annexures contents -...

ANNEXURES

Contents 1. Topographical Map ............................................................................................................................ 2

2. Site Layout ........................................................................................................................................... 3

3. Emission & Control ............................................................................................................................ 4

4. Water Requirement: ........................................................................................................................... 7

5. ETP Design .......................................................................................................................................... 9

6. Plant Process ...................................................................................................................................... 11

1. Topographical Map

2. Proposed Site Layout

3. Emission & Control

Air Pollution Control Measures

S. No. Stack

Attached to Fuel Used

Quantity of

Fuel APCM

Expected

Pollutants

Efficiency

of APCE

Stack

Height(m)

Flue Gas Stacks

1 Boilers

Agro waste

briquettes

(as per

availability)

4.8 tons 30 M PM, SO2

& NOx - 35

2 Thermic

Fluid Heater LDO 200 Lit/day 30 M

PM, SO2

& NOx - 30

3 DG Sets HSD 750 Ltr/day Adequate

Stack Ht.

PM, SO2

& NOx - 15

Process Stacks / Vents

1

Process

Reactor –

Vents (5

Nos.)

- - Acid

Scrubber

HCl, HBr,

NH3, NOx

& HC

99.5 % 35

2

Process

Reactor –

Vents (6

Nos.)

- - Gas

Scrubber 99.5 % 35

3

Process

Reactor –

Vents (6

Nos.)

- - Gas

Scrubber 99.5 % 35

Odour Contol System:

4. Water Requirement:

DETAILS OF WATER USAGE AND WASTE WATER GENERATION

S. No. Area of Consumption

Fresh

Water

Quantity,

KLD

Water

Recycled,

KLD

Waste Water

Generation,

KLD

Remarks

1 PROCESS 59 - 62

To MEE

(Primary

Treatment

followed by

MEE)

2 Domestic 6 - 5 To ETP via STP

(Final treatment)

3 Gardening 5 - - -

4 DM Plant 9 16* 1

* Impure Steam

Condensate

recycled to DM

Plant

4.1 Boiler - 72** 2

** Pure Steam

Condensate

recycled to

BOILER

5 Cooling Tower 14 75# 5

# Permeate from

RO Plant

recylced

6 RO Reject - - 19 To MEE

7 Floor Washing 5 - 5 To ETP (Final

treatment)

8 MEE Condensate - - 77 KLD To ETP

(Final treatment)

9 Less MEE & ETP

Residue to TSDF -5

10 TOTAL 98 - 94.0

Total 95 KLD to

be treated in ETP

followed by RO

and 81 KLD to

be processed in

MEE

5. ETP Design

6. Plant Process

Herbicides

Manufacturing Flow Diagram of Pretilachlor

2,6 DEA

(1150 KG)

Propoxy Ethyl Chloride

(440 KG)

Reactor

Reactor

NaOH (350 KG)

Distillation

Aq. Layer (417 KG) to ETP

Solid Residue

(92KG)

DEPA (856 KG) Reactor

CAC (400 KG)

Toluene (1800 KG)

HCl (133 KG)

Reactor

Water wash (500 KG)

Pretilachlor

(1000 KG) Aqueous waste

(680 KG)

Toluene recovery

(1743KG)

Excess 2,6 DEA (575 KG)

Manufacturing Flow Diagram of Sulfosulfuron

Phenyl chloroformate

(369 KG)

ADP (363 KG)

1,4 Dioxane (3000 KG)

HCl (86 KG) Reactor

Reactor Water (1500 KG)

Filtration and Drying

Filtration

Reactor

Sulfosulfuron (1000 KG)

ESPO (683 KG)

Water wash (500 KG) To ETP (1845 KG)

Aq. Layer (3000 KG)

1,4 Dioxane (2850 KG)

1,4 Dioxane loss (150 KG)

Water(1500 KG)

IPA (750 KG) IPA (713 KG)

Loss (37 KG)

Phenol (222 KG) TEA (238KG)

Acidified water (1000 KG)

Manufacturing Flow Diagram of Clodinafop Propargyl

5-chloro-2,3-difluoro pyridine

(417 KG)

DMF (1667 KG)

K2CO3

(400 KG)

R(+)-2-(4-hydroxy phenoxy) propionic acid

(533 KG)

Reactor

Reactor Propargyl chloride (200 KG)

Filtration

Filtration

Crystallization

Clodinafop Propargyl (1000 KG)

Methanol (1167 KG)

Water (2666

KG)

To ETP (3317 KG)

DMF Recovery (1633 KG)

Methanol Recovery (1100 KG)

Manufacturing Flow Diagram of Glyphosate

Water (1000 KG)

Sodium tungstate

catalyst

(3 KG)

H2O2

( 400 KG)

PMIDA (Phosphono

methylimino di acetic acid)

(799 KG)

Reactor

Filtration of

catalyst

Drying loss (200 KG)

Glyphosate

(1000 KG)

Catalyst

(3 KG)

Filtration and Drying

Aq. layer(1004 KG)

SMBS (5 KG)

Manufacturing Flow Diagram of Atrazine

Reactor

Cyanuric Chloride

(868 KG)

Isopropylamine

(278 KG)

NaOH (60 KG)

Ethylamine (212 KG) &

NaOH (60 KG)

Filtration & Drying

Atrazine

(1000 KG)

To ETP (754 KG) Water Wash (276 KG)

Manufacturing Flow Diagram of Metribuzin

DMSO4 (652 KG)

H2SO4 (1273 KG) Reactor

ATKG (1000 KG)

Sodium sulfate

(2129 KG)

Water ( 4498 KG)

NaOH (30 KG) Reactor CO2 (664 KG)

Metribuzin (1000 KG)

Centrifuge

Aqueous layer to

ETP (5259 KG)

Soda ash (1599 KG)

Manufacturing Flow Diagram of Imazethapyr

Reactor

Di ethyl 5 ethyl pyridine di-

carboxylate (970 KG) Water wash (3695 KG)

Filtration

Crystallization Ethanol (4927 KG)

Aq. Layer (5083 KG)

Imazathapyr (1000 KG)

2 Amino 2,3dimethyl Butane amide (603 KG)

Methanol (800 KG)

Ethanol recovery (4827 KG)

Toluene (3202 KG)

Sodium ethoxide (658 KG) Toluene recovery (3136 KG)

Toluene loss (66 KG)

HCl 30% (1175 KG)

Residue (218 KG)

Distillation loss (100 KG)

Insecticides

Manufacturing Flow Diagram of Dichlorvos

Reactor

Chloral (673 KG)

Degassing/Concentration Methyl chloride

(238 KG)

Dichlorvos (1000 KG)

Trimethyl Phosphate

(565 KG)

Manufacturing Flow Diagram of Propargite

2-(4-tert butyl phenoxy cyclohexanol)

(707 KG)

SOCl2 (542 KG)

Toluene (1000 KG)

Reactor

Filtration

Water(500 KG)

Propargite (1000 KG)

TEA HCl (287 KG)

HCl (104 KG)

Reaction Propargyl alcohol (160 KG)

Triethyl amine (183 KG)

Extraction Aq. Layer (701 KG)

Toluene (950 KG)

loss (50 KG)

Distillation

Manufacturing Flow Diagram of Novaluron

2,6 Difluoro benzoyl isocyanate (372 KG) Compund 1 (628 KG)

Reactor

Distillation and Filtration

Aq. waste (500 KG)

Reactor

Toluene(1000 KG)

Novaluron (1000 KG)

MCB (1500 KG)

MCB (1450 KG)

MCB loss (50 KG)

Water wash (500 KG)

Toluene (960 KG)

Toluene loss (40 KG)

Manufacturing Flow Diagram of Diafenthiuron

Reactor

DTU (1045 KG)

Reactor

Water (250 KG)

Diafenthiuron (1000 KG)

O-Xylene (5098 KG) O-xylene (4898 KG)

O-xylene loss (200 KG)

Toluene (4998 KG)

TBA (670 KG) NH3 (54 KG)

Toluene Recovery (4848 KG)

Toluene loss (150 KG)

TBA(661 KG)

Aq. Waste (250 KG)

Purification and

Drying

N-Hexane (5998 KG) n-Hexane Recovery (5748 KG)

n-Hexane loss (250 KG)

Manufacturing Flow Diagram of Chlorpyrifos

Diethylphosphorochlorido

thioate

(457 KG)

Sodium salt of 3,5,6-

trichloropyridin-2-ol

(628 KG)

Phase Transfer

Catalyst Tertiary

amine acid boric

Tampon (10 KG)

MDC (3427 KL)

Reactor

Filtration

Chlorpyrifos

(1000 KG)

Dried Under

Vaccum

To ETP (95 KG)

MDC recovery (3256 KG)

MDC loss ( 171 KG)

Manufacturing Flow Diagram of Bifenthrin

DMF

(2000 KG)

BPC

(500 KG)

KGH Acid

(650 KG)

K2CO3

(50 KG)

Catalyst (TBAB)

(25 KG)

Reactor DMF Recovery (1950 KG)

Reactor

Water (4500 KG)

Hexane (2000 KG) Sodium Bi-carbonate sol. (250 KG)

Crystallization,

Filtration & Drying

Hexane (2500 KG)

5% EtOH in Hexane (250 KG) To ETP (5000 KG)

Bifenthrin

(1000 KG)

Hexane Recovery

(2550 KG)

Hexane Recovery (1725 KG)

Solid Waste

(500 KG)

Manufacturing Flow Diagram of Imidacloprid

NNII (825 KG)

CCMP (873 KG)

Catalyst (10 KG)

Reactor

Filtration Water(485 KG)

Imidacloprid (1000 KG)

Aq. layer

DMF (2135 KG)

Reaction Na2CO3 (684 KG)

Water (485 KG)

NaOH (49 KG)

ETP (2290 KG)

Distillation and Crystalllization DMF recovery (2048 KG)

DMF loss (87 KG)

Methanol (388 KG)

Methanol (359 KG)

loss (29 KG)

Distillation residue (121 KG)

Manufacturing Flow Diagram of Buprofezin

MCB

(2400 KG)

1 - isopropyl-3 - t-butyl

thiourea(500 KG) N-chloromethyl-N-phenyl

carbamoyl chloride(640 KG)

Reactor

Separation

Ammonium bicarbonate + Water

(2400 KG) + (2000 KG)

Aqueous layer To ETP

(4500 KG)

Distillation MCB Recovery

(2380 KG)

Methanol (1400 KG) Crystallization

Filtration & Drying

Buprofezin

(1000 KG)

Methanol Recovery

(1300 KG)

Solid waste

(160 KG)

Manufacturing Flow Diagram of Thiamethoxam

4-Nitroimino-3-methyl Isoxazole (600 KG)

DMF (1999 KG)

Reactor

Distillation and Filtration

Solid waste (300 KG)

Reactor

HCl 30% (50KG)

Thiamethoxam (1000 KG)

Filtrate to ETP (257 KG)

2-Chloro-5-Chloromethyl Thiazole (638 KG)

DMF (1999 KG)

K2CO3 (270 KG)

DMF (3599 KG)

DMF loss (400 KG)

Manufacturing Flow Diagram of Fipronil

MDC (5000 KG)

BrSCN (514 KG) Reactor

Fipronil Pyrazole (1172 KG)

HBr (552 KG)

SO2(388 KG)

CF3Br (756 KG) Reactor DMF recovery (4300 KG)

Fipronil (1000 KG)

Reactor

DMF loss (200 KG)

MDC recovery (4790 KG)

MDC loss(210 KG) DMF (4500 KG)

Sodium formate (255 KG) NaBr (334 KG)

DCAA ( 1500 KG)

H2O2 (235 KG)

TCAA (4000 KG)

Water wash (8999 KG)

TCAA recovery (3813 KG)

TCAA loss (185 KG)

DCAA recovery (1385 KG)

DCAA loss (115 KG) Filtration and Drying Methanol (5000 KG)

Methanol recovery (4785 KG)

Methanol loss (215KG)

Aq. Waste (10435 KG)

Manufacturing Flow Diagram of Profenophos

O-Chlorophenol (375 KG)

MCB(mono Chlorobenzene

(1000 KG)

Br2 (470 KG)

Reactor HBr Recovery (180 KG)

Reactor Di-ethyl thiochloro phosphate

(562 KG)

Trimethylamine (147 KG)

Reactor

Organic Layer (MCB Recovery) (975 KG)

Profenophos (1000 KG)

Propyl bromide (387 KG)

Trimethylamine (147 KG)

To ETP (1524 KG)

Trimethyl ammonium bromide by-Product

(909 KG) Water (1500 KG)

Manufacturing Flow Diagram of Acephate

DMPTC

(1169 KG) NH4OH

(944 KG)

Reactor

Reactor

Reactor

Acetic anhydride (825 KG)

Acephate

(1000 KG)

MDC (1334 KG)

Neutralization

MDC (500 KG)

Aq. Layer to ETP (1014 KG)

DMPAT

Dimethyl sulfate (150 KG)

Monitor (2582 KG)

H2SO4 (21 KG)

H2O (400 KG)

NH4OH (683 KG)

Aq. Layer (2695 KG) Extraction

MDC (3147 KG)

Aq. Layer to

ETP (2367 KG)

Concentration

MDC recovery

(4792 KG)

Organic layer

(3475 KG)

Organic layer (2317 KG)

Manufacturing Flow Diagram of Permethrin

Permethrin

(1000 KG)

CMAC

(582 KG)

MPBAL(511 KG) Reactor

Reactor

Reactor

Dehydration

Water (500 KG)

Water (500 KG) Aq. Waste to ETP (481 KG)

Water of dehydration to ETP

(70 KG)

HCl (85 KG)

K2CO3(16 KG)

CO2 (5 KG) Aq. Layer to ETP (468 KG)

Manufacturing Flow Diagram of Lambda-Cyhalothrin

Lambda- Cyhalothrin

(1000 KG)

ChrysaKGhanic acid (539 KG)

Chlorination Thionyl Chloride (264 KG)

HCl (80 KG)

SO2 (142 KG)

Condensation

MPBD (440 KG)

NaCN (109 KG)

Water (1170 KG)

Caustic lye (15 KG)

Hexane (1200 KG)

Recovery

Hexane (1140 KG)

Hexane loss (60 KG)

NaOCl (75 KG)

Aq. Layer (1390 KG)

Epimerization

IPA (1000 KG) Cat-1 (100 KG)

IPA recovery

IPA rec.(920 KG) IPA loss (80 KG)

Work up vessel

Catalyst rec.(80 KG) Catalyst loss (20 KG)

Fungicides

Manufcaturing Flow Diagram of Difenoconazole

1,2,4 Triazole

(428 KG)

DMSO ( 1967 KG)

Reactor Toluene (10816 KG)

Reactor

Difenoconazole (1000 KG)

Bromoketal (1833 KG)

IPE ( 833 KG)

PE (167 KG)

Water ( 2410 KG)

Drying loss (222 KG)

Aq. Waste (3449 KG)

Filtrate (1000 KG)

DMSO (1928 KG)

DMSO loss (39 KG)

Toluene recovery (10593 KG)

Toluene loss

(223 KG)

Manufacturing Flow Diagram of Tricyclazole

AMBT (1200 KG)

Hydrazine mono hydrate(402 KG)

HCl 30% (890 KG)

Reactor

Tricyclazole (1000 KG)

HCl (578 KG)

Mix xylene (150 KG)

Reactor Formic acid (286 KG) Xylene recovery (110 KG)

Water (3998 KG)

Xylene loss(40 KG)

Aq. Waste (5198 KG)

Manufacturing Flow Diagram of Cymoxanil

Water

(333 KG)

NaNO2

(350 KG)

1-Cyanoacetyl-3-Ethylurea

(783 KG)

Nitrosation

Reactor p-TSA

(33 KG)

Reactor Sodium bi-

Carbonate Salt

(100 KG)

Methylation DMSO4 (313 KG)

Filtration & Drying Water (5999 KG)

Cymoxanil (1000 KG)

NOX gas (160 KG) to

Scrubber

CO2 gas(253 KG)

to Scrubber

To ETP (6498 KG)

Manufacturing Flow Diagram of Isoprothiolane

CS2

(300 KG)

Diisopropylmalonate

(700 KG)

1,2-Dichloroethane

(775 KG)

Condensation &

Layer Separation

NaOH

(725 KG)

Aq. Layer TO ETP

(855 KG)

1,2-Dichloroethane Recovery

(675 KG)

Rectification n-Heptane (2250 KG) n-Heptane Recovery (2220 KG)

Isoprothiolane

(1000 KG)

Manufcaturing Flow Diagram of Propiconazole

2,4 Dichloroacetophenone (433 KG) Bromine(133 KG)

Reactor Acetic Acid ( 1167 KG)

Reactor

Reactor

Separation

Propiconazole (1000 KG)

Methanol

Recovery(317 KG)

Acetic Acid Recovery (1067 KG)

HBr to Scrubber (107 KG)

Toluene Recovery (1283 KG)

Methanol (333 KG)

1,2-Pentane Diol ( 283 KG)

PTSA ( 33 KG)

Toluene ( 1333 KG)

1,2,4 Triazole ( 150 KG) KOH ( 50 KG)

Water (500 KG) To ETP (641 KG)

Drying

Hexaconazole

(1000 KG)

Manufacturing Flow Diagram of Hexaconazole

Reactor

Valeric acid

(465 KG)

MDCB

(670 KG)

Thionyl chloride

(570 KG)

NaOH

(325 KG)

AlCl3

(820 KG)

MDC (6999 KG)

HCl

(160 KG)

MDC (6679 KG)

MDC loss (320 KG)

Reactor

DMS

(200 KG)

DMSO4

(660 KG)

KOH

(650 KG)

Water

(2900 KG)

DMS (193 KG)

Aq. Layer

(3406 KG)

Reactor Water (5999 KG) 1,2,4 Triazole (280 KG)

K2CO3 (145 KG)

DMF (8999 KG)

DMF recovery

(8600 KG)

DMF loss

(400 KG)

Aq. Layer (6979 KG)

Solid waste

(145 KG)

Poly

aluminium

chloride

(1520 KG)

SO2 (280 KG)

Manufacturing Flow Diagram of Tebuconazole

1-(4-Chlorophenyl) 4-4-Dimethyl-3-

Pentanoate (675 KG)

Sodium methoxide (162 KG)

Reactor

1,2,4 Triazole (206 KG)

Reactor

Reactor

Tebuconazole (1000 KG)

DMS (186 KG)

Toluene (1400 KG) Water (1690 KG)

DMF (1100 KG)

DMF (1070 KG)

DMF loss (30 KG)

To ETP (1809 KG)

Toluene recovery (1360 KG)

Toluene loss (40 KG)

Distillation residue (14 KG)

Methanol (96 KG)