PROPOSED EXPANSION OF RESINS, PHARMACEUTICAL …

1

FORM-1

For

PROPOSED EXPANSION OF RESINS,

PHARMACEUTICAL INTERMEDIATES, PERFUMERY

PRODUCTS AND SPECIALTY CHEMICALS IN

EXISTING UNIT

Of

M/s. Vapi Products Industries Pvt. Ltd.

Plot No. 789/3A & 791/4 & 5,

Phase-III, G.I.D.C., Vapi-396 195,

Di: Valsad, State: Gujarat

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:











Prepared By:

2

APPENDIX I (See paragraph - 6)

FORM 1

Sr.

No.

Item Details

1. Name of the project/s VAPI PRODUCTS INDUSTRIES PVT. LTD.

2. S. No. in the schedule 5(f)

3. Proposed capacity/area/length/ tonnage to be

handled/command area /lease area/number of

wells to be drilled

Existing: 150 TPM + Additional Capacity: 2750

TPM = Total after proposed expansion

capacity: 2900 TPM.

Plot Area: 9757 m2

No bore well to be drilled within the premises.

(Water source from GIDC Vapi Only).

List of Products and raw materials are given as

Annexure –2.

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. Existing Capacity: 150 TPM

Plot Area: 9757 m2

6. Category of Project i.e. ‘A’ or ‘B’ 'A' (Unit is located within the 5 km of Gujarat &

Union Territory boundary i.e. Daman and

Dadranagar Haveli)

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

please specify.

No

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

please specify.

No

9. Location

Plot/Survey/Khasra No. 789/3A &791/4 & 5,

Village GIDC, Vapi

Tehsil Pardi

District Valsad

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Railway Station: Vapi (4 km)

Airport: Surat (130 km)

11. Nearest Town, city, District Headquarters

along with distance in kms.

Nagar palika Vapi (4 kms), Valsad (District

Headquarter) (30 km)

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Vapi Nagar palika, Dist: Valsad

13. Name of the applicant VAPI PRODUCTS INDUSTRIES PVT. LTD.

14. Registered Address Plot No. 789/3A & 791/4 & 5, GIDC, Vapi -

3

396195, Dist: Valsad, State: Gujarat.

15. Address for correspondence:

Name Mr. Siddharth Shah

Designation (Owner/Partner/CEO) Director

Address Plot No. 789/3A & 791/4 & 5, GIDC, Vapi -

396195, Dist: Valsad, State: Gujarat

Pin Code 396 195

E-mail [email protected]

Telephone No. 09825140213

Fax No.

16. Details of Alternative Sites examined, if any.

Location of these sites should be shown on a

topo sheet.

NA

17. Interlinked Projects NA

18. Whether separate application of interlinked

project has been submitted?

No interlinked project has been submitted.

19. If yes, date of submission Not applicable

20. If no, reason Not applicable

21. Whether the proposal involves

approval/clearance under: if yes, details of the

same and their status to be given.

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

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

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

Not applicable, as the project is located in

notified industrial estate.

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 thereof with approximate

quantities frates, wherever possible)

with source of information data

1.1 Permanent or temporary change in

land use, land cover or topography

including increase intensity of land

use (with respect to local land use

plan)

No The plant is located in Notified Industrial

area of GIDC Vapi.

1.2 Clearance of existing land, vegetation

and Buildings?

No The proposed expansion is within the

existing industrial set up.

1.3 Creation of new land uses?

No The project site is located on level ground,

which does not require any major land

filling for area grading work.

1.4 Pre-construction investigations e. g.

bore Houses, soil testing?

No

1.5 Construction works? Yes Construction shall be done in proposed

expansion plot showed in layout plan.

Layout Plan is Attached as Annexure 1.

1.6 Demolition works? No No demolition works shall be carried out.

1.7 Temporary sites used for

construction works or housing of

construction workers?

No

1.8 Above ground buildings, structures

or earthworks including linear

structures, cut and fill or excavations

Yes As per GIDC approved Plan, Attached as

Annexure 1.

1.9 Underground works mining or

tunneling?

No

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Off shore structures? No

1.13 Production and manufacturing

processes?

Yes Please refer Annexure: 3

1.14 Facilities for storage of goods or

materials?

Yes Existing goods or material stored in

existing storage facilities which are

sufficient for proposed expansion.

1.15 Facilities for treatment or

disposal of solid waste or liquid

Yes Total Domestic waste water (12 m3/day) is

disposed through septic tank/soak pit.

5

effluents? After proposed expansion; to treat entire

effluent load (118.0 m3/day), company

proposed to install additional effluent

treatment plant consisting of primary

treatment, secondary treatment & then

evaporate it. Please refer as Annexure -5.

Solid/hazardous waste shall be disposed

into approved TSDF site of M/s. VWEMCL,

GIDC Vapi.

1.16 Facilities for long term housing of

operational workers?

No

1.17 New road, rail or sea traffic

during Construction or operation?

Yes Developed Industrial Area with

infrastructure facilities.

1.18 New road, rail, air waterborne or

other transport infrastructure

including new or altered routes

and stations, ports, airports etc?

No

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in Traffic

movements?

No

1.20 New or diverted transmission

lines or Pipelines?

No

1.21 Impoundment, damming, culver

ting, realignment or other

changes to the hydrology of

watercourses or aquifers?

No

1.22 Stream crossings? No

1.23 Abstraction or transfers of water

form ground or surface waters?

Yes No ground water shall be used. The water

shall be supplied by GIDC (surface water).

1.24 Changes in water bodies or the

land surface affecting drainage or

run-off?

No No ground water shall be used. The water

shall be supplied by GIDC. Separate rain

water drains have been provided.

1.25 Transport of personnel or

materials for construction,

operation or decommissioning?

Yes Not applicable.

1.26 Long-term dismantling or

decommissioning or restoration

works?

No Not applicable. No dismantling or

decommissioning is required for the

project.

1.27 Ongoing activity during

decommissioning which could

have an impact on the

environment?

No Not applicable.

6

1.28 Influx of people to an area either

temporarily or permanently?

No

1.29 Introduction of alien species? No

1.30 Loss of native species or genetic

diversity?

No

1.31 Any other actions? No

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 thereof (with approximate

quantities /rates, wherever possible) with

source of information data

2.1 Land especially undeveloped or

agricultural land (ha)

No Site is located in notified Industrial area of

GIDC Vapi.

2.2 Water (expected source &

competing users) unit: KLD

Yes Notified area authority will supply total

water 261 KL/day. Notified area takes its

water from the weir storage constructed

on the River Daman Ganga. Please refer

as Annexure 4.

2.3 Minerals (MT) No

2.4 Construction material - stone,

aggregates, And / soil (expected

source - MT)

Yes Construction materials (steel, cement,

sand, stone, aggregates, etc.) shall be

purchased from local market.

2.5 Forests and timber (source - MT) No

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes Power requirement:

Existing: 80 KVA from DGVCL

After Proposed Expansion: 500 KVA

1 DG Set – 250 KVA (In case of Emergency)

Fuel requirement:

Existing: Natural gas @ 150 SCM/day

After Proposed Expansion: Natural gas @

4750 SCM/day

Diesel @ 83 lit/hr.

2.7 Any other natural resources (use

appropriate standard units)

No

7

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


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 List hazardous raw material is attached at

Annexure 9.

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No Not applicable.

3.3 Affect the welfare of people e.g. by

changing living conditions?

Yes The site is in notified industrial area of GIDC

Vapi, thus there will not be change in living

condition of the people in the nearby

vicinity. The proposed expansion will

generate additional employment

opportunity for local people.

3.4 Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the elderly

etc.

No The site is in notified industrial area of

GIDC Vapi, The nearest town Vapi is 4.0

km having population of about 3.5 lacs

people.

3.5 Any other causes No

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

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



4.1 Spoil, overburden or mine wastes No Not applicable.

4.2 Municipal waste (domestic and or

commercial wastes)

No Not applicable.

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes The list of hazardous waste is attached as

Annexure 6.

4.4 Other industrial process wastes Yes

The list of hazardous waste is attached as

Annexure 6.

4.5 Surplus product No

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Attached Annexure : 6

8

4.7 Construction or demolition wastes No

4.8 Redundant machinery or equipment No

New machineries & equipment shall be

installed.

4.9 Contaminated soils or other materials No

4.10 Agricultural wastes No

4.11 Other solid wastes No

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


quantities/rates, wherever possible)


5.1 Emissions from combustion of fossil

fuels from stationary or mobile

sources

Yes Attached Annexure : 7

5.2 Emissions from production processes No

5.3 Emissions from materials handling

storage or transport

No

5.4 Emissions from construction activities

including plant and equipment

No

5.5 Dust or odors from handling of

materials including construction

materials, sewage and waste

No

5.6 Emissions from incineration of waste No

5.7 Emissions from burning of waste in

open air e.g. slash materials,

construction debris)

No

5.8 Emissions from any other sources No

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



source of information data with source of

information data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes Expected Noise monitoring results are

shown in table attached as Annexure 8.

All precautionary measures like acoustic

enclosure, anti vibrating pad/foundation for

equipments, etc. shall be taken.

9

6.2 From industrial or similar processes Yes Expected Noise monitoring results are

shown in table attached as Annexure 8.

All precautionary measures like acoustic

enclosure, anti vibrating pad/foundation for

equipments, etc. shall be taken.

6.3 From construction or demolition No

6.4 From blasting or piling No

6.5 From construction or operational

traffic

No

6.6 From lighting or cooling systems No

6.7 From any other sources No

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

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

Sr.

No.

Information/Checklist

confirmation

Yes/No Details there of (with approximate



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.

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes • Please refer annexure –IV and V.

7.3 By deposition of pollutants emitted

to air into the and or into water

No The factory is located in notified industrial area

of GIDC, Vapi. The emissions shall confirm the

GPCB / CPCB norms. The effluent shall be

treated and shall be sent to underground

drainage line to CETP Vapi and finally

discharged in Arabian sea.

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 Full- fledged Environmental Management

System (EMS) will be installed i.e. ETP, Air

Pollution Control systems, Solid/Hazardous

Waste Handling and Management as per

norms, etc. which will eliminate the possibility

of building up of pollution.

10

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)


8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes Risk assessment will be carried out &

Mitigations measures shall be taken as

per the report. Details of Hazardous

Chemicals is referred as Annexure: 9

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 There is no history of flood in GIDC Vapi. The

buildings are designed considering seismic

zone III which is not earthquake prone area.

The land is plain terrain – no scope of

landslide.

This area is having moderate rainfall and

there is no history of cloudburst.

9. Factors which should be considered (such as consequential development) which could lead to

environmental effects or the potential for cumulative impacts with other existing or planned

activities in the locality

Sr.

No.

Information/Checklist confirmation

Yes/No

Details there of (with approximate



9.1 Lead to development of supporting.

utilities, ancillary development or

development stimulated by the

project which could have impact on

the environment e.g.

• Supporting infrastructure

(roads, power supply, waste or

waste water treatment, etc.)

• housing development

• extractive industry

• supply industry

• other

Yes Site is located in Notified Industrial area of

GIDC Vapi.

Local people will be employed.

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

No

11

(III) 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

- Site is located in Notified Industrial Area

of GIDC Vapi.

2 Areas which important for are or sensitive

Ecol logical reasons - Wetlands, watercourses

or other water bodies, coastal zone,

biospheres, mountains, forests


of GIDC Vapi.

3 Area used by protected, important or

sensitive Species of flora or fauna for

breeding, nesting, foraging, resting, over

wintering, migration


of GIDC Vapi.

4 Inland, coastal, marine or underground

waters

- Arabian Sea : 15 kms

Damanganga River: 3 kms

5 State, National boundaries - Daman UT Boundary : 4.8 km

6 Routes or facilities used by the public for

access to recreation or other tourist, pilgrim

areas

-

7 Defense installations - Daman Coast Guard Station is 10 km

away.

8 Densely populated or built-up area Valsad Vapi GIDC and Vapi Town – 3.5 Lakhs

population at 4 km

9 Area occupied by sensitive man-made land

uses Hospitals, schools, places of worship,

community facilities)

No The site is located in notified industrial

area of GIDC Vapi.

10 Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture,

fisheries, tourism, minerals)

No

11 Areas already subjected to pollution

environmental damage. (those where

existing legal environmental standards are

exceeded)or


of GIDC Vapi.

12 Areas susceptible to natural hazard which

could cause the project to present

environmental problems (earthquake s,

subsidence ,landslides, flooding erosion, or

extreme or adverse climatic conditions)

- The area falls under seismic zone III

which is non earthquake prone area.

The area is plain terrain with sandy loam

soil.

There is no heavy rain in the area and it is

away from coastal area. So erosion of

land is very little.

The area has no history of flooding in

GIDC Vapi area.

The climate of area is moderate. There is

no history of cloud burst.

IV). Proposed Terms of Reference for EIA studies: Please refer Annexure – 11

projects with similar effects

12

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

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

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

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

and cost.

Date: 03/05/2016

Place: Vapi

For VAPI PRODUCTS INDUSTRIES PVT. LTD.

Mr. Siddharth Shah

(Director)

NOTE:

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

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

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

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

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

Notification, 1991 for the activities to be located in the CRZ.

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

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

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

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

the stage of EC).

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

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

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

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

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

13

LIST OF ANNEXURE

SR.

NO.

ANNEXURE NO. PARTICULARS PAGE NO.

1 - Application Form 2

2 Annexure: 1 Lay out plan 14

3 Annexure: 2 List of Products/by product with monthly

Capacity

15

4 Annexure: 3 Mass balance, Chemical reaction, flow diagram

& brief process

21

5 Annexure: 4 Water consumption & effluent generation &

Water balance diagram

54

6 Annexure: 5 Details of Effluent Treatment Plant 57

7 Annexure: 6 Details of hazardous waste generation, storage

& disposal

62

8 Annexure: 7 Details of flue gas & proposed pollution control

equipment

64

9 Annexure: 8 Expected Noise Level 65

10 Annexure: 9 Details of Storage, Handling of Hazardous

Chemicals

66

11 Annexure: 10 Socio Economic Impacts 67

12 Annexure: 11 Proposed Terms of Reference for EIA for

Proposed Resin Plant

68

Annexure 1- Layout Plan

15

Annexure –2

List of the Products along with its capacity

Sr. No. Name of Product

Existing

Capacity

(MT/Month)

Additional

Capacity

(MT/Month)

Total after

Proposed

Expansion

(MT/Month)

1.0 Acrylic Polymers 50 200 250

2.0 Emulsion Polymers 100 900 1000

3.0 4- Nitro N- Methyl PhthaIimide 00 250 250

4.0 3- Amino 4- Methoxy Acetanilide 00 100 100

5.0 Specialty Chemicals

5.1 2-Aminobenzene Dimethyl -1,4-Dicarboxylate / 2-

Amino Di Methyl Terephthalate

00

500

500

5.2 2,4 DCNB Nitrated Ether / OPNA (NITRATED

AROMATIC ETHER)

5.3 N-Hydroxy Methyl Benzamide

5.4 N- Hydroxymethyl Chloro Acetamide 90 % / N-

Hydroxy methyl Chloro Acetamide

5.5 Di Phenyl Sulphone

5.6 4-4” Di Hydroxy Di Phenyl Sulfone

6.0 Pharma Intermediates

6.1 Ethyl 2-Chloro-2 -(4-Methoxy

PhenylHydrazinylidene) Ethanoate

00 500 500

6.2 5 - (4-Bromophenyl)-4,6-Di hydroxyl pyrimidine

/(BDP)

6.3 3-Acetamidophthalic Anhydride (APA)

6.4 6 - Chloro 1,3 Di hydro- 2H – Indole-2- One

6.5 Dibenzo [b.f][1,4]thiazepin-11(10H)-one ( DTO)

6.6 2,4 Dimethyl Benzene Thiol

7.0 Perfumery Products

7.1 Phenyl Ethyl Alcohol 00 300 300

7.2 Phenyl Ethyl Methyl Ether

Total 150 2750 2900

16

List of By-Products

Sr.

No. Name of Products

Existing

Capacity

(MT/Month)

Additional

Capacity

(MT/Month)

Total after Proposed

Expansion (MT/Month)

1.0 Sulphuric Acid (By-Product) -- 2248 2248

2.0 Aluminum Chloride -- 1125 1125

3.0 Phosphoric Acid -- 680 680

4.0 Acetic Acid -- 60 60

5.0 Sodium Thiosulphate -- 365 365

6.0 Sodium Sulfite -- 15 15

7.0 Aluminium Chloride (28%) -- 1642 1642

17

List of Raw Materials

Product Name of Raw Material Requirement MT/MT

Styrene Acrylic Resins

(Synthetic Monomer)

Styrene Monomers 0.280

Acrylic Acid 0.308

Alpha Methyl Styrene 0.359

Ethyl Carbitol 0.030

Catalyst 0.022

Emulsion Polymers Monomers 0.257

Acrylates 0.064

Resin 0.120

Ammonia 0.020

Ammonium per sulphate 0.0035

Surfactants 0.025

4-NPI MMA 40 % 0.433

Phthalic Anhydride 0.722

HNO3 0.356

Sulphuric Acid 2.800

Specialty Chemicals

2-Aminobenzene

dimethyl -1,4-

Dicarboxylate

2-Nitro Benzene

Dimethyl -1,4-

Dicarboxylate

1.350

Iron Powder 1.300

Solvent -1 0.300

Acetic Acid 80% 0.050

Solvent-2 0.100

Soda Ash 0.100

Catalyst 0.048

2,4 DCNB Nitrated Ether 2,4 Di Nitro Chloro

Benzene 1.155

Caustic Flakes 0.237

Solvent-1 0.050

Stabilizer 0.010

Soda Ash 0.050

4-Methoxy 3-Amino

Acetanilide

Para Anisidine ( 4 -

Methoxy Aniline) 0.990

Acetic Anhydride 0.830

Soda Ash 0.580

Catalyst 0.020

Solvent 0.050

Sulphuric Acid 98% 3.680

Nitric Acid 98% 0.520

Soda Ash 0.130

18

NaSH 30-33% 2.130

Caustic lye 0.060

SBS 1.010

N- Hydroxymethyl

Benzamide

Benzoyl Chloride 1.160

Ammonia 23 1.200

Catalyst-1 0.010

Salt 0.250

Solvent 0.100

Soda Ash 0.120

Para formaldehyde 0.300

Caustic lye 48 0.050

Di Phenyl Sulphone Benzene 0.050

Chloro Sulfonic Acid 0.560


5 % Soda Ash Solution 0.050

4,4 ' Di Hydroxy Di

Phenyl Sulfone

Phenol 0.830

Solvent – MCB 0.050


Sodium Bisuphite 0.025

Soda Ash 0.025

Activated Carbon 0.020

Solvent – Methanol 0.060

Pharma Intermeidates

Ethyl 2-Chloro-2 - (4-

Methoxy

Phenylhydrazinylidene)

Ethanoate

Para -Anisidine 0.560

30 % HCl Solution 0.450

Sodium Nitrite 0.290

Urea 0.150

Sodium Acetate 0.035

Ethyl 2-Chloro Aceto

Acetate 0.630

Chloroform 0.120

Isopropyl Alcohol (IPA) 0.200

5 - (4-bromophenyl)-4,6-

di hydroxyl Pyrimidine.

(BDP)

4-Bromophenyl Acetic

Acid 1.050

Sulfuric Acid 0.450

Methanol 0.300

Dichloromethane (MDC) 0.200

Sodium Hydrogen

Carbonate 0.500

Tetrahydrofuran(THF) 0.100

Sodium Methoxide 0.290

Hydrochloric Acid 0.800

19

IPA 0.200

Sodium Sulfate 0.070

POCl3 0.900

3-Acetamidophthalic

Anhydride

3-Nitrophthalic Acid (3-

NPA ) 1.210

Palladium (Pd/C) 0.014

Methanol 0.200

Acetone 0.050

Acetyl Chloride 0.382



6 - Chloro 1,3 Di hydro-

2H -Indole -2- One

Di Chloro Nitro Benzene 1.420

K2CO3 1.180

DMSO 0.150

DMM 1.025

Methanol 1.300

Reducing Agent 0.100

Acetic Acid 0.150

Ethyl Acetate 0.020

Activated Carbon

Dibenzo

[b.f][1,4]thiazepin-

11(10H)-one ( DTO)

1- Chloro 2- Nitro

Benzene 1.020

Thiophenol 0.710

30 % Hydrochloric Acid 0.250

Phenyl Chloro Formate 0.153

Soda Ash 1.000

Caustic Soda 0.260

PPA 0.025


2,4-

Dimethylbenzenethiol

(DMT)

Meta-Xylene 0.905

Chlorosulphonic Acid 1.040


Zinc Metal 0.240

30 % Hydrochloric Acid 0.100

Sodium Sulfate 0.100


Perfumery Products

Phenyl Ethyl Alcohol Benzene with Aluminium

Chloride 3.800

Benzene with Ethylene

Oxide 3.800

Anhydrous Aluminium 1.230

20

Chloride

Ethylene Oxide 0.380


Phenyl Ethyl Methyl

Ether

Phenyl Ethyl Alcohol 1.035

Di Methyl Sulphate 1.120

Caustic Soda Lye 48 %

Solution 2.485

Catalyst 0.025


21

n

HC CH2

+

C

CH3

CH2

+ O C

HO

CH2

HC

Styrene Monomer Alpha Methyl Styrene Acrylic Acid

Styrene Acrylic Resin

Styrene Acrylic Resin

2

HC CH2 CH

CH3

CH2 C

HOOC

CH2 CH CH2 CH

CH3

CH2 C

HOOC

CH2 HC

COOH

CH2

Annexure –3

Manufacturing Process and Mass Balance

1. MANUFACTURING PROCESS FOR STYRENE ACRYLIC POLYMER:-

Styrene Acrylic polymer is a polymer product which is obtained by Polymerisation reaction in S.S

316 reactor.

Step – 1

Ethyl Carbitol is heated to certain temperature and when the desired temperature is obtained

Monomers is added under stirring at elevated temperature to get the crude product.

Step – 2

After completion of addition of monomers the crude Product mass is forwarded to ATFE where the

excess Solvent is distilled of & recovered under vacuum. This recovered Solvent is collected

separately and reused back in next Batch and the Final Product is collected from Bottom.

Chemical Reaction:

22

Material Balance / Mass Balance

Styrene Acrylic Resin – Polymer

Input Output

Sr.

No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch

1 Styrene Monomer 280.0 Styrene Acrylic Resin

Product 1000.0

2 Acrylic Acid 308.0 Recovered Ethyl Carbitol 560.0

3 Alpha Methyl Styrene 359.0 Ethyl Carbitol Loss 9.0

4 Ethyl Carbitol 600.0

5 Catalyst 22.0

Total 1569.0 Total 1569.0

23

Resin

Emulsions Polymer

HC CH2 CH

CH3

CH2 C

HOOC

CH2 CH CH2 CH

CH3

CH2 C

HOOC

CH2 HC

COOH

CH2

+ H2C CH

C O

O CH2 HC

CH2 CH3

(CH2)3 CH3

2 Ethyl Hexyl Acrylate

+

HC CH2

Styrene Monomer NH3

H2O

HC CH2 CH

CH3

CH2 C

COOH

CH2 CH CH2 CH

CH3

CH2 C

COOH

CH2 HC

COOH

CH2 CH2 CH

C O

O CH2 HC

CH2 CH3

(CH2)3 CH3

CH CH2

n

2. MANUFACTURING PROCESS FOR EMULSION POLYMER:-

Emulsion Polymer is manufactured by mixing phenomena.

Step -1

Styrene Acrylic Resin and water is first mixed in to Kettle and heated to achieve desired

temperature under stirring.

Step -2

Addition of Monomers is carried out at elevated temperature under stirring followed by addition of

Surfactant. Finally Water is added to bring down the Viscosity to the required level.

The final product obtained is in liquid form which is packed in Plastic Drums/ Barrels.

Chemical Reaction:

24

Mass Balance:

Emulsion – Polymer

Input Output

Sr.No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch

1 Monomer 257.2 Emulsion Polymer Final

Product 1000.0

2 Acrylate 64.3

3 Resin 120.0

4 Water 510

5 Liquor Ammonia 20.0

6 APS 3.5

7 Surfactant 25.0

Total 1000.0 Total 1000.0

25

Step-1

Step-2

+

Phthalic Anhydride

M.W. 148.0

O

H2O CH3 NH2 + Methylation / H2O

N-Methyl Phthalimide

M.W. 161.0

C

Water

M.W. 18.0

C

O

O

Mono Methyl Amine

M.W. 31.0

O

C

C

O

N – CH3

HNO3 +

N-Methyl Phthalimide

M.W. 161.0

Nitric Acid

M.W. 63.0

O

O

N – CH3

C

C

H2SO4 +

Sulphuric Acid

M.W. 98.0

Nitration

O

O

N – CH3

C

C NO2

4-Nitro N-Methyl Phthalimide

M.W. 206.0

H2O

Water

M.W. 18.0

+

3. 4- Nitro N- Methyl Phthalamide 4- NPI

MANUFACTURING PROCESS FOR 4- NPI:-

Step – 1

Phthalic Anhydride undergoes methylation reaction by Mono Methyl Amine 40 % Solution in

presence of water to give an intermediate as N-Methyl PhthaIimide.

Step – 2

N-Methyl Phthalamide finally undergoes Nitration reaction by Nitric Acid in presence of Sulphuric

Acid to give the Final Product as 4- Nitro N- Methyl Phthalamide. Reaction mass is drowned to Water

for isolation of product which is obtained as wet cake. Spent Acid is generated which is sold to End

User.

Chemical Reaction:

26

Mass Balance:


4- Nitro N- Methyl PhthaIimide

Input Output

Sr.

No

Raw Materials / Items Kg/Batch Product/By Products Qty/Batch

1 Mono Methyl Amine 40 % 513 4- Nitro N- Methyl PhthaIimide

as Wet Cake -

1184

2 Water for Reaction 200 Dilute Sulphuric Acid 35-40 % 6600

3 Phthalic Anhydride 855 Distillate water recycled to

process

200

4 Sulphuric Acid 2780 Aqueous Effluent to ETP 5456

5 Nitric Acid 422

6 Water for Drowning 4170

7 1st Water Wash to Product 2500

8 2nd Water Wash Product 2000

9 Total 13440 13440

27

4. 3- AMINO 4- METHOXY ACETANILIDE:

Step – I

Para Anisidine (4- Methoxy Aniline) when reacted with Acetic Anhydride in presence of Solvent

as well as Catalyst to gives an intermediate Product as 4- Methoxy Acetamide (Stage -1).

Step – II

4- Methoxy Acetamide (Stage -1) further undergoes nitration reaction by Nitric Acid in presence

of Sulfuric Acid to give the intermediate Stage - II as 3- Nitro 4- Methoxy Acetanilide.

Step – III

3- Nitro 4- Methoxy Acetanilide finally undergoes reduction reaction in presence of Solvent as

well Catalyst to give the final Product as 3- Amino 4- Methoxy Acetanilide.

Chemical Reactions:

STEP -I

STEP -II

STEP -III

Solvent + Catalyst

CH3 CO +

Acetic Anhydride

Para Anisidine

M.W. 123.0

NH2

O CH3 CO

OCH3

4- Methoxy Acetanilide

NHCOCH3

OCH3

4Methoxy Acetanilide

NHCOCH3

OCH3

Nitration HNO3

+

Nitric Acid

H2 SO4

+

NO2

NHCOCH

Sulfuric Acid

H2O + H2SO4

+

OCH3

4-Methoxy 3- Nitro Acetanilide

M.W. 210.0

NHCOCH3

OCH3

Reduction

H2O +

+ 6 NaSH

NH2

NHCOCH

OCH3

NO2

4-Methoxy 3-Amino Acetanilide

M.W. 180.0

4-Methoxy 3- Nitro

Acetanilide

+ CH3COOH

Acetic Acid

Water

Water

Sodium Bisulphite M.W. 104.0

Sodium Supha Hydride

3 Na2S2O3

+

Sodium Sulphate

M.W. 142.0

Water

M.W. 18.0

2

2

+ H2O

28

MASS BALANCE:

4-Methoxy 3-Amino Acetanilide

Input – Quantity Output - Quantity

Sr.

No Raw Materials / Items Kg/Batch Product/By Products Kg/Batch

1 Para Anisidine ( 4 - Methoxy

Aniline) 990

4- Methoxy 3- Amino

Acetanilide 1000

2 Acetic Anhydride 830 Recovered Acetic Acid 600

3 Soda Ash 580 Spent Sulphuric Acid 60-70% 4350

4 Catalyst 20 Recovered Solvent 550

5 Solvent 600 Solvent Loss 50

6 Salt 60 Sodium Thio Sulphate Solution 3628

7 Sulphuric Acid 98% 2680 Aqueous layer to ETP 982

8 Nitric Acid 98% 520

9 Water 550

10 Soda Ash 130

11 NaSH 30-33% 2130

12 Caustic lye 60

13 ICE 1000

14 SBS 1010

Total 11160 Total 11160

29

5) Specialty Chemicals

MANUFACTURING PROCESS & MASS BALANCE DETAILS: -

1. 2-AminobenzeneDimethyl -1,4-Dicarboxylate / (2- Amino Dimethyl Terephthalate)

2-Nitro benzenedimethyl -1,4-dicarboxylate undergoes reduction reaction in presence of Solvent –

Methanol as well as Catalyst to give the Products as 2-aminobenzenedimethyl -1,4-dicarboxylate.

Chemical Reactions:


3 [ Fe(OH)2 ]

Reduction

3 [ Fe]

+

2-Nitro benzene dimethyl

-1,4-dicarboxylate

M.W. 239.0

NO2

COOCH3

CH3OOC

+

4 [ H2O ]

+

NH2

COOCH3

CH3OOC

2-Aminobenzene-

dimethyl 1,4-

dicarboxylate

Iron Powder

M.W. 56.0

Iron Sludge

M.W. 90.0

30

2. OPNA- NITRATED AROMATIC ETHER

Step – 1

2,4 Di Nitro Chloro benzene under goes in etherification in presence of caustic soda and Solvent

gives us the co responding ether, which will wash with water and recover the balance Solvent.

Chemical Reactions:

Step-1


2,4 DCNB Nitrated Ether

Input – Quantity Output - Quantity

Sr.


1 2,4 Di Nitro Chloro

Benzene 1155 2,4 DCNB Nitrated Ether 1000

2 Caustic Flakes 237 Recover Solvent 650

3 Solvent-1 700 Loss Solvent 50

4 Catalyst-1 70 Residue 30

5 Water 2500 Salt Solution NaCl 2992

6 Stabilizer 10

7 Soda Ash 50


NaOH

+

Sodium Hydroxide OPNA Nitrated

Aromatic

M.W. 122.0

2,4 Di Nitro Chloro Benzene

M.W. 78.0

NO2

NO2

Cl

Solvent

+

NO2

NO2

O_

Solvent

+ NaCl

Sodium Chloride

31

3.0 -N- HYDROXY METHYL BENZAMIDE:

Step – I

Benzoyl Chloride undergoes ammonolysis reaction by liquor ammonia in presence of Solvent as

well as Catalyst to gives an intermediate Product as Benzoyl Amine Stage - I

Step – II

Benzoyl Amine (Stage -1) finally reacted with Para Formaldehyde in presence of Solvent as ell as

Catalyst to give the final Product as N- Hydroxymethyl Benzamide.

Chemistry:

STEP -I

STEP -II

Mass Balance:

N- Hydroxymethyl Benzamide

Input – Quantity Output – Quantity

Sr.


1 Benzoyl Chloride 1160 N- Hydroxymethyl Benzamide 1000

2 Ammonia 23 1200 Recover Solvent 2400

3 Catalyst-1 10 Loss Solvent 100

4 Salt 250 Ammonium Chloride Solution 2250

5 Solvent 2500 Aqueous layer to ETP 990

6 Soda Ash 120

7 Para formaldehyde 300

8 Caustic lye 48 50

9 Water 1150

Benzoyl Chloride

COCl Ammonolysis

2 NH3

+

Ammonia

O = C - NH2

NH4Cl +

Benzamide M.W. 121.0

Condensation

HCHO

+

Para Formaldehyde

HN = C - NH - CH2

N-Hydroxy Methyl Benzamide

O= C - NH2

Ammonium Chloride

Benzamide

32


4.0 N- HYDROXYMETHYL CHLORO ACETAMIDE:

Chloro Acetamide when reacted with Para Formaldehyde in presence of Solvent as well as Catalyst

to give N- Hydroxymethyl Chloro Acetamide. Addition condensation reaction.

Chemistry:

Mass Balance:

N- Hydroxy Methyl Chloro Acetamide


Sr.


1 Chloro Acetamide 780 N- Hydroxy methyl Chloro Acetamide 90 1000

2 Formaldehyde 850 Salt Solution 830

3 Catalyst -1,2 5

4 Solvent 100

5 Potassium Carbonate 40

6 Acetic Acid 40

7 Caustic Lye 48% 15


Cl - CH2- CO -NH2

Chloro Acetamide M.W. 109.5.0

Condensation

HCHO

Para Formaldehyde

M.W. 30.0

+ Cl - CH2- CO –NH-CH2OH

N - Hydroxymethyl Chloro Acetamide

M.W. 125.5 g/m

33

Chemical Reactions:

Step-1:

Step-2:

Sulfonation +

Chloro Sulfonic Acid M.W. 116.5

Benzene Sulphonic Acid

M.W. 176.5

Benzene M.W. 78.0

Cl SO3H + H2O

Water M.W. 18.0

SO2Cl

Condensation +

Benzene

M.W. 78.0

Di Phenyl Sulphone

M.W. 218.0

Benzene Sulfonic Acid

M.W. 176.5

+ HCl

Hydrochloric Acid M.W. 36.5

S

SO2Cl O

O

5. DIPHENYL SULFONE: -

Brief Manufacturing Process:

Step – 1

Benzene is reacted with Chloro Sulfonic Acid and undergoes sulfonation reaction in presence of

Sulphuric acid as well as excess quantity of Benzene to give an intermediate Product as Benzene

Sulfonyl Chloride. Excess Benzene is utilized as Solvent which is finally recovered by recovered and

recycled to fresh Batch.

Step – 2

Benzene Sulfonyl Chloride is finally reacted with Benzene to give the final Product as Di Phenyl

Sulfone. Crude Mass is subjected to washing by Soda Ash Solution which goes to ETP for further

treatment.

Chemical Reactions:

34

Mass Balance:


Benzophenone


Sr.


1 Benzene 3000 Di Phenyl Sulphone 1010

2 Chloro Sulfonic Acid 560 Water distillate 90

3 Sulphuric Acid 30 Recovered Benzene 2200

4 Water for 30 % HCl Soln

Formation 410 Benzene Loss 50

5 5 % Soda Ash Solution 50 30 % HCl Solution for

Sale 570

6 Aqueous Washing to

ETP 130


35

Chemical Reactions:

Sulphonatn / Cat +

Sulphuric Acid M.W. 98.0

4,4’ Di Hydroxy Di Phenyl

Sulphone

M.W. 218.0

Phenol

M.W. 94.0

+ 2 H2O

Water

M.W. 18.0

S H2SO4

O

O

HO HO OH OH +

Phenol M.W. 94.0

6.0 - 4, 4 ' Di Hydroxy Di Phenyl Sulfone


Step – 1

Phenol is reacted with Sulphuric Acid and undergoes Sulfonation reaction in presence of Solvent

– Mono Chloro Benzene ( MCB) as well as catalyst to give as crude Product as 4,4’ Di Hydroxy Di

Phenyl Sulfone. Water molecule is formed during Sulfonation reaction which is removed from

reaction mass by means of zeotropic distillation.

Step – 2

Organic mixture of Product is subjected to neutralization and washings by Sodium Bi sulphite

solution followed by Soda Ash Solution. Finally, this washed mass is decolorized by means of

activated carbon & MCB is recovered. Methanol is then charged to this concentrated mass for

crystallization and to get the pure Product as 4,4’ Di Hydroxy Di Phenyl Sulfone.

36

Mass Balance

4, 4 ' Di Hydroxy Di Phenyl Sulfone

Input Output Remarks

Sr.

No Raw Materials / Items Qty/Batch

Product/By Products Qty/Batch

1 Phenol 830

4,4 ' Di Hydroxy Di

Phenyl Sulfone 1010

Product

2 Solvent – MCB 2500

Recovered Solvent -

MCB 2450

Recyle to

fresh

Batch

3 Sulphuric Acid 435 MCB Loss

50 Lost

4 5 % Sodium Bisuphite

Solution 450

Recovered - Methanol

1940

Recycled

to fresh

Batch

5 5 % Soda Ash Solution 450

Methanol Loss 60 lost

6 Activated Carbon 20

Used Carbon - 25 Sent to

TSDF Site

7 Solvent – Methanol 2000 Water Distillate 150

Recycle to

fresh

Batch

8 Aqueous Effluent to

ETP 1000

Sent to

ETP

Total 6685

Total 6685

37

5) Pharma Intermediates

Product:Ethyl 2-Chloro-2(4-Methoxy Phenyl Hydrazinylidene) Ethanoate (EMA).

Brief Manufacturing Process: -

Step – 1 Para-Anisidine undergoes diazotization reaction with Sodium Nitrile / Nitrosyl Sulphuric

Acid in presence of DM water as well as 30 % HClsolution to get an intermediate diazomass.

Step - 2

The diazo mass further reacted with Ethyl 2-Chloro Aceto Acetate in presence of chloroform, after

completion of reaction aqueous layer is separated & extracted with chloroform.

Organic layer mixed together with all extracts & washed with water.

Chloroform is distilled out to recover & reuse &Product is recrystallized using IsoPropyl Alcohol

(IPA) to give Final Product as Ethyl 2-Chloro-2(4-Methoxy Phenyl Hydrazinylidene) Ethanoate (EMA).

Chemistry:

NH2

OCH3

N

OCH3

N

Cl

+

O

O

Cl

CH3

O

CH3

NH

OCH3

N

ClO

O

CH3

NaNo2,HCl

-5-0 oC

4-methoxyaniline (E)-1-chloro-2-(4-methoxyphenyl)diazene

ethyl (2Z)-chloro[2-(4-methoxyphenyl)hydrazinylidene]ethanoate

Molecular Formula = C7H9NOMolecular Formula = C7H7ClN2O

Molecular Formula = C11H13ClN2O3

Formula Weight = 123.15246Formula Weight = 170.59628

Formula Weight = 256.68552

ethyl 2-chloro-3-oxobutanoate

Molecular Formula = C6H9ClO3


Chloroform, CH3COONa

38

Mass Balance / Material Balance

Mass Balance / Material Balance

Ethyl 2-Chloro-2 - (4- Methoxy Phenylhydrazinylidene) Ethanoate


Sr

No Raw Materials / Items Kg/Batch Product / Bi Products Kg/Batch Remarks

1 Para -Anisidine 560

Ethyl 2-Chloro - 2 (4-

Methoxy Phenyl

Hydrazinylidene)

1000 Desired

Product

2 30 % HCl Solution 450 Recovered Chloroform 3880 Reuse

3 Sodium Nitrite 290 Chloroform loss 120 Scrubber

4 Urea 150 Recovered Iso Propyl

Alcohol 3300 Reuse

5 Sodium Acetate 35 Iso Propyl Alcohol loss 200 Scrubber

6 Ethyl 2-Chloro Aceto

Acetate 630 Aqueous Effluent 1485

Goes to

ETP

7 Chloroform 4000 Organic Residue 30 Incinerator

8 Isopropyl Alcohol (IPA) 3500

9 D. M. Water 400


39

Product: 5 - (4-bromophenyl)-4,6-Di hydroxyl pyrimidine. (BDP)


STEP - I:-

4-Bromophenyl Acetic Acid undergoes esterification reaction with Methanol in presence of

Sulphuric Acid to give crude Product as Methyl 4- Bromophenyl Acetate.

Excess Methanol is recovered by distillation under vacuum & Product is extracted by Methylene

Dichloride (MDC) .

Finally, MDC is distilled of to get the Final Product as Methyl ( 4- Bromophenyl) Acetate

STEP- II : -

4-Bromophenylacetic Acid Methyl Ester (BDP-I) further reacted with Sodium Methoxide in presence

of Solvent – Tetra Hydro Furan (THF) Then resulting mixture is reacted with Dimethyl Carbonate

(DMC) . The mixture is neutralized to pH 6-7 with dilute HCl solution &then THF is recovered by

vacuum distillation. The residual Mass is dissolved in MDC, washed with brine; MDC is distilled off &

finally IPA is used to get crystallized Product as 2-(4-bromophenyl)-malonic acid dimethyl ester.

STEP- III :-

Further Sodium Methoxide) is added to a solution of dimethyl-(O-Methoxyphenoxy) malonate in

methanol. Upon completion of the addition stirring was continued at r.t. for 30 min followed by the

addition of formamide. Eventually, the solvent is distilled off under reduced pressure and the

remaining residual mass is suspended in water & acidified with HCl solution to give the product as

5-(4- Bromophenyl)-4, 6-Dihydroxy-Pyrimidine.

STEP - IV

5-(4-phenyl)-4,6-dihydroxy-pyrimidine is further reacted with POCl3 at elevated temperature.

The mixture is heated to elevated temperature & finally quenched into ICE water. The precipitated

Product is isolated by mean of filtration. Then washes with methanol and dried to give the final

Product as 4, 6-Dichloro-5-(O-Methoxyphenoxy)- Pyrimidine.

40

Chemistry:

STEP-I

Br

OH

O

(4-bromophenyl)acetic acid

Br

O

O

CH3

methyl (4-bromophenyl)acetate

Sulphuric Acid

Methanol, MDC

STEP – II

Br

O

O

CH3

methyl (4-bromophenyl)acetate Br

O

O

CH3

OOCH3

dimethyl (4-bromophenyl)propanedioate

THF,

IPA,

CH3ONa

Dimethyl Carbonate

BDP -IBDP -II

STEP - III

Br

O

O

CH3

OOCH3


Br

N

N

OH

OH

5-(4-bromophenyl)pyrimidine-4,6-diol

+ HCONH2

BDP -II BDP -III

CH3ONa , Methanol

STEP - IV

Br

O

O

CH3

OOCH3


Br

N

N

OH

OH

5-(4-bromophenyl)pyrimidine-4,6-diol

+ HCONH2

BDP -II BDP -III

CH3ONa , Methanol

41


Material Balance

5 - (4-bromophenyl)-4,6-di hydroxyl Pyrimidine. (BDP)

Sr

No. Input Raw Material Name

Quantity

Kg Out put

Quantity

Kg Remarks

1 4-Bromophenyl Acetic Acid 1050 Final Product BDP 1000 Desired

Product

2 Sulfuric Acid 450 Dilute Sulfuric Acid 70% 650 By product

3 Methanol 7000 Recovered Methanol 6700 Reuse

4 Dichloromethane (MDC) 6000 Methanol loss 300 Scrubber

5 Sodium Hydrogen

Carbonate 500 Recovered MDC 5800

Reuse

6 Tetrahydrofuran(THF) 5000 MDC loss 200 Scrubber

7 Sodium Methoxide 290 Recovered THF 4900 Reuse

8 Hydrochloric Acid 800 THF loss 100 Scrubber

9 IPA 6000 Recovered IPA 5800 Reuse

10 Sodium Sulfate 70 IPA loss 200 Scrubber

11 POCl3 900 Inorganic Salt 220

12 DM Water 610 Recover Phosphoric

Acid 1360 By product

13 Aqueous Effluent 1400

14 Organic Residue 40

Incineration


Product: 3-Acetamidophthalic Anhydride (APA)

42


STEP - I: -

3-Nitro Phthalic Acid ( 3- NPA) undergoes hydrogenation reaction by hydrogen Gas under pressure

in presence of Solvent Methanol & reduction Catalyst Palladium Charcoal . After completion of

reaction, the mass is subjected to Filtration.

Methanol is recovered by distillation under vacuum & product is crystallized using Acetone as

Solvent & forwarded to Stage-II.

STEP - II

The Product from Stage- I as 3- Amino Phthalic Acid is further reacted with Acetyl Chloride at

elevated temperature. After the completion of reaction, mass is subjected to filtration and

washings with MDC to get the final Product as 3- Acetamidophthalic Anhydride.

Chemistry:

STEP -I:

NO 2

COOH

COOH

3-nitrophthalic acid

Molecular Formula = C8H5NO6


Reduction

H 2 / Pd/c

COOH

COOH

NH2

3-am inophthalic acid


Methanol


STEP – II

COOH

COOH

NH2

3-am inophthalic acid



Acetyl chloride

NH

O

CH3

O

O

O

N-(1,3-dioxo-1,3-dihydro-2-benzofuran-4-yl)acetamide



MDC

43

Material Balance/ Mass Balance


3-Acetamidophthalic Anhydride (APA)

Sr


Quantity

Kg Out put

Quantity

Kg Remarks

1 3-Nitrophthalic Acid (3-NPA

) 1210

3-Acetamidophthalic

Anhydride 1000

Desired

product

2 Palladium (Pd/C) 14 Recover Palladium (Pd/C) 14 Reuse

3 Methanol 4000 Recovered Methanol 3800 Reuse

4 Acetone 1000 Methanol loss 200 Scrubber

5 Acetyl Chloride 382 Recovered Acetone 950 Reuse

6 Dichloromethane (MDC) 500 Acetone loss 50 Scrubber

7 5 % Soda Ash Solution 1000 Water Distilate 88 Reuse

8 Aqeoues Layer to ETP 1486 Scrubber

9 Recovered MDC 470 Reuse

10 MDC loss 30 Scrubber

11

Organic Residue 18 to

Incinerator

Total Quantity input 8106 Total Quantity output 8106

Product: 6 – Chloro 1,3 Di hydro- 2H – Indole-2- One


STEP - I: -

2,5 Di Chloro Nitro Benzene as well as Di Methyl Malonoate are reacted at elevated temperature in

presence of Solvent -Di Methyl Sulfoxide (DMSO), and Acid scavenger potassium Carbonate to give

an intermediate product as 2- Dimethyl ( 5- Chloro Nitro phenyl ) Malonate.

After the completion of reaction mass is quenched to ice +water, Filtered it off. ML is collected for

DMSO recovery and re-use, product proceed for Stage-II.

44

STEP- II

2- Dimethyl ( 5- Chloro Nitro Phenyl ) Malonate (Satge – I) undergoes cyclization reaction in

presence of metal - catalyst as well as 30 % HCl Solution and water t to give the final product in

crude form

Crude product is further undergoes purification by using Ethyl Acetate as well as Activated Carbon

to obtain the final Product in Pure form. The ethyl acetate is recovered and re-used from the ML.

45

Chemistry :

Step: - I

Step : - II

Cl NO2

COOCH 3

COOCH 3

NH

O

Cl

dimethyl (4-chloro-2-nitrophenyl)malonate

metal+HCl

Formula Weight = 287.653 Formula Weight = 167.592

6-chloro-1,3-dihydro-2H-indol-2-one

Crude

Cl

Cl N+

O-

O+

O

O

O

O

CH3

CH3

K2CO

3

DMSO

Cl N+

O-

O

O

O

O

CH3

CH3

O

2,5-dichloro nitrobenzeneDimethyl malonate

2-dimethyl (5-chloro-nitrophenyl)malonatecrude stape-1

Formula Weight = 191.999Formula Weight = 132.115 Formula Weight = 287.653

46


Material Balance

6-Chloro 1,3 Di hydro -2-Oxindole

Sr

No.

Input Raw Material

Name

Quantity

Kg Out put

Quantity

Kg Remarks

1 Di Chloro Nitro Benzene 1420

6 - Chloro 1,3 Di hydro- 2H -

Indole -2- One 1000

Desired

Product

2 DM Water 700 Recovered DMSO 3350 Reuse

3 K2CO3 1180 DMSO loss 150 Scrubber

4 DMSO 4000 Recovered Methanol 3350 Reuse

5 DMM 1025 Methanol loss 150 Scrubber

6 Methanol 3500 Recovered Ethyl Acetate 2850 Reuse

7 Reducing Agent 1300 Ethyl Acetate loss 150 Scrubber

8 Acetic Acid 100

Aqeous Effluent 1500 ETP

9 Ethyl Acetate 3000

Sludge from Reducing Agent 3723 TSDF

10 Activated Carbon 20

Organic Residue 22


47

Product: Dibenzo [b.f][1,4]thiazepin-11(10H)-one ( DTO)


STEP - I: -

1-Chloro 2- Nitro Benzene is reacted with Thiophenol in presence of Solvent- Methanol and Acid

scavenger such as Potassium Carbonate to give an intermediate product as 2- Nitro Di phenyl

Sulphide which further undergoes reduction reaction by Acid Iron combination in presence of

Solvent- Methanol to give the Stage- 1 intermediates as 2- ( Phenyl Sulfanyl ) Aniline / 2- Amino Di

phenyl Sulphide.

STEP - II: -

Stage- 1 is further reacted with Phenyl Chloro Formate in presence of Solvent- Toluene and Sodium

Hydroxide as well as Sodium Carbonate (Soda- Ash) to give the Stage- II intermediates as Phenyl [ 2-

(phenylthio)Phenyl] Carbamate

STER- III

Phenyl [ 2- (phenylthio ) Phenyl ] Carbamate finally undergoes cyclization reaction on presence of

Solvent as well as Catalyst to give the final Product as Dibenzo [b.f][1,4]thiazepin-11(10H)-one

48

Chemistry :

STEP- I

STEP- II

STEP- III

Cl

N+

O-

O

+SH

Methanol

Na2CO3

1-chloro-2-nitrobenzene

Formula Weight 110.178

Thiophenol


N+

O-

O

S


2-nitro-diphenyl sulphide

NH2

SMeOH

Fe + HCl


2-(phenylsulfanyl)aniline

NH2

S

2-Am ino diphenyl sulphide

OO

Cl

Phenyl chloro form ate

+Toluene

NaO H,Na2CO 3

NH

S

OO

phenyl [2-(phenylthio)phenyl]carbam ate

Formula Weight = 201.288Formula Weight = 156.566


NH

S

OO

Pure phenyl [2-(phenylthio)phenyl]carbam ate

PPA

NH

S

O

+

OH


dibenzo[b,f][1,4]thiazepin-11(10H )-one


phenol

Form ula weight 321.394

49


Material Balance

Dibenzo [b.f][1,4]thiazepin-11(10H)-one ( DTO)

Sr


Quantity

Kg Out put

Quantity

Kg Remarks

1 1- Chloro 2- Nitro Benzene 1020

Product:- 1(2(2-

Hydroxy Ethoxy)

Ethyl) Piperazine

1000 Desire

product

2 D. M. Water 350 Recover Methanol 950

3 Thiophenol 710 Methanol loss 50 Scrubber

4 30 % Hydrochloric Acid 250 Inorganic Salt 500

5 Phenyl Chloro Formate 153 Aqueous effluent 1490

6 Soda Ash 1000 Organic Residue 28 Incineration

7 Caustic Soda 260

8 PPA 25



50

Product: 2,4 Dimethyl Benzene thiol


STEP - I

Meta Xylene reacted with Chloro Sulfonic Acid in presence of Solvent – MDC to give crude Product

as 2,4 Dimethyl Benzene Sulfonyl Chloride. After completion of reaction mass is quenched to Ice

water, then layers are separated. Aq. layer is extracted with MDC, All organic layer mixed together

washed with water, MDC is distilled out under vacuum to get the liquid Product in pure form.

STEP -II

2,4 Di Methyl Benzene Sulfonyl Chloride undergoes reduction reaction in presence of Water as well

as reducing agent as Zinc Dust and 30 % Hydrochloric Acid to form the Product.

After completion of reaction mass is allowed to settle &layers are separated.

Product layer washed with Brine solution followed by Sodium Sulphate to give the liquid product in

pure form.

Chemistry: -

Stage: - I

C H 3

S OO

C l

C H 3

2 ,4 -d im e th y lb e n z e n e su lfo n y l c h lo r id e

C H 3

C H 3

m -x y le n e

ClSO 3 H

Molecular Formula = C8H10 Molecular Formula = C8H9ClO2S


MDC

51

STEP-II

SH

C H 3

C H 3

2,4 -d im e thy lbenzene th io l

C H 3

S OO

C l

C H 3

2 ,4 -d im e thy lbenzenesu lfony l ch lo ride

Zn + HCl

reduction

Molecular Formula = C8H9ClO2S


Molecular Formula = C8H10S



Material Balance

2,4-Dimethylbenzenethiol (DMT)

Sr


Quantity

Kg Out put

Quantity

Kg Remarks

1 Meta-Xylene 905

Product:- DMT 1000 Desired

Product

2 Chlorosulphonic Acid 1040 Recover MDC 2950 Reuse

3 Dichloromethane (MDC) 3000 MDC loss 50 Scrubber

4 Zinc Metal 240

Aqueous

effluent 1505 ETP

5 30 % Hydrochloric Acid 100

Inorganic Salt 200 TSDF

6 Water 100 Organic Residue 30 Incineration

7 Sodium Sulfate 100



52

6) Perfumery Products BRIEF MANUFACTURING PROCESS FOR PHENYL ETHYL ALCOHOL (PEA): -

Step – 1

Benzene undergoes Friedel Crafts reaction to react with Ethylene Oxide in presence of excess

quantity of Benzene to give crude Product as Phenyl Ethyl Alcohol.

Step – 2

Reaction Mass is drowned to chilled water for Isolation of crude PEA Mass from Aluminium Chloride

Solution is separated from reaction mass and stored at separate storage Tank.

Crude Mass is subjected to washing first by Soda Ash Solution & finally by water & both these

washing layers are mixed with main Aluminium Chloride solution.

Crude Mass is taken for distillation where by excess Benzene is recovered by distillation & Product

is distilled out to get the pure Product,

Chemical Reactions

Step-1


Phenyl Ethyl Alcohol


Sr.


1 Benzene with Aluminium

Chloride 3800 Phenyl Ethyl Alcohol 1010

2 Benzene with Ethylene Oxide 3800 20-28 % Aluminium

Chloride Solution 5474

3 Anhydrous Aluminium Chloride 1230 Recovered Benzene 6720

4 Ethylene Oxide 380 Benzene Loss 206

5 Water for Drowning 3200


7 Water for Washing 500


CH2 – CH2OH

Friedel Craft reaction

CH2 - CH2

+

Ethylene Oxide Phenyl Ethyl Alcohol

Benzene

M.W. 78.0

O

53

2) PHENYL ETHYL METHYL ETHER (PEME): -

Step – 1

Phenyl Ethyl Alcohol undergoes methylation reaction to react with Dimethyl Sulphate (DMS) in

presence of excess quantity of dilute Caustic Solution as well as Catalyst to give crude Product as

Phenyl Ethyl Methyl Ether.

Step – 2

Reaction Mass is settled for Isolation of crude PEME Mass from Sodium Sulphate Solution which is

formed during reaction & separated from reaction mass and stored at separate storage Tank.

Crude Mass is subjected to washing first by Soda Ash Solution & finally by water & both these

washing layers are mixed with main sodium Sulphate solution.

Crude Mass is taken for distillation where by excess PEA is recovered by distillation & Product is

distilled out to get the pure Product,

Chemical Reactions:

Step-1


Phenyl Ethyl Methyl Ether


Sr.


1 Phenyl Ethyl Alcohol 1035 Phenyl Ethyl Methyl Ether 1010

2 Di Methyl Sulphate 1120 Sodium Sulphate Solution 3615

3 Caustic Soda Lye 48 % Solution 2485 Aqueues Washing to ETP 540

4 Catalyst 25



CH2 – CH2

OCH

Methylation / Cat.

(CH3)2

SO4

+

Di Methyl Sulphate

M.W. 126.0

Phenyl Ethyl Methyl Ether M.W. 136.0

CH2 – CH2OH Phenyl Ethyl

Alcohol M.W. 122.0

NaOH

+

Na2SO4

+

Sodium Sulphate

M.W. 136.0

Sodium Hydroxide

M.W. 40.0

H2O

Water M.W. 18.0

+

54

Annexure -4

Details of Water Consumption and Wastewater generation

Water Consumption

S.No. Particulars

Requirement (KLD)

Existing Additional Total

1. Domestic

1.6 Fresh + 0.4

Recycled

13.0 15.0

2. Gardening 5.0 Nil 5.0

3. Industrial

4. Process 2.4 115.6 118.0

5. Boiler 0.6 50.4 51.0

6. Cooling (Make-up) 1.4 50.6 52.0

7. Washing 0.0 10.0 10.0

8. Scrubber 0.0 10.0 10.0

9. Sub-Total: Industrial 4.4 236.6 241.0

10. Grand Total 11.4 249.6 261.0

Wastewater generation

S.No. Particulars Waste Water Generation (KLD)

Existing Additional Total

1. Domestic 1.5 10.5 12.0

2. Gardening --- -- --

3. Industrial

4. Process Nil 97.1 97.1

5. Boiler (Blow down) 0.1 4.9 5.0

6. Cooling (Blow down) 0.3 4.7 5.0

7. Washing 0.0 10.0 10.0

8. Scrubber 0.0 10.0 10.0

9. Sub-Total: Industrial 0.4 126.7 127.1

10. Grand Total 1.9 137.2 139.1

55

Water Balance (Existing):

Raw Water 10.0 KL/Day

Domestic 1.6 KL/Day

Industrial 4.4 KL/Day

Gardening 4.0 KL/Day

Process: 2.4 KL/Day

Boiler 0.6 KL Cooling 1.4 KL

1.5 KL Septic Tank/ Soak Pit System

0.4 KL from Blow Down

0.0 KL/Day

0.5 KL/Day Loss

0.5 KL/Day Usage

0.3 KL/Day

0.1 KL/Day

1.1 KL/Day Loss

56

Water Balance (After Proposed Expansion):

Raw Water 261.0 KL/Day

Domestic 15.0 KL/Day

Industrial 241.0 KL/Day

Gardening 5.0 KL/Day

Process – 118 KL/Day

Boiler 51 KL/Day

Cooling 52 KL/Day

12.0 KL Septic Tank/ Soak Pit

System

97.1.0 KL/Day

5.0 KL/Day

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

5.0 KL/Day

CETP for further treatment and

disposal

Washing 10 KL/Day

10.0 KL/Day

Scrubber 10 KL/Day

10.0 KL/Day

57

Annexure -5:

Details of ETP

M/s. Vapi Products Industries Pvt. Ltd. shall have an Effluent treatment plant consisting of primary,

secondary tertiary and advanced treatment units. The effluent confirming to inlet standards of GIDC

drain(CETP). The details of ETP are as follows.

For Low & Medium COD Stream

First all non-toxic and biodegradable streams (low & medium COD) of wastewater shall pass through Screen

Chamber (SC) where floating material shall be removed with help of Screen (S-01). Then effluent shall

collected in Collection cum Equalization tank-1 (CET-1). Pipe grid is provided at bottom of the CET-1 to keep

all suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1 stand-by) shall

supply air through pipe grid.

Then after, equalized wastewater shall be pumped to Neutralization Tank-1 (NT-1) where the continuous

addition and stirring of Caustic solution is done to maintain neutral pH of wastewater from Caustic Dosing

Tank (CDT) or Acid Dosing Tank (ACDT) as per requirement by gravity. Then after, neutralized wastewater

shall go to Flash Mixer-1 (FM-1) by gravity. Alum and Polyelectrolyte shall be dosed from Alum Dosing Tank

(ADT) and Poly Dosing Tank (PDT) respectively by gravity into FM-1 to carry out coagulation by using a Flash

Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler-1 (PTS-1). Clear supernatant from

PTS-1 shall be passed in Aeration Tank (AT-1) Here, Condensate from Multiple Effect Evaporator (MEE) shall

be added. Biodegradation of organic matter of the wastewater shall be carried out by bacteria (suspended

growth) in the AT-1 and for that oxygen shall be supplied by 2 nos. of air blowers (B-02) through diffusers. Air

blowers also keep MLSS in suspension. Nutrients will be added from NDT to Aeration Tank-1 for growth of

Bacteria.

Then after, wastewater shall go to Secondary Settling Tank-1 (SST-1) from AT-1. Here, the suspended solids shall

be settled. Sludge shall be removed from bottom of SST-1 and pumped to AT-1 to maintain MLSS and excess

activated sludge shall be sent to Sludge Sump (SS).

Clear supernatant from SST-1 shall go to Aeration Tank-2 (AT-2). Here biodegradation of left out organic matter

of the wastewater shall be carried out by bacteria (suspended growth) and for that oxygen shall be supplied by

two nos. of blowers (B-03) with help of diffusers. Then after, wastewater shall go to Secondary Tube Settler-2

(SST-2) from AT-2. Here, the suspended solids shall be settled. Activated sludge shall be removed from bottom

of SST-2 and pumped to AT-2 to maintain MLSS and remaining will be sent to SS.

Clear effluent is the collected in of Intermediate Sump (IS) by gravity. Thereafter, the wastewater shall be passed

through Multi Grain Filter (MGF) to remove left out TSS and Activated Carbon Filter (ACF) for final effluent

polishing. After tertiary treatment, Filter water is collected Treated Water Sump (TWS) before sent to GIDC

Drain(CETP).

Sludge settled in PTS-1 and excess sludge from SST-1 & 2 shall be collected in Sludge Sump then sludge

shall be pumped to Filter Press where, dewatering shall be carried out before storage in HWSA and

ultimate disposal to TSDF. Filterate from FP shall be sent to CET-1 for further treatment.

58

For High COD & TDS Stream

The high COD & TDS streams from the manufacturing process plants shall be collected in Collection cum

Equalization Tank-2 (CET-2). Pipe grid is provided at bottom of the CET-2 to keep all suspended solids in

suspension and to provide proper mixing. 2 nos. of Air Blowers (B-04) shall supply air through to pipe grid.

Then after, equalized wastewater shall be pumped to Neutralization Tank-2 (NT-2) where the continuous

addition and stirring of Caustic solution is done (to maintain neutral pH of wastewater) from Caustic Dosing Tank

(CDT) or Acid Dosing Tank (ACDT) as per requirement by gravity. Then after, neutralized wastewater shall go to

Flash Mixer-2 (FM-2). Alum & Poly shall be dosed from Alum Dosing Tank (ADT) & Poly Dosing Tank (PDT)

respectively by gravity into FM to carry out coagulation by using a Flash Mixer. Then after, solid from

wastewater shall be settled in Primary Tube Settler-2 (PTS-2). Sludge settled at bottom shall be sent to Sludge

Sump. Clear supernatant from PTS-2 shall be collected in Holding Tank (HT). Then effluent shall be pumped to

Stripper (S) for removal of solvent. After that effluent shall collected in MEE Feed Tank (MFT).

Then effluent shall be sent to four stages Evaporator. Condensate from MEE shall be collected in Condensate

Storage Tank (CST) and then pumped back to Aeration Tank-1 for further Treatment. Agitated Thin Film Dryer

(ATFT) is provided for dewatering of solids produced in the Evaporator. Dry cake from ATFT shall be collected

and stored in HWSA for ultimate disposal to TSDF.

59

Size of Units

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

L x B x (LD+FB) No. MOC/ Remark

Stream I (Low COD & TDS Stream) 67 m3/D

1 Screen Chamber (SC-01) 3.0 m x 0.8 m (0.05 m+0.5 FB) 1 RCC M25+A/A

Bk. Lining

2 Collection cum Equalization Tank-

1 (CET-01)

2.8 x 2.8 x (2.5 + 0.5 FB) 1 RCC M25+A/A

Bk. Lining

3 Neutralization Tank (NT-01) 1.2 x 1.2 x (2.0+ 0.5 FB) 1 RCC M25+A/A

Bk. Lining

4 Flash Mixer-1 (FM-1) 1.2 x 1.2 x (1.8 + 0.7 FB) 1 RCC M25

5 Primary Tube Settler-1(PTS-01) 2.5 x 2.0 x (1.5 SWD + 1.0 HB +

0.7 FB)

1 RCC M25

6 Aeration Tank-1 (AT-01) 10.0 m x 6.0 m x (4.0 m+0.5 m) 1 RCC M25

7 Secondary Settling Tank-1 (SST-01) 4.0 m x 2.5 m x

(2.5 m + 1.0 HB+0.5 FB)

1 RCC M25

8 Aeration Tank-2 (AT-02) 8.0 m x 6.0 m x (4.0 m+0.5 m) 1 RCC M25

9 Secondary Settling Tank-2 (SST-02) 4.0 m x 2.5 m x

(2.5 m + 1.0 HB+0.5 FB)

1 RCC M25

10 Intermediate Sump (IS-01) 3.0 m x 3.0 m x (2.5 m+0.5) 1 RCC M25

11 Multi Grain Filter (MGF) (MGF-01) 6 m3/hr 1 FRP

12 Activated Carbon Filter (ACF-01) 6 m3/hr 1 FRP

13 Treated Water Sump (TWS-01) 5.0 m x4.0 m x (3.0 m+0.5 FB) 1 RCC M25

14 Sludge Sump(SS-01) 3.0 m x 3.0 m x (2.5 m + 0.5) 1 RCC M25

15 Filter Press(FP-01) 30 m3

/ day 1 PP + MS

60

Stream II (High COD & High TDS stream) 60 m3/D

Sr.

No.

Name of Unit Size (m X m X m) No.

MOC / Remark

1 Collection Cum Equalization

Tank-2 (CET-2)

2.8 x 2.8 x (2.5 + 0.5 FB) 1 RCC M25 +

A/A BK. Lining

2 Neutralization Tank-2 (NT-2) 1.2 x 1.2 x (2.0+ 0.5 FB) 1 RCC M25 +

A/A BK. Lining

3 Flash Mixer-2 (FM-2) 1.2 x 1.2 x (1.8 + 0.7 FB) 1 RCC M25

5 Primary Tube Settler-2 (PTS-2) 2.5 x 2.0 x (1.5 SWD + 1.0

HB + 0.7 FB)

1 RCC M25

6 Holding Tank (HT) 4.0 x 3.0 x (2.5 +0.5 FB) 1 RCC M25

7 MEE Feed Tank (MFT) 6.0 x 4.0 x (2.5 + 0.5 FB) 1 RCC M25

8 Stripper, Four Stage Evaporators,

Agitated Thin Film Dryer (ATFT)

60 m3/D 1 RCC M20

9 Condensate Storage Tank (CST) 3.0 x 2.0 x (2.5 +0.5 FB) 1 RCC M25

61

Flow Diagram:

62

Annexure -6

Details of hazardous waste generation, storage & disposal

Type of waste &

Category

Source Existing Additional

Total Disposal Method

ETP Sludge

(Cat. 34.3)

ETP -- 30

MT/Month

30

MT/Month

Collection. Storage,

Transportation and

dispose to TSDF

Spent solvent

(Cat. 20.2)

Process 0.0

MT/Month

110.5

MT/Month

110.5

MT/Month

Collection, Storage,

& Reprocess/Reuse

back in process.

Discarded Drums

/Containers

(Cat. 33.3)

Process 16

Nos/Month

464

Nos/Month

480

Nos/Month


Transportation,

Disposal by selling to

registered recycler

Iron Sludge Process -- 1227

MT/Month

1227

MT/Month


Transportation and

dispose to TSDF or

send to cement

industries

Organic Residue Distillation -- 100

MT/Month

100

MT/Month


Transportation and

dispose to common

incineration Site or co-

processing in cement

industries

Inorganic Salt Process -- 3000

MT/Month

3000

MT/Month


Transportation and

dispose to TSDF

Spent HCL Process -- 272

MT/Month

272

MT/Month


Transportation and sell

to end user

Sulphuric Acid Process -- 2248

MT/Month

2248

MT/Month


Transportation and sell

to end user

Process Sludge Process -- 180

MT/Month

180

MT/Month


Transportation and

dispose to common



industries

63

Spent Carbon Process -- 12

MT/Month

12

MT/Month


Transportation and

dispose to common



industries

64

Annexure -7

Details of flue gas & proposed pollution control equipment

Particulars Fuel Fuel Quantity Stack height Emission

Norms

Existing scenario

Boiler (800

kg/hr.)#

Natural Gas 150 SCM/day 11 m PM<150

mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

Proposed Scenario after expansion (Flue Gas Emission)

Boiler (3000

kg/hr.)


mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

TFH (2 lakh

kcal/hr.)


mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

D.G.Set (250

KVA)

Diesel 83 lit/hr. 11 m PM<150

mg/Nm3

SO2< 100 ppm

NOx< 50 ppm

Proposed Scenario (Process Gas Emission)

Process Vent* -- -- 11m HCl < 20

mg/Nm3

Process Vent* -- -- 11m SO2 < 40

mg/Nm3

# Existing Boiler (800 kg/hr.) will be replaced by new Boiler (3000 kg/hr.) in proposed

scenario after expansion

* Two stage scrubber

65

Annexure -8

Expected Noise Level

Sr.

No.

LOCATION NOISE LEVEL

Day Time Night Time

1. Near FG godown (E) 62.0 dB(A) 60 dB(A)

2. Near D.G. Set room (S) 68.0 dB(A) 66 dB(A)

3. Near Boiler (W) 65.0 dB(A) 62 dB(A)

4. Near plant (N) 67.0 dB(A) 64 dB(A)

66

Annexure -9

Storage Details of Hazardous Chemicals

Raw Material/ finished goods CAS No Source Means

of

storage

Means of

transport

Max.

Qty.

stored

MT

Raw Materials

Styrene Monomers 100-42-5 Local/Import Tank By Road 25.0

Acrylic Acid 79-10-7 Local/Import Tank By Road 20.0

Alpha Methyl Styrene 98-83-9 Local/Import Tank By Road 20.0

Monomethyl Amine 74-89-5 Local/Import Drums By Road 10.0

Ethyl Carbitol 111-90-0 Local/Import Tank By Road 10.0

Catalyst -- Local/Import Drums By Road 1.0

2 Ethyl Hexyl Acrylate 103-11-7 Local/Import Drums By Road 5.0

Butyl Acrylate 141-32-2 Local/Import Tank By Road 5.0

Ethyl Acrylate 140-88-5 Local/Import Tank By Road 5.0

Methyl Methacrylate (MMA) 80-62-100 Local/Import Drums By Road 5.0

Methacrylic acid (MAA) 79-41-4 Local/Import Drums By Road 5.0

Wax Emulsion -- Local/Import Drums By Road 5.0

Surfactants -- Local/Import Drums By Road 5.0

Ammonia 7664-41-7 Local Drums By Road 2.0

Ammonium per Sulphate APS 7727-54-0 Local Bags By Road 2.0

Methanol Local/Import Drums By Road 2.0

Acetic Anhydride Local/Import Drums By Road 2.0

Sulphuric Acid Local Tank By Road 20.0

Nitric Acid Local Tank By Road 10.0

Benzoyl Chloride Local/Import Drums By Road 2.0

Para Formaldehyde Local/Import Drums By Road 2.0

Benzene Local/Import Drums By Road 2.0

Phenol Local/Import Drums By Road 2.0

IPA Local/Import Drums By Road 2.0

THF Local/Import Drums By Road 2.0

Acetone Local/Import Drums By Road 2.0

MDC Local/Import Drums By Road 2.0

Acetic Acid Local/Import Drums By Road 2.0

Products

Styrene Acrylic Resin (Synthetic

Monomer)

Product By Road

Emulsion Polymers Product By Road

4-NPI Product By Road

67

Annexure – 10

Socio - Economic Impacts

1) Employment Opportunities

The manpower requirement for the proposed expansion project is being expected to

generate some permanent jobs and secondary jobs for the operation and maintenance of

plant. This will increase direct / indirect employment opportunities and ancillary business

development to some extent for the local population.

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

environment.

2) Industries

Required raw materials and skilled and unskilled laborers will be utilized maximum from the

local area. The increasing industrial activity will boost the commercial and economical status

of the locality, to some extent.

3) Public Health

The company regularly examines, inspects and tests its emission from sources to make sure

that the emission is below the permissible limit. Hence, there will not be any significant

change in the status of sanitation and the community health of the area, as sufficient

measures have been taken and proposed under the EMP.

4) Transportation and Communication

Since the existing factory is having proper linkage for the transport and communication, the

development of this project will not cause any additional impact.

In brief, as a result of the proposed there will be no adverse impact on sanitation,

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

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

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

68

Annexure-11

__________________________________________________________________________

Proposed Terms of Reference for EIA Studies

1. Project Description

• Justification of project.

• Promoters and their back ground

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

industries, surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Existing infrastructure facilities

• Water source and utilization including proposed water balance.

• List of Products & their capacity

• Details of manufacturing process of proposed products

• List of hazardous chemicals

• Mass balance of each product

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

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

in 5 km area.

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

site.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

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

the study area were surveyed.

4. Impacts Identification And Mitigatory Measures

• Identification of impacting activities from the proposed project during construction and

operational phase.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

69

• Proposed schedule for environmental monitoring including post project

6. Risk Assessment

• Objectives, Philosophy and methodology of risk assessment

• Details on storage facilities

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

capabilities to be adopted.

• Identification of hazards

• Consequence analysis

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Information on Rain Water Harvesting

9. Green Belt Development plan

Documents

PROPOSED EXPANSION OF RESINS, PHARMACEUTICAL …