PROPOSED EXPANSION OF SYNTHETIC ORGANIC CHEMICALS …environmentclearance.nic.in/writereaddata/Online/TOR/30_Jun_2016... · No Proposed exp ansion is within existing premises located

1

FORM-I

for

PROPOSED EXPANSION OF SYNTHETIC ORGANIC

CHEMICALS AND PESTICIDE INTERMEDIATES IN

EXISTING UNIT

of

M/s. ORGANIC INDUSTRIES PVT. LTD.

PLOT NO. S/163, GIDC, DAHEJ-I, TALUKA: VAGRA,

DISTRICT: BHARUCH-392 130, GUJARAT

2

APPENDIX I

(See paragraph - 6)

FORM 1

Sr.

No.

Item Details

1. Name of the project/s M/s. Organic Industries Pvt. Ltd.

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

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. Please refer Annexure –I

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

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. Plot No. S/163

Village GIDC Dahej-I

Tehsil Vagra

District Bharuch – 392 130

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Railway Station: Bharuch (45 km)

Airport: Vadodara (90 km)

11. Nearest Town, city, District Headquarters along

with distance in kms.

Nearest town: Bharuch : 45 km,

Nearest District Head quarter: Bharuch : 45 km

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Village: Dahej, Taluka: Vagra, Dist. Bharuch – 392 130,

Gujarat

13. Name of the applicant M/s. Organic Industries Pvt. Ltd.

14. Registered Address Plot No. S/163, GIDC Dahej-I,

Tal: Vagra, Dist. Bharuch – 392 130, Gujarat

15. Address for correspondence:

Name Mr. Narendra J. Jakkanni

Designation (Owner/Partner/CEO) Director (Works)

Address M/s. Organic Industries Pvt. Ltd.

Plot No. S/163, GIDC Dahej-I,

Tal: Vagra, Dist. Bharuch – 392 130, Gujarat

Pin Code 392 130

E-mail [email protected]

Telephone No. Phone : 02641 –252021/22/23

Mobile: +91 9819498174

Fax No. Fax : 02641 - 252020

16. Details of Alternative Sites examined, if any. NA

3

Location of these sites should be shown on a

topo sheet.

17. Interlinked Projects No interlinked project

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?

Not applicable, as the project is located in GIDC

Dahej-I.

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 Proposed expansion is within existing premises

located in GIDC Dahej-I. Expected cost of the

project is Rs. 5088.47 Lacs (Existing = Rs.

3793.47 Lacs + Proposed = Rs. 1295 Lacs).

Total Plot Area = 1,71,579 m2

Green Belt = 60,000 m2

1.2 Clearance of existing land, vegetation and

Buildings?

No

1.3 Creation of new land uses? No

1.4 Pre-construction investigations e.g. bore

Houses, soil testing?

Yes For details refer Annexure-II

1.5 Construction works? Yes For details refer Annexure-II

1.6 Demolition works? No

1.7 Temporary sites used for construction

works or housing of construction workers?

No

1.8 Above ground buildings, structures or

earthworks including linear structures, cut

and fill or excavations

Yes For details refer Annexure-II

1.9 Underground works mining or tunneling? No

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Off shore structures? No

1.13 Production and manufacturing processes? Yes 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 – V & VI.

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 leading to changes

in Traffic movements?

No

1.20 New or diverted transmission lines or

Pipelines?

No

1.21 Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No

1.22 Stream crossings? No

5

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

Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel or 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

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 Proposed expansion is within existing

premises located in GIDC Dahej-I.

2.2 Water (expected source & competing users)

unit: KLD

Yes The entire water requirement will be met

through GIDC. For detail please refer

Annexure – IV

2.3 Minerals (MT) No

2.4 Construction material – stone, aggregates,

and / soil (expected source – MT)

Yes Construction materials, like steel, cement,

crushed stones, sand, rubble, etc. required for

the project shall be procured from the local

market of the region.

2.5 Forests and timber (source – MT) No

2.6 Energy including electricity and fuels (source,

competing users) Unit: fuel (MT), energy

(MW)

Yes For detail please refer Annexure – IV

2.7 Any other natural resources (use appropriate

standard units)

No

6

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

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

Sr.

No.




4.1 Spoil, overburden or mine wastes No

4.2 Municipal waste (domestic and or commercial

wastes)

No

4.3 Hazardous wastes (as per Hazardous Waste

Management Rules)

Yes Please refer Annexure – VI

4.4 Other industrial process wastes No

4.5 Surplus product No

4.6 Sewage sludge or other sludge from effluent

treatment

Yes

Please refer Annexure – VI

4.7 Construction or demolition wastes No

4.8 Redundant machinery or equipment No

4.9 Contaminated soils or other materials No

4.10 Agricultural wastes No

4.11 Other solid wastes Yes

Please refer Annexure – VI

7

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

Sr.

No.




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 For details Please refer Annexure – VIII

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

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:

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


source of information data with source of

information data

6.1 From operation of equipment e.g. engines,

ventilation plant, crushers

Yes Please refer 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

8

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. All liquid raw materials

shall be transported through pumps and closed

pipelines and no manual handling shall be

involved. 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 final treated effluent will be discharged

through GIDC pipeline in to deep sea.

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.



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

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


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

No Site is located in Dahej-I GIDC, having all required

infrastructure.

This industrial zone is having existing road

infrastructure and power supply are to be utilized.

Local people are employed and no housing is

required. 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

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

No Proposed expansion is within existing premises in

Dahej-I Industrial Estate (GIDC, Gujarat).

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 - Narmada estuary is 3.5 km away.

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 Dahej

9 Area occupied by sensitive man-made land uses

Hospitals, schools, places of worship, community

facilities)

No

10 Areas containing important, high quality or scarce

resources (ground water resources, surface

resources, forestry, agriculture, fisheries, tourism,

minerals)

No

11 Areas already subjected to pollution

environmental damage. (those where existing

legal environmental standards are exceeded)

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

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: June 16, 2016

Place: Dahej

Narendra J. Jakkanni

Director (Works)

M/s. Organic Industries Pvt. Ltd.

Plot No. S/163, G.I.D.C., Dahej-I, Tal.: Vagra,

District: Bharuch-392 130, Gujarat

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.

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 Water, Fuel & Energy Requirements

V Description of Effluent Treatment Plant with flow diagram

VI Details of Hazardous Waste

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

13

ANNEXURE-I

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

SR.

NO.

PRODUCT NAME EXISTING

CAPACITY

(MT/Annum)

ADDITIONAL

PROPOSED

CAPACITY

(MT/Annum)

TOTAL

PROPOSED

CAPACITY

(MT/Annum)

Plant-01 (Existing)

1 Potassium Permanganate 8400 - 8400

2 Boric Acid Technical (All Grades) 24000 - 24000

3 Borax Decahydrate (All Grades) 8400 - 8400

4 Di-Sodium Octaborate Tetrahydrate 1200 - 1200

Plant-02 (Existing)

5 Herbal Products by Herbal Extracts (Water

Based)

1020 - 1020

i. Aswagandha – Withania Somanifera

ii. Brami – Bacopa Monnieri

iii. Andhrographis Pariculata – Kalmegh

iv. Asphalt – Shilajit

v. Azartica Indica – Neem

vi. Asparagus Racemogus – Shatavari

vii. Boswllia Serrata – Salaji Guggal

viii. Commiphora Mukal – Guggal

ix. Garcinia Combogia

x. Glycyrliza Glabra – Mulethi

xi. Gymnema Sylvester – Gurmar

xii. Lagastrolmia Splciosa – Karela

xiii. Momordica Pureins – Kaunch

xiv. Mucana Pureins – kaunch

xv. Ocimum Santium – Tulsi

xvi. Terminalia Arjuna – Arjuna

xvii. Tribulus Terestris - Gokharu

Plant-03 (Existing)

6 Roasted Bentonite Granules 9000 - 9000

7 Soil Conditioner 28800 - 28800

8 Plant Growth Regulator 120 - 120

9 NPK Mixed Granulated Fertilizer 6000 - 6000

Plant-02-A (Proposed)

10 Herbal Products by Herbal Extract (Solvent

based)

- 1020 1020

Plant-04-A (Proposed) - ETHOXILATES & PROPOXYLATES and there condensates

11 Ethylene Oxide / Propylene Oxide Condensate

- Direct Sale

- Internal Consumption

--

4000 4000

12 Anionic Surfactants -- 1000 1000

13 Cationic Surfactants -- 1000 1000

14

14 Blended Surfactants (using Intermediates) -- 2000 2000

15 Powder Surfactants -- 1000 1000

Plant-04-B (Proposed)

16 Sulphocuecinated Products - 250 250

17 Phosphatised Products - 100 100

Plant-04-C (Proposed)

18 Alkonol Amines (Methyl Diethanol Amines) - 10000 10000

Plant-04-D (Proposed)

19 Single Compound 1200 1200

20 Double Compound

21 CBS (50%, 60% & 70%)

Plant-05 (Proposed)

22 Di-Ethyl-Phthalate - 2400 2400

23 Di-Methyl – Phthalate - 2400 2400

24 Di-Methyl – Sulphate - 5400 5400

25 Di-Methyl - Aniline - 2400 2400

26 Di-Ethyl-Aniline - 960 960

27 N-Ethyl-Aniline - 1440 1440

28 Ethyl – Benzyl Aniline - 1200 1200

29 Di-Ethyl-Ether - 1200 1200

Plant-06 (Proposed)

30 Sodium Saccharine - 350 350

31 Lasamide - 350 350

32 3,3’ DINITRODIPHENYL SULFONE - 350 350

Plant-07 (Proposed) – Pesticide Intermediates

33 2- Chloro 6- Nitro Benzonitrile - 300 300

34 4 - Amino Dimethyl Pyridine -

35 4-Amino-2,5-dimethylphenol -

36

4-Chloro-2,6-dimethylbromobenzene

(CLDMBB)

-

TOTAL 86,940 40,320 1,27,260

List of By-Products

By-Productis Existing Quantity Proposed Quantity Total Quantity

Manganese -Silicon 5460 MT/Year i.e.

455 MT/Month

-- 5460 MT/Year i.e.

455 MT/Month

Gypsum 288000 MT/Year i.e.

24000 MT/Month

-- 288000 MT/Year i.e.

24000 MT/Month

Calcium Sulphate

sludge generated

during the

production of CABS

70%

-- 1200 MT/Year i.e.

100 MT/Month

1200 MT/Year i.e.

100 MT/Month

15

Dil. H2SO4 -- 2727

MT/Year i.e.

227 MT/Month

2727

MT/Year i.e.

227 MT/Month

Sodium Phthalate -- 65

MT/Year i.e.

5.4 MT/Month

65

MT/Year i.e.

5.4 MT/Month

Poly -- 375

MT/Year i.e.

32 MT/Month

375

MT/Year i.e.

32 MT/Month

Liquor Ammonia -- 300

MT/Year i.e.

25 MT/Month

300

MT/Year i.e.

25 MT/Month

Ammonium

Chloride

-- 600

MT/Year i.e.

50 MT/Month

600

MT/Year i.e.

50 MT/Month

Cuprous Chloride 185

MT/Year i.e.

15.4 MT/Month

185

MT/Year i.e.

15.4 MT/Month

16

LIST OF RAW MATERIAL

Plant 01 (Existing Plant)


Sr.

No

Name of the Product Quantity

MT/Annum

Name of the Raw Materials Quantity

MT/Annum

01 Potassium

Permanganate

8400 MnO2

KOH

Lime

5880

3360

720

02 Boric Acid Technical(All

Grade)

24000 Calcium Borate

Sulphuric Acid

Potassium Permanganate

Activated Carbon

51000

16500

15

60

03 Borax Decahydrate (All

Grade)

8400 Borax Pentahydrte (Sodium Borate)

Soda Ash

6720

84

04 Di-Sodium Octaborate

Tetra-hydrate

1200 Boric Acid (From Captive Production)

Borax Pentahydrate (Sodium Borate)

792

889.2

Sr.

No.

Raw materials used for Herbal extraction Quantity of Raw

Materials

01

Name of Herbal Part of Herb Used For

Extraction

Aswagandha-(Withania Somanifera), Brami-

(Bacopa Monnieri), Andhrographis

Pariculata (Kalmegh), Asphalt (Shilajit),

Azartica Indica (Neem), Asparagus

Racemogus (Shatavari), Boswllia Serrata

(Salaji Guggal), Commiphora Mukal

(Guggal), Garcinia Combogia, Glycyrliza

Glabra (Mulethi), Lagerstroemia Splciosa

(Karela), Momordica Puriens (Kaunch),

Mucana Puriens (Kaunch), Gymnema

Sylvester (Gurmar), Ocimum Santium

(Tulsi), Terminalia Arjuna (Arjuna), Tribulus

Terestris (Gokharu).

Root, Leaves, stems,

Solid Vock, Bark,

Gums, Fruit, Seeds,

Flakes

3060 MT Any of

them/Annum

02 Calcium Chloride 60 MT/ Annum

03 Caustic Lye 42 MT/ Annum

04 Yellow Dextrin 30 MT/ Annum

05 Sodium Benzoate 3.0 MT/ Annum

17


Sr.

No.

Name of the Products Quantity

MT/Annum

Name of the Raw materials Quantity

MT/Annum

06 Roasted Bentonite

Granules

9000 Bentonite Powder 9060

07 Soil Conditioner 28800 Ball Clay/Gypsum 34560

Bentonite 3000

Dolomite 2100

Sulphur 1440

Magnesium 1440

08 Plant Growth Regulator 120 Black Bentonite Granules 108

Natural Potassium Humet 12

09 NPK Mixed Granulated

Fertilizer

6000 Urea 2088

Di Ammonium Phosphate (DAP) 816

Murat of Potash (MOP) 1020

Single Super Phosphate (SSP) 972

Rock Phosphate 300

Dolamite 558

Plant 02-A (Proposed Plant)

Sr.

No.

Name of the Products Proposed EC

Product Quantity

MT/Annum


MT/Annum

10 Herbal Products by Herbal

Extract (Solvent based)

1020 Raw Herb Roots/Leaves/Stems/ Solid

Vock/Bark/ Gums/ Fruit/Water/

Seeds

Calcium Chloride

Caustic Lye

Yellow Dextrin

Sodium Benzoate

Solvent

CO2 Gas

3060

60

42

30

3.0

120

60

18

Plant 04-A (Proposed Plant)

Sr.

No.

Name of the Products Name of the Raw

Materials

MT/Annum

ETHOXILATES & PROPOXYLATES & THEIR CONDENSATES – 4000

MT/Annum

Ethylene Oxide/PO 3200

Castor Oil 330

Nonyl Phenol 330

Tridecyl Alcohol 150

Lauryl Alcohol 125

Cetosteayl Alcohol 30

Hydrogenated Castor Oil 30

Diethylene Glycol 45

Stearic Acid 5

Oleic Acid 5

Styrenated Phenol 5

P Octyl Phenol 5

Other Hydrophobes 50

Raw Material QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

CABS 1000

ACID SLURRY

BUTANOL

REMAX

LIME POWDER

556

153

211

80

PHOSPHATE ESTERS 1000

ALKYL PHENOL ETHOXYLATE

FATTY ALCOHOL ETHOXYLATE

P2O5

TEA

WATER

485

205

130

12

168

PAP 1000

IPA

P2O5

600

400

611 1000


SULFURIC ACID

IPA

WATER

758

86

129

27

19

SDD PASTE / OTHERS 1000

ACID SLURRY

PROPYLENE GLYCOL

CAUSTIC SODA

UREA

WATER

350

50

50

50

500

MISCELLANEOUS SULFATE (XLA) 1000

ACID SLURRY

CAUSTIC SODA

CASTOR OIL ETHOXYLATE

STEARIC DIETHANOLAMIDE

SALT

WATER

175

30

37

125

20

613

RAW MATERIAL FOR CATIONIC SURFACTANTS

RAW MATERIAL QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

CATIONIC SURFACTANTS 1000

FATTY AMIDE

IMIDAZOLINE

FATTY AMINE

QUATERNARY COMPOUND

100

200

500

200

TOTAL 1000

B. TOTAL RAW MATERIAL FOR CATIONIC SURFACTANTS

PRODUCT QTY.

(MT/Annum)

FATTY ACID

DETA

DEA

NH3

HYDROGEN

DIALKYL AMINE

QUATERNARY COMPOUND

600

75

25

50

50

150

50

TOTAL 1000

20

EMULSIFIERS FOR GENERAL APPLICATIONS

A. RAW MATERIAL FOR INDIVIDUAL PRODUCTS

PRODUCT QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

EC 2000

CASTOR OIL ETHOXYLATES / HYDROGENATED

CASTOR OIL ETHOXYLATES

ALKYL PHENOL ETHOXYLATES

FATTY ALCOHOL ETHOXYLATES

SORBITAN ESTERS ETHOXYLATES

FATTY ACID ETHOXYLATES

ALKYL ARYL SULPHONATES

AROMATIC SOLVENTS

METHANOL

180

400

35

150

35

800

200

200

ADJUVANT FOR GLYPHO 2000

TALLOW AMINE ETHOXYLATES


GLYCERINE ETHOXYLATES

DEG / MEG

GLYCERINE

DEA

WATER

1200

67

266

200

133

67

67

SULFO + PARAQUAT 2000


DEA

G-5

GLYCERINE

DEG

WATER

1000

67

300

232

300

101

METSULFURON 2000

RESIN

A.P.E.

WATER

SILICON DEFOAMER

800

250

930

20

PAD 2000

A. P. E.

DEG

GLYCERINE

750

625

312

21

G-5 313

10 M / AB-91(M) 2000

A. P. E.

DEG

WATER

1285

570

145

MISCELLANEOUS 2000

METHYL ESTERS 2000

B. TOTAL RAW MATERIAL FOR EMULSIFIERS FOR GENERAL APPLICATIONS

PRODUCT QTY.

(MT/Annum)

NONIONIC EO / PO CONDENSATES 1000

CASTOR OIL ETHOXYLATES / HYDROGENATED CASTOR OIL

ETHOXYLATES





FATTY AMINE ETHOXYLATES

GLYCERINE ETHOXYLATE

120

408

22

105

22

250

13

ALKYL ARYL SULFONATE / CABS

SILICON DEFOAMER

RESIN

DEA

METHYL ESTERS

MEG / DEG

GLYCERINE

AROMATIC SOLVENT

METHANOL

WATER

1000

10

105

20

100

125

100

200

200

140

22

Plant 04-B (Proposed Plant)

Sr.

No.


Product Quantity

in MT/Annum


MT/Annum

1 Agro Emulsifiers Tailor made 1200

a) Single compound system Linear Alkyl Benzene Sulphonate

Calcium Hydroxide

N-Butanol

Castor Oil Ethoxylate

Nonyl Phenol Ethoxylate

Styrenated Phenol Ethoxylate

Other Hydrophobe Based Ethoxylate

1020

276

1800

720

720

360

360

b) Two compound system

c) CABS – 50%, 60%, 70%

2 Sulphocuecinated Products 250 Di Octyl Maleate

Sodium Meta Bi-Sulphite Water

DOSS 70%

150

50

5

3 Phosphatised Products 100 Nonyl Phenol Ethoxylate,

2 Phosphorous Pentoxide

90

13

Plant 04-C (Proposed Plant)

Sr.

No.


Product Quantity

in MT/Annum


MT/Annum

1 Alkonol Amines

( Methyl Diethanol Amines)

10000 Ethylene Oxide

Mono Methyl Amine

7800

2750

Plant 05 (Proposed Plant)

Sr.

No.


Product Quantity

in MT/Annum

Name of the Raw

Materials

Quantity

MT/Annum

1 Di-Ethyl Phthalate 2400 Ethanol

Phthalic Anhydride

Caustic Flake

Sulfuric Acid

1440

1632

48

12

2 Di-Methyl Phthalate 2400 Methanol

Phthalic Anhydride

Caustic Flake

1200

1920

48

3 Di-Methyl Sulphate 5400 Methanol

Liquid SO3 Caustic Flake

3240

3672

81

4 Di-Methyl Aniline 2400 Methanol

Aniline

1392

2016

5 Di-Ethyl Aniline 960 Ethanol

Aniline

864

653

6 N-Ethyl Aniline 1440 Ethanol

Aniline

828

1210

7 Ethyl Benzyl Aniline 1200 N Ethyl Aniline 780

23

Benzyl Chloride

Caustic Flakes

720

252

8 Di-Ethyl Ether 1200 Ethanol

Sodium Bi Sulphite

Caustic Flakes

2340

150

60

Plant 06 (Proposed Plant-Speciality Chemicals)

Sr.

No.


Product Quantity

in MT/Annum


MT/Annum

1. Sodium Saccharine 350 Sacchrin

Potassium Permanganate

Ammonia

Toluene

CSA

Potassium Pentachloride

Caustic Lye (48%)

600

305

200

980

135

268

327

2. Lasamide 350 2,4 DCBA

CSA

Ammonia

HCl

950

4720

720

1296

3. 3,3’ DINITRODIPHENYL

SULFONE

350 Diphenyl Sulfone

Sulphuric Acid

Nitric Acid

750

3750

477

Plant 07 (Proposed Plant-Pesticide Intermediates)

Sr.

No.


Product Quantity

in MT/Annum


MT/MT

1 2- Chloro 6- Nitro Benzonitrile

300 2:3 DCNB

DMF

NaCN

CuCN

Ammonia

Sodium Hypochlorite soln

MCB

1.10

0.23

0.23

0.15

0.80

0.87

2.97

2 4 - Amino Dimethyl Pyridine Pyridine

Di Methyl Amine

Catalyst – Raney Nickel

Chlorine

MDC

Soda Ash

0.73

2.10

0.01

0.59

0.85

0.20

3 4-Amino-2,5-dimethylphenol

(AMP)

Sulphanilic Acid

2,5-dimethylphenol

Sodium Nitrate

Sodium Carbonate

1.55

1.04

0.65

0.46

24

Sodium Hydrosulphide

HCl

Casutic

4.79

1.95

1.70

4 4-Chloro-2,6-

dimethylbromobenzene

(CLDMBB)

2,6 Dimethylaniline

Chlorine

HCL -30%

EDC

Caustic lye 48%

Acetic Acid

Sodium Nitrite

HBr 48%

CuBr

0.99

0.31

1.06

1.20

0.23

0.12

0.45

0.64

0.20

25

ANNEXURE-II

LAYOUT MAP OF THE PLANT

26

ANNEXURE-III

BRIEF PROCESS DESCRIPTION

Process Description of Potassium Permanganate

Potassium Permanganate is manufactured by the following process which consists of mainly

two stages

First Stage

Potassium Hydroxide Liquid is taken in reactor. Manganese dioxide powder is added in

batches at 2-3 hrs intervals. Air is bubbled for oxygen which is required for oxidation in

reaction. Reaction takes place at 2100C. Temperature is achieved by circulating hot oil in

jacket of reactor. Potassium Hydroxide, Manganese Dioxide and air are mixed by agitator at

high rpm. Intermediate product Potassium Manganate is formed. The whole batch is

transferred to settler where intermediate product Potassium Manganate gets settled.

Supernant is taken back in reactor and next batch is started.

Settled Potassium Manganate is diluted with mother liquor and transferred to settler cum

cooler. Batch is cooled with running cooling water in coils. Here also potassium Manganate

is settled and cooled. Supernant is removed by pumping and settled potassium Manganate

is taken down for leach preparation where mother liquor and wash water is added.

Leach batch is prepared above is filtered through filter press. In filter press solid impurities

are filtered. Filter press cake is taken to sludge mixing tank where under stirring batch is

transferred to KOH recovery section. Here sludge is washed with water several times to

recover Potassium Hydroxide. Washed solids are neutralized with acids. Then solids are

again filtered. Water is used for gardening and solid waste is disposed off and used for land

filling. Filtered leach is taken in cell feed tanks where the solution is heated up to 650C by

passing steam in steam coils.

Second Stage

Potassium Manganate solution which is filled in cell feed tank and heated to 650C is

circulated in electrolyte cells. Rectifiers are used to get direct current which is passed in

electrolytic cells. Batch takes 6hrs whereby potassium Manganate is converted to potassium

permanganate. After the reaction is over cell feed tank solution is transferred to vacuum

crystallizer where batch is cooled over crystals of potassium permanganate are formed and

settled. Settled potassium permanganate crystals are centrifuged in centrifuges.

Product 1

Centrifuged crystals are dried in rotary drier. Dried crystals are passed through vibro sieve to

remove big lumps. Screened crystals are packed and marketed as Technical Grade

Potassium Permanganate.

Product 2

Centrifuged crystals are taken to crystal dissolving tank where water is added and heating is

done to increase the temperature up to 800C. Agitator is started to dissolve the crystals. Hot

solution is filtered through filter press. Filtered solution is stored in recrystallisation tanks

where it is cooled by natural cooling. After batch is cooled, solution is pumped out and

crystals are separated, centrifuged and dried. Dried crystals are packed and marked as Pure

Grade Potassium Permanganate.

27

Product 3

Technical Grade dried potassium permanganate is taken in blender where anti-caking agent

is added upto 2% by weight. Blended material is passed through vibro sieve where fine

powder is separated. After fines are separated product received is free flowing Grade

Potassium Permanganate. This is for export to USA fines separated are packed and sold as

technical grade potassium permanganate.

Supernant separated from settler cum cooler is taken in a tank where lime is added, stirring

is done to convert potassium silicate to potassium hydroxide and calcium silicate. Solution is

filtered through filter press where solids are removed. These solids are taken to KOH

recovery section where KOH is recovered by washing. Wash water is disposed off for land

filling. Filtered solution received from filter press is concentrated first in double effect

evaporator where potassium permanganate and potassium Manganate is separated, then

further concentrated to 725 gpl of KOH. This concentrated potassium hydroxide is added to

reactors in first stage.

28

Chemical Reaction

29

Process Flow Diagram

30

Process Description of Boric Acid

Boric Acid is produced by decomposition of Ulexite with Sulfuric Acid to form Boric Acid and

Calcium Sulphate (Gypsum). Ulexite is charged in the Boric Acid mother liquor to form a

slurry which is fed to ball Mill for grinding the Ulexite Ore Slurry to form a fine homogenous

slurry having (Slurry 80% passing through 60 mesh).

This slurry is passed to the 1st

stage reaction where the slurry is preheated before the

sulfuric acid addition is done. Sulfuric acid is added till the required pH 5.3 +/- 0.2 is attained

at a temp of 900C +/- 5

0C potassium permanganate, super floc and activated carbon is

added, if required and the mass is digested for ¼ hr at 900C +/- 5

0C temp.

When the first stage reaction is completed the decomposer batch is filtered in 1st

stage filter

press where the calcium sulphate is precipitated out and the filtrate is sent to an oxidation

and 2nd

stage reaction.

Potassium permanganate is added in the oxidation vessel and sulfuric acid is added to get

the pH 2.5 +/- 0.5 at a temp of 900C +/- 5

0C, the mass is digested for ½ hr and filtered

through 2nd

stage filter press. The filtrate is collected in the granulator where the boric acid

liquor is cooled to 420C +/- 2

0C.

On cooling the boric acid liquor is passed through the 3rd

stage filter press where the

granules boric acid is separated from the ML and is send back to the ML storage tank. Wet

Boric Acid Cake is dumped in the leaching tank where it contains ML of Boric Acid, circulated

through ion exchange column. Wet Boric Acid Slurry is fed to centrifuge where the granules

Boric Acid are separated and ML is passed to dissolver tank for passing through ion

exchange column. Boric Acid is dried in the Rotary Drier and packed for Boric Acid granular

product.

Powdered Boric Acid is produced by grinding granular Boric Acid in the grinder.

Chemical Reaction

31

Flow Diagram of Boric Acid Plant

33

Process Description of Borax Decahydrate from Pentahydrate

Borax in the form of Borax Decahydrate is produced by dissolution of Pentahydrate in Borax

ML/water followed by oxidation, filtration, granulation, centrifuging and drying.

Pentahydrate loose from jumbo bags is heated to 900C +/- 95

0C for 1 hr minimum to form

thick liquor (slurry).

The concentrated liquor (slurry) is then oxidized where oxidizing agent KMnO4 is added, if

require to oxidize metallic impurities. After oxidation the mass is digested at 900C +/- 5

0C for

½ hr and then filtered through filter press and taken into granulator where this liquor is

cooled from 900C to 42

0C +/- 2

0C.

After cooling the solid liquid separation is done in centrifuge from where ML is recirculated

and Borax granules is separated from centrifuge, then dried in a rotary dryer and packed as

Borax Granular Powder. Borax is produced by grinding the granules/crystal prior to grinder

classifier is adjusted according to the mesh requirement viz. (325 mesh, 200 mesh, 100

mesh, 60 mesh).

For Borax Decahydrate Crystals

After oxidation the mass is digested at 9000C +/- 50

0C for ½ hr and then filtered through

filter press and taken into the crystal tanks for normal cooling. After 4-5 days of natural

cooling the crystals formed on the rods, side & bottom of the tank is extracted and packed

as Borax Decahydrate Crystal Technical.

Chemical Reaction

Na2B4O7.5H2O + 5H2O Na2B4O7.10H2O

291 90 381

34

Flow Diagram of Borax Decahydrate Plant

36

Process Description of Disodium Octaborate Tetrahydrate

The process involves reaction between Borax Decahydrate with Boric Acid to form Disodium

Octaborate Tetrahydrate. It is manufactured by dissolving Borax Decahydrate in water. The

mass is heated after which Boric Acid is added to form Disodium Octaborate. The hot

solution is filtered and received in a service tank, and then spray dried to give fine powder of

Disodium Octaborate Tetrahydrate.

Note: 12 moles of water is evaporated during spray drying

Chemical Reaction

Flow Diagram of Disodium Octaborate Tetrahydrate

37

Process Description of Herbal Products (Water Based)

1. Raw herb sorted out foreign particles

2. Pulverized the herb

Ist

Extraction

3. Charge water then raw herb

4. Heat it to reflux

5. Maintain the reflux temperature and circulated the liquid 4 hrs.

6. After completion of extraction, transfer the extracted liquid to concentrator

7. Distill out water reuse in next extraction

IInd

Extraction

8. The distilled water + remake-up volume up to required level

9. Repeat the extraction as on step 4 & 5

10. After completion of 2nd extraction transferred to the concentrator

11. Repeat the process of step no. 7

12. Finally combine the concentrated and extracted liquid.

Drying (Spray Drying)

13. Charge the liquid in the feed tank of the spray dryer

14. Already preheated chamber of the spray dryer, feed the liquid through top atomizer

(nozzle)

15. The liquid is converted into powder form

16. The dried material is packed as per requirement.

38

Flowchart

40

Process Description of Bentonite Granules

First of all we charged the basic Bentonite Powder in a mixture machine and allow to

rotating with rotor and then pass through Granulator Machine here lightly impregnation

done with water for round boll shape. Then after materials carry forwarded through

conveyer belt and pass with Dryer for Strength making, here material allow to give hot air

for remove the moisture and backed the product then it’s comes and pass through Cooler

system, other fine particle carry with exhaust air pass through Cyclone Separator and exes

air goes to atmosphere and dust will be collected in Bag filter and reuse in product again.

Granules allow to cool and pass through sew machine for segregation in different mess size

and then pack in plastic bag and ready to dispatch. In material cooling system, cyclone

separators attached for collect the fine particle in bag filter and reuse it again in product as

a raw material

Flow Chart

41

Process Description of Soil Conditioner

First of all we charged the basic raw materials in a mixture machine and allow to rotating

with rotor and then pass through Granulator Machine here lightly impregnation done with

water for round boll shape. Then after materials carry forwarded through conveyer belt and

pass with Dryer for Strength making, here material allow to give hot air for remove the

moisture and backed the product then it’s comes and pass through Cooler system, other

fine particle carry with exhaust air pass through Cyclone Separator and exes air goes to

atmosphere and dust will be collected in Bag filter and reuse in product again.

Granules allow to cool and pass through sew machine for segregation in different mess size

and then pack in plastic bag and ready to dispatch. In material cooling system, cyclone

separators attached for collect the fine particle in bag filter and reuse it again in product as

a raw material.

Flowchart

42

Process Description of Growth Regulator

There is two raw materials Black Bentonite Granules & Natural Potassium Humet use for

mfg. of plant growth regulator. First we take the Black Bentonite Granules in a mixture

machine and here we allow to impregnation (Natural Potassium Humet) as per % wise

materials required. It is totally formulation process there is no chemically reaction after

impregnation done materials take in tray and allow to dry in open atmosphere pack in bags

and ready to sell.

Flowchart

43

Process Description of NPK Mixed Granulated Fertilizer

All the raw materials charge in a mixture machine and make a mixture add some water for

wetting purpose and then same allow pass through dryer and then pass through granule

making machine. After granulation material pass through different mess size sew machine

for segregate the granules size wise, rest of if any powder particles reuse in again product

manufacturing.

Flowchart

44

Process description for Herbal Products (Solvent Based) - Proposed

1. Raw herb sorted out foreign particles

2. Pulverized the herb

IST

Extraction

3. Charge solvent then raw herb and other in RM as per ratio given in above

4. Heat it to reflux

5. Maintain the reflux temperature and circulated the liquid 4 hrs

6. After completion of extraction, transfer the extracted liquid to concentrator

7. Distilled out solvent reuse in next extraction

IIND

Extraction

8. The distilled solvent + remake-up volume up to required level

9. Repeated the extraction as on step 4 and 5

10. After completion of 2nd extraction transferred to the concentrator

11. Repeated the processing of step no 7

12) Finally combined the concentrated and extracted liquid

Drying (Spray Drying)

13) Charge the liquid in the feed tank of the spray dryer

14) Already preheated chamber of the spray dryer, feed the liquid through top atomizer

(nozzle)

15) The liquid converted into powder form

16) The dried material packed as per requirement

45

ETHYLENE OXIDE CONDENSATES/PROPYLENE OXIDE CONDENSATES

Process Description for Ethoxylation

A. Ethylene oxide tanker unloading process

1) Check the tanker for details like, weight, pressure, temp

2) if ok, take it inside and do the connection as required

3) Depressurize the Ethylene oxide storage tank

4) check the connection for leakage and then start the unloading in to the storage tank

5) As the pressure is reduced in the ethylene oxide tanker fresh nitrogen is allowed to

enter and tanker pressure is maintained at 3.5 kgs/sq.cm.

6) As all ethylene oxide is transferred the line valves closed and Nitrogen pressure in

storage tank is taken up to 3.5 kgs/sq.cm.

7) After this the tanker connections removed and allowed the tanker to go.

B. Ethylene oxide transfer from storage tank to batch tank of ethylene oxide

1) check the batch tank weight and pressure and then depressurize the batch tank

2) By opening the valves of storage tank and batch tank the ethylene oxide transfer is

started

3) As the pressure in storage tank is reduced fresh nitrogen is allowed to enter up to

3.5 kgs/sq.cm.

4) As the required quantity is transferred to batch tank, the storage tank valve is closed,

and line is flushed in to batch tank, then the batch tank valve is closed

5) Then nitrogen pressure is taken in the ethylene oxide batch tank.

C. General process of ethoxylation

1) Check the reactor for the empty and clean

2) In clean and dry reactor the required Hydrophobe is charged

3) the charge the catalyst, and close the man hole,

4) take nitrogen pressure and start the heating

5) Heat the reactor slowly up to 120 to 140 deg. Cent.

6) Purge the reactor with nitrogen twice and then take nitrogen pressure up t

0.5kgs/sq.cms.

7) Start the ethylene oxide addition slowly and the reaction is to be controlled at 120 to

175 deg. Cent and the pressure is controlled at 0.5 to 3.5kgs/sq.cms. With the help

of ethylene oxide addition rate and the cooling water as the reaction is highly

exothermic.

8) As the required quantity of ethylene oxide is added the sample is checked for the

required parameters, if OK, then the line is flushed and valves are closed

9) Then it is cooled up to 55deg. Cent. And the Ph. Is adjusted as per required and then

it is filled in required packing.

46

Chemical Reaction

R-X-H + KOH------------> R-X-K + HOH (STEP ONE)

R-X-K + n(CH2CH2O) -----------> R X(CH2CH2O)nk (STEP TWO)

R- X-(CH2CH2O)n K + CH3COOH -----------> R X (CH2CH2O)n H + CH3COOK

Where -X-H- is polar group with an active hydrogen atom, e.g.a carboxyl or hydroxyl group

and R a hydrophobic radical, e.g. an alkyl,aryl or alkyl aryl group. And ethylene oxide is

added to the reactive hydroxyl group.

For ex. Lauryl Alcohol Ethoxylate

C12H25OH + KOH -----------> C12H25OK + HOH (STEP ONE)

C12H25OK + n (CH2CH2O) -------------> C12H25O (CH2CH2O) Nk (STEP TWO)

C12H25O (CH2CH2O)Nk + CH3COOH ------------> C12H25 O(CH2CH2O) nK + CH3COOH

FLOW CHART FOR ETHYLENE OXIDE CONDENSATES

N2

Finished EO

Condensate

Storage.

Ethylene

Oxide

Raw

Material

Reaction

Vessel

47

Material Balance

Material balance is as below for 100kgs product (considering Lauryl alcohol with 15 mole)

Input Qty. (kg) Output Qty. (kg)

C12H25OH 22.64 Product 100

KOH 0.15 Loss 03

(CH2CH2O)n 80.06

CH3COOH 0.15

Total 103 Total 103

48

ANIONIC/CATIONIC SURFACTANTS

Process Description for CABS

1) Charge required quantity of linear alkyl benzene in a reactor

2) Then charge the required quantity of N-Butanol and water

3) Now start the addition of calcium hydroxide slowly so that the neutralization takes

place

4) Check the pH should be neutral

5) After this it is filtered through the filter press and clear filtrate is collected

6) This collected clear filtrate is taken in to the distillation reactor

7) Slowly it is distilled to remove the moisture content and N-Butanol

8) As the concentration is increased and M.C. in the mass is less than 0.5% the material

is cooled

9) Then the product is adjusted as per the required parameters and filled in the

containers.


Linear Alkyl Benzene Sulphonate

N-Butanol

Water

Calcium Hydroxide

REACTOR

FILTER

PRESS

DISTILLATION

UNIT

FINISHED

PRODUCT

49

Material Balance

Material balance is as below for 100 kgs product


Linear Alkyl Benzene

Sulphonate

85 Product 100

N-Butanol 150 Calcium Sulphate formed along with

N-Butanol

30

Water 30 N-Butanol Recovered used in next

Batch

95

Calcium Hydroxide 23 Water removed is utilized 35

Loss 28

Total 288 Total 288

Chemical Reaction

Rxn-1

(C12H25C6H5SO3)2 + Sulphuric acid of product + Ca (OH) 2

(C12H25C6H5SO3)2 Ca + CaSO4

Rxn-2

Linear Alkyl Benzene Sulphonate + Calcium Hydroxide

Calcium Salt of Linear Alkyl Benzene Sulphonate + Calcium Sulphate

50

Mass Balance:

ANIONIC SURFACTANTS

A. RAW MATERIAL FOR ANIONIC SURFACTANTS

PRODUCT QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

ANIONIC SURFACTANTS 1000

CABS

PHOSPHATE ESTERS

SULFATE ESTERS (IM-611) – INTERNAL CONSUMPTION

SULFATE ESTERS (MISC.)

MISCELLANEOUS SURFACTANTS

620

230

60

17

73

TOTAL 1000

B. RAW MATERIAL FOR INDIVIDUAL PRODUCTS

PRODUCT QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

CABS 1000

ACID SLURRY

BUTANOL

REMAX

LIME POWDER

556

153

211

80

PHOSPHATE ESTERS 1000


FATTY ALCOHOL ETHOXYLATE

P2O5

TEA

WATER

485

205

130

12

168

PAP 1000

IPA

P2O5

600

400

611 1000


SULFURIC ACID

IPA

WATER

758

86

129

27

51

SDD PASTE / OTHERS 1000

ACID SLURRY

PROPYLENE GLYCOL

CAUSTIC SODA

UREA

WATER

350

50

50

50

500

MISCELLANEOUS SULFATE (XLA) 1000

ACID SLURRY

CAUSTIC SODA

CASTOR OIL ETHOXYLATE

STEARIC DIETHANOLAMIDE

SALT

WATER

175

30

37

125

20

613

CATIONIC SURFACTANTS

A. RAW MATERIAL FOR CATIONIC SURFACTANTS

PRODUCT QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

CATIONIC SURFACTANTS 1000

FATTY AMIDE

IMIDAZOLINE

FATTY AMINE

QUATERNARY COMPOUND

100

200

500

200

TOTAL 1000

B. TOTAL RAW MATERIAL FOR CATIONIC SURFACTANTS

PRODUCT QTY.

(MT/Annum)

FATTY ACID

DETA

DEA

NH3

HYDROGEN

DIALKYL AMINE

QUATERNARY COMPOUND

600

75

25

50

50

150

50

TOTAL 1000

52

BLENDED SURFACTANT

Production done is batch process. Required qty of intermediate is transferred from

storage tank/drums to homogenizing vessel & mix thoroughly for about 2.-4 hrs to get

homogenize product.

After adjusting the pH & checking other quality parameters material is packed in

Drums/HDPE carboys or store in storage tank. This process involves simple mixing &

standardization. The out put is almost 100% with out generating any bye products.

The process is totally free from effluents. No solid waste & bye products are generated

during the process.

FLOW CHART FOR BLENDED SURFACTANTS

NONIONIC ETHYLENE

OXIDE CONDENSATE 1

NONIONIC ETHYLENE

OXIDE CONDENSATE 2

ANIONIC SURFACTANT

/ CABS

INERT SOLVENT -

WATER

Q.C. Packing Blending and

Standardisation

53

EMULSIFIERS FOR GENERAL APPLICATIONS

A. RAW MATERIAL FOR INDIVIDUAL PRODUCTS

PRODUCT QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

EC 2000

CASTOR OIL ETHOXYLATES / HYDROGENATED

CASTOR OIL ETHOXYLATES





ALKYL ARYL SULPHONATES

AROMATIC SOLVENTS

METHANOL

180

400

35

150

35

800

200

200

ADJUVANT FOR GLYPHO 2000



GLYCERINE ETHOXYLATES

DEG / MEG

GLYCERINE

DEA

WATER

1200

67

266

200

133

67

67

SULFO + PARAQUAT 2000


DEA

G-5

GLYCERINE

DEG

WATER

1000

67

300

232

300

101

METSULFURON 2000

RESIN

A.P.E.

WATER

SILICON DEFOAMER

800

250

930

20

PAD 2000

A. P. E.

DEG

GLYCERINE

750

625

312

54

G-5 313

10 M / AB-91(M) 2000

A. P. E.

DEG

WATER

1285

570

145

MISCELLANEOUS 2000

METHYL ESTERS 2000

C. TOTAL RAW MATERIAL FOR EMULSIFIERS FOR GENERAL APPLICATIONS

PRODUCT QTY.

(MT/Annum)

NONIONIC EO / PO CONDENSATES 1000

CASTOR OIL ETHOXYLATES / HYDROGENATED CASTOR OIL

ETHOXYLATES





FATTY AMINE ETHOXYLATES

GLYCERINE ETHOXYLATE

120

408

22

105

22

250

13

ALKYL ARYL SULFONATE / CABS

SILICON DEFOAMER

RESIN

DEA

METHYL ESTERS

MEG / DEG

GLYCERINE

AROMATIC SOLVENT

METHANOL

WATER

1000

10

105

20

100

125

100

200

200

140

55

OIL FIELD CHEMICALS

A. LIST OF PRODUCTS

1. DEMULSIFIERS

2. CORROSION INHIBITORS

3. SURFACTANTS

4. DEOILER

5. NON EMULSIFIERS

6. ACID EMULSIFIERS

7. WAX DISPERSANTS

8. OTHER MISC. SURFACTANTS

B. RAW MATERIAL FOR INDIVIDUAL PRODUCTS

PRODUCT QTY.

(MT/Annum)

TOTAL QTY.

(MT/Annum)

DEMULSIFIERS 1000

GLYCOL ETHOXYLATE / PROPOXYLATE

RESIN ETHOXYLATE / PROPOXYLATE

ALKYL PHENOL ETHOXYLATE / PROPOXYLATE

FATTY ALCOHOL ETHOXYLATE / PROPOXYLATE

AROMATIC SOLVENT

METHANOL

WATER

170

90

30

30

440

150

90

CORROSION INHIBITORS 1000

IMIDAZOLIN QUATERNARY

FATTY ALCOHOL ETHOXYLATE / PROPOXYLATE

FATTY AMINE ETHOXYLATE

IPA

WATER

416

166

166

83

169

SURFACTANTS 1000

FATTY ALCOHOL ETHOXYLATED / PROPOXYLATED

ALKYL PHENOL ETHOXYLATED / PROPOXYLATED

WATER

METHANOL

200

200

500

100

DEOILER 1000

POLY ACRYL AMIDE

QUATERNARY AGENT

WATER

IPA

500

200

200

100

NON EMULSIFIERS 1000

56


GLYCOL ETHOXYLATED / PROPOXYLATED

METHANOL

WATER

50

250

85

615

ACID EMULSIFIERS 1000

SORBITAN ESTERS

SORBITAN ESTER ETHOXYLATES

855

145

WAX DISPERSANTS 1000

ALKYL PHENOL ETHOXYLATED / PROPOXYLATED 1000

MISCELLANEOUS SURFACTANTS 1000

FATTY ACID

DMAPA

H2O2

MONOCHLORO ACETIC ACID

GLYCOL

WATER

290

125

67

67

100

350

57

Agro Emulsifier

Single Compound Emisifier

Manufacturing Process:

Castor oil ethoxylate with 40 mole ethylene oxide is mixed with nonyl phenol ethoxylate

with 15 mole ethylene oxide and linear alkyl benzene sulphonate( CABS 70 percent) then it

will be ready and pack it.

Mass Balance:


Castor oil ethoxylate with 40 mole

ethylene oxide

60 Product 100

nonyl phenol ethoxylate with 15

mole ethylene oxide

35 Loss 1

linear alkyl benzene sulphonate(

CABS 70 percent)

2

Total 101 Total 101

58

Double Compound Emisifier


Calcium salt of linear alkyl benzene sulphonate ( CABS 70 percent) is mixed with castor oil

ethoxylate with 40 mole of ethylene oxide solvent C9 then it will be ready and pack it.

Mass Balance:


Calcium salt of linear alkyl benzene

sulphonate ( CABS 70 percent)

60 Product 100

castor oil ethoxylate with 40 mole

of ethylene oxide

30 Loss 1

solvent C9 11

Total 101 Total 101

59

Process Description for Sulpho Succinate (DOSS)

1) In clean and dry reactor required quantity of Dioctyl Maleate (DOM) is charged

2) Then water plus DOSS 70% (Dioctyl Sulpho Succinate 70%) is added as per the

required quantity.

3) Then add the required water contain and required quantity of sodium meta bi

sulphite

4) Slowly increase the temperature up to 100 deg. Cent. And it is self exothermic

reaction takes place, allow it to react for four to six hours till the complete

conversion takes place

5) Check for the active matter and if ok, by laboratory for active matter the batch solids

are adjusted as per the requirement, if OK, then to be filled in required containers.


Di octyl Maleate

Water

DOSS

Sodium Meta Bisulphite

Chemical Reaction

C20H36O4 + Na2S2O5 C20H37NaO7S

Dioctyl Maleate Sodium Metabisulphite Dioctyl Sodium Sulfosuccinate

Material Balance

Material balance is as below for 100 kgs product


Dioctyl Maleate 60 Product 100

Water 35 Loss 17

DOSS 2

Sodium Metabisulphite 20

Total 117 Total 117

REACTOR

FINISHED

PRODUCT

(DOSS)

60

Process Description for Phosphate Ester

1) Charge required quantity of Nonyl Phenol Ethoxylate (or product of which phosphate

ester to be prepared)

2) Then slowly phosphorous pentoxide is added as per the required quality

3) During the addition of phosphorous pentoxide the exotherm is controlled at 50 deg.

Cent. By the cooling and phosphorous pentoxide addition

4) As the required acid value is reached, and confirm by Q.C.LAB, the product is cooled

and then filled in suitable packing


Nonyl Phenol Ethoxylate with 9.5 mole Ethylene Oxide

Phosphorous pentoxide

Chemical Reaction

C9H19C6H5O(CH2CH2O)9.5H + 2P2O5 C9H19C6H5O(CH2CH2O)9.5H5P3O10

Material Balance

Material balance is as below for 100kgs product


Nonyl phenol Ethoxylate with 9.5 mole of Ethylene

Oxide

90 Product 100

Phosphorous Pentoxide 13 Loss 03

Total 103 Total 103

REACTOR

FINISHED PRODUCT

(Nonyl Phenol Ethoxylate with 9.5

mole with phosphate ester)

61

BRIEF PROCESS FOR MANUFACTURE OF ETHANOLAMINES / METHYL ETHANOLAMINES

The two raw materials Ethylene Oxide and Ammonia or Mono Methylamine (MMA) in an

aqueous solution are continuously charged into long a tubular reactor under carefully

controlled conditions of temperature, pressure and composition.

The ensuing product after reaction contains a mixture of the ethanolamines/Methyl

Ethanolamines, water and excess ammonia or MMA. This is processed through a series of

towers where the excess ammonia or MMA and water are removed progressively and finally

a dehydrated mixture of the amines is obtained.

The dehydrated mixture of amines is then purified into distillation columns where each of

the amines, namely Monoethanolamine or Methyl Monoethanolamine, Diethanolamine or

Methyl Diethanolamine, Triethanolamine and Poly Ethanolamines are obtained after the

controlled fractional distillation.

The products are collected in intermediate tanks, checked for quality and then are stored in

the respective product storage tanks.

In case of any interruption during the process even for a second (power failure, cooling

water failure, instrument air failure etc) total process will be disturbed, and to stabilize the

process again it will take long time .During this stabilization period huge amount of off spec

material is produced and afterwards it will need to reprocess again. It is actually results

time, energy and raw material loss. So product quality and quantity both are affected in case

of any type of interruption occurred.

Provision has been made to recycle the product back in case non-standard product is

obtained.

As we are using Ethylene Oxide as our main raw material which is very very hazardous and

highly explosive and it is to be kept under nitrogen blanketing and at low temperature at

around 10 deg. Cent. So to keep this low temperature we have run our chilled water plant

and required continuous power supply. At higher temperature there is a chance of

polymerization of E.O . Once polymerization reaction started at higher temperature huge

amount of heat is produced which is not possible to control and may lead to explosion also.

62

Process Flow Diagram:

63

REACTION-1

(CH2 ) 2 O + NH3 → NH2-CH2-CH2-OH

EO + AMMONIA → MEA

MEA + (CH2 ) 2 O → NH(CH2-CH2-OH)2

DEA

DEA + (CH2 ) 2 O → N(CH2-CH2-OH)3

TEA

IN PUT OUT PUT

Sr

no

Raw material MT Product/ Bi Product MT

1 EO 6225 MEA 1875 Product

2 AMMONIA 1575 DEA 3375 Product

3 WATER 1200 TEA 1875 Product

4 Poly 375 Bi Product

5 Effluent 1500 ETP/MME

Total 9000 9000

REACTION-2

2(CH2 ) 2 O + CH3-NH2 → CH3-N(CH2-CH2-OH)2

EO + Mono Methyl Amine → Methyl Di Ethanol Amines

IN PUT OUT PUT

Sr

no


1 EO 7600 MDEA 9500 Product

2 MMA 2700 Poly 400 Bi Product

3 WATER 1500 Effluent 1900 ETP/MME

4

5 11800 11800

REACTION-3

(CH2 ) 2 O + (CH3-CH2 ) 2 NH → (CH3-CH2 ) 2 -N-CH2-CH2-OH EO + Di Ethyl Amine → Di Ethyl Ethanol Amines

IN PUT OUT PUT

Sr

no


1 EO 380 DEEA 930 Product

2 DEA 625 Poly 45 Bi Product


4

64

5 1205 1205

REACTION-4

(CH2 ) 2 O + (CH3 ) 2 NH → (CH3) 2 -N-CH2-CH2-OH

EO + Di Methyl Amine → Di Methyl Ethanol Amines

IN PUT OUT PUT

Sr

no


1 EO 585 DMEA 885 Product

2 DMA 585 Poly 90 Bi Product


4

5 1270 1270

65

Process Description for Di-Ethyl-Phthalate (DEP)

Phthalic Anhydride and Ethanol are charged together in a stainless steel 316 reactor along

with appropriate acid catalyst. Heat is applied in the reactor till temperature is around 110

to 1200C. Reflux starts’, refluxing is carried out for 24 to 28 hrs to complete the reaction,

thus crude DEP is formed. Crude DEP sample is checked by titrating crude DEP sample with

0.1N NaOH solution to conclude the end of the reaction.

This crude DEP is cooled to room temperature 35 to 450C and then washed with 20% caustic

solution to remove the acidity (Phthalic Acid). This neutral DEP is again washed with plain

water to remove the excess alkali and then neutralized DEP is vacuum dried to remove

moisture and filtered through sparkler filter to get pure Di-Ethyl-Phthalate.

Chemical Reaction

2C2H5OH + C6H4(CO)2O C6H4(COOC2H5)2 + H2O

2 Ethanol Phthalic Anhydride Di-Ethyl-Phthalate Water

92 148 222 18

Raw Material

1. Phthalic Anhydride

2. Ethyl Alcohol (Ethanol) – Specially Denatured Spirit

Chemical Properties

1. Colorless oily liquid insoluble in water

2. Specific gravity 1.12 at room temp.

3. Acidity as Phthalic Acid < 0.01%

4. Viscosity 1.5 CPS

5. Purity by GLC 99.5% minimum

Uses

1. Used as a fixative in preparation of perfumes and fragrance

2. Used in manufacture of Agarbatti (Incense Stick)

3. DEP is exported worldwide

Packing

Packed in blue HDPE barrels (225 kgs) and HDPE Carbuoys (35 Kgs)

66

Mass Balance:


Ethanol 610 Product 1000

Phthalic Anhydride 680 Effluent 281

Caustic Flakes 20 Sodium Phthalate 107

Water 200

Total 1388 Total 1388

67

Process Description for Di-Methyl-Phthalate (DMP)

Phthalic Anhydride and Methanol are charged together in a stainless steel reactor along

with acid catalyst. External heating is started (steam heating) in the reactor till the

temperature reaches around 1000C to 120

0C. Reflux starts, this process is carried out for 20

to 24 hrs till the end of the reaction, crude Di-Methyl-Phthalate (DMP) is formed.

This crude DMP is cooled to 400C to 50

0C and then washed with dilute caustic solution to

remove the acidity of unreacted Phthalic Acid. This neutral DMP is again washed with plain

water to remove the excess alkali and then dried under vacuum to make DMP moisture free

and then filtered and stored in storage tank (Pure DMP).

Chemical Reaction

Rxn-1

2CH3OH + C6H4(CO)2O Cat C6H4(COOCH3)2 + H2O

2 Methanol Phthalic Anhydride Di-Methyl-Phthalate Water

Raw Material

1. Phthalic Anhydride

2. Methanol

Mass Balance:


Methanol 500 Product 1000

Phthalic Anhydride 800 Loss 40

Caustic Flakes 20 Effluent 280


68

Chemical Properties

1. Appearance – Clear Colorless Oily Liquid Immiscible in Water

2. Specific Gravity – 1.19 at Room Temperature

3. Molecular Weight - 194

4. Purity by GLC 99.5% minimum

Uses

1. Used as a Plasticizer

2. Used in Mosquito Repellant

3. Used as a Solvent for making Methyl-Ethyl-Ketone-Peroxide used for FRP

4. DMP has got Export market

Packing

DMP is packed in blue HDPE Drums (225 Kgs Net) and 35 Kgs Carbuoys

69

Process Description for Di-Methyl-Sulphate (DMS)

Methanol is continuously evaporated in a vaporizer and the vapors of Methanol super

heated in a heat exchanger is passed through a converter containing Alumina catalyst at

2500C to 260

0C to convert methanol to Di-Methyl-Ether (DME) which is further reacted with

liquid SO3 to form crude Di-Methyl-Sulphate (DMS). This crude Di-Methyl-Sulphate is

purified by vacuum distillation to get pure Di-Methyl-Sulphate (DMS).

Chemical Reaction

Rxn-1

2CH3OH Cat CH3OCH3 + H2O

2 Methanol DME Water

Rxn-2

CH3OCH3 + SO3 Cat C6H4(COOCH3)2 + H2O

DME Di-Methyl-Phthalate Water

Mass Balance:



Liquid SO3 680 Spent Acid 137

Effluent 143


Chemical Properties

1. DMS is odorless colorless liquid immiscible in water

2. Specific Gravity – 1.32

3. Readily Hydrolyses in water

4. Purity by GLC 99% minimum

Note: Very Poisonous and Harmful when inhaled

Uses

1. Used as a very strong methylating agent in manufacturing drug intermediate

2. Used in perfumery industry

3. Used in dyes industry

4. DMS is exported worldwide

Packing

1. Packed in Blue HDPE drums of 250 kgs net

2. Goes in Tanker load also (20 MT)

70

Process Description for Di-Methyl-Aniline (DMA)

Methanol is vaporized and fed into a converter. Methanol gets converted to Di-Methyl-

Ether (DME) which is mixed with Aniline and vaporized and the vapors of mixed DME +

Aniline is fed into another converter at 2600C to get Di-Methyl-Aniline (DMA Crude). This

crude DMA is purified by vacuum distillation to get pure Di-Methyl-Aniline.

Chemical Reaction

Rxn-1

2CH3OH Cat CH3OCH3 + H2O

2 Methanol DME Water

Rxn-2

CH3OCH3 + C6H4NH2 (CH3)2C6H4N + H2O

DME Aniline Di-Methyl-Aniline Water

Chemical Properties

1. DMA is oily colorless to mild yellow colored liquid, immiscible in water

2. Boiling point is 1840C at NTP

3. Purity by GLC 99% minimum

Uses

1. Used in manufacture of Dyes

Packing

Packed in blue HDPE barrels (200 kgs)

Mass Balance:



Aniline 800 Effluent 300

Disti. Residue 40


71

Process Description for N-Ethyl-Aniline, Di-Ethyl-Aniline

Mixture of Ethanol (60%) & Aniline 40% is pumped continuously into a vaporizer. Vapours of

Aniline/Ethanol mixture are fed into a converter at high temperature at 2500C it gets

converted to form N-Ethyl-Aniline 60% + Di-Ethyl-Aniline 35% & unconverted Aniline 5%

(Mixture).

The mixture of N-Ethyl-Aniline, Di-Ethyl-Aniline and Aniline are fed into a rectification

column where Aniline is separated and re-used. Balance mixture of N-Ethyl-Aniline (NEA) &

Di-Ethyl-Aniline (DEA) are fed into separate distillation column where NEA & DEA are

separated to get pure N-Ethyl-Aniline from top of column & pure Di-Ethyl-Aniline from

bottom of the column.

Chemical Reaction

Rxn-1

C2H5OH + C6H4NH2 C2H5C6H4NH4 + H2O

Ethanol Aniline N-Ethyl-Aniline Water

46 92 120 18

Rxn-2

2C2H5OH + C6H4NH2 (C2H5)2C6H4N + 2H2O

2 Ethanol Aniline Di-Ethyl-Aniline Water

92 92 148 36

72

Mass Balance:



Aniline 840 Effluent 150

Disti. Residue 138


73

Ethyl Benzyl Aniline


Caustic solution is mixed with N Ethyl Aniline in a SS reactor under stirring at room

temperature and then benzyl chloride is slowly added into the mixture to form crude Ethyl

Benzyl Aniline which further purified by vaccum distillation to get pure Ethyl Benzyl Aniline.

Chemical Reaction:

C2H5C6H4NH + C6H5Cl + NaOH � C2H5C6H5C6H4N + NaCl + H2O

NEA Benzyl Chloride Caustic Sol. EBA

Mass Balance:


N Ethyl Aniline 630 Product 1000

Benzyl Chloride 600 Effluent (NaCl) 702

Caustic Lye 210 Disti. Residue 38

Water 300


74

Di Ethyl Ether


Ethanol is vaporised and fed into conveter containing De-hydration catalyst to form crude Di

Ethyl Ether, which is further purified by distillation to get pure Di Ethyl Ether.

Chemical Reaction:

2 C2H5OH � C2H5O2C2H5 + H2O

Ethanol Di Ethyl Ether Water

Mass Balance:



Effluent 282

Disti. Residue 158


75

Process Description for Sodium Saccharine

Chemical formula C7H5NO3S Na

Saccharin's Chemical Structure

Molecules contain carbon. There are two main approaches to making saccharine the

Remsen-Fahlberg process (named after the two scientists who discovered the compound)

and the Maumee, or Sherwin.

PROCESS DESCRIPTION

Saccharin is an artificial sweetener with effectively no food energy which is about 300–400.

The word saccharine is used figuratively, often in a derogative sense, to describe something

"unpleasantly over-polite" or "overly sweet". The form used as an artificial sweetener is

usually its sodium salt. Food processing.

Remsen-Fahlberg Process

While production requires multiple steps, the Remsen-Fahlberg process requires reacting

toluene, which has a natural sweet smell, with chlorosulfonic acid, which is a colorless

liquid. This acid compound is then synthesized with a series of compounds, including

potassium permanganate and ammonia. This compound is then heated, and the introduced

heat creates saccharin. Saccharin's hydrogen bonds are the chief contributors to the sweet

taste when consumed. Because this process.

Saccharin, an artificial sweetener that is 3000 times sweeter than sucrose, is composed of

45.90% carbon, 2.73% hydrogen, 26.23% oxygen, 7.65% nitrogen, and 17.49% sulfur.

76

Me(NH4)2CO3

SO2Cl

KMnO4

SO2

NH

SO2NH2

CO2NaO

PCl5

Cl

SO2

N

Chemical Reaction

Mass Balance


Saccharin 600 Product 1000

Potassium permanganate 305 Toluene Loss 30

Ammonia 200 Recovered

Toluene

950

Toluene 980 Liqour

Ammonia

850

Chloro Sulphonic Acid 135 Effluent 1740

Water 1755

Potassium Pentachloride 268

Caustic Lye (48%) 327


77

Lasamide


2,4 Dichloro Benzoic acid is reacted with Chlorosulfonic acid(CSA) at elevated temperature.

The product formed is isolated by quenching in ice water, the product is filtered and

subjected to ammoniation to get Lasamide.

Chemical Reaction:

C7H4Cl2O2 + 2ClSO3H C7H3Cl3O4S + H2SO4 + HCl

2,4 Dichloro Benzoic acid CSA 2,4 Dichloro Benzoic acid Sulfonyl Chloride

C7H3Cl3O4S + 3NH3 C7H8Cl2N2O4S + NH4Cl

C7H8Cl2N2O4S + HCl C7H5Cl2NO4S + NH4Cl

Mass Balance:


2,4 Dichloro Benzoic acid 950 Product 1000

Chlorosulfonic acid 4720 Effluent 1810

Ammonia 720 Dil. Sulphuric Acid 1316

HCl 1296 Dil. HCl 4150

Water 2320 Ammonium Chloride 1730


78

3,3’ DINITRODIPHENYL SULFONE

Brief manufacturing process:-

Diphenyl Sulfone is dissolved in concentrated Sulfuric acid, and fuming Nitric acid is added at

low temperature, after addition the reaction mass is quenched in ice water to get a slurry in

60% Sulfuric acid, filtered, the cake is washed and dried.

Chemical Reaction:

(C6H5)2SO2 + HNO3 + H2SO4 O2NC6H5SO2H5C6NO2 + H2O + H2SO4 Diphenyl Sulfone Nitric Acid Sulfuric acid 3,3’ Dinitrodiphenyl Sulfone Water Sulfuric acid

Mass Balance:


Diphenyl Sulfone 750 Product 1000

Sulfuric Acid 3750 Dil. H2SO4 6477

Nitric Acid 477

Water 2500


79

Pesticide Intermediates

2- Chloro 6- Nitro Benzonitrile


2:3 Dichloro Nitro Benzene (2:3 DCNB) on Cyanation by Sodium cyanide and cuprous

cyanide gives the nitrile product as 2 - Chloro 6- Nitro Benzonitrile

The excess Sodium cyanide and cuprous cyanide is treated by 10 % Sodium Hydrochloride to

0.2 ppm level and then drained to ETP.

Chemical Reactions:

Material Balance

Sr.

No. Input

Quantity

in Kg Output

Quantity

in Kg

1. 2:3 DCNB 1110.0 Product 1010.0

2. DMF 225.0 Recovered DMF 217.0

3. NaCN 225.0 DMF Loss 8.0

4. CuCN 150.0 MNCB 70.0

5. Water 1500.0 DCNB 40.0

6. Ammonia 800.0 MCB recovered 2955

7. Sodium Hypochlorite

soln 880.0 MCB Loss 45.0

8. MCB 3000.0 Effluent 2991.0

9. Cupric Chloride 530.0

10. Dist. Residue 24.0

TOTAL 7890.0 TOTAL 7890.0

+

NaCl

NO2

2:3 Di Chloro Nitro

Cl

NaCN

+

2- Chloro 6-Nitro

Benzonitrile (CNBN)

MW. - 182.5

+

CuCN

Cl

NO2

Cl

CN

+

CuCl

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