUJ.)
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
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
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
2
APPENDIX I
(See paragraph - 6)
FORM 1
Sr.
No.
Item Details
1. Name of the project/s M/s. Amar Pigments
2. S. No. in the schedule 5(f)
3. Proposed capacity/ area/ length/ tonnage
to be handled/ command area/ lease area/
number of wells to be drilled
Please refer Annexure – I
4. New/Expansion/Modernization Expansion
5. Existing Capacity/Area etc. Total Proposed Capacity: 40 MT/Month
6. Category of Project i.e. ‘A’ or ‘B’ A
7. Does it attract the general condition? If yes,
please specify.
Yes. Located within 5 km of critically
polluted area (Ankleshwar).
8. Does it attract the specific condition? If yes,
please specify.
No
Location
Plot/Survey/Khasra No. Plot No. 3012-3013
Village GIDC Panoli
Tehsil Ankleshwar – 394 116
District Bharuch
9.
State Gujarat
10. Nearest railway station/airport along with
distance in kms.
Railway Station: Ankleshwar (5 km)
Airport: Surat (60 km)
11. Nearest Town, city, District Headquarters
along with distance in kms.
Panoli Village (2 km),
Bharuch (20 km)
12. Village Panchayats, Zilla Parishad, Municipal
Corporation, local body (complete postal
address with telephone nos. to be given)
Panoli Village, Taluka: Ankleshwar – 394 116,
Dist: Bharuch (Gujarat)
13. Name of the applicant M/s. Amar Pigments
14. Registered Address Plot No. 3012-3013, GIDC Panoli, Tal:
Ankleshwar, Dist: Bharuch-394116 (Guj)
Address for correspondence:
Name Mr. Vinubhai M. Dobaria
Designation (Owner/Partner/CEO) Partner
Address M/s. Amar Pigments
Plot No. 3012-3013, GIDC Panoli, Tal:
Ankleshwar, Dist: Bharuch (Guj)
Pin Code 394 116
15.
E-mail [email protected],
3
Telephone No. Phone : 02646 –650947, 272756
Mob. : +919824407734
Fax No. --
16. Details of Alternative Sites examined, if any.
Location of these sites should be shown on
a top of sheet.
NA
17. Interlinked Projects NA
18. Whether separate application of interlinked
project has been submitted?
NA
19. If yes, date of submission NA
20. If no, reason NA
21. Whether the proposal involves
approval/clearance under: if yes, details of
the same and their status to be given.
(a) The Forest (Conservation) Act, 1980?
(b) The Wildlife (Protection) Act, 1972?
(c) The C.R.Z. Notification, 1991?
No
22. Whether there is any Government
Order/Policy relevant/relating to the site?
No
23. Forest land involved (hectares) NA
24. Whether there is any litigation pending
against the project and/or land in which the
project is propose to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if any
and its relevance with the proposed
project.
NA
• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,
mining lease area and production capacity for mineral production, area for mineral
exploration, length for linear transport infrastructure, generation capacity for power
generation etc.,)
4
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of with approximate quantities
frates, wherever possible) with source of
information data
1.1 Permanent or temporary change in land
use, land cover or topography including
increase intensity of land use (with
respect to local land use plan)
No Proposed expansion is within the existing
premises of GIDC Panoli. Expected cost of the
project is Rs. 3.75 Crores.
Total Plot Area = 2,000 m2
Green Belt = 200 m2
1.2 Clearance of existing land, vegetation
and Buildings?
No Proposed expansion is within the existing
premises of GIDC Panoli.
1.3 Creation of new land uses? No
1.4 Pre-construction investigations e.g.
bore Houses, soil testing?
No
1.5 Construction works? Yes Plant Layout attached as Annexure - II
1.6 Demolition works? No
1.7 Temporary sites used for construction
works or housing of construction
workers?
No
1.8 Above ground buildings, structures or
earthworks including linear structures,
cut and fill or excavations
No Plant Layout attached as Annexure - II
1.9 Underground works mining or
tunneling?
No
1.10 Reclamation works? No
1.11 Dredging? No
1.12 Off shore structures? No
1.13 Production and manufacturing
processes?
Yes For detail Please refer Annexure –III
1.14 Facilities for storage of goods or
materials?
Yes Specified storage area shall be provided for
storage of goods, Raw materials & Finished
products.
1.15 Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes For detail please refer Annexure – IV & V
1.16 Facilities for long term housing of
operational workers?
No
1.17 New road, rail or sea traffic during
Construction or operation?
No
1.18 New road, rail, air waterborne or other
transport infrastructure including new
or altered routes and stations, ports,
airports etc?
No
1.19 Closure or diversion of existing
transport routes or infrastructure
No
5
leading to changes in Traffic
movements?
1.20 New or diverted transmission lines or
Pipelines?
No
1.21 Impoundment, damming, culverting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water form
ground or surface waters?
No No ground water shall be used. The raw water
shall be supplied by GIDC Authority.
1.24 Changes in water bodies or the land
surface Affecting drainage or run-off?
No
1.25 Transport of personnel or materials for
construction, operation or
decommissioning?
Yes Transportation of personnel, raw material and
products will be primarily by road only
1.26 Long-term dismantling or
decommissioning or restoration works?
No
1.27 Ongoing activity during
decommissioning which could have an
impact on the environment?
No
1.28 Influx of people to an area either
temporarily or permanently?
No This is a well developed GIDC Estate and due to
the expansion of this project, M/s. Amar
Pigments will give direct employment to local
people based on qualification and
requirement. In addition to direct employment,
indirect employment shall generate ancillary
business to some extent for the local
population.
1.29 Introduction of alien species? No
1.30 Loss of native species or genetic
diversity?
No
1.31 Any other actions? No
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
Sr.
No.
Information/checklist confirmation Yes/No Details there of (with approximate quantities
frates, wherever possible) with source of
information data
2.1 Land especially undeveloped or
agricultural land (ha)
No GIDC land of 2,000 m2.
2.2 Water (expected source & competing
users) unit: KLD
Yes The entire water requirement will be met
through GIDC. Water available from GIDC. For
detail please refer Annexure – VI
2.3 Minerals (MT) No
6
2.4 Construction material: stone, aggregates,
and / soil (expected source – MT)
Yes Construction materials like crushed stones, sand,
rubble, cement, steel, etc. required for the
project shall be procured from the local market of
the region.
2.5 Forests and timber (source – MT) No
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel
(MT), energy (MW)
Yes For detail please refer Annexure – VI
2.7 Any other natural resources (use
appropriate standard units)
No
3. Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
Yes For detail please refer Annexure –VII.
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
No
3.4 Vulnerable groups of people who could
be affected by the project e.g. hospital
patients, children, the elderly etc.
No
3.5 Any other causes No
(II) Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
4.1 Spoil, overburden or mine wastes No
4.2 Municipal waste (domestic and or
commercial wastes)
No
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Please refer Annexure – V
4.4 Other industrial process wastes No
4.5 Surplus product No
4.6 Sewage sludge or other sludge from
effluent treatment
Yes
Please refer Annexure – V
7
4.7 Construction or demolition wastes No
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes Yes
Please refer Annexure – V
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr.)
Sr.
No.
Information/Checklist
confirmation
Yes/No Details there of (with approximate quantities/rates,
wherever possible) with source of information data
5.1 Emissions from combustion of
fossil fuels from stationary or
mobile sources
Yes For details Please refer Annexure – VIII
5.2 Emissions from production
processes
Yes For details Please refer Annexure – VIII
5.3 Emissions from materials handling
storage or transport
Yes All liquid raw materials shall be procured
in tankers and shall be transferred through a closed
circuit pipe lines.
Solid raw materials shall be charged through close
pipeline into reactors and the dust collection hopper
shall be connected to a bag filter and ID fan.
Also all the hazardous chemicals storage tanks will be
provided with flame arrestors & breather valves for
safety.
5.4 Emissions from construction
activities including plant and
equipment
Yes During construction work, only dust contamination will
be there, water sprinklers shall be utilized whenever
necessary.
5.5 Dust or odours from handling of
materials including construction
materials, sewage and waste
Yes Solvent vapors shall be cooled in appropriate
condensers and shall be passed through trap vessel
fitted with condensers. All the waste shall be stored in
designated place and shall be transported to TSDF site
in approved closed vehicles owned by the TSDF
authority.
Dust from drying will be collected in to dust collector
through cyclone separator & recovered powder will be
recycled back to process. Air Handling Unit will be
provided where ever applicable.
5.6 Emissions from incineration of No 5.7 Emissions from burning of waste
in open air e.g. slash materials,
construction debris)
No
5.8 Emissions from any other sources No
8
(III) Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data with source of
information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes All machinery / equipment shall be well
maintained, shall be proper foundation with
anti vibrating pads wherever applicable and at
noise levels within permissible limits. DG set
shall have acoustic enclosure. Expected Noise
level at different locations in the plant is
enclosed as Annexure – IX
6.2 From industrial or similar processes Yes Please refer Annexure – IX
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational traffic No
6.6 From lighting or cooling systems Yes Please refer Annexure – IX
6.7 From any other sources No
7. Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
7.1 From handling, storage, use or spillage
of hazardous materials
Yes Hazardous material shall be stored in designated
storage area with bund walls for tanks. Other
material will be stored in bags/drums on pallets
with concrete flooring and no spillage is likely to
occur. All liquid raw materials shall be
transported through pumps and closed pipelines
and no manual handling shall be involved. Spill
Container will be kept at appropriate places to
collect spillage. SOP for collection,
decontamination & disposal of spilled material
will be displaced at necessary locations. For
details please refer Annexure – VII
7.2 From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
Yes The neutralized low COD effluent after primary
treatment will be sent to the CETP of M/s PETL,
Panoli for the further treatment and final
disposal. The neutralize high COD effluent after
primary treatment will be sent to the Common
Spray Dryer of M/s PETL, Panoli for the further
9
treatment and final disposal.
7.3 By deposition of pollutants emitted to
air into the and or into water
No
7.4 From any other sources No
7.5 Is there a risk of long term build up of
pollutants in the environment from
these sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with source
of information data
8.1 From explosions, spillages, fires etc
from storage, handling, use or
production of hazardous substances
Yes For detail please refer Annexure – VII
8.2 From any other causes No
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No
9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Sr.
No.
Information/Checklist confirmation
Yes/
No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
9.1 Lead to development of supporting. utilities,
ancillary development or development stimulated
by the project which could have impact on the
environment e.g.
• Supporting infrastructure (roads, power supply,
waste or waste water treatment, etc.)
• housing development
• extractive industry
• supply industry
• other
Yes For detail please refer Annexure – X
9.2 Lead to after-use of the site, which could have an
impact on the environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to proximity to other
existing or planned projects with similar effects
No
10
(IV) Environmental Sensitivity
Sr.
No.
Areas Name/
Identity
Aerial distance (within 15km.) Proposed
project location boundary
1 Areas protected under international
conventions, national or local legislation
for their ecological, landscape, cultural
or other related value
No Proposed Expansion project site is within the
GIDC Estate of Panoli
2 Areas which important for are or
sensitive Ecol logical reasons –
Wetlands, watercourses or other water
bodies, coastal zone, biospheres,
mountains, forests
No
3 Area used by protected, important or
sensitive Species of flora or fauna for
breeding, nesting, foraging, resting,
over wintering, migration
No
4 Inland, coastal, marine or underground
waters
No No inland, costal or marine within 5 km from
the proposed project
5 State, National boundaries No 6 Routes or facilities used by the public
for access to recreation or other tourist,
pilgrim areas
No
7 Defense installations No
8 Densely populated or built-up area - Panoli Village
9 Area occupied by sensitive man-made
land uses Hospitals, schools, places of
worship, community facilities)
No
10 Areas containing important, high quality
or scarce resources (ground water
resources, surface resources, forestry,
agriculture, fisheries, tourism, minerals)
No
11 Areas already subjected to pollution
environmental damage. (those where
existing legal environmental standards
No
12 Areas susceptible to natural hazard
which could cause the project to
present environmental problems
(earthquakes, subsidence, landslides,
flooding, erosion, or extreme or adverse
climatic conditions)
No
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – XI
11
12
LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE
I List of Products with their Production Capacity
II Layout Map of the Plant
III Brief Manufacturing Process Description
IV Description of Effluent Treatment Plant with flow diagram
V Details of Hazardous Waste
VI Water, Fuel & Energy Requirements
VII Details of Hazardous Chemicals Storage & Handling
VIII Details of Stacks and Vents
IX Expected Noise level at Different source within the premises
X Socio-economic Impacts
XI Proposed Terms of Reference for EIA studies
XII GIDC Letter for Water Consumption
XIII NCTL Membership Letter for Wastewater Disposal
13
ANNEXURE-I
LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY
Production Capacity (MT/Month) Sr.
No.
Name of Product
Existing Total After Proposed
Expansion
1 Pigment Beta Blue 3.5 0
2 α-Phenyl-2-Pyridyl Acetonitrile -
3 α-Phenyl-2-Pyridyl Acetamide -
4 L-(+) 4-Nitro Tartranilic Acid -
5 9-Methyl-1,2,3,9-Tetrahydro-4H-
Carbazol-4-One
-
6 2,2’,4’-Trichloro Acetophenone -
7 1-(2,4-Dichloro Phenyl)-2-(1H-
Imidazol-yl) Ethanol
-
8 Ritanilic Acid -
9 α-Phenyl-2-Piperidyl Acetamide -
10 P-Chloro Benzophenone -
11 P-Chlorobenzhydryl Chloride -
12 p-Chlorobenzhydryl Piperazine -
13 2-[4-(4-Chlorobenzhydryl)-1-
Piperazinyl] Ethanol
-
14 Lamotrigine -
15 Roxithromycin EP/BP -
40
Total 3.5 40
Note: Pigment Beta Blue (Existing Product) shall be discontinued after proposed expansion
14
LIST OF RAW MATERIAL
SR.
NO.
PRODUCT WISE RAW MATERIALS QUANTITY
(MT/MT)
1. Pigment Beta Blue
Crude CPC 1.20
Rosin 0.04
Xylene or MCB 0.01
Dispersing Agent 0.01
Caustic Flakes 0.06
HCl 0.09
2. α-Phenyl-2-Pyridyl Acetonitrile
2-Chloro Pyridine 0.67
p-Chloro Benzyl Cyanide 0.77
Sodamide 0.50
Toluene 2.70
Methanol 1.50
Sulfuric Acid 0.85
3. α-Phenyl-2-Pyridyl Acetamide
α-Phenyl-2-Pyridyl Acetonitrile 1.12
Sulfuric Acid 5.60
Sodium Hydroxide 4.50
Iso Propyl Alcohol 3.00
4. L-(+) 4-Nitro Tartranilic Acid
L-(+)-Tartaric Acid 0.85
Acetic Anhydride 2.70
P-Nitro Aniline 0.62
Ethylene Dichloride 6.00
Sodium Hydroxide 1.05
Hydrochloric Acid 3.50
5. 9-Methyl-1,2,3,9-Tetrahydro-4H-Carbazol-4-One
1,3 Cyclohexane Dione 1.00
Phenyl Hydrazine Hydrochloride 1.65
Hydrochloric Acid 7.50
Methanol 2.00
Dimethyl Sulphate 1.08
Methylene Dichloride 6.00
Sodium Hydroxide 0.42
TBAB 0.05
15
6. 2,2’,4’-Trichloro Acetophenone
1,3 Dichloro Benzene 0.72
Chloro acetyl Chloride 0.63
Aluminum Chloride 0.65
7. 1-(2,4-Dichloro phenyl)-2-(1H-Imidazol-1yl)Ethanol
2,2’,4’-Trichloro Acetophenone 0.90
Sodium Borohydride 0.05
Methanol 0.30
Toluene 2.00
DMSO 0.70
Sodium Hydroxide 0.21
Imidazole 0.26
8. α-Phenyl-2-Piperidyl Acetamide
α-Phenyl-2-Pyridyl Acetamide 1.10
Acetic Acid 6.60
Pd on Charcoal 0.10
Sodium Hydroxide 0.30
9. DL-Ritanilic Acid
α-Phenyl-2-Piperidyl Acetamide 1.00
Iso Butanol 4.00
Sodium Hydroxide 1.50
Hydrochloric Acid 3.75
Activated Charcoal 0.05
10. P-Chloro Benzophenone
Benzoyl Chloride 0.83
Mono Chlorobenzene 0.67
Aluminum Chloride 0.80
Methanol 3.00
Sodium Hydroxide 0.24
11. P-Chlorobenzhydryl chloride
P-Chloro Benzophenone 1.00
Methanol 1.00
Sodium Borohydride 0.07
Hydrochloric Acid 2.00
Sodium Hydroxide 0.40
12. P-Chlorobenzhydryl Piperazine
P-Chloro Benzhydryl Chloride 1.00
Piperazine 1.24
Toluene 3.00
16
Hydrochloric Acid 1.00
Sodium Hydroxide 1.00
13. 2-[4-(4-Chlorobenzhydryl)-1-Piperazinyl]Ethanol
P-Chloro Benzhydryl Piperazine 0.87
2-Chloro Ethanol 0.52
Toluene 3.20
Tri Ethyl Amine 0.80
Sodium Hydroxide 0.10
14. Lamotrigine
Sulfuric Acid 20.10
Amino Guanidine bicarbonate 2.05
Acetonitrile 3.95
2.3 DBN 2.00
Sodium Hydroxide 1.30
N-Propanol 73.40
Hyflow 0.20
15. Roxithromycin BP/EP
Methoxy Ethoxy Methyl Chloride 0.20
Sodium Methoxide 0.09
Oxime base 1.09
Acetone 5.44
17
ANNEXURE-II
LAYOUT MAP OF THE PLANT
N
18
ANNEXURE-III
BRIEF PROCESS DESCRIPTION
Pigment Beta Blue
Process Description
Charge the required quantity of CPC blue in the ball mill to prepare fine powder. Because of
heat generation while ball milling, it is required to be kept cooled through the jacketed
recirculation system of water. The mass thus prepared is refluxed. In a reactor the ground
CPC is refluxed with water, rosin, dispersing agent, caustic soda and solvent. On completion
of the reaction, the refluxed mass is distilled out to recover unreacted Xylene. The pH is
corrected to neutral using small quantity of HCL if required. Then slurry of each batch is
subsequently filtered and washed. The wet cake is dried, pulverized and packed.
Flow Chart
19
α-Phenyl-2-Pyridyl Acetonitrile
Process Description
In an S.S.Reactor 2-Chloro Pyridine reacts with Benzyl Cyanide in the presence of Sodamide
and the solution worked up to give Nitrile Compound.
Chemical Reaction
STAGE-1
N Cl
+
CN
+ NaNH2Toluene NH3NaCl
N
CN
+ +
M.Wt.:113.54 M.Wt.:117.15 M.Wt.: 39.01 M.Wt.: 194.23 M.Wt.: 58.44 M.Wt.: 17.03
NH3
M.Wt.:34.06
2
By Product Generate in Scrubber
+
M.Wt.:98.08
H2SO
4 (NH4)2SO
4
M.Wt.:132.14
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
2-Chloro Pyridine 67.0 Kgs α-Phenyl-2-Pyridyl Acetonitrile 100.0 Kgs
p-Chloro Benzyl Cyanide 77.0 Kgs Toluene Recovery 250.0 Lts
Sodamide 50.0 Kgs Toluene Loss 20.0 Lts
Toluene 270.0 Kgs Methanol Recovery 135.0 Lts
Methanol 150.0 Lts Methanol Loss 15.0 Lts
Water 400.0 Lts Residue 20.0 Kgs
Water For Scrubber 260.0 Lts Waste Water 469.0 Kgs
Sulfuric acid For Scrubber 85.0 Kgs Ammonium Sulfate Solution 350.0 Kgs
Total 1359.0 Kgs Total 1359.00 Kgs
20
α-Phenyl-2-Pyridyl Acetamide
Process Description
α-Phenyl-2-Pyridyl Acetonitrile hydrolyses with Sulfuric Acid which is treated with NaOH and
gives α-Phenyl-2-Pyridyl Acetamide.
Chemical Reaction
M.Wt.: 18.02
2N
CN
M.Wt.: 194.23
+
M.Wt.:98.08
H2SO
4
NaOH
IPA
OH2
M.Wt.:142.04
Na2SO4N
CONH2
+
M.Wt.: 212.25M.Wt.: 80.00
+ OH2
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
α-Phenyl-2-Pyridyl
Acetonitrile
112.0 Kgs α-Phenyl-2-Pyridyl Acetamide 100.0 Kgs
Sulfuric acid 260.0 Kgs IPA Recovery 270.0 Lts
Sodium Hydroxide 350.0 Kgs IPA Loss 30.0 Lts
Iso Propyl Alcohol 300.0 Lts residue 15.0 Kgs
Water 1000.0 Lts Waste water (Sodium Sulfite
solution)
1607.0 Kgs
Total 2022.0 Total 2022.0
21
L-(+) 4-Nitro Tartranilic acid
Process Description
Acetic Anhydride react with L-(+) Tartatic Acid and convert to Diacetate Tartaric Anhydride
which is reacted with p-Nitro Aniline and convert to L-P-Nitro Diacetyl Tartarate and after
hydrolyze with Sodium Hydroxide and acidify with HCl gives L-(+) 4-Nitro Tartranilic Acid.
Chemical Reaction
STAGE-1
COOH
COOH
OH H
H OH CH3
CH3
O
O
O
O
O
O
O
O
CH3
CH3
O
O3
CH3COOH4
M.Wt.: 240.22+
+
M.Wt.: 306.27M.Wt.: 150.09 M.Wt.: 216.14
STAGE-2
O
O
O
O
O
CH3
CH3
O
O
NH2
NO2
NH
COOH
O
O
O
CH3
CH3
O
O
NO2
+
M.Wt.: 138.12 M.Wt.: 354.26
EDC
M.Wt.: 216.14
+ NaOHNH
COONa
O
O
O
Na
Na
NO25 + CH3 COONa2
M.Wt.: 200.0 M.Wt.: 336.14
M.Wt.: 164.06
+
M.Wt.: 54.06
OH23
ClH
M.Wt.: 182.3
NH
COOH
O
OH
OH
NO2 + CH3 COOH2 Na Cl+ +5
5
M.Wt.: 270.20
M.Wt.: 120.1
M.Wt.: 292.2 M.Wt.: 54.06
OH23
22
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Stage-1
L-(+)-Tartaric Acid 85.0 Kgs Stage-1 110.0 Kgs
Acetic Anhydride 270.0 Kgs Acetic Acid (R) 235.0 Kgs
Residue 10.0 Kgs
Total 355.0 Kgs Total 355.0 Kgs
Stage-2
Stage-1 110.0 Kgs PNTA 100.0 Kgs
P-Nitro Aniline 62..0 Kgs EDC Recovery 540.0 Lts
Ethylene Dichloride 600.0 Lts Loss Of EDC 60.0 Lts
Sodium Hydroxide 105.0 Kgs Residue 10.0 Kgs
Hydrochloric Acid 350.0 Kgs Waste Water 710.00Lts
Water 600.0 Kgs
Total 1827.0 Kgs Total 1827.00
23
9-Methyl-1, 2, 3, 9-Tetrahydro-4H-Carbazol-4-One
Process Description
1,3 Cyclohexane Dione react with Phenyl Hydrazine HCl and convert in to 3-(2-
Phenylhydrazino) cyclohex-2-en-1-one which is cyclize in acidic media and convert to 9-
Methyl-1,2,3,9-Tetrahydro-4H-Carbazol-4-One and methylation of 1,2,3,9-Tetrahydro-4H-
Carbazol-4-One by Dimethyl Sulphate in Alkaline media is convert in to 9-Methyl-1,2,3,9-
Tetrahydro-4H-Carbazol-4-One.
Chemical Reaction
STAGE-1
O
O
NH
NH2
ClH
++
NH
O
ClH
M.Wt.: 112.13 M.Wt.: 144.60
M.Wt.: 36.46
M.Wt.: 185.22
+ ClH NH4Cl
M.Wt.: 18.02
OH2+
M.Wt.: 53.49M.Wt.: 36.46
STAGE-2
N
H
O
M.Wt.: 185.22
+ (CH3)2SO4 + NaOH
M.Wt.: 40.0M.Wt.: 126.13
N
O
CH3
MDC
M.Wt.: 199.25
+ CH3
OH
M.Wt.: 32.04
NaHSO4+
M.Wt.: 120.06
24
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Stage-1
1,3 Cyclohexane Dione 100.0 Kgs Stage-1 100.0 Kgs
Phenyl Hydrazine
Hydrochloride
165.0 Kgs Methanol Recover 235.0 Kgs
Hydrochloric Acid 750.0 Lts Methanol Loss 10.0 Kgs
Methanol 200.0 Lts Residue 10.0 Kgs
Water 1000.0 Lts Waste Water 1860.0 Kgs
Total 2215.0 Kgs Total 2215.0 Kgs
Stage-2
Stage-1 100.0 Kgs 9-Methyl-1,2,3,9-Tetrahydro-
4H-Carbazol-4-One
100.0 Kgs
Dimethyl Sulphate 108.0 Kgs MDC Recovery 540.0 Lts
Methylene Dichloride 600.0 Lts Loss of EDC 60.0 Lts
Sodium Hydroxide 42.0 Kgs Residue 5.0 Kgs
TBAB 5.0 Kgs Waste Water 650.0 Lts
Water 500.0 Kgs
Total 1355.0 Kgs Total 1355.0 Kgs
25
2, 2’, 4’-Trichloro Acetophenone
Process Description
1, 3 Dichlorobenzene react with Chloro Acetyl Chloride in presence of Aluminum Chloride
and gives 2, 2’, 4’-Trichloro Acetophenone
Chemical Reaction
Cl
Cl
+ Cl CH2 COCl
M.WT.: 133.34
AlCl3
CCl CH2
Cl
Cl
O
+ AlCl3
M.WT.: 133.34
M.WT.: 223.48M.WT.: 112.94
M.WT.: 147.00
ClH
M.Wt.: 36.46
+
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
1,3 Dichloro Benzene 71.5 Kgs 2,2’,4’-Trichloro
Acetophenone
100.0 Kgs
Chloro acetyl chloride 63.0 Kgs AlCl3 Solution 500.0 Kgs
Aluminum Chloride 65.0 Kgs Water 599.5 Kgs
Water 1000.0 Kgs
Total 1199.5 Kgs Total 1199.5 Kgs
26
1-(2, 4-Dichloro phenyl)-2-(1H-Imidazol-1yl) Ethanol
Process Description
Reduction of 2,2’,4’-Trichloro Acetophenone by Sodium Borohydride produce Alcohol
compound and there after react with Imidazole in Alkaline media gives 1-(2,4-Dichloro
Phenyl)-2-(1H-Imidazol-1yl)Ethanol
Chemical Reaction
C ClCH2
Cl
Cl
O
M.WT.: 223.48
+ NaBH4
M.WT.: 37.81
NaBH2
M.WT.: 35.81
MeOH
Toluene
CH ClCH2
Cl
Cl
OH
+
M.WT.: 225.50
NaOH
M.Wt.: 40.0
DMSON
NH
M.Wt.: 68.08
CH NCH2
Cl
Cl
OH
N
+ NaCl + OH2
M.Wt.: 257.12
M.Wt.: 58.44 M.Wt.: 18.02
27
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Stage-1
2,2’,4’-Trichloro
Acetophenone
90.0 Kgs Stage-1 90.0 Kgs
Sodium Borohydride 5.15 Kgs Toluene (Recovery) 190.0 Lts
Methanol 30.0 Lts Toluene Loss 10.0 Lts
Toluene 200.0 Lts Water 335.15 Lts
Water 300.0 Lts
Total 625.15 Kgs Total 625.15 Kgs
Stage-2
Stage-1 90.0 Kgs 1-(2,4-Dichloro phenyl)-2-
(1H-Imidazol-1yl) Ethanol
100.0 Kgs
DMSO 70.0 Lts Water 607.0 Kgs
Sodium hydroxide 21.0 Kgs
Imidazole 26.0 Kgs
water 500.0 Kgs
Total 707.0 Kgs Total 707.0 Kgs
28
α-Phenyl-2-Piperidyl Acetamide
Process Description
Catalytic Reduction of α-Phenyl-2-Pyridyl Acetamide in presence of Pd gives α-Phenyl-2-
Piperidyl Acetamide
Chemical Reaction
N
CONH2
+ H2Pd on charcoal
Acetic Acid
NH
CONH2
M.Wt.: 212.25 M.Wt.: 218.29M.Wt.: 2.02
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
α-Phenyl-2-Pyridyl Acetamide 110.0 Kgs Stage-1 100.0 Kgs
Acetic Acid 660.0 Lts Pd on Charcoal reuse in next
batch
9.9 Kgs
Pd on Charcoal 10.0 Kgs Acetic Acid (Recovery) 600.0 Lts
Sodium Hydroxide 30.0 Kgs Acetic Acid Loss 60.0 Lts
Water 800.0 Lts Water 840.1 Lts
Total 1610.0 Kgs Total 1610.0 Kgs
29
DL-Ritanilic Acid
Process Description
Hydrolysis of α-Phenyl-2-Piperidyl Acetamide in alkaline media gives Ritanilic Acid
Chemical Reaction
NH
CONH2
Na OH+
NH
COOH
ClH
M.Wt.: 72.92
+ OH2 + NH4Cl
M.Wt.: 53.49
+
M.Wt.: 58.44M.Wt.: 219.18M.Wt.: 218.29
M.Wt.: 40.0 M.Wt.: 18.02
+ OH2
M.Wt.: 18.02
2Na Cl
Isobutanol
Mass Balance
INPUTS for 100.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
α-Phenyl-2-Piperidyl
Acetamide
100.0 Kgs Ritanilic Acid 100.0 Kgs
Iso Butanol 400.0 Lts Iso Butanol 370.0 Lts
Sodium Hydroxide 150.0 Kgs Iso Butanol Loss 30.0 Lts
Hydrochloric Acid 375.0 Kgs Activated Charcoal 5.0 Kgs
Activated Charcoal 5.00 Kgs Water 1725.0 Kgs
Water 1200.0 Lts
Total 2230.0 Kgs Total 2230.0 Kgs
30
p-Chloro Benzophenone
Process Description
In Glass line reactor charge Monochloro Benzene & Aluminium Chloride at RT then slowly
adds Benzoyl Chloride into reaction mass at 48ºC & Stir for 3 hrs. Then heat to 100ºC and
maintain for 2 hrs. Then add slowly water into reaction mass (during addition of water
generate HCl gas – scrub with NaOH soln. using scrubber) separate p-Chloro Benzophenone.
Chemical Reaction
Stage-1
ClO
+
Cl
M.WT.: 133.34
AlCl3
O
Cl
+
M.WT.: 140.57 M.WT.: 112.66M.WT.: 216.66
ClH
M.Wt.: 36.46
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
Benzoyl Chloride 415.0 Kgs p-Chloro Benzophenone 500.0 Kgs
Mono Chlorobenzene 333.0 Kgs Methanol 1430.0 Lts
Aluminum Chloride 400.0 Kgs Alcl3 Solution (25%) 1000.0 Kgs
Methanol 1500.0 Lts Water 1338.0 Kgs
Water (Scrubber) 600.0 Lts Residue 30.0 Kgs
Sodium Hydroxide (Scrubber) 120.0 Lts
Water 900.0 Lts
Total 4268.0 Kgs Total 4268.0 Kgs
31
p-Chlorobenzhydryl Chloride
Process Description
In Reactor charge MeOH and p-Chloro Benzophenone and cool to 25˚C ,then slowly add
Sodium Borohydride and maintain for 4 hr, there after distilled out MeOH and charge
hydrochloric acid and stir the mass for 6 hr. discard acidic layer and collect p-
Chlorobenzhydryl Chloride.
Chemical Reaction
O
Cl
M.WT.: 216.66
+ NaBH4
M.WT.: 37.81
OH
Cl
M.WT.: 218.68
NaBH2+
M.WT.: 35.81
MeOH
ClH
M.Wt.: 36.46Toluene
Cl
Cl
M.WT.: 237.12
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
p-Chloro Benzophenone 500.00 Kgs p-Chloro Benzhydryl chloride 500.0 Kgs
Methanol 500.0 Lts Methanol 470.0 Lts
Sodium Borohydride 35.0 Kgs Water 1735.0 Kgs
Hydrochloric Acid 1000.0 Kgs Residue 30.0 Kgs
Sodium Hydroxide 200.0 Kgs
Water 500.0 Lts
Total 2735.0 Kgs Total 2735.0 Kgs
32
p-Chlorobenzhydryl Piperazine
Process Description
IN reactor charge Toluene, p-Chlorobenzhydryl Chloride and Piperazine into heat to 70ºC &
maintain for 3 hrs. Then add HCl at RT & product extract with HCl & side up Toluene layer
and recover for next batch. Product contains HCl charge into reactor & adjusts 9 pH by
NaOH soln. & centrifuge the product and dry at 50ºC.
Chemical Reaction
Cl
Cl
M.WT.: 237.12
NH
N
H
+
M.WT.: 86.14
TolueneNaOH
M.Wt: 40.00
Na Cl OH2
M.Wt.:58.44 MWt: 18.02
+
N
Cl
NH
+ +
M.WT.: 286.80
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
P-Chloro Benzhydryl chloride 500.0 Kgs P-Chloro Benzhydryl
Piperazine
500.0 Kgs
Piperazine 620.0 Kgs Toluene 1420.0 Lts
Toluene 1500.0 Lts Piperazine 400.0 Kgs
Hydrochloric acid 500.0 Kgs NaOH Sol 900.0 Kgs
Sodium Hydroxide 500.0 Kgs Water 1380.0 Kgs
Water 1000.0 Lts Residue 20.0 Kgs
Total 4620.0 Kgs Total 4620.0 Kgs
33
2-[4-(4-Chlorobenzhydryl)-1-Piperazinyl] Ethanol
Process Description
S.S.R. to be clean and dry. Charge Toluene, p-Chloro Benzhydryl Piperazine, Triethyl Amine
and 2-Chloro Ethanol at RT. Then heat up to reflux and maintain reflux for 8 hr. Then
distilled out toluene completely & collect product.
Chemical Reaction
Stage-1
N
Cl
NH
+
M.WT.: 286.80
NaOH
M.Wt: 40.00
OH Cl +
M.WT.: 80.51
Toluene
Tri Ethyl AmineN
Cl
N
OH
OH2
M.Wt.:58.44
MWt: 18.02
+ Na Cl
M.WT.: 330.85
+
Mass Balance
INPUTS for 500.0 Kgs Out Puts
RM QTY Product & By Product &
waste
QTY
p-Chloro Benzhydryl
Piperazine
435.00 Kgs p-Chloro Benzhydryl
Piperazine
500.0 Kgs
2-Chloro Ethanol 260.0 Kgs Toluene 1520.0 Lts
Toluene 1600.0 Lts TEA reuse in Next Batch 380.0 Kgs
Tri Ethyl Amine 400.0 Lts Water 1345.0 Kgs
Sodium Hydroxide 50.0 Kgs
Water 1000.0 Lts
Total 3745.0 Kgs Total 3745.0 Kgs
34
Lamotrigine
Process Description
Amino Guanidine bicarbonate is reacted 2,3 DBN & then purified in n-Propanol.
Chemical Reaction
35
Mass Balance
Stage - 1
Raw Material In Put Quantity
Kgs
Product Out Put Quantity
Kgs
Out Put Details
4113.0
9326.0
2512.5
15359.8Aqueous Effluent Process water
Process water for cake
wash Sulphuric Acid
256.3 752.0Aqueous Wash
Dichloro Benzoyl Nitrile 250.0 115water loss in drying
Acetonitrile 4.0 235Output
235
Total 16461.8 16461.8
Stage - 2
Raw Material In Put Quantity
Kgs
Product Out Put Quantity
Kgs
Out Put Details
1026.2 6.1
3.1 1026.2
62.0 8.06
Spent carbon + Hyflow
Dilute n-Propanol
vapor loss on Drying
n-Propanol
Activated carbon
Lamotrigine (Stage-I)
Hyflo 3.0 53.94 Output
53.94
Total 1094.3 1094.3
Stage - 3
Raw Material In Put Quantity
Kgs
Product Out Put Quantity
Kgs
Out Put Details
n-Propanol 5192.1 21.8 Spent carbon + Hyflow
Activated carbon 18.8 5192.1 Dilute n-Propanol
Lamotrigine (Stage-I) 375.0 48.75 vapor loss on Drying
Hyflo 3.0 326.25 Output
Total 5588.8 5588.8
36
Roxithromycin
Process Description
Erythromycin Thiocyanate reacts with liq. Ammonia in presence of methylene chloride to
give Erythromycin base. Methylene chloride is separated and distilled off. Residual
Erythromycin base reacts with Hydroxyl Amine Hydrochloride and Triethyl Amine in
presence of Methanol to give Erythromycin Oxime Hydrochloride. Methanol is distilled out
and Erythromycin Oxime Hydrochloride reacts with Liq. Ammonia in presence of
Isopropanol to give Erythromycin Oxime Base.
Erythromycin Oxime Base reacts with sodium Methoxide and Methoxy Ethoxy methylene
chloride in presence of acetone to give Roxithromycin Crude. Roxithromycin crude is
purified in methanol to give Roxithromycin pure.
Chemical Reaction
37
Mass Balance
38
ANNEXURE-IV
TREATMENT PROCESS
Details of Effluent Treatment Plant along with flow diagram
Stream I (Low COD & TDS Stream) = 17.33 KL/Day
First all non-toxic and biodegradable streams (low & medium COD & TDS) of wastewater
shall pass through Screen Chamber where floating material shall be removed with help of
Screen. Then effluent shall be passed through Oil & Grease Removal Tank. Automatic
mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and grease
from the wastewater to Oil & Grease Collection Tank. Then effluent shall be collected in
Collection cum Equalization tank-1. Pipe grid is provided at bottom of the CET-01 to keep all
suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1W+1
stand-by) shall supply air through to pipe grid.
Then after, equalized wastewater shall be pumped to Neutralization Tank-1 where the
continuous addition and stirring of Caustic solution is done to maintain neutral pH of
wastewater from Caustic Dosing Tanks as per requirement by gravity. Then after,
neutralized wastewater shall go to Flash Mixer-1 by gravity. Alum and Polyelectrolyte shall
be dosed from Alum Dosing Tank and Polyelectrolyte Dosing Tank respectively by gravity
into FM-1 to carry out coagulation by using a Flash Mixer. Then after, coagulated
wastewater shall be settled in Primary Clarifier. Treated effluent will be sent to CETP of
PETL, Panoli for further treatment.
Stream II (High COD & TDS Stream) = 1.67 KL/Day
High COD effluent shall be passed through collection cum neutralization tank where the
continuous addition and stirring of Caustic solution is done to maintain neutral pH of
wastewater from Caustic Dosing Tanks as per requirement by gravity. Treated neutral
effluent will be sent to Common Spray Dryer facility of PETL, Panoli for further treatment.
39
FLOW DIAGRAM OF ETP:
Screen Chamber Oil & Grease
Trap
Collection cum
Equalization
Tank
Neutralization
Tank
Primary Settling
Tank
CETP of PETL,
Panoli
Common
Spray Dryer
of PETL,
Panoli
Raw Effluent
Low COD
Collection cum
Neutralization
Tank
High COD
40
SIZE OF TANKS
S.N. Name of unit Size (m x m x m) No. MOC/ Remark
Stream I (Low COD & TDS Stream) 17.33 KL/Day
1 Screen Chamber 2.5 x 1.0 x (0.05 +0.3 FB) 1 RCC M25+A/A Bk.
Lining
2 Collection cum Equalization
Tank-1
3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
3 Neutralization Tank 3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
4 Flash Mixer-1 0.8 x 0.8 x (1.5 LD +0.5 FB) 1 RCC M25
5 Primary Clarifier 2.0 x 1.2 x (2.0 LD + 0.75
HB+ 0.5 FB)
1 RCC M25
6 Aeration Tank-1 7.0 x 5.2x (3.5 LD +0.5FB) 1 RCC M25
7 Secondary Clarifier-1 2.0 x 1.2 x (2.0 LD + 0.75
HB+ 0.5 FB)
1 RCC M25
Stream II (High COD & TDS Stream) 1.67 KL/Day
1 Collection cum
Neutralization Tank-1
3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)
PCC = PLAIN CEMENT CONCRETE
PP = POLYPROPELENE
MSEP = MILD STEEL EPOXY PAINTED
SS = STAINLESS STEEL
41
EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-I)
Sr.
No.
Category of Wastewater Before Treatment After Treatment
1 pH 3.5-6.5 6.5-8.0
2 COD (mg/L) 5,500 1,000
3 BOD3 (mg/L) 1,700 300
4 TDS (mg/L) 3,500 3,200
5 Ammonical Nitrogen (mg/L) 30 20
EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-II)
Sr.
No.
Category of Wastewater Before Treatment
1 pH 2-10
2 COD (mg/L) 55,000
3 BOD3 (mg/L) 12,000
4 TDS (mg/L) 40,000
5 Ammonical Nitrogen (mg/L) 300
42
ANNEXURE-V
HAZARDOUS WASTE GENERATION AND DISPOSAL
Generation Sr.
No
Type of Waste Category
Existing Total
Proposed
Mode of Treatment & Disposal
1. ETP Waste 35.3 0.017
MT/Month
5
MT/Month
Collection, Storage, Transportation &
Sent to TSDF site of M/s. PSWML,
Panoli or M/s. BEIL, Ankleshwar
2. Used Oil 5.1 1.67
Lit/Month
18
Lit/Month
Collection, Storage, Transportation &
Sale to registered re-processor or use
for lubrication within premises
3. Spent Carbon 28.3 - 0.09
MT/Month
Collection, Storage, Transportation &
co-processing in cement industries or
Send to TSDF of M/s. PSWML, Panoli
or M/s. SEPL, Jambusar or M/s. BEIL,
Ankleshwar
4. Empty Bags 33.1 12
Nos/Month
40
Nos/Month
Collection, Storage, Transportation,
Decontamination & sale to
registered vendors
5. Discarded Containers
33.1 - 30
Nos/Month
Collection, Storage, Transportation,
Decontamination & sale to
registered vendors
6. Discarded Liners
33.1 - 50
Nos/Month
Collection, Storage, Transportation,
Decontamination & sale to
registered vendors
7. Distillation Residue 36.1 - 3
MT/Month
Collection, Storage, Transportation &
Sent to Common Incineration of M/s.
SEPPL, Dahej or M/s. BEIL,
Ankleshwar or cement industries for
Co-Processing
8. AlCl3 Soln. - - 80
MT/Month
Collection, Storage & Sold to end
users
43
ANNEXURE-VI
_______________________________________________________________________
WATER, FUEL & ENERGY REQUIREMENT
WATER CONSUMPTION AND WASTEWATER GENERATION
Water Consumption
(KL/Day)
Waste Water
Generation (KL/Day)
Sr.
No.
Category
EXISTING TOTAL
PROPOSED
EXISTING TOTAL
PROPOSED
1. Domestic 1 2 0.7 1.4
2. Other (Gardening) NIL 1 NIL NIL
3. Industrial
Process 1.5 21.5 1.2 19
Boiler 1.5 2 0.2 0.3
Cooling NIL 0.5 NIL 0.3
Washing 11 12 11 12
Total Industrial 14 36 12.4 31.6
Grand Total 15 39 13.1 33.0
44
WATER BALANCE DIAGRAM (EXISTING)
Domestic
1
Boiler
1.5
Washing
11
Water Consumption
15
Domestic
0.7
Wastewater
13.1
Boiler
0.2
Washing
11
ETP
Process
1.5
Sent to PETL, Panoli
Process
1.2
All Figures in KL/Day
Septic Tank/Soak Pit
45
WATER BALANCE DIAGRAM (TOTAL PROPOSED)
All Figures in KL/Day
Domestic
2
Boiler
2
Washing
12
Water Consumption
39
Domestic
1.4
Cooling
0.5
Wastewater
29.93
Boiler
0.3
Washing
12
Cooling
0.3
ETP
Process
21.5
Sent to PETL, Panoli
Process
19
Gardening
1
High COD &
High TDS �
1.67
Common Spray
Dryer of PETL,
Panoli for further
treatment
Septic Tank/Soak Pit
46
TOTAL POWER REQUIREMENT & SOURCE OF POWER
Power requirement will be 125 HP which will be taken from DGVCL. 1 No. of 62 KVA DG Set
will be kept for emergency power back up.
FUEL REQUIREMENT
SR.
NO.
NAME OF FUEL QUANTITY
1 Natural Gas 700 Nm3/day
2 LDO 500 Lit/day
47
ANNEXURE-VII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
Quantity Sr.
No.
Name of Hazardous
Chemicals Max.
That can be
stored
State Operating
Pressure &
Temp.
Type of
Hazard
Possible
(Fire, Explosion, etc.)
Remarks
1 2-Chloro Pyridine 500 kg NTP Harmful HDPE DRUM
2 Benzyl Cyanide 500 kg NTP Harmful HDPEDRUM
3 Sodium Amide 250 kg NTP Flammable MSDRUM
4 Toluene 1000 kg NTP Flammable MSDRUM
5 Methanol 1000 kg NTP Flammable MSDRUM
6 Sulfuric Acid 1000 kg NTP Corrosive CARBOYS
7 Sodium Hydroxide 300 kg NTP Corrosive BAGS
8 Iso Propyl Alcohol 1000 kg NTP Flammable MSDRUM
9 L-(+)-Tartaric Acid 500 kg NTP Harmful BAGS
10 Acetic Anhydride 1000 kg NTP Flammable MSDRUM
11 P-Nitro Aniline 500 kg NTP Harmful BAGS
12 Ethylene Dichloride 1000 kg NTP Flammable MSDRUM
13 Hydrochloric Acid 1000 kg NTP Flammable MSDRUM
14 1,3 Cyclohexane Dione 250 kg NTP Corrosive, Harmful BAGS
15 Phenyl Hydrazine
Hydrochloride
250 kg NTP Corrosive, Harmful BAGS
16 Dimethyl Sulphate 500 kg NTP Corrosive, Harmful HDPEDRUM
17 Methylene Dichloride 1000 kg NTP Flammable MSDRUM
18 1,3 Dichloro Benzene 1000 kg NTP Flammable MSDRUM
19 Chloro acetyl chloride 1000 kg NTP Flammable MSDRUM
20 Aluminium Chloride 500 kg NTP Corrosive, Harmful BAGS
21 Sodium Borohydride 50 kg NTP Corrosive,
Flammable
MS CARBOY
22 DMSO 500 kg NTP Flammable MSDRUM
48
23 Imidazole 500 kg NTP Corrosive, Harmful BAGS
24 Acetic Acid 1000 kg NTP Flammable MSDRUM
25 Pd on Charcoal 20 kg NTP Flammable CARBOY
26 Iso Butanol 750 kg NTP Flammable MSDRUM
27 Activated Charcoal 100 kg NTP - BAGS
28 Monochlorobenzene 750 kg NTP Irritant MS DRUM
29 Benzoyl Chloride 250 kg NTP Corrosive, Irritant HDPE DRUM
30 Piperazine 500 kg NTP Corrosive, Irritant BAGS
31 2-Chloro Ethanol 500 kg NTP Harmful HDPEDRUM
32 Tri Ethyl Amine 500 kg NTP Harmful MSDRUM
49
ANNEXURE-VIII
_______________________________________________________________________
DETAILS OF STACKS & VENTS
Details of Flue Gas Emissions
Sr. No. Source of
Emission
Type of
Emission
Stack Height
(meter)
Stack
Diameter
(meter)
Pollution Control
Equipment
1 Boiler SPM, SO2,
NOx
15 0.5 -
2 Process Vent-1 SO2,
HCl, HBr
15 0.3 Two stage
Scrubber
3 Process Vent-1 NH3 15 0.3 Two stage
Scrubber
50
ANNEXURE-IX
_______________________________________________________________________
EXPECTED NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES
Various sources of noise in industry have been identified as under,
• Pumps
• Boiler
• Reaction vessel
The typical noise levels of equipments, as indicated by the equipments manufacturers are
given below:
Sr. No. Name of Machinery / Units Noise level, dB(A)
1 Pumps 60 – 65
2 Boiler 65 – 75
3 Reaction Vessel 55 – 60
EXPECTED NOISE LEVELS:
SR.
NO.
SOURCE OF NOISE PERMISSIBLE LIMIT
(DAY/NIGHT)
dB (A)
EXPECTED NOISE
LEVEL dB (A)
1. Near Security Gate 75/70 60
2. Near Administration Building 75/70 60
3. Near Boiler & Utility Block 75/70 65
4. Near ETP 75/70 65
5. Near Process Plant 75/70 65
6. Near Canteen 75/70 50
• DG set with acoustic enclosure, housed in a separate room, erected on anti vibrating
pad.
• Ear muffs are provided to the operators.
• Regular preventive maintenance of equipments will be carried out.
51
ANNEXURE-X
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SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
During construction phase, skilled and unskilled manpower will be needed. This will
temporarily increase the employment opportunity. Secondary jobs are also bound to be
generated to provide day-to-day needs and services to the work force. This will also
temporarily increase the demand for essential daily utilities in the local market. The
manpower requirement for the proposed diversification is expected to generate some
permanent jobs and secondary jobs for the operation and maintenance of plant. This will
increase direct / indirect employment opportunities and ancillary business development to
some extent for the local population. This phase is expected to create a beneficial impact on
the local socio-economic environment.
2) INDUSTRIES
During construction of the project, the required raw materials and skilled and unskilled
laborers will be utilized maximum from the local area. The increasing industrial activity will
boost the commercial and economic status of the locality, to some extent.
3) PUBLIC HEALTH
During construction period, workers will be provided with basic amenities like safe water
supply, low cost sanitation facilities, first aid, required personal protective equipment, etc.
Otherwise, there could be an increase in diseases related to personal hygiene. Emission, if
uncontrolled from process and utility stacks may cause discomfort, burning of eyes to the
recipients in the down wind direction. This may be caused due to the failure of control
equipment / process. The company regularly examines, inspects and tests its emission from
sources to make sure that the emission is below the permissible limit. Hence, there will not
be any significant change in the status of sanitation and the community health of the area,
as sufficient measures will be taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION
Since the new factory will have proper linkage for the transport and communication, the
development of this project will not cause any additional impact. In brief, as a result of the
project there will be no adverse impact on communication, as sufficient measures will be
proposed to be taken under the EMP. The proposed project is not expected to make any
significant change in the existing status of the socio - economic environment of this region.
52
ANNEXURE-XI
_______________________________________________________________________
PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various
industries, surface water bodies, forests etc.
• Project cost
• Regulatory framework
• Project location and Plant layout.
• Existing infrastructure facilities
• Water source and utilization including proposed water balance.
• Product spectrum (proposed products along with production capacity) and process
• List of hazardous chemicals with their toxicity levels.
• Mass balance of each product along with the batch size
• Storage and Transportation of raw materials and products.
• Existing environmental scenario
2. Description of the Environment and Baseline Data Collection
• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall
in 5 km area.
• Study of Data from secondary sources.
• Other industries in the impact area
• Prevailing environment quality standards
• Existing environmental status vis a vis air, water, noise, soil in 5 km area from the project
site. For SPM, RSPM, SO2, NOx.
• Ground water quality at 5 locations within 5 km.
• Complete water balance
3. Socio Economic Data
• Existing socio-economic status, land use pattern and infrastructure facilities available in
the study area were surveyed.
4. Impacts Identification and Mitigatory Measures.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
• Control of fugitive emissions
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
53
6. Risk Assessment
• Objectives, Philosophy and methodology of risk assessment
• Details on storage facilities
• Identification of hazards
• Consequence analysis through occurrence & evaluation of incidents
• Recommendations on the basis of risk assessment done
• Disaster Management Plan.
• Safety precautions for the storage of Chemicals and vapour condensation.
7. Information for Control of Fugitive Emissions
8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Occupational Health and Safety Program for the Project.
10. Information on Rain Water Harvesting
11. Green Belt Development Plan
54
ANNEXURE-XII
_______________________________________________________________________
GIDC LETTER FOR WATER CONSUMPTION
55
ANNEXURE-XIII
_______________________________________________________________________
PETL MEMBERSHIP LETTER
56
57
ANNEXURE-XIV
_______________________________________________________________________
BEIL MEMBERSHIP LETTER