form-i · 2017-06-27 · form-i for proposed expansion of pesticides & pesticide intermediates...

FORM-I

for

PROPOSED EXPANSION OF PESTICIDES & PESTICIDE

INTERMEDIATES MANUFACTURING UNIT

of

M/s. MEGHMANI ORGANICS LIMITED

Plot No. 5001/B, 5027 to 5034 & 5037, 4707 B & 4707 P,

GIDC Industrial Estate, Ankleshwar-393 002,

Dist. Bharuch, Gujarat.

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

APPENDIX I

FORM 1 (I) Basic Information

Sr.

No.

Item Details

1. Name of the Project/s M/s. Meghmani Organics Limited

2. S. No. in the Schedule 5(b)

3. Proposed capacity / area / length /

tonnage to be handled/command

area/lease area/number of wells to be

drilled

• Existing Production Capacity: 259.412 MT/Month

• Total Production Capacity after Proposed Expansion:

1374.5 MT/Month (Refer: Annexure-1).

• Total Plot Area: 57,986 m2

• No bore well is and will be drilled within the

premises.

4. New/Expansion/Modernization Expansion

5. Existing capacity/area etc. • Existing Production Capacity: 259.412 MT/Month

• Existing Plot Area: 57,986 m2

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

7. Does it attract the general condition?

If yes, please specify.

Yes. Located within critically polluted area

(Ankleshwar).

8. Does it attract the specific condition?

If yes, please specify.

No.

9. Location

Plot/Survey/Khasra No. Plot. No. 5001/B, 5027 to 5034, 5037, 4707 B &

4707P

Village GIDC Industrial Estate

Tehsil Ankleshwar – 393 002

District Bharuch

State Gujarat

10. Nearest railway station/airport along

with distance in kms.

By road distance:

Nearest Railway Station: Ankleshwar - 4 km (approx.)

Nearest Airport : Surat - 60 km (approx.)

11. Nearest Town, city, District

Headquarters along with distance in

kms.

By road distance: Nearest Town : Ankleshwar - 4 km (approx.) Nearest District Head Quarter : Bharuch - 15 km (approx.)

12. Village Panchayats, Zilla Parishad,

Municipal corporation, Local body

(Complete postal addresses with

telephone nos. to be given)

Notified Area Authority, Ankleshwar

13. Name of the applicant M/s. Meghmani Organics Limited

14. Registered address Meghmani House, B/h. Safal Profitaire, Corporate

Road, Prahladnagar, Ahemdedabad-380015, Gujarat.

15. Address for correspondence:

Name Mr. Vasant Patel

Designation (Owner/Partner/CEO) General Manager

Address M/s. Meghmani Organics Limited

Plot. 5001/B, 5027 to 5034, 5037, 4707 B & 4707 P

GIDC Industrial Estate, Ankleshwar – 393 002, Dist:

Bharuch, Gujarat.

Pin Code 393 002

E-Mail [email protected]

Telephone No. Tel: +91-2646-222971

Mob.: +91 9879507391 / 9909949438

Fax No. --

16. Details of Alternative Sites examined,

if any location of these sites should be

shown on a topo sheet.

No

17. Interlinked Projects No

18. Whether separate application of

interlinked project has been

submitted?

No interlinked project has been submitted.

19. If Yes, date of submission Not applicable

20. If no., reason Not applicable

21. Whether the proposal involves

approval/clearance under: If yes,

details of the same and their status to

be given.

(a) The Forest (Conservation) Act,

1980?

(b) The Wildlife (Protection) Act,

1972?

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

Not applicable as proposed expansion activity will be

within GIDC Industrial Estate, Ankleshwar,

Dist. Bharuch, Gujarat.

22. Whether there is any Government

order/policy relevant/relating to the

site?

No

23. Forest land involved (hectares) No

24. Whether there is any litigation

pending against the project and/or

land in which the project is propose to

be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court,

if any and its relevance with the

Yes (Refer-Annexure-17)

proposed project.

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which

will cause physical changes in the locality (topography, land use, changes in water

bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes

/No?

Details thereof (with approximate

quantities / rates, wherever possible)

with source of information data

1.1 Permanent or temporary change in land

use, land cover or topography including

increase in intensity of land use (with

respect to local land use plan)

No --

1.2 Clearance of existing land, vegetation

and buildings?

No --

1.3 Creation of new land uses? No Land is for industrial purpose. Proposed

expansion activity will be carried out

within existing site which is located on

level ground does not require any land

filling for area grading work.

1.4 Pre-construction investigations e.g. bore

houses, soil testing?

No --

1.5 Construction works? Yes • Additional required construction works

will be carried out in proposed expansion

project.

• Refer: Annexure - 2.

1.6 Demolition works? No --

1.7

Temporary sites used for construction

workers or housing of construction

workers?

No --

1.8 Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

Yes • Additional buildings, structures required

etc. shall be as per plant design above

ground level.

• Refer: Annexure - 2.

1.9

Underground works including mining or

tunneling?

No --

1.10 Reclamation works? No --

1.11 Dredging? No --

1.12 Offshore structures? No --

1.13 Production and manufacturing

processes?

Yes Refer: Anneure-3.

1.14 Facilities for storage of goods or

materials?

Yes •Existing storage facilities/area is available

as an existing infrastructure for storage of

existing raw materials, finished products,

hazardous/solid wastes etc.

• Additional storage facility for additional

raw materials, finished goods,

hazardous/solid wastes etc. will be

developed as per requirement.

1.15

Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes • Water consumption & Waste water

generation details

– Refer: Anneure-4.

• Effluent Treatment Plant details


• Hazardous/Solid wastes generation and

disposal mode details


1.16

Facilities for long term housing of

operational workers?

No --

1.17 New road, rail or sea traffic during

construction or operation?

No --

1.18 New road, rail, air waterborne or other

airports etc?

No The proposed expansion activity will be

carried out within existing site located in

well developed Industrial Estate having all

the infrastructure facilities. Existing

transportation system is adequate too.

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No --

1.20 New or diverted transmission lines or

pipelines?

No --

1.21

Impoundment, damming, converting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No --

1.22 Stream crossings? No --

1.23

Abstraction or transfers or the water

form ground or surface waters?

Yes • No ground water is and shall be used.

• Raw water requirement is met through

GIDC water supply and will be met

through same source after proposed

expansion.

1.24

Changes in water bodies or the land

surface affecting drainage or run-off?

No --

1.25

Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel or raw

materials/finished products is primarily by

road only & it will be done through the

same way after proposed expansion.

1.26 Long-term dismantling or

decommissioning or restoration works?

No --

1.27 Ongoing activity during

decommissioning which could have an

impact on the environment?

No --

1.28

Influx of people to an area in either

temporarily or permanently?

No --

1.29 Introduction of alien species? No --

1.30 Loss of native species of genetic

diversity?

No --

1.31 Any other actions? No --

2. Use of Natural resources for construction or operation of the Project (such as land, water,

materials or energy, especially any resources which are non-renewable or in short supply):

Sr.

No

Information/checklist confirmation Yes/

No?

Details there of (with approximate

quantities/rates, wherever possible) with

source of information data

2.1 Land especially undeveloped or

agriculture land (ha)

No --

2.2 Water (expected source & competing

users) unit: KLD

Yes • Raw water requirement is met through

GIDC water supply and will be met

through the same source after proposed

expansion.

• Water consumption & Waste water

generation details


2.3 Minerals (MT) No --

2.4

Construction material - stone,

aggregates, sand / soil (expected source

MT)

Yes Construction materials will be procured

from local market.

2.5 Forests and timber (source - MT) No --

2.6

Energy including electricity and fuels

source, competing users Unit: fuel (MT),

energy (MW)


2.7 Any other natural resources (use

appropriates standard units)

No --

3. Use, storage, transport, handling or production of substances or materials, which could be

harmful to human health or the environment or raise concerns about actual or perceived risks

to human health.

Sr.

No.

Information / Checklist confirmation Yes/

No?


quantities / rates wherever possible) with


3.1 Use of substances or materials, which are

hazardous (as per MSIHC rules) to human

health or the environment (flora, fauna,

and water supplies)

Yes

Refer: Annexure -8.

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No --

3.3 Affect the welfare of people e.g. by

changing living conditions?

No --

3.4

Vulnerable groups of people who could

be affected by the project e.g. hospital

patients, children, the elderly etc.,

No

--

3.5 Any other causes No --

4. Production of solid wastes during construction or operation or decommissioning

MT/month)

Sr.

No.

Information/Checklist confirmation Yes/

No?


quantities / rates, wherever possible)

with source of information data

4.1 Spoil, overburden or mine wastes No --

4.2

Municipal waste (domestic and or

commercial wastes) No --

4.3

Hazardous wastes (as per Hazardous

Waste Management Rules)


4.4 Other industrial process wastes Yes Refer: Anneure-6.

4.5 Surplus product No --

4.6

Sewage sludge or other sludge from

effluent treatment


4.7 Construction or demolition wastes Yes Structural waste will be sold to authorized

vendor.

4.8 Redundant machinery or equipment No --

4.9 Contaminated soils or other materials No --

4.10 Agricultural wastes No --

4.11 Other solid wastes Yes Refer: Anneure-6.

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

Sr.

No.


No?


quantities/rates, wherever possible) with


5.1 Emissions from combustion of fossil

fuels From stationary or mobile sources

Yes Refer: Annexure - 9.

5.2 Emissions from production processes Yes Refer: Annexure - 9.

5.3 Emissions from materials handling

including storage or transport.

Yes • Raw materials receive in

drums/bags/tankers and handled in

closed charging system with proper

ventilation and charged through close

pipeline in to reactors/treatment units. It

will be done through same way after

proposed expansion.

• Thus there is no any kind of emission

through storage and transport.

5.4 Emissions from construction activities

including plant and equipment

Yes Water sprinkling during construction to

avoid dusting and Barication of

construction area.

5.5

Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Water sprinkling during construction to

avoid dusting and Barication of

construction area.

5.6 Emissions from incineration of waste No --

5.7 Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No --

5.8 Emissions from any other sources No --

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

Sr.

No.


No?

Details there of (with approximate

Quantities /rates, wherever possible) With

source of source of information data

6.1

From operation of equipment e.g.

engines, ventilation plant, crushers

Yes • There are few activities due to which noise

generates. The equipments resulting in

noise generation are machineries of plant

and diesel generator. Adequate noise

controls measures are provided.

• Proper and timely oiling, lubrication and

preventive maintenance is carried out for

the machineries & equipments to reduce

noise generation.

• Use of PPE like ear plugs and ear muffs are

made compulsory near the high noise

generating machines.

• Noise monitoring is done regularly in plant

area.

• The D.G. Sets will be installed in a closed

room and shall be provided with acoustic

enclosure.

• Above system will be followed after

proposed expansion to prevent/reduce

noise to be generated.

• The unit has developed plantation within

the premises which helps to prevent the

noise pollution within sit as well as

surrounding area.

6.2 From industrial or similar processes Yes • All machinery/equipment is well

maintained, have proper foundation with

anti vibrating pads wherever applicable and

thus noise levels is within permissible

limits.

• An acoustic enclosure will be provided for

D.G. sets.


proposed expansion to prevent/reduce

noise to be generated.

6.3 From construction or demolition No --

6.4 From blasting or piling No --

6.5 From construction or operational traffic No --

6.6 From lighting or cooling systems No --

6.7 From any other sources No --

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

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

Sr.

No


No?


quantities / rates, wherever possible) with


7.1 From handling, storage, use or spillage Yes • All hazardous materials stored safely

of hazardous materials separately in designated storage area.

• Dyke walls are provided around

raw/hazardous materials storage tanks.

• Materials stored in bags/drums kept on

pallets with concrete flooring and company

takes preventive action for no spillage likely

to occur.


proposed expansion.

• Refer: Annexure -8.

7.2

From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes Sewage is sent to effluent treatment plant

for treatment and disposal & to be done

through same way after proposed

expansion.

7.3

By deposition of pollutants emitted to

air into the land or into water

No --

7.4 From any other sources No --

7.5 Is there a risk of long term build up of

pollution in the environment from

these sources?

Yes

• Environmental Management System (EMS)

is installed i.e. ETP, Air Pollution Control

systems, Hazardous Waste Handling and

Management system as per rules, etc.

which eliminates the possibility of building

up of pollution.

• In proposed expansion activity, above EMS

will be implemented, if required.

8. Risks of accident during construction or operation of the Project, which could affect

human health or the environment:

Sr.

No

Information/Checklist confirmation

Yes/

No?




8.1 From explosions, spillages, fires etc.

from storage, handling, use or

production of hazardous substances

Yes Refer: Annexure -8.

8.2 From any other causes No --

8.3 Could the project be affected by natural

disasters causing environmental damage

(e.g. floods, earthquakes, landslides,

cloudburst etc)?

No --

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

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

planned activities in the locality

Sr.

No.


No?




9.1 Lead to development of supporting.

laities, ancillary development or

development stimulated by the project

which could have impact on the

environment e.g.:

* Supporting infrastructure (roads,

power supply, waste or waste water

treatment, etc.)

• housing development

• extractive industries

• supply industries

• other

Yes • Plot is located within GIDC, Ankleshwar,

having entire required infrastructure

facilities i.e. road infrastructure, water

supply, power supply, etc.

• Local people are employed and no housing

is required.

• Refer: Annexure – 10.

9.2

Lead to after-use of the site, which

could have an impact on the

environment

No

--

9.3 Set a precedent for later developments No --

9.4 Have cumulative effects due to

proximity to Other existing or planned

projects with similar effects

No --

(III) Environmental Sensitivity

Sr.

No

Information/Checklist confirmation Name /

Identity

Aerial distance (within 25 km). Proposed

Project Location Boundary.

1 Areas protected under international

conventions national or local

legislation for their ecological,

landscape, cultural or other related

value

No Plot is located in GIDC, Ankleshwar, Dist.

Bharuch, Gujarat.

2 Areas which are important or sensitive

for Ecological reasons - Wetlands,

watercourses or other water bodies,

coastal zone, biospheres, mountains,

forests


Bharuch, Gujarat.

3 Areas used by protected, important or

sensitive species of flora or fauna for

breeding, nesting, foraging, resting,

over wintering, migration


Bharuch, Gujarat.

4 Inland, coastal, marine or

underground waters

Yes • Sea Coast : 20 Km (approx.)

• River Narmada : 9 Km (approx.)

• Amla Khadi : 5 Km (approx.)

5 State, National boundaries No --

6 Routes or facilities used by the public

for to recreation or other tourist,

pilgrim areas.

No --

7 Defense installations No --

8 Densely populated or built-up area Yes Ankleshwar city: 2 Lakh population

(approx.)

9 Areas occupied by sensitive man-

made land community facilities)

No

10 Areas containing important, high

quality or scarce resources (ground

water resources, surface resources,

forestry, agriculture, fisheries,

tourism, tourism, minerals)

Yes

• No ground water is and shall be used.

• Plot is located in industrial area does not

affect agricultural land.

11 Areas already subjected to pollution

or environmental damage. (those

where existing legal environmental

standards are exceeded)

Yes Plot is located in GIDC, Ankleshwar, Dist.

Bharuch, Gujarat.

12 Are as susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquakes, subsidence ,landslides,

flooding erosion, or extreme or adverse

climatic conditions)

No --

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

ANNEXURES

ANNEXURE

NO.

PARTICULARS

1 List of Products with their Production Capacity and Raw Materials Consumption

2 Plot layout

3 Brief Manufacturing Process Description

4 Details of water consumption & waste water generation

5 Description of Effluent Treatment Plant

6 Details of Hazardous/Solid Wastes Generation, Management and Disposal Mode

7 Power and Fuel Requirement

8 Hazardous Chemicals Storage and Handling Details

9 Details of Sources of Emissions and Air Pollution Control Equipments (APCM)

10 Socio - Economic Impacts

11 Proposed Terms of References

12 Copy of Land Possession/Plot Allotment document

13 Copy of common TSDF & CHWIF Membership Letter

14 Toposheet

15 Copy of GIDC letter for water supply

16 Copy of FETP Membership Certificate & Copy of Application for Additional

Quantity of Effluent Discharge

17 Copy Of Case Document, Closure Notice, Request Letter for Revocation And

Revoked Letter

ANNEXURE – 1

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr.

No.

Products CAS No. Production Capacity

(MT/Month)

Existing Total after Proposed

Expansion

1 Sodium Salt of Trichloro

Pyridinol Organic

(Sodium Salt of HTCP)

37439-34-2 73.75 100

2 2-(2’, 2’-dichlorovinyl)-3-3-

Dimethylcyclopropane

carboxylic Acid Chloride

(D.V. Acid Chloride) (CMAC)

52314-67-7 17 200

3 1,2,4 Triazole 288-88-0 4.5 4.5

4 Acetamaprid 135410-20-7 4.167 20

5 Imidacloprid 138261-41-3 8.33 20

6 Chloropyriphos 2921-88-2 104.16 150

7 Triazophos 24017-47-8 16.67 20

8 Bifenthrin 82657-04-3 4.167 20

9 Cyfluthrin and Beta

Cyfluthrin

68359-37-5 4.167 20

10 Lambda Cyhalothrin 91465-08-6 4.167 15

11 Indoxacarb 144171-61-9 10 10

12 Deltamethrin 52918-63-5 4.167 20

13 Trichlopyr Ester 64700-56-7 4.167 50

14 Cypermethrin 52315-07-8 -- 150

15 Beta Cypermethrin 65731-84-2 -- 25

16 Alphamethrin 67375-30-8 -- 25

17 Thiocyclam Oxalate 31895-22-4 -- 50

18 Zeta Cyper 52315-07-8 -- 100

19 Lambda Cyhalothric Acid 72748-35-7 -- 100

20 Diafenthiuron 80060-09-9 -- 25

21 Permethrin 52645-53-1 -- 150

22 Metaphenoxy Benzyl Alcohol

(MPB Alcohol)

13826-35-2 -- 100

Total 259.412 1374.5

RAW MATERIAL CONSUMPTION:

Sr.

No.

Raw Material Consumption Quantity

(MT/MT)

1. Sodium Salt of Trichloro Pyridinol Organic (Sodium Salt of HTCP)

Nitrobenzene 4.65

Acrylonitrile 0.411

Trichloro acetyl chloride 1.2

Catalyst 0.008

Caustic 0.625

2 DV Acid Chloride (CMAC)

Acrylonitrile 0.51

Carbon Tetrachloride (CTC) 1.64

Acetonitrile 0.06

DEA HCL 0.02

Cupric chloride 0.02

H2SO4 (98%) 1.995

DMF 0.02

Thionyl chloride 1.95

Caustic 2.28

Hexane 5.46

Isobutylene (IB) 0.75

Triethanolamine (TEA) 0.85

NaHCO3 0.25

BF3 0.008

3 1,2,4 Triazole

N,N Diformyl Hydrazin 1.40

Catalyst 2.40

Ammonium Bicarbonate 2.52

H2SO4 (98%) 1.27

4 Acetamaprid

Methanol 1.4

K2CO3 0.73

CCMP 0.99

CMA 0.64

MMA

0.2

5 Imidachloprid

CCMP 0.97

N-nitro iminoidmmidazolidine(N-NII) 0.9

Acetonitrile 1.37

K2CO3 0.94

6 Chloropyriphos

Nitrobenzene 3.5

Acrylonitrile 0.311

Trichloroacetylchloride 0.9

Catalyst 0.006

Caustic 0.473

Ethylene Dichloride 5.35

Catalyst ( TABA + TEDA) 0.015

DETCL 0.563

Activated Carbon 0.011

7 Triazophos

EDC 1.14

1-Phenyl-2-hydroxy-1,2,4 triazole 0.57

Triethylamine 0.39

Diethylthiophoryl chloride 0.66

Caustic 0.25

8 Bifenthrin

L C Acid 0.74

Thionyl Chloride 0.45

DMF 0.0062

Caustic 0.385

Toluene 2.54

Bifenthrin Alcohol 0.51

Catalyst( 4-DMAP) 0.0062

HCl 0.074

Methanol 1.44

9 Cyfluthrin

CMC 0.66

CPFBA 0.72

Toluene 1.2

Caustic

0.13

Beta Cyfluthrin

Crude Cyfluthrine 1.24

IPA 3.0

Catalyst 0.04

10 Lambda Cyhalothrin

L C Acid 0.642

Thionyl Chloride 0.385

DMF 0.005

Caustic 0.052

Hexane 4.1

Soda Ash 0.014

TEBA ( Catalyst) 0.013

NaCN 0.154

Meta phenoxy Benzaldyhyde 0.475

Sodium Hypo Chloride 0.103

Sodium Bicarbonate 0.006

Acetic Acid 0.007

Isopropyl Alchohol 0.8

DIPA ( Catalyst) 0.062

HCL (30%) 0.224

11 Indoxacarb

Toluene 0.58

Catalyst 0.2

A 0.6

B 0.7

Caustic Lye 0.08

12 Deltamethrin

DCA 0.55

CPBA 0.5

Benzene 0.6

Catalyst 0.18

Caustic 0.1

13 Trichlopyr Ester

2, Butoxy Ethanol 0.5

Chloro Acitic Acid 0.46

Sulphuric Acid 0.034

Hexane 1.45

Sodium Carbonate 0.12

NaHTCP Salt 0.944

Catalyst ( TBAB) 0.06

Sodium Chloride 0.27

14 Cypermethrin

CMAC 0.59

MPB 0.485

NaCN 0.145

PTC 0.006

Haxane 1.09

Sodium Hypo chloride 1.63

15 Beta Cypermethrin

Cypermethrin 1.5

Isopropyl Alcohol 1.17

Catalyst 0.15

Sulphuric Acid 0.4


Acetic Acid 0.002

Caustic 0.3

16 Alphamethrin

Cypermethrin 1.48

Hexane 1.26

Triethyl Amine (TEA) 0.55

Sulphuric Acid 0.429


Acetic Acid 0.002

Caustic 0.286

17 Thiocyclam Oxalate

Bensultap 2.0

Sodium Sulfide 0.365

Methanol 2.0

Toluene 2.0

Oxalic acid 0.417

18 Zeta Cyper

Mix Heptane 2.13

Cypermethrin 1.22

Heptane 0.514

HCL 1.5

Soda ash 0.092

Aliquote 0.009

Acetic Acid 0.001

19 Lambda Cyhalothric Acid

Metyl 3-3 Dimethyl 4-pentene 0.84

R-113A 1.411

T-Butanol 14.18

Catalyst-1 0.0065

Catalyst-2 0.019

DMF 1.76

Sodium t-Butoxide 0.553

KOH 0.588

HCl 1.18

20 Diafenthiuron

DIPPT 0.9

Xylene 2.58

Sulphuric Acid 0.15

Ter-butyl Amine 0.27

Acetonitrile 0.96

21 Permethrin

CMAC 0.611

MPB Alcohol 0.525

Soda Ash 0.05

22 MPB Alcohol

MPBD 0.99

Hydrogen 0.012

Raney Nickel 0.049

IPA 1.125

ANNEXURE-2

PLOT LAYOUT

Cyclisation & Aromatization

CCl 3 + CH 2 = CHCN Nitrobenzene, Solvent

Catalyst, 130 0 C N

Cl Cl

Cl OH

+ HCl

Saponification

+ NaOH

OH Cl

Cl Cl

N

+ H 2 O

ONa Cl

Cl Cl

N

TCAC ACN

HTCP

HTCP Sodium Salt of HTCP

COCl

ANNEXURE-3

BRIEF MANUFACTURING PROCESS DESCRIPTION

1. Sodium Salt of HTCP

Process Description:

In a glass-lined reactor, Try Chloro Acetyl Chloride (TCAC) and Acrylonitrile are reacted using

Nitrobenzene as solvent. Reaction mass heated to 130°C. During reaction HCl gas is generated.

Which is scrubbed in scrubbing system till 30% HCl obtained by circulation water as absorbing

media by adiabatic absorption system. The unabsorbed HCl is further scrubbed by circulating

4% NaOH Solution in Venturi Scrubber. The product HTCP is formed as solution in NB. The

whole mass is transferred to other reactor to recover unreacted raw materials and solvent by

distillation process. The mass in reactor i.e. HTCP is drowned in a SS reactor containing 10 %

NaOH under chilling conditions. The reaction mass is purified by removing traces of TCP by

steam distillation. The distillate is sent to ETP. The mass is now cooled to 10° during which

Sodium Salt of HTCP crystallized. The material is filtered and then packed in drum.

Chemical Reaction:

Mass Balance:

2. DV Acid Chloride (CMAC)


(i) CBN reaction and Purification:

Charge Acetonitrile, Catalyst and heat at 120°C and add Carbon Tetra Chloride and Acrylonitrile

slowly till reaction is completed. Recover Acetonitrile is recycle back in to reaction. Collect pure

CBN for further reaction.

(ii) CBA reaction:

Charge H2SO4 and water , heat at 100°C then add CBN slowly till reaction is completed. Collect

Spent Acid will be sold to actual user and transfer CBA mass for further reaction.

(iii) CBC reaction and Purification:

Add Thionyl Chloride at 50°C to CBA mass. SO2 and HCl will be liberated are scrubbed in 4%

NaOH solution and water respectively. Distill out CBC for further reaction.

(iv) 2 CB Reaction:

Charge Hexane, Isobutylene and heat at 50°C. Add TEA and CBC slowly till reaction is

completed. Give water wash and Sodium Bicarbonate wash. Recover TEA by NaOH treatment

and recycle back. Centrifuge to recover 2 CB crystals and collect Hexane for recovery.

(v) NaCMA Reaction:

Charge Hexane and Isobutylene and heat to 50°C. Add TEA and CBC slowly till reaction is

completed. Give water wash and Sodium bicarbonate wash. Recover TEA by NaOH treatment

and recycle back. Centrifuge to recover 2 CB crystal and collect Hexane for recovery.

(vi) CMA Reaction:

Receive NaCMA mass, add Hexane and heat at 40°C. Add dilute Sulfuric Acid till reaction

completed. Aq. Layer transfer to ETP and organic layer transfer for CMAC reaction.

(vii) CMAC reaction:

Receive CMA organic mass and remove Hexane then add SOCl2 slowly at 50°C. During reaction

SO2 and HCl gases liberated are scrubbed in 4% NaOH solution and water respectively. Recover

pure CMAC by distillation and packed in the drum for dispatch.

Chemical Reaction:

1) CBN Reaction

CH2 = CH-CN + CCl4 Acetonitrile Solvent CCl3-CH2-CH-CN

Catalysts

Acrylonitrile Carbon Cl

Tetra Chloride 2,4,4,4-Tetrachlorobutyro nitrile

(CBN)

2) 2CBA Reaction

2 CCl3 – CH2 – CH – CN + H2SO4 + 4H2O 2 CCl3 – CH2 – CH – CO2H + (NH4)2SO4

Cl Sulfuric Cl Ammonium

Acid Sulphate

2,4,4,4-Tetrachlorobutyric Acid

(CBN) (CBA)

3) CBC Reaction

Cl3C – CH2 – CH – CO2H + SOCl2 CCl3 – CH2 – CH – COCl + SO2 + HCl

Cl Cl

2,4,4,4 – Tetrachlorobutyric acid chloride

(CBA) (CBC)

4) 2CB Reaction

H2C

CCl3 – CH2 – CH – COCl + (C2H5)3N C = CH2 Hexane (Solvent)

H3C Catalyst

Cl

Triethylamine Isobutylene

(CBC)

O

+ (C2H5)3 NHCl

H3C TEA.HCl Salt

3 2 Cl

CH3 CH2CCl3

2-Chloro-2 (2’2’2’ – trichloroethyl) –3-3-dimethyl cyclobutanone (2 CB)

5) NaCMA Reaction

O

+ 3NaOH Catalyst + 2 NaCl + H2O

H3C Cl CO2Na

CH3 CH2CCl3 Cl2C CH

Sodium 2-(2’, 2’-trichloromethyl)

-3’ – 3 – dimethyl cyclo propane carboxylate

(2 CB) (NaCMA)

6) CMA Reaction

Hexane

+ H2SO4 + SO2 + HCl

CO2Na CO2H

Cl2 = CH Cl2C = CH

2 – (2’-2’-dichlorovinyl) –3-3-

dimethyl cyclo propane carboxylic

Acid

(NaCMA) (CMA)

7) CMAC Reaction

+ SOCl2 + SO2 + HCl

CO2H COCl

Cl2C = CH Cl2 = CH

2-(2’, 2’-dichlorovinyl)-3-3-

dimethylcyclopropane carboxylic

Acid chloride

(CMA) (CMAC)

Mass Balance:

C - N - N - C

O

H H

H O

H

+ 2 (N H 4 ) H CO 3 Cata lyst (CH 3 NO )

N ,N - Diformylh ydrazin

H C N

N CH

N

+ 2 CO 2 + N H 3 + 4H 2 O

1,2,4 Triazole

Ca rbon Dioxide A mm onia Water

3.0 1,2,4 Triazole


N, N’ Diformylhydrazine and catalyst are reacted in reactor, at 160°C. Ammonium bicarbonate

added slowly till the reaction is completed. During process Carbon dioxide and excess ammonia

evolve are scrubbed in water to form ammonium carbonate. After completion of the reaction

distill off excess catalyst and 1,2,4 Triazole under high vacuum and packed in drum for dispatch.

Chemical Reaction:

Mass Balance:

Water 1287

Diformyl

Hydrazine 1400

Sulphuric Acid 1274

Catalyst 2400

Ammonium

Bicarbonate 2520

Ammonium

Sulphate 1716

Water 1287

Waste

Water 3665

Sulphuric

Acid 1274

catalyst for

Reuse 2300

Distillation

Residue 200

Product 1000 Kg

4.0 Acetamaprid


Chemical Reaction:

Mass Balance:

5. Imidachloprid


Chemical Reaction:

Mass Balance:

Cyclisation & Aromatization

CCl 3 + CH 2 = CHCN Nitrobenzene, Solvent

Catalyst, 130 0 C N

Cl Cl

Cl OH

+ HCl

Saponification

+ NaOH

OH Cl

Cl Cl

N

+ H 2 O

ONa Cl

Cl Cl

N

TCAC ACN

HTCP

HTCP Sodium Salt of HTCP

COCl

6. Chloropyriphos


In a glass-lined reactor, Try Chloro Acetyl Chloride (TCAC) and Acrylonitrile are reacted using

Nitrobenzene as solvent. Reaction mass heated to 130°C. During reaction HCl gas is generated.

Which is scrubbed in scrubbing system till 30% HCl obtained by circulation water as absorbing

media by adiabatic absorption system. The unabsorbed HCl is further scrubbed by circulating

4% NaOH Solution in Venturi Scrubber. The product HTCP is formed as solution in NB. The

whole mass is transferred to other reactor to recover unreacted raw materials and solvent by

distillation process. The mass in reactor i.e. HTCP is drowned in a SS reactor containing 10 %

NaOH under chilling conditions. The reaction mass is purified by removing traces of TCP by

steam distillation. The distillate is sent to ETP. The mass is now cooled to 10° during which

Sodium Salt of HTCP crystallized. The material is filtered and then packed in drum.

Sodium Salt of HTCP and Ethylene Dichloride as solvent are reacted in reactor. Diethyl thionyl

phosphoryl chloride is added slowly at 40°C till reaction is completed. After completion of the

reaction water wash is given, after the water wash the mass is filter and EDC is remove under

vaccum to get Chloropyrifos. Then packed in MS drums for dispatch.

Chemical Reaction:

H

Cl

ONa

Cl

Cl

Na-HTCP

+ P

S

(OCH2CH3)2

EDC Solvent

40 0 C

Diethylthio Phosphoryl Chloride

DETCL

Cl

Cl

O - P

Cl

N

S

(OCH2CH3)2

+ NaCl

Sodium Chloride

Chloropyrifos

Cl -

(OCH2CH3)2

Mass Balance:

7. Triazophos


Chemical Reaction:

Mass Balance:

8. Bifenthrin


Charge the Cyhalothric Acid and hexane in Reactor. Start the addition of thionyl chloride at 30 °

C. Cook the mass for 2 hrs at 30°C. Check the unreacted Cyhalothric Acid. It should be less than

0.5 %. Distilled out the Hexane by vacuum pump. we will get Cyhalothric Acid chloride.

Take Toluene solvent, Lambda Cyhalothric AcidChloride, Bifenthrin Alcohol and Catalyst (4-

DMAP) and NaOH in the reactor. Maintain the mass up to 15°C . After completion of the

reaction mass heat up to 30 deg. then separate the waste water and give HCL and NaOH wash

and water wash .Separate organic layer and then remove solvent under vacuum and mass

transfer for purification. Charge methanol in crude Bifenthrin and heat mass up to 65 deg. after

cool the mass for crystallization. Filter and dry the mass and packed in to drums.

Chemical Reaction:

COOH

CH3 CH3

Cl

F

FF

Mol. Wt. = 242.62

+ +

thionyl chloride

Mol. Wt. = 118.97

2-chloro-3,3,3-trifluoro-1-propen-1-yl]-2,2-dimethylcyclopropanecarboxylic

acid

SOCl2COCl

CH3 CH3

Cl

F

FF

2-chloro-3,3,3-trifluoroprop-1-en-1-yl]-2,2-dimethylcyclopropanecarbonyl chloride

Mol. Wt. = 261.06

HCl + SO2

COCl

CH3

CH3Cl

FF

F

3-[(1Z)-2-chloro-3,3,3-trifluoroprop-1-en-1-yl]-2,2-dimethylcyclopropanecarbonyl chloride

HOH2C CH3

(2-methylbiphenyl-3-yl)methanol

M.Wt-261.06 M.Wt-198.26

CH3 CH3

Cl

F

FF

O

O

CH3

Bifenthrin

M.Wt-422.86

+ NaOH

Toluene

Catalyst

Mass Balance:

9. Cyfluthrin and Beta-Cyfluthrin


Chemical Reaction:

Beta Cyfluthrin

Mass Balance:

10. Lambda Cyhalothrin


Charge the Cyhalothric Acid and hexane in Reactor. Start the addition of thionyl chloride at 30 °

C. Cook the mass for 2 hrs at 30°C. Check the unreacted Cyhalothric Acid. It should be less than

0.5 %. Distilled out the Hexane by vacuum pump. we will get Cyhalothric Acid chloride.

Charge sodium cyanide, phase transfer catalysis and water in reactor. Charge Cyhalothric Acid

Chloride, Meta Phenoxy Benzaldehyde and hexane in another reactor. Dissolve the sodium

cyanide then add hexane. Start the addition of pre-mixture of Cyhalothric Acid Chloride and

Meta Phenoxy Benzaldehyde at 30°C. Cook the mass for 2 hrs at 30°C. Check the unreacted

MPB. It should be less than 2 %. Separate the organic layer. Give two water wash to organic

layer. Take organic layer for hexane distillation. Distilled out hexane by vacuum pump. we will

get Cyhalothrin Technical.

Charge Cyhalothrin Technical and Isopropyl Alcohol in Reactor. Cool the mass up to –5 °C. After

reaching the temperature –5°C add Diiso propyl amine and small quantity of Lambda

Cyhalothrin crystal. Maintain the mass for 72 hrs at -5°C. After 72 hrs maintaining, filter the

crystal’s of Lambda-Cyhalothrin through ANF. Give one water wash to cake and one wash of

Isoprpyl alcohol to cake. Dry the material at 30°C under vacuum. After drying pack the material

in drum.

Chemical Reaction:

COOH

CH3 CH3

Cl

F

FF

Mol. Wt. = 242.62

+ +

thionyl chloride

Mol. Wt. = 118.97

2-chloro-3,3,3-trifluoro-1-propen-1-yl]

-2,2-dimethylcyclopropanecarboxylic acid

SOCl2COCl

CH3 CH3

Cl

F

FF

2-chloro-3,3,3-trifluoroprop-1-en-1-yl]-2,2-dimethylcyclopropanecarbonyl chloride

Mol. Wt. = 261.06

HCl + SO2

C l

F 3 C C = C H

3

C O 2

H

C H

C N

O

IPA S o lv en t + C ata l y s t

C y h a l o th r in

C O 2 C H 3 C H = C

F 3 C

C l

H

C H 3

C

C N

H

O

L a m bd a C v ha l o thr in

H

E pim e ri

C H C H 3

H

COCl

CH3 CH3

Cl

F

FF

O

O

3-Phenoxybenzaldehyde

NaCN

TEBA

CH3CH3

Cl

FF

F

O

O

CNO

Cyhalothrin recemic mixture(45:55)

Mol. Wt. = 198.21 Mol. Wt. = 449.85

Cis-2-chloro-3,3,3-trifluoroprop-1-en-1-yl]-2,2-

dimethylcyclopropanecarbonyl chloride

Mol. Wt. = 261.06

[Acid Chloride] [MPB]

Mass Balance:

11. Indoxacarb


Chemical Reaction:

Mass Balance:

12. Deltamethrin


Chemical Reaction:

Mass Balance:

13. Trichlopyr Ester


Charge Butoxy ethanol, Monochloro Acetic Acid (MCA) and hexane and then remove the water

by azeotropy distillation. Distill out hexane and take crude in another reactor charge to Sodium

Salt of HTCP, water, Soda Ash, Sodium Chloride, catalyst and sodium bicarbonate, Heat the

mass up to 65°C for 12 hrs. After reaction completion add hexane and separate the aq. Layer

and give water wash. Recover hexane by distillation and reuse in the process. Distil out

Triclopyr Ester under vacuum at high temp.

Chemical Reaction:

Mass Balance:

14. Cypermethrin


Metaphenoxy benzaldehyde and Cypermethric acid chloride are reacted with Sodium cyanide

in solvent Hexane. This reaction mass is washed with water and solvent is distilled out by

vacuum. Product is packed as per requirement. The Cyanide containing effluent is fully

detoxified with Sodium Hypochlorite, checked for the presence of excess Hypochlorite

(indicating complete cyanide destruction) and then sent for Incineration as concentrated

stream.

Chemical Reaction:

Mass Balance:

C CH

Cl

Cl

CH3

CH3

CO2CH O

CN

15. Beta Cypermethrin


Technical cypermethrin is heated to 45oC and Catalyst is added. Later the mixture is gradually

cooled from 45oC to 25oC and the temperature is maintained for 2 hours. It is further chilled to

21oC and maintained for 12 hours. The solid crystallized is filtered through ANF and the cake

obtained is dissolved in Isopropyl Alcohol. Isopropyl Alcohol phase is washed with dilute

sulphuric acid till pH of the product becomes 3 to 5. It is further washed with water and again

chilled to 21oC. Solid mass obtained is filtered through ANF and vacuum dried to get Beta

cypermethrin.

Chemical Reaction:

Catalyst Iso Propyl Alcohol

Beta Cypermetrhin

Mass Balance:

16. Alphamethrin


Technical cypermethrin is heated to 45 o

C and Triethylamine (TEA) is added. Later the mixture is

gradually cooled from 45 o

C to 25 o

C and the temperature is maintained for 2 hours. It is further

chilled to 21oC and maintained for 12 hours. The solid crystallized is filtered through ANF and

the cake obtained is dissolved in n-hexane. Hexane phase is washed with dilute sulphuric acid

till pH of the product becomes 3 to 5. It is further washed with water and again chilled to 21 o

C.

Solid mass obtained is filtered through ANF and vacuum dried to get Alphamethrin.

Chemical Reaction:

Mass Balance:

17. Thiocyclam Oxalate


Bensultap is reacted with sodium sulfide at 50 - 58°C in presence of methanol. After

completion of the reaction, methanol is distilled out followed by extraction of Thiocyclam with

toluene. Toluene layer of thiocyclam is further reacted with oxalic acid at 40-50°C to form

Thiocyclam oxalate crude. Toluene is distilled out under vacuum and the reaction mass is

taken in methanol again. Crystallization from methanol, centrifugation and drying is done to

get technical Thicyclam oxalate. Methanol is distilled out of the ML and recycled.

Chemical Reaction:

Mass Balance:

18. Zeta Cyper


Step-1: PURIFICATION OF LIQUID CYPERMETHRIN

Charge Mix Heptane into reaction flask under stirring and charge slowly Pre heated liquid

Cypermethrin (65/35) into it.Heat the mix. to 50 o ± C to dissolve Cypermethrin .Cool the mass

up to 0 to 4°C.Stir the mass for 1 hour.Charge solid Cypermethrin for seeding.Maintain the mass

at 0 to 4°C temp for 20 hrs.After this , filter the mass and wash the cake with cold mix

heptanes.Maintain the temperature of wet cake < 15degreeC.Use wet cake for Epimerization.(

next step)

Step-2: EPIMERISATION OF SOLID CYPERMETHRIN:

Charge wet cake of solid Cypermethrin (contains heptanes), mixed Heptanes (Cooled below

23oC), Aliquot 336 (1%of the weight of solidCypermethrin) & Sodium Carbonate (1%of the

weight of solid Cypermethrin) and continue string at 23o ± 2° C for several hours till the desired

degree of epimerization has reached based on HPLC analysis of a sample. At the end of

epimerization reaction, charge water in reactor.Slowly add 30 % HCl solution below 15°C

temperature.Check the pH. It should be less than 2.0.Start the heating up to 55 ± 5°C. Stir the

mass for 1 hour at 55 ± 5°C.Settle the mass for 1 hour and then separate out the aq. Layer.Give

the water wash to organic layer at 55 ± 5°C.Settle the mass for 1 hour and then separate out

the aq. Layer.Transfer the organic layer in to reaction flask for mix heptane recovery.

RECOVERY OF MIX HEPTANE:

Start the heating and distilled out mix heptane at 85 ± 5°C under vacuum.Check the sample for

% solvent content. It should be less than 0.5 %.After solvent content is less than 0.5 %, pack

Zeta Cypermethrin in drums.

Chemical Reaction:

Mass Balance:

19. Lambda Cyhalothric Acid


Step-1: Methyl 3, 3-dimethyl-4-pentenoate, R-113A gas, Catalyst-I, Catalyst-2 and tertiary butyl

alcohol were charged in reactor. Heat the reaction mass to reflux temperature and hold under

stirring till completion of reaction. Upon completion of reaction, solvent was distilled off and

obtained crude product was subjected to fractional distillation to obtain pure Heptanoate

intermediate.

Step-2: Dimethyl formamide, t-butanol and sodium t-butaoxide were charged in reactor. Then,

Heptanoate intermediate was dropwise added at -5°C and hold under stirringfor completion of

reaction. Upon completion of reaction, potassium hydroxide was charged in to reaction mass

and agitated till completion. Upon completion of reaction, distilled out solvent mixture,

obtained mass was diluted with water and heated to reflux. Then, acidified with 15%

hydrochloric acid filtered and dried to get lambda cyhalothric acid.

Chemical Reaction:

Mass Balance:

20. Diafenthiuron


1-(2,6-diisopropyl-4-phenoxyphenyl)thiourea(DIPPT) is heated to reflux in presence of xylene as

solvent to give 1,3-diisopropyl-2-isothiocyanato-5-phenoxybenzene. Condensation of

1,3-diisopropyl-2-isothiocyanato-5-phenoxybenzene with Ter-butyl Amine (TBA) in presence of

Acetoniril as solvent to give Difenthiuron technical. Finally purification is carried out in to yield

pure Diafenthiuron. Recovered Acetoniri is distilled and recycled.

Chemical Reaction:

Mass Balance:

21. Permethrin


In a Glass lined reactor, CMAC charged. Addition of MPBA is started at temperature of 20oC.

The addition is completed within 3 to 4 hours and the same temperature is maintained for 3

hours. The sample is checked for unreacted MPBA. If not found, hexane is added and the

hexane layer is washed with soda ash solution, followed by plain water. The hexane layer is

separated and transferred to another reactor for distillation. Hexane is recovered by distilling

under vacuum. The material remaining in the reactor is permethrin technical, which is packed

suitably in lacquered MS drums.

Chemical Reaction:

Mass Balance:

22. MPB Alcohol


Raney Nickel is Slurried in Isopropyl alcohol (solvent) and Metaphenoxy benzaldehyde (MPB) is

added to this Slurry. Hydrogen is passed through this mixture and then the MPB is

hydrogenated to form Metaphenoxy benzaldehyde (MPBA). The Slurry is filtered and Raney Ni

is separated & recycled to next batch, and the clear solution containing MPBA in Isopropyl

alcohol is distilled to recover the solvent. The pure product is collected in Drums.

Chemical Reaction:

C6H5O-C6H4-CHO + H2 C6H5O-C6H4-CH2OH

MPB IPA SOLVENT/ RANEY NICKEL MPBA

Mass Balance:

ANNEXURE-4

DETAILS OF WATER CONSUMPTION & WASTE WATER GENERATION

SR.

NO.

DESCRIPTION EXISTING TOTAL AFTER PROPOSED

EXPANSION

WATER

CONSUMPTION

(KL/Day)

WASTE

WATER

GENERATION

(KL/Day)

WATER

CONSUMPTION

(KL/Day)

WASTE

WATER

GENERATION

(KL/Day)

1 Process 110 110 206 222

2 Boiler 75 10 400 314

3 Cooling & Chilling 87 18 400 100

4 Washing 64 64 134 134

Total Industrial 336 202 1140 770

5 Domestic 18 18 30 30

6 Gardening 16 -- 30 --

Grand Total 370 220 1200 800

ANNEXURE-5

TREATMENT PLANTS

M/s. Meghmani Organic Ltd. has an existing effluent treatment plant (ETP) of capacity 300

KL/day consists of primary, secondary and tertiary treatment facility and MEE of capacity 200

KL/day to treat waste water generated in existing. In proposed expansion project, company is

going to increase capacity of existing ETP to 800 KL/day (total) by adding certain treatment

units and also going to install one MEE of capacity 200 KL/day as standby.

EXISTING EFFLUENT TREATMENT PLANT (ETP) - Capacity: 300 KL/day:

Total process waste water (110 KL/Day) is segregated into High COD & TDS (84 KL/day) and Low

COD & TDS stream (26 KL/day).

Low COD & TDS process waste water (26 KL/day) along with waste water from utilities, washing

and Domestic waste water (92 KL/day) is brought to the treatment plant through pipe line and

channel. Effluent is collected in the equalization tank, where effluent is equalized

homogeneously.

From equalization tank, effluent is pumped to the primary reactor for dosing of chemical such

as Lime, Ferrous sulphate and Polyelectrolyte where Chemical flocs are formed by coagulation

and flocculation. Waste water transfer in to clariflocculator. Here the suspended solid are

settled. Settled sludge is pumped to the filter press and sludge drying bed for drying. The dried

sludge is sent to common TSDF site of SEPPL or BEIL for final disposal.

Overflow of the clariflocculator enters the Aeration Tank -I for Biological Treatment. Domestic

(18 KL/day) waste water is also added in aeration tank. In the Aeration Tank, waste water

undergoes Biological treatment by extended aeration activated sludge process.

Urea and DAP Nutrients required for Microbial growth are also added in to the Aeration tank.

The Organic content in the waste water and the Nutrients act as Food for the Microorganisms.

Mixed Liquor from the Aeration Tank- I flow in to the Clarifier –I where the Microorganisms in

the form of the MLSS are separated from waste water. The Activated sludge is recirculated to

maintain the concentration of Microorganisms in the Aeration tank-I. The sludge is pumped to

sludge drying bed as required. Clarifier – I overflow goes to the Second Aeration tank – II and

Clarifier–II for further doing activated sludge process as above. Clarifier – II effluent is collected

in the Holding Tank and pump to the Sand filter and Carbon Filter for Tertiary Treatment. After

the treated waste water is discharge in to GIDC Underground drainage lead to Final Effluent

Treatment Plant of M/s. Narmada Clean Tech (NCT) for further treatment and final disposal into

deep sea.

High COD and TDS process waste water (84 KL/day) is collected in the separate collection Tank

and the collected effluent treat in to the Quadruple Multi Effect Evaporator Plant followed by

solvent stripper where the condensate is collected in the Holding Tank and mix with dilute

stream in ETP plant for further Treatment. Rich water (Concentrate) feed in to the ATFD

(Agitated thin film dryer) for sludge drying. Generated dry sludge is collected and stored in to

sludge storage area and is sent to common TSDF site of M/s. SEPPL or M/s. BEIL for final

disposal.

EXISTING ETP UNITS AND THEIR SIZE:

Sr.

No.

Name of Unit Dimension

(Size in meter)

No. of

Unit

Total Capacity in

m3

(Dilute Stream)

1. Equalizatio Tank 8.0 X 8.0 X 4.7 2 300

2. Flash Mixer 2.0 X 2.0 X 2,5 1 10

3. Flocculator 2.0 X 2.0 X 2,0 1 8

4. Lime Dosing Tank 2.0 X 2.0 X 2,0 1 8

5. Alum Dosing Tank 2.0 X 2.0 X 2,0 1 8

6. Poly Floc Dosing Tank HDPE Tank 1 1

7. Primary Settling Tank (Clarifocculator) 6.50 dia X 3.00 1 100

8. Aeration Tank – I 19.0 X 9.5 X 6.0 1 1100

9. Secondary Settling ( Clarifier– I) 6.50dia x3.00 1 100

10. Aeration Tank – II 15.0 x 7.80 x 4.0 1 468

11. Secondary Settling–( Clarifier– II) 6.50 dia x 3.00 1 100

12. Holding Sump 8 x 8 x 8 2 1024

13. Pressure Sand Filter 1.5 dia x 1.8 1 14 M³/hr

14. Activated Carbon Filter 1.5 dia X 1.8 1 8.5 M³/Hr

15. Sludge Drying Beds 3.0 x 3.0 x 1.0 8 72 M²

14 Filter Press 36” x 36” 1 5 KL

(Concentrated Stream)

15. Collection cum Equalization for

Concentrated stream

20 KL 2 40

16. Quadruple Multi Effect Evaporator Plant 200 KL/day 1 150 KL/day

17. Agitated Thin Film Dryer 500 kg/hr 2 1000 kg/hr


18. Condensate Collection/ Holding Tank 20 KL 1 20 KL

ETP FLOW DIAGRAM:

UPGRADED EFFLUENT TREATMENT PLANT (ETP) – Total Capacity: 800 KL/day:

Total process waste water (222 KL/Day) is segregated into High COD & TDS (170 KL/day) and

Low COD & TDS stream (52 KL/day).

Low COD & TDS process waste water along with waste water from utilities & washing (600

KL/day) and domestic waste water (30 KL/day) will be treated in upgraded ETP through same

process as existing process and waste water is discharge in to GIDC Underground drainage lead

to Final Effluent Treatment Plant of M/s. Narmada Clean Tech (NCT) for further treatment and

final disposal into deep sea.

High COD and TDS process waste water (170 KL/day) will be treated in Quadruple Multi Effect

Evaporator Plant followed by solvent stripper as existing and condensate from MEE will be sent

to upgraded ETP for further treatment.

Proposed ETP Units and their Size:

Sr.

No.

Name of Unit Dimension

(Size in meter)

No. of

Unit

Total Capacity in

m3

Dilute Stream

1. Equalizatio Tank 8.0 X 8.0 X 4.7 2 300

2. Flash Mixer 2.0 X 2.0 X 2,5 2 10

3. Flocculator 2.0 X 2.0 X 2,0 2 8

4. Lime Dosing Tank 2.0 X 2.0 X 2,0 1 8

5. Alum Dosing Tank 2.0 X 2.0 X 2,0 1 8

6. Poly Floc Dosing Tank HDPE Tank 1 1

7. Primary Clarifier 10.0 dia X 3.0 1 235

8. Primary Sludge Thickener 6.50 dia X 3.00 1 100

9. Aeration Tank – IA 19.0 X 9.5 X 6.0 1 1100

10. Secondary Settling ( Clarifier– IA) 6.50 dia x3.00 1 100

11. Aeration Tank – IB 15.0 x 7.80 x 4.0 1 468

12. Secondary Settling–( Clarifier– IB) 6.50 dia x 3.00 1 100

13. Aeration Tank – 2A 15.0 X13.5X4.0 1 800

14. Secondary Settling ( Clarifier– 2A) 7.50 dia x 3.00 1 130

15. Aeration Tank – 2B 13.5 X 8.0 X4.0 1 430

16. Secondary Settling–( Clarifier– 2B) 7.50 dia x 3.00 1 130

17. Holding Sump 8 x 8 x 8 2 1024

18. Pressure Sand Filter 1.5 dia x 1.8 1 14 M³/hr

19. Activated Carbon Filter 1.5 dia X 1.8 1 8.5 M³/Hr

20. Sludge Drying Beds 3.0 x 3.0 x 1.0 8 72 M²

21 Filter Press 36” x 36” 1 5 KL

22. Decainter/Belt press ------ --- ---

Concentrated Stream

1. Collection cum Equitant for Concentrated

stream

20 KL 3 60

2. Quadruple Multi Effect Evaporator Plant 200 KL/day 2 200 KL/day



5. Condensate Collection/ Holding Tank 20 KL 2 40 KL

UPGRADED ETP FLOW DIAGRAM:

ANNEXURE-6

DETAILS OF HAZARDOUS/SOLID WASTE GENERATION, MANAGEMENT AND DISPOSAL

SR.

NO.

TYPE OF WASTE CATEGORY

NO.

QUANTITY MODE OF DISPOSAL

EXISTING

(as per

CCA)

(MT/Mont

h)

TOTAL AFTER

PROPOSED

EXPANSION

(MT/Month)

1 Used or Spent

Oil

5.1 0.02 0.05 Collection, Storage,

Transportation & Disposal by

reuse in plant & machinery

as lubricant or sell to GPCB

authorized re-processor

2 Process Waste

(Distillation

Residue)

29.1 10 23.67 Collection, Storage,

Transportation and send to

cement industries for co-

processing or CHWIF of

BEIL/SEPPL for incineration.

3 ETP Waste 35.3 38 83.33 Collection, Storage,


TSDF site of

BEIL/SEPPL/NECL/NEPL/EIPL

for disposal.

4 Spent Carbon

from ETP

35.3 1 1.25 Collection, Storage,





5 Packing Material

(HDPE Drums,

fibber drums,

Bags)

33.1 7

(75 Nos.)

584 Nos. Collection, Storage,

Decontamination and Reuse

or sell to registered recycler.

6 Process waste

(Spent Carbon

or filter

medium)

36.2 10 10 Collection, Storage,





7 Organic Nitro- B31 13.1 13.1 Collection, Storage,

and Nitroso-

Compounds

Transportation and sell to

GPCB authorized end users.

8 Spent Sulphides

(NaHSO3)

C13 161.5 1924.17

9 Spent

Ammonium

Sulphate

A10 15 17.92

10 Exhaust Air or

Gas cleaning

residue

35.1 10 10 Collection, Storage and send

to cement industries for co-


BEIL/SEPPL for incineration. 11 Date expired /

off specification

pesticides

29.3 0.5 10

12 In Organic Acid

(HCl)

D2 29.4 562.5 Collection, Storage,



13 In Organic Acid

(Spent Acid)

B15 -- 463.34 Collection, Storage,



14 Spent Solvent 20.2 1 1 Collection, Storage,

Recovery and Captive

Consumption.

15 MEE Salt

37.3 -- 840 Collection, Storage,


TSDF site of

BEIL/SEPPL/NECL/NEPL/EIPL

for disposal.

16 Insulation Waste -- -- 11

17 Fly Ash -- -- 150 Collection, Storage,


brick manufacturer.

ANNEXURE-7

POWER AND FUEL REQUIREMENTS

• Power Requirement

Sr.

No.

Requirement Source

Existing Total After

Proposed

Expansion

Existing After Proposed Expansion

1. 2950 KVA 6000 KVA • DGVCL (GEB)

• DGVCL (GEB)

• D.G. Set – 4 no.

- 1250 KVA x 3 nos.

- 750 KVA x 1 nos.

(emergency standby)

• Fuel Requirement

Sr.

No.

Fuel Requirement (to be used in emergency only)

Existing Total After Proposed

Expansion

1. Natural Gas 23000 sm3/day 24000 sm

3/day

2. Coal 1000 MT/Month 2500 MT/Month

3. Furnace Oil (FO) -- 5000 MT/day

4. HSD -- 1500 Liter/hr.

ANNEXURE-8

HAZARDOUS CHEMICAL STORAGE AND HANDLING DETAILS

Sr.

no

Name of Raw

Material

Quantity Places of its

Storage

(Storage

tank/drums

/Cylinders

/barrels)

No. of

Storages

Places of

its Storage

State Type of

Hazards

Control measures

provided Max. that

can be

stored

(KL)

Actually

stored

(including

in process

&

handling)

1 Acetonitrile 2 2 Drums --- RM Store Liquid Flammable 1. Closed System,No

Manual handling.

2. Earthling provided

on all equipment and

taks to avoid any

Electrical Hazards.

3. All Electrical Motor

and pumps are

flameproof type.

4. Lighting arrestor has

been providsed on the

Buliding and Stacks.

5. Flame arrestor and

Breather valve

provided on the tank

vent line.

6. Duuble safety valve

provided on the

pressure vessels.

2 Acrylonitrile 30+20 25+16 Storage tank 2 Tank Farm Liquid Flammable &

toxic

3 Bensultap 10 T 8 Bag --- RM Store Solid Toxic

4 Benzene 1 1 Drums --- RM Store Liquid Flammable

5 Caustic 25+25+20 20+20+16 Storage tank 3 Tank farm Liquid Corrosive

6 CTC 32+32 25+25 Storage tank 2 Tank Farm Liquid Toxic

7 Cypermethrin 20 15 Drums ----- RM Store Liquid Toxic

8 DETCL 10 10 Drums ----- RM Store Liquid Toxic

9 DMF 20 15 Drums ---- RM Store Liquid Flammable &

Toxic

10 EDC 20 16 Storage tank 1 Tank farm Liquid Flammable

11 H2SO4 20+20 16+16 Storage tank 2 Tank farm Liquid corrosive

12 Haptane Mix 5 5 Drums ---- RM Store Liquid Flammable

13 HCl 20 16 Storage tank 1 Tank farm Liquid corrosive

14 Hexane 25+25 20+20 Storage tank 2 Tank farm Liquid Flammable &

explosive

15 Sodium Hypo 20 16 Storage tank 1 Tank farm Liquid Toxic

16 Iso Propyl

Alcohol

2 2 Drums ---- RM Store Liquid Flammable

17 Isobutelene 20+20 16+16 Storage tank 2 Tank farm Liquidef

ed Gas

Flammable &

Explosive

18 Methanol 15 12 Storage tank 1 Tank farm Liquid Flammable

19 MPB Alcohol 10 5 Drums --- RM Store Liquid Flammable

20 MPBD 20 16 Drums ---- RM Store Liquid Flammable 7. Information

regarding the various

hazards materials has

been displayed near

storage area..

21 NaCN 3 3 MS Drums --- RM Store Solid Toxic

22 NaHTCP 10 10 Bag --- RM Store Solid Toxic

23 Nitrobenzene 25 20 Storage tank 1 Tank farm Liquid Flammable

24 R-113A

(Imported Gas)

20 20 ---

25 T-Butanol 20+20 16+16 Storage tank 2 RM Store Liquid Flammable

26 TEA 5 3 Drums --- RM Store Liquid Flammable &

Toxic

27 Thionyl

chloride

25+25 20+20 Storage tank 2 Tank farm Liquid Toxic & Non

flammable

28 Toluene 15 12 Storage tank 1 Tank farm Liquid Flammable

29 Trichloroacetyl

chloride

30 25 Drums --- RM Store Liquid Corrosive

30 Xylene 2 2 Drums --- RM Store Liquid Flammable

ANNEXURE-9

DETAILS OF SOURCE OF EMISSION

Sr.

No.

Stack/Vent

attached to

Stack

Height

(meter)

Stack

Diameter

(meter)

Fuel name & Quantity Type of

Emission

APCM

Existing

1 Boiler-I *

(6 TPH) -

Standby

30 0.74 Natural Gas

(7000 sm3/day)

-- --

2 Boiler-II *

(10 TPH)

Natural Gas

(16000 sm3/day)

Or

Furnace Oil (Proposed)

(5000 TPD)

-- --

PM

SO2

NOx

Economizer

3 Boiler-III

(10 TPH)

40 1.2 Coal

(1000 MT/Month)

PM

SO2

NOx

ESP & Water

Scrubber

4 Process

Vent-I**

(Reactors)

18 0.1 -- HCl Two Stage

Water

Scrubber and

Caustic

Scrubber

5 Process

Vent-II**

(Reactors)

-- HCl

SO2

Additional Proposed

6 Boiler-IV

(10 TPH)

40 1.2 Coal

(1500 MT/Month)

PM

SO2

NOx

ESP & Water

Scrubber

7 Thermic Fluid

Heater-I

(20 Lac KL/hr.)

30 0.3 Natural Gas

(500 sm3/day)

PM

SO2

NOx

--

8 Thermic Fluid

Heater-II

(20 Lac KL/hr.)

30 0.3 Natural Gas

(500 sm3/day)

PM

SO2

NOx

--

9 Process Vent-III

(Reactor)

18 0.1 -- NH3 Two Stage

Water

Scrubbers &

Acidic

Scrubber

10 D.G. Set-I #

(1250 KVA)

11 0.1 HSD

425 Liter/hr.

PM

SO2

NOx

--

11 D.G. Set-II #

(1250 KVA)

11 0.1 HSD

425 Liter/hr.

PM

SO2

NOx

--

12 D.G. Set-III #

(1250 KVA)

11 0.1 HSD

425 Liter/hr.

PM

SO2

NOx

--

13 D.G. Set-IV #

(750 KVA)

11 0.1 HSD

225 Liter/hr.

PM

SO2

NOx

--

* Common stack

** Common stack

# To be used in emergency only.

ANNEXURE - 10

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement is expected to generate some permanent jobs and secondary jobs

for the operation and maintenance of plant. This will increase direct/indirect employment

opportunities and ancillary business development to some extent for the local population. This

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

2) INDUSTRIES

Require raw materials and skilled & unskilled laborers are and will be utilized maximum from

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

the locality, to some extent.

3) PUBLIC HEALTH

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

the emission has kept below the permissible limit. Hence, there is no and will not be any

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

measures is and will be taken under the EMP.

4) TRANSPORTATION AND COMMUNICATION

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

development of this project will not cause any additional impact.

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

sanitation, communication and community health, as sufficient measures will be proposed to be

taken under the EMP. Hence, proposed expansion project is not expected to make any significant

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

ANNEXURE – 11

PROPOSED DRAFT TERMS OF REFERENCE

1. Project Description

• Justification of project.

• Promoters and their back ground

• Project site location along with site map of 10 km area and site details providing various

industries, surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Infrastructure facilities

• Water source and utilization including water balance.

• List of Products & their production capacity

• Details of manufacturing process of existing and proposed products

• List of hazardous chemicals

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5 km

area.

• Other industries in the impact area

• Prevailing environment quality standards

• Existing environmental status vis a vis air, water, noise, soil in 10 km area from the project site.

• Ground water quality at 5-6 locations within 10 km.

• Complete water balance

3. Socio Economic Data

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

area were surveyed.

4. Impacts Identification and Mitigatory Measures

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

and operational phase.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Hazardous/Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including

6. Risk Assessment

• Objectives, Philosophy and methodology of risk assessment

• Details on storage facilities

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

be adopted.

• Identification of hazards

• Consequence analysis

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Information on Rain Water Harvesting

9. Green Belt Development plan

ANNEXURE – 12

LAND POSSESSION / PLOT ALLOTMENT DOCUMENT

ANNEXURE – 13

COMMON TSDF & HWIF MEMBERSHIP LETTER

ANNEXURE – 14

TOPOSHEET

ANNEXURE – 15

GIDC LETTER FOR WATER SUPPLY

ANNEXURE – 16

COPY OF FETP MEMBERSHIP CERTIFICATE

COPY OF APPLICATION FOR ADDITIONAL QUANTITY OF EFFLUENT DISCHARGE

ANNEXURE – 17

COPY OF CASE DOCUMENT, CLOSURE NOTICE, REQUEST LETTER FOR REVOCATION AND REVOKED

LETTER

form-i · 2017-06-27 · form-i for proposed expansion of pesticides & pesticide intermediates...

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