Proposed Expansion Project For Manufacturing of Agrochemical …environmentclearance.nic.in/writereaddata/Online/TOR/03... · 2017-05-03 · PROJECT PRE-FEASIBILITY REPORT For Proposed

PROJECT PRE-FEASIBILITY REPORT

For

Proposed Expansion Project

For

Manufacturing of

Agrochemical Active Ingredients & Intermediates and Fine Chemicals

AT

Plot No. 3505 to 3515, 6008 to 6010,

6301 to 6313 & 6316/B1, GIDC Estate, Ankleshwar

Project Proponent

M/s. Deccan Fine Chemicals (India) Pvt. Ltd.

Project Pre-feasibility report

i

CONTENTS

CHAPTERS S. No. Particulars Page No.

1 EXECUTIVE SUMMARY 1-3 2 INTRODUCTION OF THE PROJECT 4-6

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT 4

2.1.1 IDENTIFICATION OF THE PROJECT 4

2.1.2 DETAILS OF PROJECT PROPONENT 6

2.1.3 NATURE OF THE PROJECT 6

2.2 NEED OF PROJECT & DEMAND-SUPPLY GAP 6

2.2.1 IMPORTS VS. INDIGENOUS PRODUCTION 6

2.2.2 DOMESTIC / EXPORT MARKETS 6

2.2.3 EMPLOYMENT GENERATION DUE TO PROJECT 6

3 PROJECT DESCRIPTION 7-23 3.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT 7

3.1.1 IDENTIFICATION OF THE PROJECT 7

3.1.2 LOCATION 7

3.2 DETAILS OF ALTERNATIVE SITE 9

3.3 SIZE & MAGNITUDE OF OPERATION 9

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS 9

3.5 RAW MATERIAL FOR FINISHED PRODUCT 9

3.6 MATERIAL STORAGE & TRANSPORTATION 13

3.7 RESOURCE OPTIMIZTION & AVAILABILITY 14

3.7.1 LAND 14

3.7.2 BUILDING 14

3.7.3 EQUIPMENTS 14

3.7.4 POWER & FUEL REQUIREMENT 14

3.7.5 WATER 14

3.7.6 MAN-POWER 15

3.8 QUNTITY OF WASTE TO BE GENERATED 15

3.8.1 WASTE WATER GENERATION & MANAGMENT 15

3.8.2 WASTE WATER CHARACTERISTICS 19

3.8.3 WASTE WATER TREATMENT & DISPOSAL 19

3.8.4 AIR EMISSION & CONTROL 21

3.8.4.1 PROCESS EMISSION 21

3.8.4.2 UTILITY EMISSION 22

3.8.4.3 FUGITIVE EMISSION 22

3.8.5 HAZARDOUS/NON-HAZARDOUS WASTES MANAGEMENT 22

3.8.6 NOISE CONTROL 22

3.9 HEALTH & SAFETY MEASURES 22

3.10 ENVIRONMENTAL HEALTH & SAFETY PLAN 23

3.11 POST PROJECT MONITORING PLAN 23

4 SITE ANALYSIS 24-27 4.1 CONNECTIVITY 24

4.2 LAND FORM, LAND USE & LAND OWNERSHIP 24

4.2.1 LANDFORM 24

4.2.2 LANDUSE PATTERN 24

4.2.3 LAND OWNERSHIP 24

4.3 TOPOGRAPHY 24

4.4 SALIENT FEATURES 24

4.5 EXISTING INFRASTRUCTURE 25

Project: Project for manufacturing of Pesticides & Synthetic Organic Chemical ii | P a g e

S. No. Particulars Page No.

4.6 SOIL CLASSIFICATION 25

4.7 CLIMATE & METEROLOGY 25

4.7.1 TEMPERATURE 26

4.7.2 HUMIDITY 26

4.7.3 CLOUD COVER 26

4.7.4 RAINFALL 26

4.7.5 WIND PATTERN 26

4.7.6 SOCIAL INFRASTRUCTURE 26

4.7.7 EDUCATION FACILITY 27

4.7.8 MEDICAL FACILITY 27

5 PLANNING BRIEF 28-29 5.1 PLANNING CONCEPT 28

5.2 POPULATION PROJECTION 28

5.3 AREA STATEMENT 28

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

28

5.5 AMENITIES/FACILITIES 29

5.5.1 DRINKING WATER FACILITY 29

5.5.2 POWER & SUPLY FACILITY 29

5.5.3 COMMUNICATION & BANKING FACILITY 29

5.5.4 TRANSPORT FACILITY 29

6 PROPOSED INFRASTRUCTURE 30-30 6.1 INDUSTRIAL AREA 30

6.2 RESIDENTIAL AREA 30

6.3 GREENBELT 30

6.4 SOCIAL INFRASTRUCTURE 30

6.5 CONNECTIVITY 30

6.6 DRINKING WATER MANAGEMENT 30

6.7 SEWERAGE SYSTEM 30

6.8 INDUSTRIAL WASTE MANAGEMENT 30

6.9 SOLID WASTE MANAGEMENT 30

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY 30

7 REHABILITATION & RESETTLEMENT (R&R) PLAN 31-31 7.1 POLICY TO BE ADOPTED 31

8 PROJECT SCHEDULE & COST ESTIMATES 32-32 8.1 TIME SCHEDULE OF THE PROJECT 32

8.2 ESTIMATED PROJECT COST 32

9 ANALYSIS OF PROPOSAL 33-33 9.1 FINANCIAL & SOCIAL BENEFITS 33

Project: Project for manufacturing of Pesticides & Synthetic Organic Chemical iii | P a g e

LIST OF TABLES

S. No. Particulars Page No. TABLE 1.1 PROJECT SUMMARY 1

TABLE 2.1 LIST OF PROPOSED PRODUCTS 4

TABLE 2.2 LIST OF FORMULATION PRODUCTS 5

TABLE 2.3 LIST OF DIRECTORS 6

TABLE 3.1 LIST OF RAW MATERIALS 9

TABLE 3.2 LIST OF PROPOSED EQUIPMENT 14

TABLE 3.3 TOTAL WATER CONSUPTION (KLD) 15

TABLE 3.4 MAN-POWER REQUIREMENT 15

TABLE 3.5 CATEGORY-WISE WASTEWATER GENERATION (IN KLD) 16

TABLE 3.6 COMPOSITE CHARACTERISTICS OF WASTEWATER TO ETP 19

TABLE 3.7 ETP UNIT DETAILS 21

TABLE 3.8 DETAILS OF PROCESS EMISSIONS 21

TABLE 3.9 SAFETY DETAILS 23

TABLE 3.10 ENVIRONMENT MONITORING PLAN 23

TABLE 4.1 SALIENT FEATURES OF THE PROJECT SITE 24

TABLE 4.2 SUMMARY OF METEOROLOGICAL DATA AT NEAREST IMD STATION –BHARUCH

25

TABLE 5.1 DISTRIBUTION OF POPULATION 28

TABLE 5.2 AREA STATEMENT 28

TABLE 8.1 TOTAL CAPITAL COST PROJECTION 32

TABLE 8.2 RECURRING COST FOR EHS 32

LIST OF FIGURES

S. No. Particulars Page No. FIGURE 3.1 PROJECT SITE 7

FIGURE 3.2 SATELLITE IMAGE OF THE PROJECT SITE 8

FIGURE 3.3 WATER BALANCE DIAGRAM-EXISTING SCENARIO (In kl/day) 17

FIGURE 3.4 WATER BALANCE DIAGRAM-PROPOSED SCENARIO (In kl/day) 18

FIGURE 3.5 PROCESS FLOW DIAGRAM OF ETP 20

LIST OF ANNEXURES

ANNEXURE No. Particulars ANNEXURE-1 NAME CHANGE LETTER

ANNEXURE-2 COPY OF EXISTING CC&A

ANNEXURE-3 (a) COPY OF EXISTING EC

ANNEXURE-2 (b) FORWARDING LETTER TO EC COMPLIANCE REPORT SUBMITTED TO RO BHOPAL

ANNEXURE-4 LAYOUT OF PROJECT SITE

ANNEXURE-5 PROCESS TECHNOLOGY

ANNEXURE-6 STORAGE & TRANSPORTATION OF MATERIALS

ANNEXURE-7 CHARACTERISTICS OF MATERIALS

ANNEXURE-8 LAND DOCUMENTS

ANNEXURE-9 POWER & FUEL CONSUMPTION DETAILS

ANNEXURE-10 UTILITY EMISSION DETAILS

ANNEXURE-11 HAZARDOUS & SOLID WASTE GENERATION & ITS MANAGEMENT

ANNEXURE-12 MEMBERSHIP CERTIFICATE FOR SOLID WASTE DISPOSAL AND COMMON INCINERATION FACILITY

ANNEXURE-13 MEMBERSHIP CERTIFICATE FROM NARMADA CLEAN TECH (NCT) FOR ETP WASTEWATER DISCHARGE


Project: Project for manufacturing of Pesticides & Synthetic Organic Chemical 1 | P a g e

CHAPTER – 1

EXECUTIVE SUMMARY The project is summarized in the below table:

Table1.1: Project Summary

PARTICULARS DETAILS Name of the unit M/s. Deccan Fine Chemicals (India) Pvt. Limited Occupier Mr. Pankaj Ranpura (Site Manager)Products Please refer chapter-2 table 2.1 for the list of products Location Plot No. 3505 to 3515, 6008 to 6010, 6301 to 6313 & 6316/B1, GIDC Industrial

Estate, P.B. No. 142, Ankleshwar-393002, Gujarat. Nature of project

Proposed expansion project for manufacturing of Agrochemical active ingredients, intermediates and fine chemicals

RESOURCES Resource type Requirement SourceLand Existing: 76691 m2

Proposed additional: NIL

GIDC Ankleshwar

Water Existing Operations:Domestic: 130 kl/day Industrial: 565 kl/day Gardening: 70 kl/day Total: 765 kl/day (Fresh – 645 + Recycle - 120) After Proposed Expansion Project: Domestic: 210 kl/day Industrial: 4322 kl/day Gardening: 70 kl/day Total: 4602 kl/day (Fresh – 3849 + Recycle - 753)

GIDC water Supply

Power Existing: 2000 kVA Proposed additional: 29200 kVA

Dakshin Gujarat Vij Co. Ltd. (DGVCL)

Fuel Existing: Natural gas: 24978 SCM/day HSD: 200 liter/hr. After Proposed Expansion Project: Natural gas: 119538 SCM/day HSD: 3750 liter/hr

Natural gas is/will be supplied through Gujarat Gas Company Limited.

HSD is/will be purchased from local market.

POLLUTION POTENTIAL & MITIGATION MEASURES Parameter Potential Mitigation Wastewater Existing Operations:

Domestic: 75 kl/day Industrial: 371 kl/day Total: 441 kl/day After Proposed Expansion Project: Domestic: 145 kl/day Industrial: 1474 kl/day Total: 1619 kl/day

The wastewater generated from the existing operations is total 441 kl/day. Out of which 75 kl/day is domestic wastewater & 371 kl/day is industrial wastewater.

Total 441 kl/day effluent is treated in in-house ETP and out of this 320 kl/day is discharged to NCTL for final treatment & ultimate disposal to deep sea and 121 kl/day is treated in RO.

Permeate from RO @97 kl/day is recycled as cooling tower makeup & 24 kl/day RO reject is sent to MEE.

From MEE, 23 kl/day condensate is recycled as cooling tower makeup



PARTICULARS DETAILS & salt is disposed to TSDF.

After proposed expansion projects, about 1619 kl/day wastewater will be generated. Out of which 145 kl/day is domestic wastewater & 1474 kl/day will be industrial wastewater.

Total 1619 kl/day effluent will be treated in in-house ETP and out of this 862 kl/day will be discharged to NCTL for final treatment & ultimate disposal to deep sea and 757 kl/day will be treated in RO.

Permeate from RO @657 kl/day will be recycled as cooling tower makeup & 152 kl/day RO reject will be sent to MEE.

From MEE, 148 kl/day condensate will be recycled as cooling tower makeup & salt will be disposed to TSDF.

Existing Installations: Steam Boiler 8 TPH - 2 Nos.

(working – 1+ Standby - 1) N. G. Based captive co-gen plant–

1.4 MW - standby D.G. set (250 kVA) - Stand by Incinerator Proposed Additional Installations after Proposed Exapnsion Project: Steam Boiler 25 TPH - 2 Nos DG Set (1500 KVA) – 10

Nos. – All standby

In Existing operations, the company has 2 Nos. of NG fired steam boilers of capacities 8 TPH. (working – 1+ Standby - 1), One NG based Captive Power Plant of 1.4 MW (stand-by unit), incinerator & One D.G. set of 250 kVA.

Natural gas is used as fuel in all installations except D.G. Set.

HSD is used as fuel in D. G. Set. After proposed amendment project

additionally 2 steam boilers of 25 TPH capacity & 10 D.G. sets of 1500 kVA capacity will be installed.

Natural gas will be used as fuel in steam boilers & HSD in D.G. set.

Adequate stack height is/will be provided.

Process gases are/ will be generated in form of HCl, HC, NOx, SO2, CO2, NH3, H2S from manufacturing process.

Multi stage scrubber is/will be provided to scrub out gases generated from the process using water and caustic soda solution.

Raw Materials & Products is/ will be stored in properly designated storage area and under good storage conditions to prevent any volatilities.

Regular monitoring is/ will be done of piping and fittings for checking of any leakages.

Good housekeeping will be maintained in the plant.



PARTICULARS DETAILS Air Emissions Regular and good housekeeping

is/will be done to reduce fugitive emissions.

Hazardous & solid waste

The details of hazardous and solid waste generation and its management is provided in Annexure-11 of the project pre-feasibility report.

Chemical sludge from wastewater treatment and inorganc salt from MEE plant is/ will be disposed to TSDF.

Discarded empty containers is/ will be sold to approved vendors after de-contamination within premises and inspected by AEPS.

Used oil and oil filter is/will be disposed by selling to registered refiners/in-house incineration within the premises/common incineration facility of BEIL, Ankleshwar.

Spent solvent (incinerable organic waste), solvent recovery/recovered solvent, spent carbon (from nitrogen plant) and distillation residue is/will be disposed by in-house incineration within the premises/common incineration facility of BEIL, SEPPL or GSPL or sending to RSPL as an alternative fuel resource or to cement industries for co-processing.

Discarded asbestos (cement sheet/roof sheet, rope, gasket) is/ will be disposed to TSDF after solidification.

Noise Plant premises <75 dB(A) during day time <70 dB(A) during night time

Regular maintenance is/will be done to reduce the noise levels.

D.G. set is/will be provided with acoustic enclosures

Ear plugs is/will be provided to operating personnel.

(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)



CHAPTER – 2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 Identification of the Project

M/s. Deccan Fine Chemicals (India) Pvt. Ltd. formerly known as “Bayer Crop Science Ltd.” is an operational manufacturing unit and manufacturing “Agrochemical active ingredients and intermediates and fine chemicals” at Plot No. 3505 to 3515, 6008 to 6010, 6301 to 6313 & 6316/B1, GIDC Estate, Ankleshwar.

The company has been changed the name as Deccan Fine Chemicals (India) Pvt. Ltd. since 1st June 2014. The name change letter from GPCB is attached as Annexure – 1.

Earlier the company had obtained EC in the name of Bayer Crop Science at 31st May 2006 & 8th Dec 2008. The copy of same is attached as Annexure – 2. The unit has obtained CC&A for its existing plant vide CC&A No.: AWH-80972 dated 16/09/2016 and valid up to 11/03/2019.

Now the company is planning for increase in existing production capacity by adding similar category product from 7430 T/Annum to 16055 T/Annum.

The copy of existing CC&A is attached as Annexure - 3.The list of products are as follows:

Table 2.1: List of Proposed Products

Sr. No.

Name of Products Quantity MT/Year

Existing Proposed

Additional Total

A. Herbicides Group – 1 1. Aclonifen

2350 1050 34002. Oxadiargyl Group – 2 3. Pyridate

---- 1500 15004. Amicarbazone 5. Flucarbazone 6. Diuron B. Veterinary Product 7. Deltamethrin

70 30 1008. Flumethrin 9. Permethrin C. Pesticides Group – 1 10. Benfuresate

555 245 80011. Flupicolide 12. Anilophos 300 ---- 30013. Triazophos 2800 ---- 2800D. Intermediate Group – 1 14. SOD

1100 100 120015. Dichlorohydroxyketone-NBA

(DS 36) 16. Dichlorooxime – NBE (DS 38) 17. DMTA 255 ---- 25518. PBQ ---- 1800 1800Group – 2



Sr. No.

Name of Products Quantity MT/Year

Existing Proposed

Additional Total

19. Methoxy AA

---- 2000 200020. ABA HCl 21. DAT 22. Azura 5 E. Fungicides 23. Propiconazole

---- 900 90024. Tricyclazole 25. Fenbuconazole F. Others 26. Vulcuren

---- 1000 100027. Vulkalent – E

Total 7430 8625 16055(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)

Table 2.2: Formulations Products

Sr.

No. Name of Products

Quantity MT/Year

ExistingProposed

Additional Total

1. Isoproturon 350 0 3502. Diuron 50 0 503. Carbendazim 150 0 1504. Sevin 550 0 5505. Endosulfan 700 0 7006. Anilophos 300 0 3007. Triazophos 1600 0 16008. Deltamethrin 55 0 559. Fenoxaporp- Ethyl 50 0 50

10. Glufosinate Ammonium 20 0 2011. Quintol 150 0 15012. Alliet 50 0 5013. Cypermethrin 800 KL (80)* 0 800 KL (80)*14. Ediphenphos 200 KL (100)* 0 200 KL (100)*15. Fenthion 300 KL (250)* 0 300 KL (250)*16. Propoxur 100 KL (20)* 0 100 KL (20)*17. Baytex Gr 100 KL (3)* 0 100 KL (3)*18. Imidachloropid 400 KL (85)* 0 400 KL (85)*19. Buprofezin 800KL(46)* 0 800KL(46)*20. Fipronil 4500 0 450021. Bendicarb WP 20 0 2022. Betacyfluthrin SC 25 0 2523. Capromide SC 25 0 2524. Atlantis 20 0 2025. Deflobenzuron WP 20 0 20



2.1.2 Details of Project Proponent

The list of the board of directors are given below:

Table 2.2: List of Directors

S. No.

Name of Directors Designation Residential Address

1. Mr. G. Satyanaryan Raju Managing Director Plot No. 211, Road No. 14, Prashasan Nagar, Jubilee Hills, Hyderabad – 500 033

2. Mr. K. V. Lakshmipathi Raju Director - Technical Flat No. – 101, Block A, KSR Green Valley, Madhavadhara, Visakhapatanam

3. Mr. G. Vamsi Director Plot No. 211, Road No. 72, Prashasan Nagar, Jubilee Hills, Hyderabad – 500 033

4. Mr. Makoto Okabe Director (representing Mitsubhishi Corporation Japan)

4-26-1-303, Shimomaruko, Ota-Ku, Tokyo – 1460092, Japan

5. Mr. Robert Necolas Ernest Durand

Director (representing Belchim Management International Holdings, BVBA, Belgium)

34 Rue De Lectoure, Saint Luois – 68300, NA, France

(Source: Deccan Fine Chemicals Pvt. Ltd.)

2.1.3 Nature of the Project

The proposed expansion project involves the production of “Agrochemical active ingredients, intermediates and fine chemicals”, which falls under item no. 5(b) i.e. Pesticide Industry &

Pesticide Specific Intermediates (excluding formulations) & item no. 5(f) i.e. Synthetic Organic Chemical (Synthetic Rubber) manufacturing and under the category A as per the EIA notification, 14 September 2006 (& amendments).

2.2 Need of Project & Demand-Supply Gap

The proposed products has domestic as well as international demand. Approximately 90% of the volume will be for exports which will in turn generate dollar revenue for the nation. Also proposed project will help to provide new jobs for nearby people

2.2.1 Imports vs. Indigenous Production

It is in the company policy to procure indigenously produced raw materials. Only when a particular raw material is not available locally, we Import it.

2.2.2 Domestic / Export Markets

Market for the proposed products includes not only the domestic market but also the international market.

2.2.3 Employment Generation due to Project

The proposed expansion project will provide direct employment opportunity to additional 300 persons. The man-power required for the proposed expansion project will be employed locally from the nearby areas.



CHAPTER – 3

PROJECT DESCRIPTION

3.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

3.1.1 Identification of the Project

The proposed project is the type of expansion project for manufacturing of Agrochemical active ingredients, intermediates and fine chemicals.

3.1.2 Location

M/s. Deccan Fine Chemicals (India) Pvt. Ltd. is presently engaged in manufacturing of Agrochemical active ingredients, intermediates and fine chemicals at Plot no. 3505 to 3515, 6008 to 6010, 6301 to 6313 & 6316/B1, GIDC Industrial Estate Ankleshwar, Dist. Bharuch, Gujarat.

The project site is located in the GIDC notified industrial area of Ankleshwar. This region has very good infrastructure facility. The resources are also readily available. Moreover, there is availability of Common Solid Waste Disposal (CSWD) facilities and the Disaster Prevention & Management Centre (DPMC) is located in the GIDC industrial estate.

Location of project site is shown in figures 3.1 & 3.2 and Layout of project site is attached as

Annexure-4.

Figure 3.1: Project Site

(Source: Google)



Figure 3.2: Satellite Image of the Project Site

(Source: Google Earth)



3.2 DETAILS OF ALTERNATIVE SITE

As the proposed expansion project to be established in existing site. Hence, there is no alternative site considered for the proposed project.

3.3 SIZE & MAGNITUDE OF OPERATION

The total magnitude of operation will be @ 16055 T/Annum after proposed expansion project.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

The proposed products process details like Process description, Material Balance and Chemical Reaction are given in Annexure – 5.

3.5 RAW MATERIAL FOR FINISHED PRODUCT

The raw materials for the proposed range of products will be indigenously available and will be also imported. The product-wise raw-material consumption is given in table 3.1.

Table 3.1: List of raw materials

Sr. No. Product CAS No.

Raw Material CAS No. Quantity in

MT/MT1 Aclonifen 74070-46-5

DCONA --- 0.7971Phenol 108-95-2 0.0548MCB 108-90-7 0.0755KOH 1310-58-3 0.27487Caustic(48%) lye 1310-73-2 0.0294Methanol 67-56-1 0.0010HCl 7647-01-0 0.1433

2 Oxadiargyl 39807-15-3 Sulfuric Acid 7664-93-9 0.405Oxadizon 19666-30-9 0.6559Xylene 1330-20-7 0.0999Acetonitrile 75-05-8 0.02342Propargyl chloride 624-65-7 0.0202Pottassium carbonate 584-08-7 0.1808

3 Deltamethrin --- Sodium Cyanide 143-33-9 0.183MPBA 13826-35-2 0.502Isopropyl Ether 108-20-3 0.0234Sulphuric Acid 7664-93-9 0.282Becis themic Acid 544-63-8 0.73Thionyl Chloride 7719-09-7 0.8675Phenocyanol 122-99-6 0.5693Becisthemyl Chloride 108-77-0 0.7742Ethyelene Dichloride 107-06-2 0.7066Charcoal 7440-44-0 0.0489Iso propyl Alcohol 67-63-0 0.5088Di Isopropyl Amine 108-18-9 0.0992

Flumethrin 69770-45-2 Bayticol P Acid 69770-45-2 0.5805Thionyl Chloride 7719-09-7 0.2902Toluene 108-88-3 0.0768Sodium Hydroxide @ 47%

1310-73-20.1217

FluroPhenoxy Benzaldehyde

68359-57-9 0.4233

Sodium Cyanide 143-33-9 0.2071Bayticol P Acid chloride 69770-45-2 1.5245Sodium Bisulphite 7631-90-5 0.1077





MT/MTTBAB 1643-19-2 0.0038

5 Permethrin 13826-35-2 Cypermethric Acid Chloride

2719-27-90.621

Meta Phenoxy Benzyl Alcohol

13826-35-20.521

Hexane 110-54-3 0.1308Soda Ash 497-19-8 0.099

6 Benfurasate 6855-69-1 NC9770 in toluene (80%)

108-88-31.4879

CSL(48%) 1310-73-2 0.517NaBH4(98%) 16940-66-2 0.0483Toluene 108-88-3 0.411355H2SO4 7664-93-9 0.3255Xylene 1330-20-7 0.75065

Catalyst

7440-02-0, 7732-18-5,7429-90-5 0.074

7 Fluopicolide 239110-15-7 Toluene 108-88-3 0.0562956Benzophenone 119-61-9 0.1382PTSS --- 0.0446DIPEA 7087-68-5 0.1183K2CO3 584-08-7 1.5584TEBRO --- 0.0484DCTFP 1737-93-5 0.8133

BXA 10101-89-0,

7558-79-4 0.0446HCl (30%) 7647-01-0 0.959NaOH (48% Solution) 1310-73-2 0.7822DCBC 2905-62-6 0.138

8. SOD

---- Caustic (100%) 1310-73-2 0.1614NaHCO3 144-55-8 0.2521SAA(96%) --- 0.3807Toluene 108-88-3 0.0349PDC(97%) 97-53-0 0.6114RFA(99%) 7631-99-4 0.726DMAC 127-19-5 0.4966p-TSA(40%) 6192-52-5 0.1562H2O2(35%) 7722-84-1 0.3152Na2SO3(15%) 7757-83-7 0.3972NaOH (48%) 1310-73-2 0.0894

9 Dichlorohydroxyketone-NBA (DS 36)

99-96-7 Xylene 1330-20-7 0.263Na Metal 7440-23-5 0.340t-BuOH 75-65-0 0.069CTCMCP --- 1.330TGL --- 0.032Dil.HCl 7647-01-0 1.079THF 109-99-9 0.059AlCl3 7446-70-0 0.050PBQ --- 0.071Ethanol 64-17-5 0.292TBA 75-65-0 0.223IPA 67-63-0 0.017Cat/IPA 67-63-0 0.017





MT/MTKOH 1310-58-3 0.136CO2 124-38-9 0.003H2SO4 7664-93-9 0.040NaOH 1310-73-2 0.006

10.

Dichlorooxime - NBE (DS 38)

99-96-7 Xylene 1330-20-7 0.263Na Metal 7440-23-5 0.340t-BuOH 75-65-0 0.069CTCMCP --- 1.330TGL --- 0.032Dil.HCl 7647-01-0 1.079THF 109-99-9 0.059AlCl3 7446-70-0 0.050PBQ --- 0.071Ethanol 64-17-5 0.292TBA 75-65-0 0.223IPA 67-63-0 0.017Cat/IPA 67-63-0 0.017KOH 1310-58-3 0.136CO2 124-38-9 0.003H2SO4 7664-93-9 0.040NaOH 1310-73-2 0.006Toluene 108-88-3 0.112BzAcid 7664-93-9 0.008HAS --- 0.352

11 Triazophos 24017-47-8 100% PHSC --- 0.5165Fresh 100% FA 69-72-7 0.2278100% Fresh Sul. Acid 7664-93-9 0.0441Soda Ash 497-19-8 0.4960DETCL --- 0.4986Cucl 7758-89-6 0.0078KCl 7447-40-7 0.0078

Solvesso 91-20-3,95-63-6 1.7423

12 Anilophos 64249-01-0 PClPA --- 0.600CAC --- 0.450DMTA --- 1.210Soda Ash 497-19-8 0.350 Xylene 1330-20-7 0.434DMS 77-78-1 0.038Caustic 1310-73-2 0.0900

13 DMTA --- P2S5 1314-80-3 0.741Methanol 67-56-1 0.32Xylene 1330-20-7 0.27

Tetrabutyl amonium 2052-49-5,7732-18-5 0.001

14 PBQ --- Hydroquinone (99.0%) 123-31-9 1.190IPA --- 3.669Iodine 7553-56-2 0.017

H2O2 (50%) 7732-18-5,7722-84-1 0.529

15 ABA HCl 7647-01-0 Methanol 67-56-1 2.000DNDC --- 0.6880APD 7732-18-5, 0.551





MT/MT9048-46-8,7647-14-5,

77-86-1,26628-22-8

Bis Amide 1070-89-9 1.061Pd/C 7440-05-3 0.0062Dry HCl 7647-01-0 0.1122

16 Methoxy AA 108-65-6 Toluene 108-88-3 2.0402-Methoxyethanol --- 0.3940Sodium (Metal) 7440-23-5 0.116Ethyl-4-Chloroacetoacetate

638-07-30.868

HCl (36%) 7647-01-0 2.061048% NaOH 1310-73-2 1.6940

17 Azura 5 531-53-3 Toluene 108-88-3 12.03085

Azura- wet 7440-05-3 0.85TEBA 56-37-1 0.058Thionyl Chloride 7719-09-7 0.263025DMA 68334-30-5 0.2748(COCL)2 7791-13-1 0.209DMF 68-12-2 0.0331NH3 gas 7664-41-7 0.112Acetone NH3 gas 0.0300

18 Diuron 330-54-1 Toluene 108-88-3 0.2033,4-Dichloro Phenyl Isocyanate

102-36-30.833

Anhydrous DMA 124-40-3 0.17319 DAT ---- Toluene 108-88-3 2.3582

Sodium Thiocynate 540-72-7 0.5615Pyridine 110-86-1 0.007Ethyl Chloroformate 541-41-3 0.326

ADMP

497-19-8,6834-92-0,2893-78-9 0.419

Hydroxylamine 7803-49-8 0.1140Methanol 67-56-1 1.2930

20 Pyridate 55512-33-9 Toluene 108-88-3 1.929Acetophenone 98-86-2 0.6870Glyoxalic Acid 563-96-2 0.423Benzoyl Acetic Acid 94-02-0 1.110NH4OH (25%) 1336-21-6 0.7220Hydrazine Hydrate 7803-57-8 0.1800Chlorine 7782-50-5 0.505Acetone 67-64-1 0.9290Phosphorus trichloride 7719-12-2 0.49Sodium Hydroxie (48%) 1310-73-2 0.286

21 Propioconazole 60207–90–1 Toluene 108-88-3 2.1272,4 DICAP 77-78-1 0.5530Pentane-1,2-diol 5343-92-0 0.304Bromine 7726-95-6 0.482Sodium Hydroxide (48%) 1310-73-2 0.01501,2,4-Triazole 288-88-0 0.2050DMSO 67-68-5 3.191





MT/MTPotassium Hydroxide 1310-58-3 0.177

22 Tricyclazole 41814-78-2 MCB 108-90-7 5.855O-Toludine 95-53-4 0.6950Hydrazine 302-01-2 0.682HCl ( 32%) 7647-01-0 0.740Chlorine gas 7782-50-5 0.4370Formic acid 64-18-6 0.2560Xylene 1330-20-7 5.7600

23 Fenbuconazole 114639-43-6 MDC 75-09-2 0.820Benzyl Cyanide 140-29-4 0.4920P-Chlorostyrene 1073-67-2 0.5811H-1,2,4 Triazole 288-88-0 0.227Potassium Hydroxide 1310-58-3 0.184DMSO 67-68-5 1.967IPA 67-63-0 1.475

24 Amicarbazone 129909-90-6 MCB --- 4.058Iso Butric Acid 79-31-2 0.4180Terbutyl Alcohol 75-65-0 0.333Sodium Cynate 917-61-3 0.293Hydrazine Hydrate 7803-57-8 0.4620 HCl 7647-01-0 0.4980COCl2 7791-13-1 0.456

25 Flucarbazone 37526-59-3 Methanol 67-56-1 0.468Methoxy Acetyl Chloride (MAC)

38870-89-20.5290

Hydrazine hydrate 7803-57-8 0.272Methanol 67-56-1 0.468Sodium Thiocyanide 540-72-7 0.454

Dimethyl Sulfate 77-78-1 0.8580KOH (50%) 1310-58-3 1.216MIBK 108-10-1 1.762MMT --- 0.322Caustic (48%) 1310-73-2 0.208

26 Vulcuren ---- Toluene 108-88-3 1.200

Dibenzil Amine 100-46-9 0.577Carbon Disulfide 75-15-0 0.222Sodium Hydroxide (48%) 1310-73-2 0.2561,6 Dichloro Hexane 2163-00-0 0.223Sodium Thio Sulfate 10102-17-7 0.786

27 Vulkalent-E ---- Xylene ( 1330-20-7 0.814Carbon DiSulphide 75-15-0 0.2050Chlorine 7782-50-5 0.929Sodium Hydroxide (48%) 1310-73-2 1.309N-Phenyl Benzene Sulfonamide

526-08-9 0.624

(Source: Deccan Fine Chemicals (India) Pvt. Ltd.)

3.6 MATERIAL STORAGE & TRANSPORTATION

Hazardous chemicals will be used as raw material in the manufacturing process. The storage & transport of chemicals is given in Annexure - 6 and characteristics of raw material is attached as Annexure - 7.



3.7 RESOURCE OPTIMIZTION & AVAILABILITY

The major resources for the proposed project will be plant & machinery, raw-materials, power, fuel, water, man-power, etc.

3.7.1 Land

The existing set up is sufficient to accommodate the proposed expansion project which has been purchased from GIDC, Ankleshwar. The total plot area of the unit is 76691 m2. The Plot allotment certificate from GIDC, Ankleshwar has been attached as Annexure - 8.

3.7.2 Building

The existing built-up area of the unit is 27853.39 m2. After proposed expansion total built-up area will be 33861.72 m2. Some of the existing plant will also be demolished as per new requirements.

3.7.3 Equipment’s

Based on process necessity, list of the proposed equipments and machinery is as given below in

table 3.2.

Table 3.2: List of Proposed Equipments

S. No. Name of Equipment Quantity (Numbers)1. Reactor 3002. Filtration unit 403. Dryer 404. Day Vessel & Storage Vessel (1 kl to 50 kl) 6005. Solvent Tank Farm 326. pumps 8407. Distillation unit (recovery unit) 208. DCS room 109. Panel room 1610. UPS room 1011. Other Instruments (like ON/OFF valve, Indicators,

temperature Controllers 24000

12. Cooling tower 14103 m3/hr13. Multi Stage Scrubber Assembly 1214. Boiler – 25 TPH 215. D. G. Set – 1500 kVA 10


3.7.4 Power & Fuel Requirement

The power and fuel requirement is provided in Annexure – 9.

3.7.5 Water

The total water requirement for existing operation is 765 kl/day. From which, 645 kl/day is fresh water & remaining 120 kl/day is recycled water. After proposed expansion project the water requirement will be increased upto 4602 kl/day. From which, 3849 kl/day will be fresh water & remaining 753 kl/day will be recycled water. The category wise bifurcation of the water requirement is given in Table 3.3. The source of water is/ will be GIDC piped water supply.



Table 3.3: Total Water Consumption (kl/day)

Particulars Water Requirement (kl/day) Remarks Existing Proposed Total

Domestic 130.0 80.0 210.0 -- Gardening 70.0 0.0 70.0 Industrial Process 94.0 252.0 346.0 -- Cooling tower Makeup 286.5 3244.0 3530.0 Fresh – 2777 + Recycle - 753 Boiler Makeup 16.0 54.0 70.0 -- Scrubber 50.0 50.0 100.0 -- DM Plant Regeneration 0.5 1.5 2.0 -- Washing 115.0 150.0 265.0 -- Softener Regeneration 3.0 6.0 9.0 -- Sub – Total: Industrial 565.0 3757.5 4322 Fresh – 3569 + Recycle - 753 Grand Total 765.0 3837.5 4602 Fresh – 3849 + Recycle - 753


3.7.6 Man-power

In existing operations, 515 (Regular – 290 + Contractual - 225) persons are employed. The manpower required for the proposed expansion project during construction activities & operational activities will be employed from local area. Skilled as well as unskilled labour will be employed for the project. Additionally 300 persons (Regular – 100 + Contractual - 200) will be employed for the operational phase of proposed expansion project.

Table 3.4: Man Power Requirement

Phase of project Type of workers

No. of workersGeneral 1st Shift 2nd Shift 3rd Shift

M F M F M F M FExisting Operations During operations Managerial 61 - - - - - - -

Skilled 61 - 56 - 56 - 56 -Un-skilled 57 - 56 - 56 - 56 -

After Proposed Project During Construction 150 During Commissioning

150

During operations Managerial 81 - - - - - - -Skilled 82 - 75 - 75 - 75 -Un-skilled 50 - 50 - 50 - 50 -


3.8 QUANTITY OF WASTE TO BE GENERATED

3.8.1 Waste water Generation & Management

The wastewater generated from the existing operations is total 441 kl/day. Out of which 75 kl/day is domestic wastewater & 371 kl/day is industrial wastewater.

Total 441 kl/day effluent is treated in in-house ETP and out of this 320 kl/day is discharged to NCTL for final treatment & ultimate disposal to deep sea and 121 kl/day is treated in RO. Permeate from RO @97 kl/day is recycled as cooling tower makeup & 24 kl/day RO reject is sent to MEE. From MEE, 23 kl/day condensate is recycled as cooling tower makeup & salt is disposed to TSDF.



After proposed expansion projects, about 1619 kl/day wastewater will be generated. Out of which 145 kl/day is domestic wastewater & 1474 kl/day will be industrial wastewater.

Total 1619 kl/day effluent will be treated in in-house ETP and out of this 862 kl/day will be discharged to NCTL for final treatment & ultimate disposal to deep sea and 757 kl/day will be treated in RO. Permeate from RO @657 kl/day will be recycled as cooling tower makeup & 152 kl/day RO reject will be sent to MEE. From MEE, 148 kl/day condensate will be recycled as cooling tower makeup & salt will be disposed to TSDF. The membership certificate for waste water discharge to NCT is attached as Annexure-12.

Table 3.5: Category-wise Wastewater Generation

Particulars Wastewater Generation (in kl/day)Existing Proposed Total

Domestic 70.0 75.0 145.0Industrial Process 86.0 266.0 352.0Cooling tower blow down 105.5 600.5 706.0Boiler blow down 11.0 29.0 40.0Scrubber 50.0 50.0 100.0DM Plant Regeneration 0.5 1.5 2.0Washing 115.0 150.0 265.0Softener Regeneration 3.0 6.0 9.0Sub – Total: Industrial 371.0 1103.0 1474.0Grand Total 441.0 1178.0 1619.0(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)



Figure 3.3: Water Balance Diagram – Existing Scenario (in kl/day)



Figure 3.4: Water Balance Diagram – Proposed Scenario (in kl/day)



3.8.2 Wastewater Characteristics

The characteristics of the untreated effluent & treated effluent is given table.

Table 3.6: Composite Characteristics of Wastewater to ETP

Sr. No.

Parameter Existing Characteristics Expected Characteristics after proposed expansion project

NCTL Discharge Norms

Untreated effluent

Treated effluent

Untreated effluent

Treated effluent

1. pH 6.0-9.0 5.5 – 8.5 6.0-9.0 6.0 – 9.0 6.0 – 9.02. TSS 800 – 1000 <100 800 – 1000 <100 1003. TDS 4500 - 5000 <10000 9000 - 10000 <10000 No limit4. COD 1400 - 2000 <100 2500 - 3200 <500 5005. BOD 400 - 700 <30 900 - 1300 <100 100(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)

3.8.3 Waste water Treatment & Disposal

The combined effluent from septic tank overflow (domestic activities), process, scrubber, cooling tower blowdown, MEE plant (Process), boiler blow down, DM plant regeneration, softener regeneration & washing water of the plant will be collected and conveyed to the continuous neutralization tank at effluent treatment plant only after pre-analysis. Effluent from collection sumps at the production units shall be pumped to the Equalization tank of the proposed ETP. The incoming process effluent shall be passed through a Bar screen & held in an oil trap chamber. The equalization tank shall be provided two chambers which work in filling & processing mode. Each chamber will have up to 24 hours hold up volume to equalize the diurnal flow & composition variations. The contents of the equalization tank shall be agitated with air blowing. The effluent shall thereafter be subjected to primary treatment by coagulation & flocculation to remove the suspended matter & partly reduce the non-biodegradable component of organic matter. Subsequently the primary treated water shall be subjected to biological treatment in an Aerobic two stage Activated Sludge system using diffused aeration. The bioreactors shall be provided with membrane diffusers and air distribution grid located at the bottom of the tank. The air supply shall be by dedicated air blowers. The air supply is required for sustaining aerobic biological activity as well as to maintain the biomass in suspension. The first stage bio-reactor shall be operated under high rate regime while, the second stage bio-reactor is operated under extended aeration. The overflow of the bioreactor shall be passed through the bio-clarifiers to separate the biomass. The biomass is returned to the bio-reactors by re-circulation pumps. The tertiary treatment system will comprise of flocculator and clarifier in a re-activator clarifier for the purpose of polishing treatment to reduce the residual COD, improve the clarity of effluent and remove the turbidity. The treated effluent from the tertiary treatment stage shall be collected in Hold tank and disinfected with chlorine prior to polishing filtration in sand filter unit & ACF unit, & finally discharged to the RO plant for recovery. The reject of RO will be sent to MEE. The condensate of MEE will be recycled for cooling tower makeup alongwith RO permeate & concentrate will be sent to ANFD for drying of solid.



The excess bio-sludge from primary, secondary & re-activator clarifiers shall be discharged to a sludge thickener tank. The combined -sludge shall be thickened to 2-5 % consistency & finally all sludge is centrifuged to separate the sludge in a continuous decanter centrifuge unit. There shall be a single front compartmental MCC panel or PLC system in the operator room to operate the plant. The sludge from ETP & Inorganic salt from MEE will be sent to TSDF for disposal.

Figure 3.5: Process flow diagram of Effluent Treatment Plant




Table 3.7: ETP Unit Details

Sr. No.

Name of the Unit Volume (m3)/ Capacity of the Unit

1. Oil Trap Chamber 352. Collection Sump 13.5

3. Continuous Neutralization 474. Equalization Tank (Existing) 450 x 25. Primary Treatment Tanks 66. Primary Clarifier 607. Bio Reactor - 1 25008. Bio Clarifier - 1 609. Bio Reactor – 2 125010. Bio Clarifier - 2 6011. Reactivator Clarifier 6012. Sand Filter 25 m3/hr13. Activated Carbon Filter – 2 Nos. 25 m3/hr14. Sludge Thickener Tank 3815. Centrate Tank 516. Filter Feed Tank 5017. Treated Water/ Backwash Tank 10018. RO 760 m3/day19. MEE 155 m3/day(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)

3.8.4 Air Emission & Control

The details of air emissions are given as follows:

3.8.4.1 Process Emission

In existing operations, the process emissions is in form of HCl, HC, H2S, HCN and SO2 gas which is scrubbed using water and caustic soda solution in the scrubber. The concentrated solution from scrubber is diverted to ETP for further treatment.

After the proposed expansion, the same process will be done to control process emissions.

The details of process emissions are provided in table 3.8.

Table 3.8: Details of process emissions

Sr. No.

Stack Attached to

Stack Details in meter

Parameter Air Pollution Control System

Existing Stack

(I) AC-I Plant

1 Reactor H: 20, D: 0.1 HC Water Scrubber 2 Reactor H: 20, D: 0.1 HC Water Scrubber

(II) AC-II Plant 3 Reactor H: 20, D: 0.1 HCl Water

Scrubber/Acid Scrubber

4 Reactor H: 20, D: 0.1 HC Water Scrubber 5 Reactor H: 20, D: 0.1 H2S Scrubber with

Caustic Solution 6 Reactor H: 20, D: 0.1 H2S Scrubber with

Caustic Solution (III) AC-III Plant

7 Reactor H: 20, D: 0.2 HCl Caustic Scrubber 8 Reactor H: 20, D: 0.2 HCN Caustic Scrubber



Sr. No.

Stack Attached to

Stack Details in meter

Parameter Air Pollution Control System

(IV) AC-IV Plant 9 Reactor H: 23, D: 0.1 HCl Water Scrubber 10 Reactor H: 23, D: 0.1 HC Water Scrubber

Proposed Additional Stack (III) AC-III Plant

11 Reactor – 3 nos. (working – 2+ Standby - 1)

H: 45, D: 0.2 (Each)

HCl, TVOC, NOx, SO2, CO2, NH3, H2S

Multi Stage Scrubber (Acid, Alkali & Water)

(V) AC-V Plant 12 Reactor

H: 45, D: 0.2 HCl, TVOC, NOx, SO2, CO2, NH3, H2S


(VI) AC-VI Plant 13 Reactor – 4 nos. (working –

2+ Standby - 2) H: 45, D: 0.2 (Each)

HCl, TVOC, NOx, SO2 CO2, NH3, H2S


(VI) AC-VII Plant 14 Reactor – 4 nos. (working –

2+ Standby - 2) H: 45, D: 0.2 (Each)

HCl, TVOC, NOx, SO2 CO2, NH3, H2S


Wastewater Management Plant 15 Reactor / vessel of TDS

removal plant (HTDS plant) H: 45, D: 0.2 TVOC

water scrubber

16 Storage & process tanks of Effluent treatment plant.

H: 45, D: 0.2 TVOC

water scrubber

17 Multi Effect Evaporator H: 45, D: 0.2 TVOC water scrubber (Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)

3.8.4.2 Utility Emissions

The details of utility emissions are provided in Annexure – 10.

3.8.4.3 Fugitive Emission

The fugitive emissions in terms of handling losses of solvent is/will be reduced by proper storage and handling. Solvents is/will be stored in drums in the solvent storage area. It is/ will be transferred to the plant by trolleys. Acids is/will be stored in carboys and the storage area is/will be provided with acid proof lining. Other RM and Finished goods is/will be stored in their designated areas.

3.8.5 HAZARDOUS/NON-HAZARDOUS. WASTES MANAGEMENT

Hazardous and non-hazardous is/will be generated from the proposed project. All wastes is/will be stored in the proper designated storage areas. The details of hazardous and non-hazardous waste generation and its management are provide in Annexure - 11. The membership certificate for disposal of hazardous waste is attached as Annexure-12.

3.8.6 NOISE CONTROL

The major noise generating installation will be the D.G. Set. It will be installed in a closed room, Acoustic enclosure will be provided around it and ear plugs will also be provided to the operating personnel. Sturdy foundation and suspension will be provided to centrifuge.

3.9 HEALTH AND SAFETY MEASURES

The company is concerned about occupational health and safety among its work force as the man power is the biggest asset to the company.



The following key safety measures are implemented in the existing operation & same will be practiced after proposed amendment project:

Table 3.9: Safety details

Sr. No. Particulars Remarks/ Details1. Safety Officer Safety officer is available 2. Manual call bells Yes 3. Emergency Control Room At main gate security office 4. Emergency Sirens Yes 5. Assembly Point 1 point 6. Ambulance Point Near main gate 7. First Aid facility Provided at prominent places by trained persons. 8. Personal Protective

Equipments Hand gloves, gum boots, safety shoes, dust masks, safety goggles, and apron.

9. Health Check ups Regular health checkups at every six months. 10. Regular Training Provided 11. Safety & Health Records Maintained as per factory act 12. MSDS MSDS available at prominent places for ready references

3.10 ENVIRONMENTAL HEALTH & SAFETY CELL

The company has a full-fledged environment health & safety cell (EHS) in order to keep a close watch on the performance of the pollution control equipment, emissions from the sources and the quality of surrounding environment in accordance with the monitoring program. The cell is also entrusted with the responsibilities of regulating the safety measures inside the plant campus. The cell is also responsible for maintaining the records of all data, documents and information in line within the legislative requirement. The EHS cell will also be responsible to plan, implement and monitor the environmental performance of the proposed expansion project.

3.11 POST PROJECT MONITORING PLAN

The proposed post-project monitoring plan to ensure effective implementation of EHS Management system is given below:

Table 3.10: Environmental Monitoring Plan

Component Parameter Frequency Air – Ambient PM, SO2, NO2 Quarterly Process Stack monitoring

HCl, SO2, HCN, H2S, CO2 Monthly

Noise monitoring Noise levels in decibels Quarterly Work place monitoring

PM, VOC Quarterly

Filing of annual returns in Form-4 for Haz. Waste handling

Annually

Maintaining records of transportation in Form-13

Regularly

CC&A Obtaining consent to operate (and renewal) under Air & Water Acts and authorization under HW rules.

Before expiry of validity

Water cess Filing of annual returns for cess incurred on water consumption

Annually

Environmental Statement

Submission of audit statement in form-V Annually

Compliance of EC conditions

Submission of compliance reports Half yearly




CHAPTER – 4

SITE ANALYSIS

4.1 CONNECTIVITY

The existing project is located at Plot No. 3505 to 3515, 6008 to 6010, 6301 to 6313 & 6316/B1, GIDC Estate, Ankleshwar. The proposed expansion will be done on existing operational site. The site is 2.75 km from National highway. The land and infrastructure is already available. And the raw material is easily available through the easy transport via road connectivity. The nearest Railway station is Ankleshwar railway station which is 3.8 km and Surat Airport is 64.52 km from the project site.

4.2 LAND FORM, LAND USE & LAND OWNERSHIP

4.2.1 Land Form

Open land of existing site will be utilized for construction of the proposed expansion project.

4.2.2 Land Use Pattern

The land will be used for proposed project is open land designated for industrial use.

4.2.1 Land Ownership

The existing plot is located in the industrial estate. The plot has been purchased from GIDC, Ankleshwar.

4.3 TOPOGRAPHY

The topography of the Ankleshwar is relatively flat terrain with series of deeply incised creeks of river. There are generally levee deposits on the bank of river.

4.4 SALIENT FEATURES Table 4.1: Salient Features of the Project Site Particulars DetailsCo-ordinates Latitude:21°37’26.59” , Longitude:73°02’23.23” Taluka/ Tehsil Ankleshwar District Bharuch Nearest Water body GIDC Water Reservior≈3.28 km(SW), River

Narmada ≈ 8.55 km (N) Nearest Highway NH 8 ≈ 2.75 km (W), SH 65 ≈ 1.25 km (N) Nearest Railway station & Railway line Ankleshwar Railway Station ≈ 3.80 km (W) Nearest Airport/ Airbase Surat ≈ 64.52 km (SW) State/ National borders Maharashtra State ≈ 77.80 km (E) Protected Area/ Sanctuaries No CRZ applicability NoSeismicity Seismic Zone – III (Moderate) Note: All the above mentioned distances are the aerial distance from the project site.



4.5 EXISTING INFRASTRUCTURE The plot is located in the industrial estate. The entire necessary infrastructure provided by GIDC.

4.6 SOIL CLASSIFICATION The soil of the area is mostly very fine to fine, Montmorillonitic, hyperthermicTypicChromusterts which is at few places calcareous in nature mixed with Udicchromusterts and VerticUstochrepts. This are deep to very deep, moderately well drained fine soils on very gently sloping alluvial plain with moderate erosion and slight to moderate salinity associated with very deep moderately well drained calcareous, very fine to fine soils with moderate erosion. In the Northern part of the study area near to the river, Fine, mixed (calcareous), hyperthermic Fluventic Ustochrepts with fine-loamy Udic Ustochrepts are present. This are deep, well drained, calcareous, fine soils on very gently sloping alluvial plain with slight erosion and slight salinity, associated with very deep, imperfectly drained, calcareous, fine-loamy soils with slight erosion.

4.7 CLIMATE & METEROLOGY The year can be divided into four seasons. Climate is warm and dry from mid-march to June, during season of summer, climate remains warm and dry, while during rainy season, from mid-June to end of September climate is humid and pleasant. From October to November mild warm climate prevails, and from December to February climate is cold. The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of IMD, Bharuch published by IMD.

Table 4.2: Summary Meteorological Data at nearest IMD Station - Bharuch

Location: Bharuch Gujarat ( Lat: N 21o42’, Long: E 73o 00’) Aerial Dist from Project Site: Approx. 23 km (SSE) Height of installation: 17 m above MSL. Month Temperature

(oC) Relative

Humidity (%) Cloud Cover

(Oktas) Mean Wind

Speed (km/s)

Pre-dominant Wind

Direction

Rainfall (mm)

Max. Min. Mor. Eve. Mor. Eve. January 34.5 7.5 71 38 0.8 0.8 6.0 NE 1.2February 37.8 9.7 64 34 0.8 0.5 6.5 NE 1.4 March 41.5 13.6 65 29 1.1 0.8 7.3 SW 0.2 April 43.3 19.7 66 31 1.4 1.1 9.3 SW 0.5 May 43.8 23.0 74 39 1.7 0.6 13.3 SW 9.2 June 39.5 23.1 81 58 4.3 3.1 16.3 SW 108.5 July 36.1 23.4 89 74 6.6 5.9 14.5 SW 290.4 August 34.9 23.2 90 79 6.7 6.1 12.4 SW 279.1 September 36.1 22.6 87 68 4.8 4.7 9.4 SW 182.7 October 38.2 17.2 76 46 1.5 1.9 6.1 SW 16.8 November 37.4 13.1 73 42 1.0 1.0 4.8 NE 21.9 December 34.3 9.3 74 44 1.1 1.0 5.4 NE 0.2 Seasonal Average Values Period Temperature

(oC) Relative

Humidity (%)

Cloud Cover (Oktas)

Mean Wind

Speed (m/s)

Avg. PDW Direction

Total Rainfall (mm)

Avg. Max.

Avg. Min.

Avg. Mor.

Avg. Eve.

Avg. Mor.

Avg. Eve.

Summer 39.0 22.5 68.3 33.0 1.4 0.8 9.9 SW 9.9 Winter 32.1 12.6 69.6 38.6 0.9 0.5 5.9 NE 2.8 Monsoon 32.9 25.2 86.7 69.7 5.6 4.9 13.1 SW 860.7



Post monsoon 35.3 19.3 74.5 44.0 1.2 1.4 5.4 SW/NE 38.7 Annual Total or Mean

34.6 20.4 76 49 2.7 2.3 9.3 SW 912.1

Note: Winter: December, January & February, Summer: March, April & May, Monsoon: June, July, August & September, Post monsoon: October & November (Source: Book “Climatological tables of Observatories in India (1961 - 1990)” published by IMD)

4.7.1 Temperature

The climate of Bharuch is warm and dry during the summer months but humid and pleasant during

the monsoon months. The south-west monsoon from June to September brings copious rain to the

territory. The winter months are generally pleasant. May is generally the hottest month with the mean

daily maximum temperature recorded at 43.8oC and mean daily minimum temperature recorded at

23oC. January is the coldest month with the mean daily maximum temperature as 34.5oC and mean

daily minimum temperature observed as 7.5oC .

4.7.2 Humidity

Humidity is usually high during the monsoon months, generally exceeding 86.7%. Humidity decreases

during the summer months. For rest of the year i.e. the period of October to February, the relative

humidity ranges around 34-76%.

4.7.3 Cloud Cover

During the South-west monsoon months, the skies are usually heavily clouded or overcast. Cloud

cover decreases during the post monsoon months. In the rest of the year the skies are mostly clear.

4.7.4 Rainfall

About 95% of the annual rainfall is received during the southwest monsoon season i.e. from June to

September, July being the month with highest rainfall. The average annual rainfall observed from the

data is 912.1 mm.

4.7.5 Wind Pattern

The annual predominant wind direction comes to South West, followed by North. Winds blows mostly

from the South West during summers and Monsoons. The post-monsoon & winter seasons

experience a change in the wind blowing from North-east. The wind speed is high during summer and

monsoon seasons, slightly moderate during winter and moderate during post-monsoon phase.

4.7.6 SOCIAL INFRASTRUCTURE

The infrastructure available in the study area denotes the economic well-being of the Ankleshwar

Taluka. There are about 56 villages and 10 Towns in the Ankleshwar Taluka.



4.7.7 Educational Facilities

As per census of India, 70 Primary schools, 6 Secondary Schools. There were no Middle School,

senior secondary schools & Training institute found in 56 villages. The female literacy rate is 43%.

4.7.8 Medical Facilities

Out of the 56 villages, Primary health centers in 5 villages and Primary health sub center in 21

villages. There was no Dispensary & hospitals found in 56 villages.



CHAPTER – 5

PLANING BRIEF

5.1 PLANNING CONCEPT

The proposed project is located at Plot no. 3505 to 3515, 6008 to 6010, 6301 to 6313 & 6316/B1, GIDC Industrial Estate, Dist.: Bharuch, Gujarat – 393 002. The nearest city is Bharuch which is a big hub for chemical & Pharmaceutical Products and also Ankleshwar itself is a big industrial center. Major raw materials will be sourced locally.

The region is well planned with all the basic infrastructural facilities like internal roads, water supply, arrangements for power, streetlights, solid waste disposal sites etc.

5.2 POPULATION PROJECTION

The average household size is around 4 to 5.

Table 5.1: Distribution of population

Sr. No. Particulars Observed values in Ankleshwar Taluka

1 Total Population 4320862 No. of Households 959883 Avg. household size (persons) 4-54 Male population 2307325 Male population (in %) 53.4%6 Female population 2013547 Female population (in %) 46.6%8 Sex ratio 873(Source: Primary Census Abstract – Census of India, 2011)

5.3 AREA STATEMENT

The total area of the plot is 76691 m2 out of which Greenbelt area of the plant is 27393.14 m2 which is approx. 35.72 %. The bifurcation of the same is given below in table no. 5.2.

Table 5.2: Area Statement

Sr. No. Particular Area (m2)1. Total plinth area 20973.572. Total road area 12647.593. Total open area (Common plot) 5933.6874. Total parking area 9743.0145. Total Green area 27393.14 Total plot area : 76691.00


5.4 ASSESSMENT OF INFRASTRUCTUTRE DEMAND (PHYSICAL & SOCIAL)

For proposed expansion project the company will acquire some plant and machinery so there will be some demand of change in physical infrastructure and social infrastructure. As manpower requirement for the proposed project shall be locally fulfilled, employment generation will lead to additional benefits to social infrastructure.



5.5 AMENITIES/ FACILITIES

5.5.1 Drinking Water Facilities

There were no Tap water available in 56 villages as per the Census 2011. 24 villages had Wells, 21 villages had tanks/pond/lake and 34 had hand pumps. 24 Villages had River/Canal passing. Power supply was also available in all the villages.

5.5.2 Power Supply Facilities

As per census 2011, all the villages have power supply facilities in the Ankleshwar Taluka.

5.5.3 Communication & Banking Facilities

Out of the 56 villages, Post Office is available in 2 villages, telephone facility exist in all the villages as per the 2011 census.

5.5.4 Transport Facilities

Bus service is available in the Ankleshwar Taluka and is the most preferable mode of transport in the Ankleshwar Taluka. The villages are well connected with the State Highways. National Highway-8 also passes from Ankleshwar. The Western railway line between Bombay to Ahmedabad passes from the Ankleshwar Taluka and Ankleshwar Town has a railway station on the same.



CHAPTER – 6

SITE ANALYSIS

6.1 PROPOSED INFRASTRUCTURE

The total area of the plot is 76691 m2 out of which total builtup area will be 20973.57 m2. Some of the existing buildings will be demolished to construct new buildings with international standards.

6.2 RESIDENTIAL AREA

In the said proposal no residential area has been proposed for workers and/or for staff.

6.3 GREENBELT

Maximum open land will be allotted for green belt development. If required, experts will also be consulted for selection of species for the development of the greenbelt. Total greenbelt area will be 35.72%. of total plot area.

6.4 SOCIAL INFRASTRUCTUTE

Existing infrastructure will be sufficient to accommodate the existing load from the proposed expansion project which is very low.

6.5 CONNECTIVITY

The existing project is located at Plot No. 3505 to 3515, 6008 to 6010, 6301 to 6313 & 6316/B1, GIDC Estate, Ankleshwar. The proposed expansion will be done on existing operational site as well as plot closer to existing site. The site is 2.75 km from National highway. The land and infrastructure is already available. And the raw material is easily available through the easy transport via road connectivity. The nearest Railway station is Ankleshwar railway station which is 3.8 km and Surat Airport is 64.52 km from the project site.

6.6 DRINKING WATER MANAGEMENT

Drinking water will be sourced from GIDC water supply for the proposed expansion project.

6.7 SEWERAGE SYSTEM

Domestic waste water generated from the existing operations is 75 kl/day & after proposed expansion project, it will be increased upto 210 kl/day. The domestic waste water is/ will be disposed of through soak pit / septic tank. The septic tank overflow will be diverted to ETP for further treatment.

6.8 INDUSTRIAL WASTE MANAGEMENT

Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained in Chapter 03, Section 3.7.3

6.9 SOLID WASTE MANAGEMENT

Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant, Used oil & Oil filter from gear boxes of the machineries & D.G. Set, Process residue from manufacturing process, discarded drums & bags from storage of raw materials. Company will provide adequate storage area for proper storage of wastes. Details of solid waste generation are given in table 3.10.

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY

The power requirement after proposed expansion project will be 29200 kVA which will be sourced from Dakshin Gujarat Vij Company Ltd..



CHAPTER – 7

REHABILITATION & RESETTLEMET (R&R) PLAN

7.1 POLICY TO BE ADOPTED

The proposed expansion project is to be developed in the land designated for industrial use. Hence, no displacement of any population is proposed for the project. Therefore, detailed Social Impact Assessment studies or R&R action study has not been proposed.



CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE OF THE PROJECT

The installation/ construction will be started after getting approval for Environmental Clearance and NOC from authorities for proposed expansion project.

8.2 ESTIMATED PROJECT COST

Environment Protection has also been considered in planning the cost projection. Green belt development is also considered. The estimated project cost will be approximately 437.70 INR (in Crores).

Table 8.1: Total Capital Cost Projection

Sr. No.

Purpose Capital Cost (INR in crores)

1. Land (Lease Cost) Nil2. Building 48.003. Plant & Machinery

388.004 Electrification and Administrative set-up5. Environment Protection (including ETP, APCD etc.)

1.00ETP APCD

6. Safety instruments 0.457. Chartered services/ Government fees 0.25

TOTAL 437.70(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)

Table 8.2: Recurring cost provision for EHS

Sr. No. Purpose Recurring Cost (INR in Lakhs)

Existing Proposed Additional

Total

1. Environment Protection (including ETP, APCD etc.) 595 580 1175ETP operations (chemicals/electricity/manpower)Air pollution control device Fees for Common disposal facilitiesEnv. Monitoring expenses 5 2.5 7.5

2. Safety instruments maintenance 15 4.5 19.5 3. Environment & safety training 1.5 2.5 4.0 4. Chartered services/ Government fees 10 5.0 15.0 5. Green belt maintenance 1.5 1.75 3.0 6. Social development (CSR) 12 10.0 22.0 7. Medical surveillance 20 30 50 TOTAL 660 636.25 1296.25(Source: Deccan Fine Chemicals (India) Pvt. Ltd., Ankleshwar)



CHAPTER – 9

ANALYSIS OF PROPOSAL

9.1 FINANCIAL & SOCIAL BENEFITS

The project benefits from proposed expansion project are as below -

Approx. 90% of the volume will be for exports which will in turn generate foreign revenue for the nation.

Considerable employment & trade opportunities in India. Considerable benefit to public infrastructure of this region.

Annexure

Annexure -1: Name Change Letter

Annexure -2: Copy of Existing CC&A

Latest Amendment in CC&A No. AWH: 65686 dated 18/11/2014

CC&A No. AWH: 65686 dated 18/11/2014

Annexure -3 (a): Copy of Existing EC

A. Environment Clearance dated 8th December 2008

Environment Clearance dated 31st May 2006

Annexure - 3(b): Copy of Forwarding letter for Submission of EC Compliance Report

Annexure -4: Layout of Project Site

Annexure -5: Process Technology EXISTING PRODUCTS

1. Aclonifen

Chemical Reaction

NH2

ClCl

NO2

OH OCl

NH2

NO2

+

Phenol DCONA Aclonifen

Manufacturing process

Potassium salt of Phenol is reacted with 2, 3 – Dichloro 6 Nitro aniline to form Aclonifen in batch process. The organic phase is washed with alkaline water to remove residual Phenol for recycling. The Phenol is aqueous is extracted with MCB and recycled in next batch. The Aclonifen then stripped to lower solvent concentration. Final Aclonifen is crystallized and packed in HDPE lined Jumbo bag.

Material Balance

2. Oxadiargyl

Chemical Reaction


Acidolysis of oxadiazone in a solution of Sulphuric Acid at 15°C gives an intermediate Phenol – Oxa. At the end of Acidolysis reaction the intermediate is introduced in water – xylene mixture to extract Phenol – Oxa. The extracted Phenol – Oxa in xylene is converted to Oxadiargyl by O- alkylation of Phenol- Oxa with Propargyl chloride in presence of Potassium Carbonate and Acetonitrile. The Oxadiargyl content in xylene is isolated by crystallization. The product is then filtered, dried and packed.

Material Balance

3. Deltamethrin

Chemical Reaction


Meta Phenoxy Benzaldehyde is converted into phenocyanol with cyanide in solvent. Acid Becisthemic is converted into acid chloride with Thionyl chloride. Phenocyanol is condensed with acid chloride to get mixed isomers of Deltamethrin. Mixed isomers are separated by selective crystallization to get pure Deltamethrin isomer, which is then crystallised, centrifuged and dried under controlled condition.

Material Balance

Step -I

Input MT/MT Output MT/MT

DM Water 2.299 Phenocyanol Crude 0.5693

Sodium Cyanide 0.183 Iso Propyl Ether (Recycle) 0.5693

MPBA 0.502 Iso Propyl Ether (Loss) 0.0235

Isopropyl Ether (Recycle+Fresh) 0.5927 Effluent 2.5680 HTDS stream

Sulphuric Acid 0.1828 Hydrogen Cyanide (To Absorber) 0.0294 Vent

Total 3.7595 Total 3.7595

Deltamethrin Flow Chart With Material Balance

Manufacturing of Phenocyanol

Step - II


Becis themic Acid 0.73 Becisthemyl Chloride 0.7742

Thionyl Chloride (Recycle+Fresh) 0.8675 Thionyl Chloride (Recycle) 0.6310

Hydrochloric Acid (GAS) 0.1923 Vent


Manufacturing of Becisthymyl Acid Chloride

Step - II


Becis themic Acid 0.73 Becisthemyl Chloride 0.7742

Thionyl Chloride (Recycle+Fresh) 0.8675 Thionyl Chloride (Recycle) 0.6310

Hydrochloric Acid (GAS) 0.1923 Vent


Manufacturing of Becisthymyl Acid Chloride

Phenocyanol 0.5693 Delthamethrin 1.0000

Becisthemyl Chloride 0.7742 Hydrochloric Acid (Gas) 0.0883 Vent

Ethyelene Dichloride (Recycle+Fresh) 7.8624 Ethylene Dichloride (Recycle) 7.1558

Charcoal 0.0489 Ethylene Dichloride (loss) 0.7067

Iso propyl Alcohol 3.952 Charcoal 0.0491 Incineration

Di Isopropyl Amine 0.0992 Mother Liquor 3.7837 For recovery

Sulphuric Acid 0.0992 Iso propyl Alcohol 0.1681 Vent

DM Water 1.06 Effluent 1.5135 HTDS stream

Total 14.4652 Total 14.4652

Demethrin Manufacturing and

purification

4. Flumethrin

Chemical Reaction


Bayticol-P acid Chloride is manufactured by reaction of Thionyl Chloride and Bayticol-P Acid in solvent in presence of a catalyst at atmospheric pressure and 50 - 70°C temperature. The excess Thionyl Chloride and solvent is distilled off and the mixture is de-solvated to get bayticol- P Acid Chloride. Flumethrin (Bayticol P) is manufactured by reacting Bayticol P Acid Chloride with Sodium Cyanide and p- fluoro m-phenoxybenzaldehyde in presence of sodium bisulphate and catalyst@ approx. 30°C and atmospheric pressure. The product is extracted in Toluene and aqueous phase separated out. The organic phase concentrated to get Flumethrin.

Material Balance


Bayticol P Acid 0.5805 Bayticol P Acid chloride 1.5245

Thionyl Chloride 0.2902 Toluene distilled out (Recycle) 0.8714

Toluene (Recycle+Fresh) 1.7681 Hydrochloride Acid 0.2063 Vent

Sodium Hydroxide @ 47% 0.1217 Effluent 1.9720 ETP

for washing of Toluene

Demineneralized water for 1.8137

Solvent washing


FluroPhenoxy Benzaldehyde 0.4233 Flumethrin 1.0000

Sodium Cyanide 0.2071 Toluene (Recycle) 2.9150

Bayticol P Acid chloride 1.5245 Toluene - loss 0.0768

Toluene 2.0951 Effluent 8.5607 HTDS stream

Sodium Bisulphite 0.1077 HCN 0.0094 Vent

TBAB 0.0038

Demneralsied water for 0.3347

Sodium cyanide solution

Demneralsied water for 0.161

Sodium Bisulphite solution

Demneralsied water for washing 7.7047 Total 12.5619

Total 12.5619

Flumethrin Flow Chart With Material Balance

Manufacturing of Phenocyanol

Manufacturing of Flumethrin

5. Permethrin

Chemical Reaction


Permethrin is manufactured in a single step by reacting Cypermethric acid chloride and Meta Phenoxy benzyl alcohol in solvent Hexane at moderate temperature. The HCl gas evolved is scrubbed using dilute caustic soda solution. The reaction mixture is washed using dilute soda ash solution followed by water washes. The organic layer is concentrated to obtain Permethrin and packed in suitable containers. The recovered Hexane is recycled in subsequent batch.

Material Balance

6. Benfuresate

Chemical Reaction


Cypermethric Acid Chloride 0.621 Permethrin 1.0000

Meta Phenoxy Benzyl Alcohol 0.521 Hydrochloric Acid (gas) 0.0933 Vent through scrubber

Hexane (Recycle+Fresh) 3.157 Hexane (Recycle) 3.0262

Soda Ash 0.099 Hexane (Loss) 0.1308

DM Water for washing 1.6071 Effluent 1.7548 ETP


Permethrin Flow Chart With Material Balance

Manufacturing of Permethrin


Benfuresate is manufactured by reducing NC 9770 with Sodium Borohydride in pressure of an alkali. The resulting SOD salt of NC24001 is acidified in pressure of Sulphuric Acid. The acidified mass is cyclised in the presence of a catalyst to give crude Benfuresate. The crude Benfuresate is extracted in solvent and the solvent is distilled off to give Benfuresate Technical (98%).

Material Balance


NC9770 in toluene (80%) 1.4879 Toluene for recovery 1.6519

CSL(48%) 0.4348 Na-NC24001 3.2660

NaBH4(98%) 0.0483

Water 1.5942

Toluene 1.3527


Na-NC24001Aq 3.2660 NC24001 cake 2.2275

H2SO4 0.3255

Water for acidolysis 1.2500 Waste Water 2.6140 HTDS stream


NC24001 cake 2.2275 Benfuresate 1.0000

Xylene (Recycle+Fresh) 2.858 xylene distilled (Recycle) 2.8098

Catalyst 0.074 xylene voc 0.0466

(phthalic anhydride+TEA) Aq.catalyst discarding 0.0740 Incineration

CSL 48% 0.0822 Waste Water 3.9579 HTDS stream

water 2.6466


Benfuresate Flow Chart With Material Balance

Reaction+ Layer Seperation

Filtration+ Washing

Crystalization

7. Fluopicolide

Chemical Reaction

NH2

O

O

ClHO N

O

O

GEE HCl

+

Benzophenone

DIPEA

BPGI

+DIPEA HCl

NO

O

NCl

Cl CF3

NO

O

NCl

CF3

BPGI

+

DCTFP PYGI

O

NO

O

NCl

CF3

NH2

O

O

NCl

CF3

ClHBenzophenone

PYGI

HCl+

PYGE HCl

NH2

O

O

NCl

CF3

ClH

NNH2

ClCF3 CO2 OH

PYGE HCl

HCl

PYMA HCl

+ +Ethanol

NNH2

ClCF3 NaOHN

NH2

ClCF3

HCl

PYMA HCl

+

PYMA

NNH2

ClCF3

Cl

O

Cl

Cl

NNH

ClCF3

O

Cl

Cl

NaOHNaCl

PYMA

+

DCBC Fluopicolide

+


Glycine ethyl ester- HCl, Benzophenone and DIEPA are mixed and reflux under pressure and moisture is removed. Toluene is added to the reaction mass. Water is added to remove the salt. Potassium carbonate and Tetraethyl ammonium bromide is added and water is removed by azetropic distillation and then Dichlorotrifluoromethyl pyridine is added to the reactor. Toluene is distilled out from the reaction mass. Water is added to remove the carbonate stl and aq. Phase is separated out, followed by addition of Disodiumtetraborate for decarboxylation and then extraction. Reaction mass is filtered and then dried to get dry Fluopicolide product.

Material Balance


Toluene(Recycle+Fresh) 1.2242 Slurry mixture 2.8315

Benzophenone (Recycle+Fresh) 1.5627

PTSS 0.0446


Mixure received 2.8315 Aq. Phase for DIPEA recovery 0.7801

DIPEA (Recycle+Fresh) 0.6971 Toluene Distillate (Recycle) 0.5298

Water for Extraction 0.5349 BPGI solution in Tol. 2.7536


BPGI solution in Tol. 2.7536 Toluene Distillate (Recycle) 0.3023

K2CO3 1.5584 Reaction mixture 6.8068

TEBRO 0.0484

Toluene (Recycle+Fresh) 1.9354

DCTFP 0.8133


Reaction mixture 6.8068 Aq. Phase 1.0014 High TDS stream

water 1.6976 Product in aq. (PyGE_HCl) 3.9087

BXA 0.0446 Organic Phase For 5.5048 For recovery

HCl (30%) 0.959 Benzo Recovery (Recycle)

Toluene 0.9069

Total 10.4149 Total 10.4149

Product in aq. (PyGE_HCl) 3.9087

Toluene (Recycle+Fresh) 2.226 Aq.Phase 3.7527 High TDS stream

CSL (48% Solution) 0.5121 PyMA in Toluene 4.1180

Water 1.2239


PyMA in Toluene 4.1180 Aq. Phase 0.5424 Incineration

CSL (48% Solution) 0.1389 Fluopicolide in Toluene 3.9127

DCBC 0.138

Toluene 0.0602


Fluopicolide in Toluene 3.9127 ML for recovery 3.3730

Toluene (Recycle)- wash 1.1221

Product 1.6618


Product 1.6618 Loss On Drying (LOD) 0.6618 Vent through scrubber

Dry Fluopicolide 1.0000


Recoveries

Organic Phase for Benzo Recovery5.5046 Aqueous layer 1.2461 Incineration

Water 0.6041 Toluene 3.5693

CSL (48% Solution) 0.1312 Benzophenone 1.4245


Aq. Phase 0.7801 Aqueous waste 0.9688 Incineration

Water 0.3474 Recovered DIPEA 0.5788

CSL (48% Solution) 0.4201


Mother Liquor 3.3730 Distilled Toluene 3.0694

Organic waste 0.0506

Loss 0.2530


Fluopicolide Flow Chart With Material Balance

Slurry Prepartion

BPGI Reaction

PYGI reaction

PYGE.HCl

Fluopicolide

Filtration

Product drying

Benzophenone recovery

DIPEA Recovery

Toluene Recovery

PYMA reaction

8. Anilophos

Chemical Reaction

STEP- I

Cl NH

CH

CH3CH3

+ Cl C

O

CH2 Cl + HClCH2

O

C

CH3 CH3CH

NCl Cl

ClCl N

CH

CH3CH3

C

O

CH2 + HS P

S

OCH3

OCH3 OCH3OCH3

S

PCH2

O

C

CH3 CH3CH

NCl S

NaCl + 1/2 CO2 + 1/2 H2O

STEP- II

PCIPA - 169.7 CAC - 113 ANILIDE- 246 HCl - 36.5

ANILIDE- 246 DMTA - 158.2 ANILOFOS- 367.5

SODIUM - 58.5 CARBON - 44 WATER- 18CHLORIDE DIOXIDE

1/2 Na2CO3


Anilophos technical is brown colored liquid with Xylene. It is manufactured with P-Chloro Isopropyl Aniline , Chloro Acetyl Chloride , Soda ash & Dimethyl Thio Phosphoric acid. Here P- Chloro Isopropyl Aniline is reacted with Chloro Acetyl Chloride to form intermediate Anilide. Anilide is reacted with Dimethyl Thio Phosphoric acid to form Anilophos. Anilophos solution in Xylene is washed & then concentrated under vacuum to make liquid concentrate & packed in required packing size drums / containers.

Material Balance

9. Triazophos

Chemical Reaction


Phenyl Hydrazine / Phenylhydrazin Semicarbazide / Phenylhydrazin sulfate is reacted with Formic Acid in acid medium at elevated temperature to form an intermediate which is filtered and then transferred to another reaction vessel where it is reacted with diethyl thiophosphoric acid chloride and sodium carbonate in aromatic solvent medium at an elevated temperature.

Resulting mass is then washed with water and seperated into two layers. Organic layer is concentrated to get Triazophos concentrate and aqueous layer is sent for incineration.

Material Balance

10. N2-(1, 1-dimethyl-2-methylsulfinylethyl)-N1-(2-methyl-4-(1, 2, 2, 2-tetrafluoro-1- (trifluoromethyl) ethyl) phenyl) phthalamide (SOD)

Chemical Reaction


(Step-I) Converting Phthaloyl dichloride to ISM

Into the aqueous solution of a mixture of Sodium hydroxide and Sodium Bicarbonate, SAA and Toluene are charged. PDC is added over a period of time .After the reaction is completed, the organic layer is separated. The ISM obtained in organic solution is used in the next step with or without washing with water.

SAA = 2-Methyl-1-methylthio-2-propanamine

PDC = Phthaloyl dichloride

ISM = N-(1, 1-dimethyl-2-(methylthio)) ethyl) isophthalimide

(Step-II) Converting ISM to SOD:

ISM solution from step 1 is charged in the presence of catalytic amount of p-toluene sulfonic acid into the solution of RFA diluted in toluene. Then an aqueous peroxide solution is added. After the reaction is completed, the residual peroxides are decomposed with aqueous sodium sulphite solution and neutralized. The crude SOD solution is purified by crystallization in Toluene, filtered and dried product in vacuum dryer for final packing in drums.

SOD = N2-(1, 1-dimethyl-2-methylsulfinylethyl)-N1-(2-methyl-4-(1, 2, 2, 2-tetrafluoro-1-(trifluoromethyl) ethyl) phenyl) phthalamide

Water/Toluene

NaHCO3/NaOH+

O

S

N

ISM

H2N

S

SAA

Cl

Cl

O

PDC

O

+

DMAC

DAM

O

O

S

NH

i-C3F7

NH

O

S

N

ISM

i-C3F7

H2N

RFA

DAM

O

O

S

NH

i-C3F7

NHH2O2/ pTSA

Na2SO3

SOD

O

O

i-C3F7

NH

S

NH

O

Material Balance


Caustic (100%) 0.1614 Step I by product 2.4906

NaHCO3 0.2521 Carbon dioxide 0.2309 Vent

SAA(96%) 0.3807 Aqueous layer 2.3218 ETP

Toluene (Recycle+Fresh) 1.7406

PDC(97%) 0.6114

Process water 1.897


Step I by product 2.4906 Organic Layer(DAM) 4.0953

RFA(99%) 0.726 HCl 0.0001 Vent

Toluene 0.3545

DMAC 0.4966

p-TSA(40%) 0.0277


Organic Layer(DAM) 4.0953 Organic Layer (SOD) 3.8986

p-TSA(40%) 0.1562 Aqueous layer 1.2690 Incinerator

H2O2(35%) 0.3152

Na2SO3(15%) 0.3972

NaOH (48%) 0.0894

Toluene 0.1143


Organic Layer (SOD) 3.8986 Dry SOD 1.0000

Toluene 0.5713 Toleune (Recycle) 1.9094

Water 0.9986 Water Wash I 0.6660 HTDS plant & to ETP

Water Wash II 1.0218 ETP

Total 5.4685 ML+ Toluene 0.8713 For Recovery

Total 5.4685

NNI0001- SOD Flow Chart With Material Balance

Step -I

Step -II

Step - III

Crystalisation and Filtration

11. Dichloro hydroxyl ketone-NBA: DS 36

Chemical Reaction


Xylene and sodium metal were charged in a reactor and heated to 105°C. A reactor was charged with CTCMCP and Tetraglyme, to which Sodium Butylate suspension was dozed at -10C. After maintaining the reaction at -10°C, dilute 1.5%HCl solution and water were added to extract the salts and water soluble impurities. AlCl3 was dissolved in THF in a reactor. P-Benzoquinone suspension in Xylene was made in another reactor. In a reactor p-Benzoquinone suspension and Step-3/xylene were added, to which AlCl3/THF solution was dozed maintaining the temperature to -10C. After completion of reaction Ethanol was added to the reactor to precipitate Step -4. The reaction mass was filtered at -5-0C to isolate Step-4 which was dried at 40C and packed in bags. A suspension of Step- 4 in THF was charged to a reactor, to which a catalyst and hydrogen were charged. The reaction was conducted at 60C and 3 bar Hydrogen pressure. After hydrogenation reaction the mass was neutralized using TBA and the catalyst was filtered at 60C, organic Step -5/THF was collected. Xylene was added to Step -5/THF solution, THF was distilled and recycled to yield Step -5/Xylene. Step -5/Xylene was charged in a reactor to which IPA, Catalyst/IPA and KOH were added. Hydrogen was subsequently added to the reactor and hydrogenation reaction conducted at 9 bar hydrogen pressure. After completion of reaction CO2 was purged in the reactor to quench the reaction. The mass was crystallized from 85-0C. The precipitated product Step -6 was filtered at 20C, dried and packed in bags. Step-6 and 90% H2SO4 were added in a reactor and dehydration reaction was conducted at 30-40C, to which toluene and water were added to obtain two layers at 10-20C.

Material Balance

12. Dichlorooxime - NBE: DS 38

Chemical Reaction


Xylene and sodium metal were charged in a reactor and heated to 105°C. A reactor was charged with CTCMCP and Tetraglyme, to which Sodium Butylate suspension was dozed at -10C. After maintaining the reaction at -10°C, dilute 1.5%HCl solution and water were added to extract the salts and water soluble impurities. AlCl3 was dissolved in THF in a reactor. P-Benzoquinone suspension in Xylene was made in another reactor. In a reactor p-Benzoquinone suspension and Step-3/xylene were added, to which AlCl3/THF solution was dozed maintaining the temperature to -10C. After completion of reaction Ethanol was added to the reactor to precipitate Step -4. The reaction mass was filtered at -5-0C to isolate Step-4 which was dried at 40C and packed in bags. A suspension of Step- 4 in THF was charged to a reactor, to which a catalyst and hydrogen were charged. The reaction was conducted at 60C and 3 bar Hydrogen pressure. After hydrogenation reaction the mass was neutralized using TBA and the catalyst was filtered at 60C, organic Step -5/THF was collected. Xylene was added to Step -5/THF solution, THF was distilled and recycled to yield Step -5/Xylene. Step -5/Xylene was charged in a reactor to which IPA, Catalyst/IPA and KOH were added. Hydrogen was subsequently added to the reactor and hydrogenation reaction conducted at 9 bar hydrogen pressure. After completion of reaction CO2 was purged in the reactor to quench the reaction. The mass was crystallized from 85-0C. The precipitated product Step -6 was filtered at 20C, dried and packed in bags. Step-6 and 90% H2SO4 were added in a reactor and dehydration reaction was conducted at 30-40C, to which toluene and water were added to obtain two layers at 10-20C. Step-7/Toluene was charged in a reactor to which Benzoic acid and water were added. 30% aqueous Hydroxylamine sulphate and NaOH were dozed in parallel at 0-85C.

Material Balance

13. DMTA

Chemical Reaction


Phosphorus Pentasulphide is reacted with Methanol in presence of Xylene and Tetra butyl ammonium iodide at temperature 31 – 36 0C under stirring to form O,O Dimethyl dithio phosphoric acid (DMTA), which is filtered and transferred in storage vessel. Hydrogen Sulphide gas is scrubbed in dilute caustic solution to make sodium hydrosulphide as byproduct.

Material Balance

PROPOSED PRODUCTS

1. Pyridate

Chemical Reaction

O

CH3 + H

OOH

O

Acetophenone Glyoxalic acid

MW = 120 MW= 74

OH

O OH

O

Benzoyl acetic acid

MW= 194

OH

O OH

O

+ NH4OHONH4

O OH

O

MW = 194 Ammonium salt of benzoyl acetic acid

MW= 211

+WaterMW. 18

MW = 35.05

ONH4

O OH

O

Ammonium salt of benzoyl acetic acid

MW= 211

+ NH2 NH2.H2OHydrazine hydrateMW = 50

NNH

O

6-phenylpyridazin-3(2H)-oneMW . 172

+ NH4OH+ 3 H2OM.W : 35 M.W:18

NNH

O

6-phenylpyridazin-3(2H)-oneMW . 172

+ 2 Cl2 + PCl3

NN

Cl

Cl

+2HCl + POCl3

MW= 73.0 MW= 153.3MW=141.81 MW=137.33

4,6-dichloro-3-phenylpyridazineMW= 225.00

NN

Cl

Cl

4,6-dichloro-3-phenylpyridazineMW= 225

+ Na OHsodium hydroxide

NN

OH

Cl

+ Na Cl

MW= 206.5

6-chloro-3-phenylpyridazin-4-ol

MW=58.5

NN

OH

Cl

MW= 206.5

6-chloro-3-phenylpyridazin-4-ol

+ Cl SC8H17

O

MW=208.5 NN

O

Cl

SC8H17

O

PyridateMW=378.5

+Na OHMw=40 + Na Cl

MW=58.5+ H OH

water


Step I: Glyoxalic acid and Acetophenone are simultaneously charged to the reactor above 55 deg. C. After the completion of reaction, the mass is cooled to ambient temperature and then transferred to next step.

Step II: Benzoyl lactic acid and Aq. Ammonia solution are charged to the reactor at 70 deg C. The mass is then allowed to settle and the aqueous and the organic layers are separated. Organic layer containing Toluene and acetophenone is recycled to the next step. Aqueous layer containing ammonium salt of Benzoyl lactic acid is sent to the next reactor.

Step III: Ammonium Salt of Benzoyl Lactic acid and Hydrazine Hydrate are charged to the reactor at 70 deg C. After the reaction is completed the mass is cooled to ambient temperature. The mass is then filtered and dried. 3-Phenyl-Pyridazone-6 dry cake is sent to the next step.

Step IV: Chlorine is charged to the reactor containing PCl3 to form PCl5. 3-Phenyl-Pyridazone- is then charged to form 3-Phenyl -4, 6-dichloropyridazine and 3-Phenyl-6-chloro pyridazine. Chlorine gas is passed to the reactor to form 3-Phenyl -4, 6-dichloro pyridazine. The reaction mass is heated to 65 deg. C and Chlorine is slowly charged. After passing chlorine POCl3 is distilled out and recycled back. The crude is then sent to the next step.

Step V: 3-Phenyl -4, 6-dichloro pyridazine is reacted with Sodium Hydroxide (saponification reaction) followed by the separation of isomers using HCl to get 3-Phenyl-4-chloro-6-hydroxy pyridazine (pH= 8.3) and 3-Phenyl-6-chloro-4-hydroxy pyridazine (pH= 3.5). Water and NaOH are charged slowly to 3-Phenyl -4, 6-dichloro pyridazine at 85 to 90 deg C. The mass is neutralized with aq. HCl. The mass is ten cooled to 30 deg C and filtered to isolate the intermediate (3-Phenyl-4-chloro-6-hydroxy pyridazine). Mother liquor is recycled back. Wet cake is washed with acetone and dried at 50 degC.

Step VI: 3-Phenyl-6-chloro-4-hydroxypyridazine dry cake and acetone are charged to the reactor and followed by water. NaOH solution is slowly added at 60 deg C. OCTF is also charged. The mass is then filtered and the sludge is sent to waste. Mother liquor containing aqueous layer at the bottom and organic layer (Pyridate) at the top are separated.

Material Balance

2. Amicarbazone

Chemical Reaction

CH3CH3

CH3OH

+ HCl

CH3CH3

CH3Cl

+ NaOCNMCB CH3

CH3

CH3

N

O

+ H2O

tert.butyl alcohol

MW.36.5

MW.74

MW.65

MW.99

MW.18

tert. Butyl isocyante

+ NaClMw.58.5

CH4

CH3

CH3

O

OH+ N2H4.H2O

Isobutyric acid

MW - 50

CH3

CH3

O

NH NH2

+ 2 H2O

MW - 102 MW - 36.0

IBH

M.W - 88.0

CH3

CH3 O

NH NH2

MW - 102

IBH

+ COCl 2

M.W - 99

N

ONHCH3

CH3

O

+2 HCl

M.W - 128 M.W - 73ODZ

N

O

NH

O

CH3

CH3+NH2NH2H2O

MCBN

N

NH

O

CH3

CH3

NH2

+2H2O

Oxadiazolinone TrizolinoneMW.128

MW.50

MW.141

MW.18

N

N

NH

O

CH3

CH3

NH2

TrizolinoneMW.141

CH3

CH3

CH3

N

O

+ MCB N

N

N

O

CH3

CH3

NH2

NH

O

CH3

CH3 CH3

tert.butyl isocyanate

Amicarbazone

MW.99.13MW.241


Step I: Tert- Butyl Isocyanate Preparation (TBIC): Hydrochloric acid is charged into reactor and cooled to ambient temperature. Tert-Butyl alcohol is charged to the HCl maintaining the temperature at less than 30 deg C. NaOH Monochlorobenzene and Sodium Cyanate are then charged into reactor . After the completion of the reaction, aq. Layer is seprated out and sent to MEE. The organic layer is cooled and TBIC is isolated by filtration. The solvent MCB is recovered by distillation and recycled back. Organic residue is sent for co-incineration to cement plants.

Step-II: IBH preparation: Charge Hydrazine Hydrate and isobutyric acid into reactor and raise the temperature to less than 40 deg C. After completion of reaction, mass is filtered and transferred to next step. Water formed in the reaction is distilled out and sent to ETP.

Step-III: ODZ preparation: Charge step-II product into the reactor add triphosgene to the mass .Maintain the mass below 15 deg C. After completion of reaction, mass is filtered and transferred to next step. HCl gas evolved during this reaction is sent to two stage scrubber

Step IV: Triazolinone (TAZ) preparation: ODZ and Hydrazine Hydrate are charged into reactor and heated to less than 50 deg C .The mass is then cooled and Triazolinone is isolated by filtration.

Step V: Amicarbazone Preparation: TBIC and Triazolinone are charged into the reactor and heated less than 60 deg C. Tert-butylisocyanate is charged at a controlled rate at more than 65 deg C. After the completion of the reaction, mixture is neutralized and cooled. Amicrabazone is isolated by filtration and then dried.

Material Balance

3. Flucarbazone

Chemical Reaction

NaSCN + ClO

CH3

O

methoxyacetyl chloridesodiumthiocyanideCH3

O

NCS

O

+ NaCl

MW.81 MW.94.5MW.117 MW.58.5

CH3OHMW.32

CH3

S

NH

O CH3

O

MW.149

O,O-dimethyl imidothiodicarbonate

+ OH2

+SH2

CH3

O

S

NH

O CH3

O

MW.149

+ NH2NH2H2O NH NH

N

O

OCH3

+ H2S CH3OH + H2O

Dimethyl sulphate + 2KOH

N NH

N

O

OCH3

CH3

CH3OH + K2SO4 + H2O

MW.50

HMT

+MW.34 MW.32 MW.18

MW. 158 MW. 56

MW.129MW.32 MW.174 MW.18

+

N

NHN

O

O

CH3

CH3

MW.129MMT

+O

F F

F

S

O

O

N

O2-(trifluoromethoxy)benzenesulfonyl isocyanate

MW.267.1

O

F F

F

S

O

O

NH N

NN

O

O CH3

O

CH3

3-methoxy-4-methyl-5-oxo-N-{[2-(trifluoromethoxy)phenyl]sulfonyl}-4,5-dihydro-1H-1,2,4-triazole-1-carboxamide

MW.396

+ NaOHMW.40

O

F F

F

S

O

O

N N

NN

O CH3

O

CH3

ONa+H2O

Flucarbazone sodium

MW.18

MW.418


Step I: Aq. Solution of Sodium thiocyanate, methyl acetylchloride and methanol are charged in the Reactor and and the mixture is heated to above 90 deg C. Water is distiiled out during the reaction period. After the completion of the reaction the mass is filtered to isolate o,o-dimethyl imidothiodicarbonate . Methanol solvent is recovered from the filtrate and recycled. Nacl

Step II: Charge Hydrazine hydrate and Step-I product, MIBK, Dimethyl sulphate and KOH into the reactor and heat the mass to about 65 deg C. Water formed during the reaction is removed by distillation. Aq. Layer is isolated MIBK presnt in water are recovered by distillation. The organic layer is cooled to ambient temperature and the intermediate is isolated by filtration and transferred to the next

step.. MIBK is recovered from filtrate by distillation and recycled back. Organic residue is sent for incineration.

Step III: MIBK and Step –II product are charged into the reactor.2-(trifluoro methoxy) benzene sulfonyl isocyanate is added at a controlled rate maintaining temperature below 80 deg C. The mass is cooled to less than 30 deg C and filtered. Cake is dried and Flucarbazone is packed. ML is taken for next batch. Residue is sent for incineration.

Material Balance

4. Diuron

Chemical Reaction

O

CH 3 | | CH3

Cl NCO + NH Cl NH -C-N

CH 3 CH3

Cl Cl

(188) (45) (233)

3,4-Dichlorophenyl Dimethyl amine Diuron

Isocyanate


Diuron technical is white colored powder. It is manufactured by reacting 3, 4-Dichlorophenyl Isocyanate with anhydrous Dimethyl amine at 130 to 135ºC 2.8 to 3.2 kg/Cm2 pressure in Xylene medium.

The product is then isolated by centrifuging the slurry, and then drying the wet cake in dryer at 65-70 ºC and at vacuum of 650-700 mm of Mercury.

Material Balance

5. PBQ

Chemical Reaction

OH

OH

H2O2

I2

IPA

O

O

+

Hydroquinone PBQ

+ 2H2O


Hydroquinone powder is charged in IPA under stirring at room temperature. Heat the mass and Hydrogen peroxide is added in presence of catalyst Iodine under controlled rate and pH is maintained. Reaction mass is maintained under reflux. Once is crystallization is completed, mass is filtered, washed and dried in ANFD. Dry powder is packed in jumbo bags as required pack size. Mother liquor transferred for fractionation distillation. IPA / water is distilled from fractionation column under vacuum & temperature and IPA is separated, recycled in process and bottom mass is sent for further treatment & disposal to ETP.

Material Balance

6. Methoxy AA

Chemical Reaction


Step I: In step 1 process toluene is initially charged into the reactor followed by sodium metal and the temperature is raised to above 100OC. 2-Methoxyethanol is added to the above mixture at a controlled rate. After the completion of the reaction, toluene is recovered by distillation and reused. Then the final reaction mixture is cooled and sent to next step.

Step II: Aq. HCl solution and Ethyl-4-Chloroacetoacetate is added gradually to the intermediate formed in the above step and the temperature is maintained above 40OC. After the completion of the reaction, aqueous layer is separated and sent to ETP for treatment. Organic layer is washed with water and Methoxy-AA is analyzed and packed.

Material Balance

7. ABA HCl

Chemical Reaction

NH2

OH

OH

3-aminopropane-1,2-diol

+

N+ O

-O

O

OCH3

O

OCH3

dimethyl 5-nitrobenzene-1,3-dicarboxylate

N+ O

-O

O

NHO

NH

OH

OH

OH

OHO

NHO

NH

OH

OH

OH

OH

NH2

ABA.HCl

Methanol

MW- 239.0 MW- 91.1 MW- 357.2 MW-363.7

methanol5% Pd/Carbon

HCl


First charge Dimethyl 5-Nitrobenzene 1,3-Dicarboxylate (DNDC), 3-aminopropen-1,2-diol (APD) & methanol in reactor. Bis Amide is formed due to the reaction. ML is removed for co-processing/ incineration. In next step, add palladium carbon, methanol & dry HCl in reaction mass. In this stage, ABA HCl is formed. The palladium carbon is then filtered from the reaction mass. After filtration crystallization is occurred. After crystallization, methanol is recovered from reaction mass & sent for methanol recovery. Now, ABA HCl is obtained in powder form after drying.

Material Balance

8. DAT

Chemical Reaction


First charge sodium thiocynate, toluene & water in reactor remove the water by doing azetropic distillation and transfer the reaction mass in next step. Add pyridine & ethyl Chloroformate in reaction mass and heat up the mass then filter the salt from the reaction mass. After filtration add ADMP in to the reaction mass and allow it for reaction, then add hydroxylamine. After completion of reaction filter the slurry solution. Give methanol wash to crude DAT and dry it by using dryer.

Material Balance

9. Azura 5

Chemical Reaction


First dehydration of Wet Azura cake is done. Then chlorination is done using SOCl2 addition slowly. After chlorination Amination is done using DMA in gas state. The reaction is done at pressure of 0.5 kg/cm2. Further chlorination of reaction mass is done using SOCl2 and COCl2. Toluene is recovered in this step. After chlorination again Amination is done using Ammonia gas then filter the mass. After filtration distillation of Acetone + Toluene is done until Acetone <1% in distillate and mass is slowly cooled for crystallization. Then filter the mass in ANF & dry the mass using dryer.

Material Balance

10. Propiconazole

Chemical Reaction


Step I: 2, 4- Dichloroacetophenone (DICAP) is reacted with pentane 1, 2 Propanediol (1,2PDL) to form acetal compound in the presence of toluene. Water formed during the reaction and PTSA remains in the aqueous layer. The acetal compound is reacted with bromine above 50 deg C to form bromoketal. A batch tank is used to add bromine to the acetal compound in toluene. Hydrogen bromide gas evolved during the reaction and it is scrubbed with water to obtain HBr solution, which is sent to bromine recovery unit. The bromoketal mass is neutralized with aqueous NaOH and the unreacted bromine reacts with NaOH to form NaBr. Water charged and the layers are then separated. The aqueous layer is sent to bromine recovery. Toluene is distilled off from the organic layer.

Step II: DMSO solvent is added to bromoketal mass to accomplish the reaction with triazole. The bromoketal mass is reacted with the potassium salt of triazole. The potassium salt of triazole is obtained by reacting 1, 2, 4 triazole with potassium hydroxide. Water is formed along with potassium triazole. After completing the reaction to form Propiconazole, Wash with water and Aq.Layer containing KBr is sent to bromine recovery. The crude Propiconazole is extracted with DMSO. Finally, Propiconazole is concentrated to the desired purity by distilling off DMSO.

Material Balance

11. Tricyclazole

Chemical Reaction

CH3

NH2

MW - 107.15

+ NH4SCN

CH3

NH NH2

S

MW - 166.24

O - Toludine OTTU

Chlorobenzene +

MW - 76.13

+ H Cl

MW - 36.5

NH4Cl

MW - 53.5

CH3

NH NH2

S

MW - 166.24OTTU

MW - 164.22AMBT

MW - 71.

+ ClCl

CH3

S

NNH2+ 2 HCl

MW - 73.1

MW - 164.22AMBTCH3

S

NNH2+ NH2

NH2CH3

S

NNH

NH2

MW - 179.24

+ NH3

HMBTMW - 17MW - 32.04

CH3

N

SNH

NH2

HMBT

CH3

N

S

N

N

TCZMW - 189.23

+ HOH

O

MW - 46.0Formic acid

+ 2 H2O

MW - 36.0


Step I: Charge Chlorobenzene into the reactor and add O-Toluidine and Hydrazine Hydrate into the reactor and Hydrochloric acid is gradually charged maintaining the temperature at 55 deg C. Filtered the product and sent to next step. Ammonium chloride and water from reaction is sent to treatment plant.

Step-II: Charge Chlorobenzene into the reactor and add step-I product and Chlorine gas is gradually charged and maintaining the temperature at 60 deg C. Filtered the product and sent to next step. HCl gas evolved during this reaction is sent to two stage scrubber

Step-III: Charge Xylene into the reactor and add step-II product and add hydrazine hydrate to the mass and maintaining the temperature at 70 deg C. Filtered the product and sent to next step. Ammonia gas evolved during this reaction is sent to two stage scrubber

Step-IV: 2-Hydrazine, 4-Methyl benzothiozole is reacted with formic acid in xylene solvent at above 65 deg C. After completion of reaction, the product is filtered and washed with water. The water wash is sent to ETP.

Material Balance

12. Fenbuconazole

Chemical reaction

N

+Cl

CH2

N

ClBenzylcyanide P-chlorostyrene

MW.255M.W-117.15 M.W-138.59

N

Cl

MW.255

+ CH2Cl2

N

Cl

Cl

+ HCl

MW.84.99 MW.36.5

MW.3044-(4-chlorophenyl)-2-phenylbutanenitrile

2-(chloromethyl)-4-(4-chlorophenyl)-2-phenylbutanenitrile

N

Cl

Cl

MW.304

2-(chloromethyl)-4-(4-chlorophenyl)-2-phenylbutanenitrile

+ NNH

N

1H-1,2,4-triazole

N

Cl

NN

N+ KCl + H2O

Fenubuconazole

MW. 74.5 MW.18

MW.336.8Mw.69

+K OH

potassium hydroxide


Step I: Benzylcyanide and P-chloro styrene are charged into the reactor at above 80 deg C. DMSO is added as a solvent for the reaction. After reaction is completed the mass is cooled to ambient temperature and filtered. Cake is charged in the next step. DMSO is distilled from the filtrate and recycled back.

Step II: Dichloromethane is charged into reactor containing step-1 product and cooled. pH of the mass is adjusted using sodium hydroxide and mass is transferred to the next step. Aqueous layer is sent for disposal.

Step III: 1, 2, 4- Triazole and KOH and IPA are charged into the reactor while stirring the step-2 product. After the completion of the reaction the organic layer is cooled. Fenbuconazole is isolated by filtration and then dried. IPA is recovered from filtrate by distillation and recycled.

Material Balance

13. Vulcuren

Chemical reaction

NH

Dibenzyl amineMW - 197.28

+S

S

Carbon disulphide

+ Na OH

MW - 76.14

MW - 40.0 NS

SNa

NaBECMW - 295.40

+Water

MW - 18.0

H2O

ClCl

1,6-dichlorohexaneMW - 155.07

+2 Na2S2O3.5H2OMW - 248.17

SS

SO

O

O NaS

O

OO

Na

Bis Bunte

MW - 354.39

+ 10 H2O

MW - 18.

+2 NaClMW - 58.4

SS

SO

O

O NaS

O

OO

Na

Bis BunteMW - 354.39

+NS

SNa

NaBECMW - 295.40

S

S

N

S

S

N

S

S

+ 2 Na2SO3MW - 126.0

VulcurenMW - 693.12

2


Step I: Dibenzil Amine, Carbon Disulphide, Sodium Hydroxide (48%) and water are charged into the reactor. At this stage, Na BEC is formed due to reaction.

Step II: 1,6 Dichlorohexane, Soidum Thiosulfate & water are charged into reactor. At this stage, Bis Butane is formed.

Step III: Na BEC from step 1 & Bis Butane from step 2 are charged in reactor with toluene. After the completion of the reaction the organic layer is seperated. Vulcuren is isolated by filtration and then dried. Toluene is recovered from filtrate by distillation and recycled. High TDS layer is sent to MEE.

Material Balance

14. Vulkalent - E

Chemical reaction


Water and xylene are charged into the reactor and cooled to 5OC. Carbon disulfide is then charged. Chlorine is charged at a controlled rate maintaining temperature at less than 30OC. Then sodium hydroxide is charged and the acid is neutralized. Benzene Sulfonamide and caustic solution are charged to neutralize the reaction mass. The mass is then cooled to crystallize the product. The mass is then filtered and dried. Xylene mother liquor is distilled and recycled.

Material Balance

Annexure – 6: Storage & Transportation of Materials S. No. Raw Material Source Means of

storage i.e. no. of container with

capacity

Means of transport

Storage conditions

Max. Qty. to be stored MT with no. & capacity of container

Pressure Temperature

1. Xylene Local Storage tank By Road 20 mbar nitrogen blanketing

Atmospheric Temperature 27 m3

2. 100% Fresh Sul. Acid

Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 8 m3

3. 100% PHSC Local 500 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 3 T 4. Acetonitrile Local 16 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 10 T 5. AlCl3 Local 500 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 5 T 6. Bayticol P Acid Imported 25 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 7. Bayticol P Acid

chloride Imported 25 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 2 T

8. Becis themic Acid Local 25 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 3 T 9. Benzophenone Imported Storage tank By Road Atmospheric Pressure Atmospheric Temperature 30T 10. BXA Imported 25 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 20 T 11. BzAcid Local 25 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 3 T 12. CAC Local 200 kg drum By Road Atmospheric Pressure Atmospheric Temperature 10 T 13. Cat/IPA Imported 150 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 4 T 14. Caustic Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 42 m3 15. Caustic (100%) Local 50 Kg bags By Road Atmospheric Pressure Atmospheric Temperature 3 T 16. Caustic(48%) lye Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 42 m3 17. Charcoal Local 40 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 2 T 18. CO2 Local 30 Kg Cylinder By Road Atmospheric Pressure Atmospheric Temperature 120 Kg 19. CSL (48%) Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 42 m3 20. CTCMCP Local Storage tank By Road Atmospheric Pressure 20 0C 20 T 21. Cucl Local 50 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 3 T 22. Cypermethric Acid

Chloride Local 50 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 2 T

23. DCBC Imported Storage tank By Road 20 mbar nitrogen blanketing


S. No. Raw Material Source Means of storage i.e. no.

of container with capacity

Means of transport

Storage conditions



24. DCONA Local 525 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 20T 25. DCTFP Imported Storage tank By Road 20 mbar nitrogen

blanketing Atmospheric Temperature 27 m3

26. DETCL Local Storage tank By Road 20 mbar nitrogen blanketing

Atmospheric Temperature 10 T

27. Di Isopropyl Amine Local 140 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 2T 28. Dil.HCl Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 10 T 29. DIPEA Local 160 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 4T 30. DMAC Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 20 m3 31. DMS Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 32. DMTA Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 33. Ethanol Local Storage tank By Road 20 mbar nitrogen


34. DCONA Local 525 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 20T 35.

DCBC Imported Storage tank By Road 20 mbar nitrogen


36. DETCL Local Storage tank By Road 20 mbar nitrogen blanketing

Atmospheric Temperature 10 T

37. Di Isopropyl Amine Local 140 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 2T 38. Dil.HCl Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 10 T 39. DIPEA Local 160 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 4T 40. DMAC Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 20 m3 41. DMS Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 42. DMTA Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 43. Ethanol Local Storage tank By Road 20 mbar nitrogen


44. Ethyelene Dichloride Local 1000 Kg IBC container

By Road Atmospheric Pressure Atmospheric Temperature 5 KL

45. FluroPhenoxy Benzaldehyde

Local 50 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 3 T



Means of transport

Storage conditions



46. H2O2 (35%) Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 40 T 47. H2SO4 Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 8 m3 48. HAS Imported 25 Kg bags By Road Atmospheric Pressure Atmospheric Temperature 3 T 49. HCl Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 13 m3 50. HCl (30%) Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 13 m3 51. Hexane Local Drums By Road Atmospheric Pressure Atmospheric Temperature 5 m3 52. Iso propyl Alcohol Local 160 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 53. Isopropyl Ether Local 145 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 54. K2CO3 Local 500 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 20 T 55. KOH Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 25 m3 56. MCB Local Storage tank By Road 20 mbar nitrogen


57. Meta Phenoxy Benzyl Alcohol

Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 2 T

58. Methanol Local Storage tank By Road 20 mbar nitrogen blanketing


59. Na Metal Imported Storage tank By Road Atmospheric Pressure 130 deg centrigate 10 T 60. Na2SO3 (15%) Local 50Kg bag By Road Atmospheric Pressure Atmospheric Temperature 4T 61. NaBH4 (98%) Local 50 K drum By Road Atmospheric Pressure Atmospheric Temperature 4T 62. NaHCO3 Local 50 Kg bags By Road Atmospheric Pressure Atmospheric Temperature 15T 63. NC9770 in toluene

(80%) Local 220 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 10T

64. Oxadizon Local 25 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 10T 65. P2S5 Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5 T 66. PBQ Local 500 Kg bag By Road Atmospheric Pressure 20 deg centrigate 2 T 67. PClPA Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 10 T 68. PDC (97%) Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 24T 69. Phenol Local Storage tank By Road Atmospheric Pressure 50-60 deg centrigate 25 m3



Means of transport

Storage conditions



70. Potassium carbonate Local 500 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 35T 71. Propargyl chloride Local 113.75 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 5T 72. P-TSA (40%) Local 25 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 2T 73. PTSS Local 25 kg bag By Road Atmospheric Pressure Atmospheric Temperature 2 T 74. RFA(99%) Local 250 Kg drum By Road Atmospheric Pressure 11 degree Centrigate 8T 75. SAA(96%) Local 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 15T 76. Soda Ash Local 50 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 15T 77. Sodium Bisulphite Local 50Kg bag By Road Atmospheric Pressure Atmospheric Temperature 4T 78. Sodium Cyanide Local 50 Kg bag By Road Atmospheric Pressure Atmospheric Temperature 4T 79. Sodium Hydroxide @

47% Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 42 m3

80. Solvesso Local Storage tank By Road 20 mbar nitrogen blanketing

Atmospheric Temperature 50 KL

81. Sulphuric Acid Local Storage tank By Road Atmospheric Pressure Atmospheric Temperature 8 m3 82. TBA Imported 155 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 7T 83. TBAB Local 25 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 2T 84. t-BuOH Imported Storage tank By Road Atmospheric Pressure Atmospheric Temperature 16 T 85. TEBRO Local 25 kg drum By Road Atmospheric Pressure Atmospheric Temperature 10 T 86. Tetrabutyl amonium Local 10 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 1 T 87. TGL Imported 200 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 6 T 88. THF Imported Storage tank By Road Atmospheric Pressure Atmospheric Temperature 10 T 89. Thionyl Chloride Local 300 Kg drum By Road Atmospheric Pressure Atmospheric Temperature 2T 90. Toluene

Local Storage tank By Road 20 mbar nitrogen


Annexure – 7: Characteristics of Materials Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

1 Acetonitrile

T/F 81.6 4.4

16 0.783

1.42

Soluble in cold water, hot water, methano

2 3 0 Flammable 40 7551 8 hours

2460 mg/kg

Absorbed through skin. Eye contact. Inhalation. Ingestion

NA

2. Cypermethric Acid Chloride

--

78-80 NA

NA

NA NA NA NA NA NA NA NA NA NA NA

3. Aluminum chloride, anhydrous

-- NA -- -- -- NA NA 3 0 0 Non-flammable

-- -- 5 8 hours

3805 mg/kg

Eye contact. Inhalation. Ingestion

NA

4. Benzophenone

-- 305.4

NA

NA

1.1108

NA Easily soluble in acetone. Soluble in methanol, diethyl ether. Insoluble in cold water

2 1 0 -- -- -- -- 2895 mg/kg


NA

5. Butyric acid

-- 163.5 2 10 0.959

3.04

Easily soluble in cold water

3 2 0 Combustible

-- -- -- 2000 mg/kg


NA

6. Catalyst -- NA 7. Custic

Soda -- 1390 N

A NA

2.13 NA Soluble in water

3 0 2 NA -- -- -- 1350 mg/kg

Eyes. Respiratory system. Skin

NA

8. Charcoal -- NA -- -- 3.51 NA Insoluble in cold water, hot water

1 3 0 Flammable

3.5 (mg

-- NA NA Inhalation. Ingestion

--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

/m3)

9. CLS -- NA NA

NA

0.5 Na SOLUBLE

-- -- -- -- NA NA -- --

10. Carbon Dioxide

-- -78.5

-- -- -- -- Water: 2000 mg/l Completely soluble

-- -- -- -- -- -- -- --

11. Cuprous chloride

T 1490 -- -- 4.14 NA Soluble in diethyl ether. Very slightly soluble in cold water

3 0 0 Non-flammable

-- -- -- 140 mg/kg


--

12. Di isopropylamine

-- 84 0.8

7.1

0.7169

3.5 Easily soluble in diethyl ether, acetone. Partially soluble in cold water. Very soluble in benzene, ethanol

2 3 0 Flammable 5 -- 4200 mg/m3 2 hours

770 mg/kg

Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion

--

13. N,N-DIMETHYLACETAMIDE

-- 164.4 - 166

1.80

11.50

9370g/cm3

-- soluble in water

-- -- -- -- 7200 mg/m3

4620 mg/kg

-- --

14. Dimethyl Sulfide

-- -- 2.2

19.7

37 -- Medium: Water

2 4 0 -- -- -- 40250 ppm

> 5,000 mg/kg

-- --

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

slightly soluble

15. Ethanol -- 78 3.3

19.0

0.790

1.59

Miscible 2 3 0 -- -- -- 12900-15300mg/l

-- -- --

16. Ethylene Dichloride

F/T 84

-- -- -- -- -- -- -- -- -- >5 mg/l / 10 hours

>2000 mg/kg

-- --

17. 4-(4'-Fluorophenoxy)benzaldehyde

-- NA NA

NA

NA NA NA NA NA NA NA NA NA NA NA

18. Hydrogen Peroxide 30%

-- 108 -- -- 1.1 1.1 Easily soluble in cold water. Soluble in diethyl ether

2 0 1 Non-flammable

1 -- 2000 mg/m 4 hours

2000 mg/kg

Absorbed through skin. Eye contact

--

19. Sulfuric acid

C 270 -- -- 1.84 3.4 Easily soluble in cold water. Sulfuric is soluble in water with liberation of much heat. Soluble in ethyl alcohol

3 0 2 Non-flammable

3 (mg/m3)

-- 320 mg/m3 2 hours

2140 mg/kg


--

20. Hydrochloric acid

C/T 108.58

-- -- 1.1- 1.19

1.267

Soluble in cold water,

3 0 1 Non-flammable

-- -- 1108 ppm,

900 mg/kg

Absorbed through skin. Dermal contact.

--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

hot water, diethyl ether

1 hours

Eye contact. Inhalation

21. Hexanes -- 68 1.15

7.5

0.66 2.97

Soluble in diethyl ether, acetone. Insoluble in cold water, hot water

1 3 0 Flammable 50 -- 48000 ppm 4 hours

25000 mg/kg

Absorbed through skin. Dermal contact. Inhalation. Ingestion

--

22. Isopropyl alcohol

F 82.5 2 12.7

0.78505

2.07

Easily soluble in cold water, hot water, methanol, diethyl ether, n-octanol, acetone. Insoluble in salt solution. Soluble in benzene. Miscible with most organic solvents including alcohol, ethyl alcohol, chloroform

1 3 0 Flammable 400 -- 16000 8 hours

3600 mg/kg

Absorbed through skin. Dermal contact. Eye contact. Inhalation

--

23. Isopropyl ether

-- 68.5 1.4

7.9

0.7257

3.52

Very slightly soluble in cold water

1 3 1 Flammable 310 -- -- 8470 mg/kg

Dermal contact. Eye contact. Inhalation. Ingestion

--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

24. Potassium carbonate, anhydrous

-- Decomposes

-- -- 2.29 NA Soluble in cold water

2 0 0 Non-flammable

-- -- -- 1870 mg/kg


--

25. Potassium chloride

-- 1420 -- -- 1.987

NA Soluble in cold water, hot water. Very slightly soluble in methanol, n-octanol

1 0 0 Non-flammable

-- -- -- 1500 mg/kg

Inhalation. Ingestion

--

26. Mono Chloro Benzene

T/F 132 1.3 - 11

7.1

-- -- -- -- Flammable -- -- 2965 ppm

1100 mg/kg

-- --

27. Meta Phenoxy Benzyl Alcohol

-- 135-140

-- -- -- -- Freely soluble in Toluene, Methanol, etc

-- -- -- -- -- -- -- --

28. Methanol F/T 64.5 6.72

36.50

0.7915

Miscible -- -- 200 ppm

-- -- -- A human poison by ingestion. Poison experimentally by skin contact. Moderately toxic experimentally by intravenous and intraperitoneal routes.

--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

Mildlly toxic by inhalation

29. Sodium sulfite

C NA NA

NA

2.63 NA Soluble in cold water, hot water. Soluble in glycerol. Almost insoluble in alcohol

1 0 0 Non-flammable

-- -- -- 820 mg/kg


--

30. Sodium borohydride

-- NA NA

NA

1.074

1.3 Easily soluble in cold water

3 4 2 Flammable -- -- -- 160 mg/kg


--

31. Sodium bicarbonate

-- NA NA

NA

2.159

NA Soluble in cold water. Slightly soluble in alcohol. Solubility in Water: 6.4, 7.6, 8.7, 10.0, 11.3, 12.7, 14.2, 16.5, 19.1 g/100 solution at 0, 10, 20, 30, 40, 50, 60, 80, adn 100 deg. C, respectively.

1 0 0 Non-flammable

-- -- -- 3360 mg/kg


--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

Solubility in Water: 6.9, 8,2, 9.6, 11.1, 12.7, 14.5, 16.5, 19.7, and 23.6 g/100g water at 0, 10, 20, 30, 40, 50, 60, 80, 100 deg. C, respectively

32. Toluene F 110.6 1.1

7.1

0.8636

3.1 Soluble in diethyl ether, acetone. Practically insoluble in cold water. Soluble in ethanol, benzene, chloroform, glacial acetic acid, carbon disulfide. Solubility in water: 0.561 g/l @ 25 deg. C

2 3 0 Flammable 50 -- 440 24 hours

636 mg/kg


--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

33. Oxadiazon

-- -- -- -- -- -- 0.7mg/l in Water, 600g/l in acetone, hypnone, 1kg/l in benzene

-- -- -- -- 9.0 ppm; 48-hour

1000mg/kg

-- --

34. Phosphorus Pentasulfide

-- 514-525

NA

NA

2.03 NA -- -- -- -- -- -- 389 mg/kg

-- --

35. Benzoquinone

-- Decomposes.

-- -- 1.318

3.7 Partially soluble in cold water, hot water

3 2 0 May be combustible at high temperature

-- -- -- 130 mg/kg

Dermal contact. Eye contact. Inhalation. Ingestion

--

36. PDC-E2 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 37. Phenoxyet

hanol -- 245 -- -- -- -- 24g/l 1 0 0 -- -- -- 1980

mg/kg -- -- --

38. Phenol F 182 1.7

8.6

1.057

3.24

Easily soluble in methanol, diethyl ether. Soluble in cold water, acetone. Solubility in water: 1g/15 ml water. Soluble in


5 -- 125 mg/l 24 hours

270 mg/kg


--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

benzene. Very soluble in alcohol, chloroform, glycerol, petroleum, carbon disulfide, volatile and fixed oils, aqueous alkali hydroxides, carbon tetrachloride, acetic acid, liquid sulfur dioxide. Almost insoluble in petroleum ether. Miscible in acetone. Sparingly soluble in mineral oil.

39. Potassium

-- Decomposes

-- -- 2.29 -- Soluble in cold water

2 0 0 Non-flammable

-- -- -- 1870 mg/kg


--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

carbonate, anhydrous

40. Propargyl chloride

-- 57 1.03 NA Insoluble in cold water

2 3 0 Flammable NA NA Eye contact. Inhalation. Ingestion

--

41. P-Toluenesulfonic acid monohydrate

-- 140 -- -- 0.72 5.9 Soluble in cold water, hot water. Solubility in water: 0.67g/ml @ 25 deg. C(77 deg. F)


-- -- -- 1683 mg/kg

Absorbed through skin. Eye contact. Inhalation. Ingestion

--

42. p-Toluenesulfonylsemicarbazide

-- -- -- -- -- -- -- -- -- -- -- -- -- -- --

43. SAA -- -- -- -- -- -- -- -- -- -- -- -- 2,460mg/kg

-- --

44. Sodium carbonate

C NA NA

NA

2.532

NA Soluble in hot water, glycerol. Partially soluble in cold water. Insoluble in acetone, alcohol

2 0 1 Non-flammable

-- -- 1200 mg/m3 2 hours

4090 mg/kg


--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

45. Sodium bisulfite

-- NA NA

NA

1.48 NA Easily soluble in hot water. Soluble in cold water. Soluble in 3.5 parts cold water. Soluble in 2 parts boiling water. Soluble in 70 parts alcohol Insoluble in liquid chloride, ammonia

2 0 0 Non-flammable

-- -- -- 2000 mg/kg

Inhalation. Ingestion.

--

46. Sodium Cyanide

-- 1496 -- -- 1.595

0.941

Soluble in cold water. Slightly soluble in Ethanol


-- -- -- 6.44 mg/kg

Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion.

--

47. Sodium hydroxide

C 1388 -- -- 2.13 NA Easily soluble in cold water.

3 0 1 Non-flammable

-- -- NA NA -- --

48. SOLVESSO 150 FLUID

-- 179 0.8

5.9

NA 4.7 Negligible

-- -- -- -- -- 6000 mg/kg

-- --

49. Sulfuric acid

C 270 -- -- 1.84 3.4 Easily soluble in cold water. Sulfuric is

3 0 2 Non-flammable

-- -- 320 mg/m

2140 mg/kg

Absorbed through skin. Dermal contact.

--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

soluble in water with liberation of much heat. Soluble in ethyl alcohol

3 2 hours

Eye contact. Inhalation. Ingestion.

50. tert-Butyl alcohol

-- 82.41 2.4

8 0.78581

2.55

Soluble in cold water, hot water. Miscible in esters, aliphatic and aromatic hydrocarbons, alcohol, and ether

1 3 0 Flammable 100 -- 10000 4 hours

2743 mg/kg

Absorbed through skin. Dermal contact. Eye contact. Inhalation

--

51. Tetrabutylammonium Bromide

-- NA NA

NA

NA NA NA NA NA NA NA NA NA NA --

52. Tetrabutylammonium Hydroxide, 40%

-- 100 -- -- 1 0.62

Easily soluble in cold water, hot water. Soluble in methanol.

3 0 0 Non-flammable

-- -- NA NA Absorbed through skin. Eye contact. Inhalation. Ingestion

--

53. Thionyl chloride

Da

ng

ero

us

76 -- -- 1.638

4.1 Insoluble in cold water. Miscible with chloroform, benzene,

4 0 2 Non-flammable.

-- -- 500 1 hours

-- Absorbed through skin. Dermal contact. Eye contact.

--

Sr. No.

Name of chemical

Haz

ard

BP

0 C

LE

L %

UE

L %

SP

. GR

. At

20 0 C

VD

So

lub

ility

w

ith

wat

er a

t 20

0 C

NFPA H F R

Haz

ard

ou

s co

mb

ust

ion

p

rod

uct

TL

V p

pm

IDL

H p

pm

LC

50

LD

50

Tar

get

o

rgan

s

Car

cin

og

eni

city

carbon tetrachloride

Inhalation. Ingestion.

54. Toluene F 110.6 1.1

7.1

0.8636

3.1 Soluble in diethyl ether, acetone. Practically insoluble in cold water. Soluble in ethanol, benzene, chloroform, glacial acetic acid, carbon disulfide. Solubility in water: 0.561 g/l @ 25 deg. C


636 mg/kg

Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion.

--

55. Xylene F 138.5 1 7 0.864

3.7 Insoluble in cold water, hot water. Miscible with absolute alcohol, ether, and many other organic liquids.


2119 mg/kg

Absorbed through skin. Dermal contact. Eye contact. Inhalation.

--

Annexure -8: Land Documents

Annexure -9: Power & Fuel Details

Power and Fuel Requirement

Sr. No.

Name of Fuels

Requirement Source Existing Proposed

Additional Total

Power 2000 KVA 27200 KVA 29200 KVA Dakshin Gujarat Vij.Co.Ltd.

Fuel 1 Natural Gas 24978 SCM/day 94560 SCM/day 119538 SCM/day Gujarat Gas

Company Ltd. 2. HSD 200 lit/hr 3550 lit/hr 3750 lit/hr Local Market


Annexure -10: Utility Emission Details

Details of utility emissions

Sr. No. Stack Attached to Fuel & Its Quantity

Stack Details in Meter

Type of Emission

Existing installations

1. Boiler 8 TPH - 2 Nos. (working – 1+ Standby - 1)

Natural Gas 688 SCM/hr

Common Stack H: 33, D: 0.3

PM, SO2, NOX

2. N. G. Based Captive Co-Gen Plant– standby Capacity: 1.4 MW

Natural Gas 312.5 SCM/hr

H: 30, D: 0.3 PM, SO2, NOX

3. Stand by DG Set (250 KVA)

HSD 200 Lit/Hrs.

H: 11, D:0.1 PM, SO2, NOX

4. Incinerator Natural Gas

150 SCM/hr

H: 40, D: 0.8 SPM, SO2, HCl, CO Total organic Carbon

Proposed Additional

1. Steam Boiler 25 TPH - 2 Nos.

Natural Gas 1970 SCM/hr

H: 33, D:0.3 PM, SO2, NOx

2 Standby DG Set (1500 KVA) – 10 Nos. – All standby

HSD 355 Lit/Hrs.

H: 31.5, D: 1.1 PM, SO2, NOx


Annexure -11: Hazardous & Solid Waste Generation and its Management Hazardous and solid waste generation and its management

Sr. No.

Name of waste

Cat. No.

Hazardous waste details (T/Annum) Mode of disposal

Existing Proposed Total after proposed

1 Used Oil 5.1 12.6 7.4 20 Collection, Storage, transportation, disposal by selling to registered refiners / in house incineration

Oil Filter 0.4 0.6 1.0 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL

2 Spent Solvent (Incinerable Organic Waste)

20.2 105 13842 13947 Collection, Storage, transportation, disposal by incineration within premises / common incineration facility of BEIL, SEPPL or GSPL or sending to RSPL as an alternative fuel resource or to cement industries for co-processing.

3 Discarded Asbestos (cement sheet / roof sheet, rope, gasket)

15.2 25 -- 25 Collection, Storage, transportation, disposal at TSDF after solidification.

4 Solid waste from surface preparation for painting

-- 2.5 -- 2.5 Collection, Storage, Transportation, Disposal at TSDF

Waste from containment / clean-up of spills.

29.1 1 -- 1 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL

Contaminated Cotton Waste, Containers, liners

10 -- 10 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL

Distillation residue

50 2505 2555 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL or GSPL or sending to RSPL as an alternative fuel resource or

Sr. No.

Name of waste

Cat. No.



to cement industries for co-processing.

Used PPE 5 5 10 Collection, Storage, decontamination / transportation, disposal at TSDF.

Waste insulation and lining material

40 20 60 Collection, Storage, transportation, disposal at TSDF.

Brick / Refractory

40 -- 40 Collection, Storage, Transportation, Disposal at TSDF

Used Liners 10 10 20 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL

5 Chemical sludge from waste water treatment

35.3 710 790 1500 Collection, Storage, Transportation, Disposal at TSDF

Inorganic Salt from MEE plant

1250 10269 11519

6 Date Expired & Off Specification Pesticides / product

29.3 23.5 -- 23.5 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL

7 Discarded empty containers

33.1 245 4715 4960 Collections, Storage, transportation, sell to approve vendors after De-contamination within premises & inspected by AEPS.

8 Ash from Incineration of Hazardous waste, flue gas cleaning residue

37.2 50 50 100 Collection, Storage, transportation, disposal at TSDF.

9 Sulphuric Acid (100% basis) / spent acid

26.3 650 -- 650 Collection, storage, transportation, disposal by selling to actual users

10 Solvent Recovery / Recovered solvent

20.1 1200 2300 3500 Collection, Storage, transportation, disposal by sell to GPCB approved end user / recyclers after incineration within premises / common incineration facility of BEIL, SEPPL or GSPL or

Sr. No.

Name of waste

Cat. No.



sending to RSPL as an alternative fuel resource or to cement industries for co-processing.

12 Used empty packing material / containers from Costumers / Distributors

33.1 200 -- 200 Reception from various customers / distributors, storage, decontamination & Environmental friendly disposal by incineration

13 NaSH -- 50 -- 50 Collection, Storage, Transportation, Disposal by selling to actual users.

14 Spent Carbon (from nitrogen plant)

28.3 -- 2 2 Collection, Storage, Transportation, Disposal by Incineration within premises / common Incineration facility of BEIL or SEPPL


Annexure -12: Membership Certificate for Solid Waste Disposal &Common Incineration Facility

Annexure -13: Membership Certificate from Narmada Clean Tech(NCT) for ETP Waste Water Discharge