heranba industries limited (unit: i).environmentclearance.nic.in/writereaddata/online/... ·...

FOR

THE PROPOSED EXPANSION PROJECT FOR THE MANUFACTURING OF PESTICIDE TECHNICAL

Category: 5(b)

OF

HERANBA INDUSTRIES LIMITED (UNIT: I).

Located at: Plot No. 1504, 1505, 1506, 3rd Phase,

GIDC Notified Industrial Area, Vapi, Dist‐ Valsad (Gujarat).

Prefeasibility Report‐Annexure Heranba Industries Limited (Unit: I).

Expansion Project Manufacturing : Pesticides technical

Project prefeasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA

Notification - 2006 1 Executive Summary:

Name & Location Name of the Project : Heranba Industries Limited (Unit: I). Location : Plot No: 1504, 1505, 1506, 3rd phase, G.I.D.C, VAPI. Pin Code: 396195 Dist. - Valsad (Gujarat) Project

Heranba Industries limited (Unit: I) is located in GIDC notified industrial area, falling under Medium Scale category manufacturing products as mentioned under for which the company had obtained Consent To Establish and Operate from Gujarat pollution Control Board.

The company proposes to introduce the new products under the category “Pesticides technical”

Proposed Project Cost: Rs. 2900 lacs. Applicability of EIA notification – 2006

Category as per the amended EIA notification-2006: as existing and proposed products (i.e. Pesticides technical) are covered under the Category-5(b) A. Hence, Environmental clearance is required.

Project Proponent • The company in India comprises of 4 directors • Medium Scale Unit

List of finished products & by- products:

No Product MT/MONTH Existing Proposed Total after

proposed expansion

1 Cyper methric Acid Chloride 12 ‐12 0 2 Deltamethrin Technical 0 30 30 3 Diclorovos Technical 0 15 15 4 Glyphosate Technical 0 30 30 5 Lamdacyhalothrin Technical 0 20 20 6 Permethrin Technical 0 20 20 7 Temephos Technical 0 10 10 8 Tricyclozole Technical 0 20 20



9 Acephate Technical 0 175 175

10 Hexaconazole Technical 0 5 5

11 Imidacloprid Technical 0 10 10

12 Profenophos Technical 0 15 15

Total 12 338 350

By‐products

1 Ammonium Chloride Powder (85%)

5.028 ‐5.028 0

2 Sodium Sulphite Powder (80%)

5.58 48.0 53.58

3 Hydro Chloric Acid solution (30%)

19.992 40.828 60.82

4 Hydro Bromic Acid solution (20%)

0 260.85 260.85

5 Sodium Sulphate powder (80%)

16.788 ‐16.788 0

6 Bromo Benzene 0 132.0 132.0

7 SS‐ CMAC 0 82.5 82.5

Total 47.388 542.362 589.75 Manufacturing process is attached as Annexure-3.

Resource Requirement:

Components Existing Proposed Resources availability

Power, KVA 550 1300 Will be sourced from Dakshin Gujarat Vij Co. Ltd.

Fresh Water, kl/day 42.67 200.29 Will be sourced from GIDC water supply dept.

Natural Gas/FO for Steam Boiler (5 Tons/Hr & 2 Tons/hr)

650 SCM/hr or 0.5 kl/hr

910 SCM/hr or 0.7 kl/hr

GSPC & local dealer

Fuel (HSD) for D.G.Set (Capacity: 380 & 620 KVA)

15 kgs/hr 40 kgs/hr Will be sourced from local dealer

Fuel (Natural Gas/FO) for incinerator

0 175 SCM/hr or 129 kgs/hr

Will be sourced from local dealer



Raw material Consumption:

Product Name of RM RM consumption in MT Per ton of product Per month

Existing After Proposed Expansion

Cypermethric acid Chloride

Forcut (Recovered) 0.380 4.56 0 Acrylo nitrile 0.522 6.264 0

CTC 1.550 18.6 0 Catalyst 0.010 0.12 0 DEA‐HCl 0.011 0.132 0 HCl 30 %

(Recovered) 1.71 20.52 0

HCl 30% (Fresh) 0.09 1.08 0 DMF 0.020 0.24 0TC 1.067 12.804 0

Soda Ash 0.005 0.06 0 Caustic Lye 48 % 3.315 39.78 0

Catalyst 0.010 0.12 0 n‐Hexane

(Recovered) 8.912 106.944 0

n‐Hexane (Fresh) 0.228 2.736 0 IB (Recovered) 0.137 1.644 0

IB (Fresh) 0.457 5.484 0 TEA (Fresh) 0.01 0.12 0

TEA (Recovered) 0.824 9.888 0 Sulphuric Acid 1.199 14.388 0

DMF 0.010 0.12 0 Thionyl Chloride 0.606 7.272 0

Total 21.073 252.876 0Delta Methrin Cypermethric acid 2.817 0 84.51

C.S.Flakes 0.695 0 20.8515% aq. Soln. of

Cat‐V 7.964 0 238.92

methylene dichloride (Recovered)

13.124 0 393.72

Methylene di chloride (Fresh)

0.4 0 12

HCl (30%) 3.745 0 112.35 Benzene 2.32 0 69.6FeCl3 0.044 0 1.32

Bromine 4.836 0 145.08 Sodium thio sulphate

0.05 1.5



Aluminum chloride 0.868 0 26.04C.S.lye 0.273 0 8.19

sulphuric acid 0.426 0 12.78 Methanol 0.63 0 18.9 Toluene 4.8 0 144

Toluene (Fresh) 0.005 0.15Thionyl chloride 1.565 0 46.95

DMF 0.013 0 0.39 m‐phenoxy

benzaldehyde 0.571 0 17.13

sodium cyanide 0.220 0 6.6soda ash 0.018 0 0.54 TEBA 0.024 0 0.72

Acetic acid 0.005 0 0.15 Sodium hypo chlorite (10%)

1.7 0 51

Isopropyl alcohol (Recovered)

6.324 0 189.72

IPA (Fresh) 0.126 0 3.78 TEA (Recovered) 0.220 0 6.6

TEA (Fresh) 0.012 0 0.36 Activated carbon 0.005 0 0.15

Hyflow 0.005 0 0.15Total 53.805 0 1614.15

Dichlorvos Tri Chloro Acetaldehyde

(Chloral)

0.642 0 9.63

Tri Methyl Phosphite (TMP)

0.586 0 8.79

Total 1.228 0 18.42 Glyphosate DEA 0.887 0 26.61

Catalyst slurry (recovered)

0.678 0 20.34

NaOH (47%) 2.412 0 72.36 HCHO (37%) 0.823 0 24.69

H3PO3 1.092 0 32.76 HCl (30%) 4.068 0 122.04Carbon 0.125 0 3.75

Ammonia solution 21%

1.044 0 31.32

Oxygen gas 0.350 0 10.5 Sulphuric acid

(98%) 0.89 0 26.7

Total 12.369 0 371.07Lamdacyhalothrin Lambda acid 0.590 0 11.8

Thionyl chloride (TC)

0.321 0 6.42



MPBD 0.466 0 9.32NaCN 0.133 0 2.66

Soda ash 0.012 0 0.24 Cat‐a 0.012 0 0.24

NaOCl (10%) 1.492 0 29.84 Acetic acid 0.016 0 0.32

IPA (Recovered) 0.753 0 15.06 IPA (Fresh) 0.023 0 0.46 Cat‐B (DIPA) 0.004 0 0.08 n‐Hexane (recovered)

1.62 0 32.4

N‐hexane (fresh) 0.43 0 8.6 HCl (30%) 0.113 0 2.2630% NaOH 0.130 0 2.6

22% NaOH solution 1.102 0 22.04 Total 7.217 0 144.34

Permethrin Cypermethric acid chloride

0.62 0 12.4

m‐Phenoxy benzyl alcohol

0.52 0 10.4

Potassium Carbonate

0.015 0 0.3

Total 1.155 0 23.1Temephos Thio Di phenol 0.49 0 4.9

DMTC 0.779 0 7.79 TEBA 0.0245 0 0.245

Methylene dichloride (Recovered)

0.745 0 7.45

Methylene dichloride (Fresh)

0.083 0 0.83

Sodium Di Thionite 0.0024 0 0.024Caustic lye (47%) 0.436 0 4.36

Total 2.5599 0 25.599 Tricyclozole 4‐HMBT 1.000 0 20

Formic acid 0.760 0 15.2 NaOH solution20% 0.406 0 8.12

Total 2.166 0 43.32 Acephate MDC (Recovered) 10.357 0 1812.475

MDC (Fresh) 0.589 0 103.075 DMPAT 1.18 0 206.5 AC2O 0.96 0 168

Sulphuric acid 0.040 0 7 Ammonia 0.22 0 38.5

Ethyl Acetate (Recovered)

1.076 0 188.3

Ethyl Acetate 0.385 0 67.375



(Fresh)Total 14.807 0 2591.225

Hexaconazole 2,4 Di chloro Valerophenone

0.950 0 4.75

Di Methyl Sulphate (Recovered)

1.262 0 6.31

Di methyl Sulphate (Fresh)

1.151 0 5.755

Potassium Hydroxide

0.913 0 4.565

DMF 3.488 0 17.44Anhydrous Potassium carbonate

0.082 0 0.41

1,2,4 triazole 0.327 0 1.635Methanol (Recovered)

1.08 0 5.4

Methanol (Fresh) 0.045 0 0.225Total 9.298 0 46.49

Imidacloprid MEK (Recovered) 6.25 0 62.5MEK (Fresh) 0.15 0 1.5 Nitro Imino Imidazolidine

0.84 0 8.4

Anhydrous K2CO3 1.2 0 12 2‐ chloro 5‐chloro methyl pyridine

1.0 0 10

Total 9.44 0 94.4 Profenophos 2‐ Chloro phenol 0.535 0 8.025

Zncl2 0.007 0 0.105 Bromine 0.660 0 9.9DETC 0.784 0 11.76 TEBA 0.0057 0 0.0855

Caustic soda solution (26%)

0.65 0 9.75

Tri methyl amine solution (30%)

1.0 0 15

HCl (30%) 0.05 0 0.75 N‐ propyl bromide

(Recovered) 0.3 0 4.5

N‐ propyl bromide (fresh)

1.24 0 18.6

Total 5.2317 0 78.4755



Water and Waste Water Management

Total Raw Water requirement is 227.60 kl/day (Fresh: 200.29 kl/day + condensate from MEE 27.31 kl/day) supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.

Total industrial Waste Water Generation is 128.99 KL/Day. Domestic waste water (10 KL/day) will be disposed off through Septic Tank.

Air Emission and its Control Measures Flue gas emission:

At present, the unit is having one number of 5 TPH steam boiler. The company shall install additional one number of Steam Boiler having capacity 2 TPH. Natural Gas/furnace oil will be used as fuel.

At present, the unit is having one number of 380 KVA of D G set (standby). The company shall install additional 620 KVA capacity of D.G. Set, as stand by. It will be used only during power failure.

Adequate stack height and stack monitoring facilities will be provided.

Process gas emission: • Presently the unit has installed two numbers of two stage water scrubber followed by alkali

scrubber to scrub HCl & SO2 gas generated from the process. After proposed expansion, the unit shall install additional two numbers of two stage water followed by alkali scrubbers to scrub HCl, Br2 & SO2 gas generated from the process. Adequate height of process vent will be provided. .(Detail of Air pollution control measures is attached as Annexure-10)

Hazardous Wastes and its Management

Sr. No.

Type of hazardous

waste

Category

Quantity, TPA Place of Storage

Disposal

Existing After proposed expansion

1 Waste from ETP 34.3 41.0 150.0 HDPE bags

TSDF, Vapi

2 Used oil 5.1 1.2 1.5 Drum Sell to registered re-

refiner3 Discarded

containers 33.3 10.0 20.0 Pallets/dr

ums Sell to

authorized recycler

4 Salt from MEE 34.3 158.4 2437.2 HDPE Bags

TSDF, Vapi

5 Process residue 26.1 14.0 963.72 HDPE drums

Sent for co-processing or

own incineration

system



6 Concentrated effluent for TEE from HIL (Unit:

II)

34.3 1080.0 6894.0 By tanker

Own MEE

7 Ash from incineration

36.2 0 125.0 HDPE bags

TSDF, Vapi

8 Ammonium Chloride Powder

(85%)

Sch:II B30

60.336 0 HDPE bags

Sell to actual users as a by-

product 9 Sodium Sulphite

Powder (80%) Sch:

II C1366.96 642.96 HDPE

bags Sell to actual users as a by-

product 10 Hydro Chloric

Acid solution (30%)

Sch:II D2

239.90 729.84 Tanker Sell to actual users as a by-

product 11 Hydro Bromic

Acid solution (20%)

Sch:II B26

0 3130.2 Tanker Sell to actual users as a by-

product 12 Sodium

Sulphate powder (80%)

Sch: II C13

201.46 0 HDPE bags


product 13 Spent/Recovere

d Solvent 20.2 118 2669 Storage

tanks Recycle in

process or sell to authorized

distillator



2. Introduction of Project / Back Ground Information : (i) Introduction of the Project and the Proponent. Name of the project Proponent: Heranba Industries Limited (Unit: I).

Heranba Industries Limited (Unit: I) is a medium scale unit is located in notified industrial estate, GIDC, Vapi Di: Valsad, Gujarat having total plot area of 9740 m2 & total investment after proposed expansion will be Rs. 2900 lacs. The proponent wishes to introduce new products. The pesticides technical products are especially used in agriculture as insecticides, fungicides & herbicides. The unit is operated by technocrats having more than 30 years of experience in manufacturing and marketing of various pesticides worldwide. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons. The proposed expansion proposes to expand the capacity of pesticides with total capacity of 350.0 MT per month and process capabilities to manufacture all types of Pesticides.

The proposed expansion project site lies on 20022’20.17” N Latitude & 72056’55.06” E Longitude. Heranba Industries Limited (Unit: I) is located at Plot. No. 1504, 1505, 1506, 3rd phase area, GIDC Vapi, Di: Valsad district in Gujarat state. GIDC Vapi is centrally located in the both sides of National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union territories of Daman on the western side and Dadra & Nagar Haveli on the eastern side. The western Railway Main Line passes through the area (Double & Electrified). Vapi is the biggest railway station in the study area; where, almost all the important mail & express trains stop. Entire study area is well connected with other major cities of the state and the country. Beside the rail connectivity, the site is also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is now a six laned, double tracked, more elevated and Jam free highway, developed by L&T Company. This highway has given a further boost to the economic growth of this area.

The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is crosses the NH – 8 in Vapi town. Almost every village in the district is now well connected to each other by a Pucca road.

About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat – Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has gained a special status on the industrial map of the country mainly for chemical industrial units. Over the years, it has emerged as a major cosmopolitan industrial township equipped with hospitals. school, colleges, community centers, temples, churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post offices, banks, telephone exchanges hotels, guesthouses etc. The town has got a major face-lift after the completion of national highway and other links roads are of good standard. Mumbai, the economic capital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is 370 kms. The district Head Quarter – Valsad is 30 km from Vapi town.



VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-1968. The entire estate, which was developed in phases, is now spread over 1140 hectares and houses more than 1400 industries, most of which are small-scale industrial units although some have grown bigger units at later stages. The industrial township is basically a declared “Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical related, such as, Dyes and Dyes intermediates, pigments pesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. One of the country’s largest common effluent treatment plants has been setup in Vapi industrial estate. Being a major industrial & commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc. HERANBA INDUSTRIES LIMITED, (HIL) was incorporated in 1992 and is engaged in the business of manufacturing and marketing agrochemicals especially pesticides and their intermediates since 1995. The company has its corporate office at 101/102, Kanchanganga, Factory Lane, Borivali (West), Mumbai – 400 092 and Manufacturing unit at Plot No. 1504/1505/1506 & A2/2214 & 2215, 3rd phase, GIDC, Vapi Dist, Valsad, Gujarat.

eIdentification of the project proponent

The Company is managed by the promoters and whole time Directors Mr. Sadashiv K. Shetty and Mr. Raghuram K. Shetty who are ably assisted by Directors Ms. Sujata S. Shetty – Post Graduate in Commerce with diploma in Finance Management and Ms. Vanita R. Shetty – Graduate in Science with specialization in Chemistry.

BACKGROUND OF PROMOTERS

Mr. Sadashiv K. Shetty

Post Graduate in Chemistry, is a technocrat with over two decades of experience and expertise in operating chemical plant and effectively running chemical business, now leading the team of HIL Mr. Raghuram K. Shetty ably supports him.

He had built up his career in renowned companies like Hoechst India Ltd., Gharda Chemicals Ltd and Sudharshan Chemical Ltd at various levels of operation of chemical plant.

Mr. Raghuram K. Shetty

Graduate in Economics with post graduation in Commerce, a professional with over two decades of experience in the administrative and financial matters is the Executive Director of the company.

Mrs. Sujata S. Shetty

Post Graduate in Commerce with Diploma in Finance Management.

Mrs. Vanita R. Shetty

Graduate in Science with Specialization in Chemistry.



(ii) Brief description of nature of the Project : Heranba Industries Limited (Unit: I) proposes the expansion of their production capacity

at Plot No. 1504,1505,1506, 3rd phase, GIDC, Vapi-396195, Dist.- Valsad (Gujarat). The proposed expansion project involves in the production of “pesticide technical”. As per the amended EIA notification- 2006, the proposed products are covered under category 5(b)- A and hence require Prior Environmental Clearance.

For the proposed project, the company intends to procure the latest technology for manufacturing the products.

(iii) Need for the project and its importance to the country and region : The proposed project provides a potential growth opportunity for the already running

business of the company. The company is engaged in the business of manufacturing of Pesticides technical. The project would increase the overall export and also increase the foreign revenue. Products are now well established and acceptable in the international markets.

Additional capacities of product range required over & above our existing capacities, as the company expects growth of exports to the extent of 40-50%. Local market is also showing strong growth potential.

(iv) Demand –Supply Gap : The products have very high specific demand as they are especially used in agriculture

as insecticides, fungicides & herbicides.

(v) Imports vs. Indigenous production : Existing products manufactured in the country will be very much economical compared

to imports of the same and also the export of the same will earn extra revenue generation for our county.

(vi) Export Possibility : Existing products have high export potential. Also these products have very good

potential in the local market. Additional capacities of product range required over & above the unit’s existing capacities, as the company expects strong growth of exports to the extent of 40-50%. Local market also shows strong growth potential.

(vii) Domestic / export Markets : The company’s products are used in agriculture as an insecticides, fungicides &

herbicides. These are having very good demand in domestic as well as international markets.



(viii) Employment Generation (Direct and Indirect) due to the project : There will be very good opportunity of employment generation directly and indirectly

due to proposed expansion project. Due to proposed project there will be requirement of manager, supervisor, operator and semi-skilled workers. For this, the company will employ about additional 30 people to fulfill it’s need to handle the plant. So that 30 people will be directly employed and more than 50 will be indirectly employed.



3 Project Description :

(i) Type of Project including interlinked and interdependent projects, If any : The proposed expansion project is an interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates :

The map showing general location, specific location and project boundary and project site lay out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.

(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted :

• The proposed activity will be accommodated in the notified industrial area having proper industrial infrastructure so; there is no alternate site consideration. Proposed expansion will be carried out in exiting premises only. (Land allotment letter is attached as Annexure-8)

(iv) Size or magnitude of operation : As per the proposed project cost, the project is covered under Medium Scale category of

manufacturing industries.

(v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given) :

Detailed project description with process details is enclosed as Annexure-3

(vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product :

Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products & characteristics of hazardous chemicals are as below:

DETAILS ON PRODUCT TRANSPORTATION

Sr. No.

Product Physical State Dispatch Means of Transportation

1 Cyper methric Acid Chloride

liquid In MS/HDPE drums

Truck or container

2 Deltamethrin Technical Powder Solid

Fibre board drums

Truck or container

3 Diclorovos Technical liquid MS/HDPE drums

Truck or container

4 Glyphosate Technical Powder solid

HDPE bags Truck or container

5 Lamdacyhalothrin Technical

Viscous liquid

MS drums Truck or container

6 Permethrin Technical Viscous MS drums Truck or



liquid container

7 Temephos Technical Viscous liquid


8 Tricyclozole Technical Powder ( Solid)


9 Acephate Technical Powder ( Solid)


10 Hexaconazole Technical

Powder ( Solid)


11 Imidacloprid Technical Powder ( Solid)


12 Profenophos Technical Viscous liquid


By-Product

1 Ammonium Chloride Powder (85%)

Solid HDPE bags Truck or container

2 Sodium Sulphite Powder (80%)


3 Hydro Chloric Acid solution (30%)

Liquid Captive use Tanker

4 Hydro Bromic Acid solution (20%)

Liquid For bromine recovery

Tanker

5 Sodium Sulphate powder (80%)


6 Bromo Benzene Liquid 200 KGS MS DRUM

Tanker

7 SS- CMAC Liquid Captive use Tanker

DETAILS ON RAW MATERIAL TRANSPORTATION

Sr. No.

Substance Physical State

Source of Supply

Means of Transpor

tation

Distance of supplier

from project

site (km) 1 Acrylo

nitrile Liquid RIL (Baroda) Tanker 250

2 Carbon Tetra chloride

Liquid GACL (Baroda) Tanker 250

3 Catalyst Solid Sahjanand chemical (Ahemdabad)

Truck 400

4 DEA-HCl Solid Alkyl amines (Pune)

Truck 300

5 HCl 30 % Liquid Shree Om Tanker 07



chemicals (Vapi) 6 DMF Liquid Khodiyar

Chemical (Mumbai)

Truck 150

7 Soda Ash Solid SMP Chemicals (Vapi)

Truck 07

8 Caustic Lye 48 %

Liquid GFCL (Dahej) Tanker 180

9 n-Hexane Liquid BPCL (Mumbai) Tanker 150 10 IB Gas & liquid

under pressure

Savla Chemicals (Ankleshwar)

Tanker ISO tank

150

11 TEA Liquid Alkyl Amines (Pune)

Truck 300

12 Sulphuric Acid

Liquid Shree Om Chemicals (Vapi)

Tanker 07

13 Thionyl Chloride

Liquid Transpek (Baroda)

Tanker 250

14 Sodium Cyanide

Liquid GACL (Baroda)) Truck 250

15 MPB Liquid BRL (Dahej) Truck 180

16 Sodium Hypo Chloride

Liquid Shree Om Chemicals (Vapi)

Tanker 07

17 Tri-ethyl Amine

Liquid Alkyl Amines (Pune)

Truck 300

18 Caustic flakes

Liquid GACL (Baroda) Truck 250

19 methylene dichloride

Liquid MJ Corporation (Vapi)

Tanker 10

20 Benzene Liquid Paresh Chemicals (Mumbai)

Tanker 200

21 FeCl3 Solid Sukha Chemicals (Ankleshwar)

Truck 200

22 Bromine Liquid Jebsen & Jebssen (Imported)

Tanker -

23 Aluminum chloride

Solid Jay Chloro Truck 200

24 Sodium bicarbonate

Solid SMP Chemicals (Vapi)

Truck 07

25 Methanol Liquid Ketul Chemicals (Vapi)

Tanker 10

26 Toluene Liquid Techno Chem (Mumbai)

Tanker 200



27 m-phenoxy benzaldehyde

Liquid UPL (Vapi) Truck 10

28 TEBA Solid Acme Sujan chemical 9 Jalgaon)

Truck 390

29 Acetic acid Liquid SMP Chemicals (Vapi)

Truck 07

30 Isopropyl alcohol

Liquid TASC Tanker 500

31 Activated carbon

Solid Local Truck 50

32 hypo super cell

Solid Techno Chem (Mumbai)

Truck 200

33 Bromo benzene

Liquid HIL-1 Truck 5

33 Tri Chloro Acetaldehyde (Chloral)

Liquid Wankson (Ankleshwar)

Truck 200

34 Tri Methyl Phosphite (TMP)

Liquid Sabero Organics (Sarigam)

Truck 25

35 DEA Liquid Alkyl Amine (Pune)

Truck 450

36 HCHO (37%)

Liquid Local Tanker 500

37 PCl3 Liquid Sabero Organics (Sarigam)

Truck 25

38 Carbon Solid Local Truck 5 39 Ammonia

20% Liquid Vadilal (Vapi) Tanker 5

40 MPBD Liquid UPL (Vapi) Truck 10 41 NaCN Liquid GACL (Baroda) Truck 250 42 NaOCl

(10%) Liquid Shree Om

chemicals (Vapi) Tanker 07

43 Acetic acid Liquid SMP Chemicals (Vapi)

Truck 07

44 IPA Liquid TASC CHEMICAL (Mumbai)

Tanker 250

45 m-Phenoxy benzyl alcohol

Liquid Kanoria Chemicals (Ankleshwar)

Truck 200

46 Potassium Carbonate

Solid MJ Corporation (Vapi)

Truck 10

47 Thiodi Solid Link Pharma, Truck 300



phenol (Baroda) 48 DMTC Liquid Sabero Organics

(Sarigam) Truck 25

49 TEBA Solid Acme Sujan Chemicals (Jalgaon)

Truck 390

50 sodium dithionite

Solid Chempek Chem (Baroda)

Truck 300

51 4-HMBT Solid Zhejiing Chem (China)

Truck Imported

52 Formic acid Liquid Paresh chemical Mumbai

Drums in truck

250

(vii) Resource optimization/ recycling and reuse envisaged in the project , if any , should briefly outlined :

Resource optimization/recycling and reuse envisaged in the project (solvent recovery system) in detail are as mentioned below. • The raw materials will be stored in closed containers and will be handled through

closed system to avoid the handling losses.

• The solvents are reused in the manufacturing of pesticides. Details of solvent use & recovery are as under.

PRODUCT WISE SOLVENT USED/RECOVERED PER TONE OF PRODUCT FOR EXISTING & PROPOSED EXPANSION

Product After

proposed Expansion

TPM

Name of RM RM consumption in MT Per ton of product

Per month Existing After

Proposed Expansion

Cypermethric acid Chloride

0 n-Hexane (Recovered)

8.912 106.944 0

n-Hexane (Fresh)

0.228 2.736 0

IB (Recovered)

0.137 1.644 0

IB (Fresh) 0.457 5.484 0 TEA (Fresh) 0.01 0.12 0

TEA (Recovered)

0.824 9.888 0

Delta Methrin 30 methylene dichloride

(Recovered)

13.124 0 393.72



Methylene di chloride (Fresh)

0.4 0 12

Toluene (Recovered)

4.8 0 144

Toluene (Fresh)

0.005 0.15

Isopropyl alcohol

(Recovered)

6.324 0 189.72

IPA (Fresh) 0.126 0 3.78 TEA

(Recovered) 0.220 0 6.6

TEA (Fresh) 0.012 0 0.36

Lamdacyhalothrin

20 IPA (Recovered)

0.753 0 15.06

IPA (Fresh) 0.023 0 0.46

n-Hexane (recovered)

1.62 0 32.4

N-hexane (fresh)

0.43 0 8.6

Temephos 10 Methylene dichloride

(Recovered)

0.745 0 7.45

Methylene dichloride

(Fresh)

0.083 0 0.83

Acephate 175 MDC (Recovered)

10.357 0 1812.475

MDC (Fresh) 0.589 0 103.075

Ethyl Acetate (Recovered)

1.076 0 188.3

Ethyl Acetate (Fresh)

0.385 0 67.375

Hexaconazole 5 Di Methyl Sulphate

(Recovered)

1.262 0 6.31



Di methyl Sulphate (Fresh)

1.151 0 5.755

Methanol (Recovered)

1.08 0 5.4

Methanol (Fresh)

0.045 0 0.225

Imidacloprid 10 MEK (Recovered)

6.25 0 62.5

MEK (Fresh) 0.15 0 1.5

OVERALL SOLVENT BALANCE AFTER PROPOSED EXPANSION

Sr. No.

Solvent used

Total Solvent

used, MT/M

Solvent Recovery &

reuse, MT/M

Solvent loss/with

residue/as reactant, MT/M

% recovery

1 n-Hexane 41 32.4 8.6 79.02

2 Tri ethyl amine

6.96 6.6 0.36 94.8

3 Methylene dichloride

2329.55 2213.645 115.905 95.02

4 Toluene 144.15 144 0.15 99.89

5 Isopropyl alcohol

209.02 204.78 4.24 97.97

6 Methanol 5.625 5.4 0.225 96.0

7 Methyl Ethyl

Ketone

64 62.5 1.5 97.65

Total 2800.305 2669.325 130.98 95.32



(viii) Availability of water its source, Energy/power requirement and source should be given : Availability of water its source, Energy/power required and its source is below. Water

withdrawal Permission is attached as Annexure: 4

WATER CONSUMPTION (m3/DAY)

Sr. No.

Particulars Existing Proposed After Proposed expansion

1 Domestic 6.0 4.0 10.0 2 Processing , washing &

scrubber 3.59 58.01 61.6

3 Cooling 12.0 18.0 30.0 4 Boiler 10.0 90.0 100.0 5 Floor/equipment/container

washing 10.0 10.0 20.0

6 Gardening & fire safety 1.084 4.916 6.0 7 Total 42.674 184.926 227.60 8 Condensate from MEE

recycle 0 27.31

27.31 9 Net fresh water 42.674 157.62 200.29

WATER BALANCE DIAGRAM AFTER PROPOSED EXPANSION)

TOTAL WATER CONSUMPTION: 227.6 M3/day (Fresh: 200.29 + Recycle from MEE: 27.31

DOMESTIC:10

PROCESS, WASHING & SCRUBBER : 61.6

COOLING: 30

SEPTIC TANK/SOAK PIT

84.0

PRIMARY, SECONDARY & TERTIARY TREATMENT UNITS

CETP, VAPI

BOILER:100

FLOOR & CONTAINER WASHING: 20

GARDENING & OTHERS:

6

2 20 20

Normal stream: 24.2 69.2 M3/Day

MEE

TIDAL ZONE OF RIVER DAMANGANGA TO ARABIAN SEA

High TDS Stream: 37.7

Salt: 6.77 MTTSDF

27.31 M3/day Condensate recycle

3

Loss: 3.62

High COD/NH3:22.1

Incinerator



ENERGY REQUIREMENTS AND ITS SOURCE

Sr. No.

Particulars Existing Proposed Source

1 Steam requirement

5000 kg/Hr

7000 Kg/Hr. Will be obtained by installation of Boiler having steam generation capacity of 5 TPH & 2 TPH

POWER REQUIREMENTS AND ITS SOURCE

Sr. No.

Particulars Existing Proposed Source

1 Power – Electricity requirement 550 KVA 1300 KVA Will be sourced from

Dakshin Gujarat Vij

Co. Ltd.

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal :

Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Annexure-5. (x) Schematic representations of the feasibility drawing which give information of EIA purpose: A Schematic representations of the feasibility drawing is enclosed as Annexure: 9

4. Site Analysis (i) Connectivity : The project is located in notified Industrial Estate of Vapi which is very well connected

to National Highway no.8 and Western Railways. The nearest airport is Mumbai which is 150 KM away from the project site by road.

(ii) Land Form, Land use and Land ownership : The land is in the form of industrial shed owned by Gujarat Industrial Development

Corporation.

(iii) Topography (along with map) : Topography map showing the elevation of the study area below. The topographical map

is enclosed as Annexure-7.



(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given :

The existing land is located in the notified industrial area and a copy of gazette notification is enclosed as Annexure-8

(v) Existing Infrastructure : GIDC notified industrial area of Vapi has available infrastructure like water, electricity,

roads, rail, transportation, availability of raw material and drainage system.

(vi) Soil classification : General soil classification of the area is as under :

• Soil Characteristics & Land use classification: The study area is located at outer part of Dadra. Northern part of the site is fully developed for settlement with cropping pattern. Eastern part of the site location has Loamy, clay, Red soil.

• The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This type of soil is not suitable for cultivation purpose.

• The land is suitable for industrial development.

Damanganga River is located at 3 km distance from the site location, both side of the river has mixed soil type (Sand, clay & Basaltic soil).

(vii) Climate data from secondary sources : Rainfall Data :

The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid climate. The remaining part of the state receives rainfall between 500-1000 mm and generally falls under semi-arid climate. Considering the abnormality of weather particularly rainfall during the monsoon period, the observed and predicted rainfall was then analyzed for its validity.



Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)

Sr. No

Region Rainfall Projection

(in mm) June - Oct

Normal Rainfall (In mm)

Rainfall Projection (% Departure from normal)

1 Middle Gujarat 905.3 796 13.7

2 South Gujarat 696.3 575 21.0

3 Project site 2071.7 1433.7 44.5

4 Saurashtra 767.1 580.4 32.2 5 Gujarat State 1110.1 846.5 31.1

Source: AAU, Anand, Gujarat

Temperature Data: The site is located in the southern part of Gujarat. The secondary data was collected from free data of Worldclim.org for the year 2010. The project site temperature regime for medium to high level temperature (30-32 °C) during the seasonal months (June to Sep).

(viii) Social Infrastructure available : Social Infrastructure in Valsad district is as under :

Education: There are 990 primary, 161 secondary and higher secondary schools. There are 6 ITIs offering several industrial training Institutes programs which includes, fitting, armature & motor rewinding, electrician, information technology and electronic system maintenance etc., 166 Higher Secondary School, One Government polytechnic College is present in the district offering courses in civil, chemical, electrical, mechanical and plastic engineering, 6 nos. of ITI’s with an intake capacity of 360, 1 nos of Polytechnic College With 120 seats, there is one Engineering College, Pharmacy College, Arts, Commerce, Science, B. Ed and Law College. Valsad district also has institutes which offers management studies with fulltime MBA. Source: Department of Education, 2007

Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10 Government and 1 Municipal hospital present in the district. Valsad has several private specialized hospitals to provide a comprehensive range of tertiary and secondary care services backed by state-of-the-art technology and trained medicos. A multi-specialty Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, providing services in general and laproscopic surgery, trauma, orthopedic and urology etc. The hospital is one of the few centers in India offering Uterine Thermochoice Thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital and Adarsh Hospital are also present in Valsad.



Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is also known Fire Temple for the Parsi community in India, makes the city a famous pilgrimage center throughout the world. Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town with pleasant climate throughout the year. The collection at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, which has increased the graph of tourist flow in the district.



5. Planning Brief :

(i) Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification :

There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Vapi.

(ii) Population Projection : • Not applicable

(iii) Land use Planning (breakup along with green belt etc) : The existing as well as proposed expansion project is located within the Notified

Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below. For Green Belt Development as per the revised layout plan, the company proposes 30% green belt of the total land, i.e. 9740 sq. meter. The company shall develop green belt along the periphery of the proposed site and in common premises available outside the company premises. While selecting the plants species to be grown in the green belt zone, following points will be taken into account:

1. Climatic condition and soil characteristics of the region. 2. The air pollution emitted by the industry – gaseous and particulate matter. Plant

interaction with both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere.

3. Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles.

4. Height of the plants should not be too high to be lethal. 5. For absorbance of gases, the duration of the foliage should be longer. 6. Vegetation controls soil erosion rates significantly. The decrease of water erosion

rates with increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked.



Site Plan with Area Table at Existing & after proposed expansion

Sr. No Particulars Area in m2

Existing Proposed

Total

1.0 Total plot Area 9740 0 9740

1.1 Production Plant 880 1820 2700 1.2 Office & lab area 290 0 290 1.3 D G set area 16.40 0 16.40 1.4 Green Belt 2000 950 2950 1.5 Raw materials & other Storage 150 0 150 1.6 Solvent storage area 700 0 700 1.7 Utility 100 200 300 1.8 Boiler shed area 130 0 130 1.9 ETP & solid waste storage area 250 100 350 1.10 Toilet block 10.0 14.50 24.50 1.11 Open space 5213.6 -3084.5 2129.1



Site map with Green Belt Development Planning

(iv) Assessment of Infrastructure demand ( Physical & Social) : There is no need for any infrastructure demand in terms of physical or social needs for

the proposed expansion.

(v) Amenities/ Facilities : GIDC notified industrial area of Vapi has the available infrastructure like water,

electricity, roads, rail, transportation, availability of raw material and drainage system.



6. Proposed Infrastructure :

(i) Industrial Area (Processing Area). The proposed infrastructure to manufacture products will be built with standard

engineering design considering all the relevant parameters related to environment, health and safety.

(ii) Residential Area (Non Processing Area) : No residential area is involved in the proposed expansion project (iii) Green Belt : Green belt will be provided and maintained at the tune of 30% of the total land area. (iv) Social Infrastructure : Not applicable (v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) : The project site is very well connected by road through National Highway no. 8, western

railways. (vi) Drinking Water management ( Source & Supply of water ) : Source of water is from GIDC water supply services. (vii) Sewerage System : GIDC has provided sewerage system to dispose the sewage effluent. (viii) Industrial Waste Management : • Industrial liquid effluent generated during the manufacturing of proposed products

will be segregated, concentrated (high TDS) effluent will be treated in MEE, High COD/NH3 will be incinerated in proposed incineration system & normal effluent will be treated in the primary, secondary & tertiary ETP and will be discharged through GIDC underground drainage to CETP.(Membership certificate is attached as Annexure-6)

• Generated domestic liquid waste is being disposed off through soak pit system to drainage.

(ix) Solid/Hazardous Waste Management :

Sr. No.

Type of hazardous

waste

Category Quantity, TPA Place of Storage

Disposal

Existing After proposed expansion

1 Waste from ETP

34.3 41.0 150.0 HDPE bags

TSDF, Vapi

2 Used oil 5.1 1.2 1.5 Drum Sell to registered re-

refiner



3 Discarded containers

33.3 10.0 20.0 Pallets/drums

Sell to authorized recycler

4 Salt from MEE

34.3 158.4 2437.2 HDPE Bags

TSDF, Vapi

5 Process residue

26.1 14.0 963.72 HDPE drums

Sent for co-processing or

own incineration

system 6 Concentrated

effluent for TEE from HIL

(Unit: II)

34.3 1080.0 6894.0 By tanker Own MEE

7 Ash from incineration

36.2 0 125.0 HDPE bags

TSDF, Vapi

8 Ammonium Chloride

Powder (85%)

Sch:II B30

60.336 0 HDPE bags


product 9 Sodium

Sulphite Powder (80%)

Sch: II C13

66.96 642.96 HDPE bags


product 10 Hydro Chloric

Acid solution (30%)

Sch:II D2 239.90 729.84 Tanker Sell to actual users as a by-

product 11 Hydro Bromic

Acid solution (20%)

Sch:II B26

0 3130.2 Tanker Sell to actual users as a by-

product 12 Sodium

Sulphate powder (80%)

Sch: II C13

201.46 0 HDPE bags


product 13 Spent/Recover

ed Solvent 20.2 118 2669 Storage

tanks Recycle in

process or sell to authorized

distillator

(Membership certificate is attached as Annexure-6)

(x) Power Requirement & Supply / Source : Power requirement for proposed project will be taken from DGVCL.

7. Rehabilitation and Resettlement (R&R) Plan: (i) Policy to be adopted (Central/ State) in respect of the project affected persons including

home oustees, land oustees and landless laborers (a brief outline to be given):

There will be no rehabilitation and resettlement undertaken as labours and workers from local & nearby areas for the proposed construction activity which will be minor as the proposed expansion activity is to be undertaken at the existing site.



8. Project Schedule & Cost Estimates :

(i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) :

After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed construction and commissioning of the project.

(ii) Estimated project cost along with analysis in terms of economic viability of the project : Estimated project cost along with the analysis in terms of economic viability of the

project is given as below.

CAPITAL COST PROJECTION

Sr. No.

Particulars Cost in INR (Crore) Existing Proposed Total

1.0 Land 9740 m2 4.0 0 4.0 2.0 Building 2.0 5.0 7.0 3.0 Plant & Machinery 3.1 Equipment & machineries 2.0 4.0 6.0 3.2 Pipes & fittings 1.0 2.0 3.0 3.3 Utilities 1.0 2.0 3.0 4.0 Environmental Management

System 2.0 4.0 6.0

5.0 Total Project Cost 12.0 17.0 29.0 6.0 Utilities 6.1 Boiler, TPH 5 2 7 6.2 Cooling Tower, TR 100 200 300 6.3 D.G. Set (Standby) 380 620 1000 7.0 Power from DGVCL, KVA 550 750 1300 8.0 Fuel 8.1 FO, kl/Hr or Natural gas,

SCM/Hr 0.5 or 650 0.33 or

435 0.83 or 1085

8.2 HSD, kgs/hr 15 25 40 9.0 Water from GIDC Vapi 42.674 184.926 227.60 10.0 Waste Water (Industrial) 16.039 112.96 129.0



PROJECT VIABILITY

Sr. No.

PARTICULARS AMOUNT (INR Crores)

1 Proposed Sale 348 2 Raw Material Cost 210 3 Power & Fuel 18 4 Labor Cost 18 5 Environmental Management System 24 6 Maintenance Cost 18 7 Selling, packing & Office Expenses 18 8 Proposed Profit 42

The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning.

RECURRING COST PER ANNUM

Sr. No. Component Proposed (Rs. in Lacs/annum)

1. Environment & Safety Management System 100

2. Greenbelt Maintenance 2.5

3. Solid waste Disposal 35

Total 137.5

9. Analysis of Proposal ( Final Recommendations): (i) Financial and social benefits with special emphasis on the befit to the local people including

tribal population, if any, in the area: Proposed expansion activity will provide benefits to the local people in terms of

financial and social welfare.

• Local people will get direct financial benefit by way of employment. • Local people will get some contracts of supply and services to get indirect income. • Company will contribute in improving education and health facilities in nearby area.



ANNEXURES



ANNEXURE: 1

Location map showing the Project site and inter-state boundary within 10 kms radius


Expansion Project: 36 Manufacturing : Pesticides technical

ANNEXURE: 2

Plant Layout



ANNEXURE: 3 Detailed project description with process details ‐ MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance & mole balance for the product.

(1.0) Process of Cyper methric Acid Chloride:

Stage ‐1:‐ Preparation of tetra Chloro Butyro Nitrite (TBN)

Reaction of Carbon Tetra Chloride with Acrylonitrile at 100°Cto 125°C in present of cupric chloride catalyst, DEA HCI as a buffer and Acetonitrile as solvent gives Tetra Chloro Butyro Nitrile ( TBN (.Excess CTC and Acetonitrile is removed by distillation. In water wash cupric chloride DEA HCI is removed.

Stage ‐ 2:‐ Preparation of tetra Chloro jiutvic Acid. (TBA)

Acid hydrolysis of crude TBN using 30 % HCI solution gives tetra Chloro Butyic Acid (TBA). After reaction TBA is separated from bottom and dehydrated up to moisture contain level of 0.1 %.

Stage ‐ 3:‐ Preparation of tetra Chloro Butyric Acid Chloride (TBAC)

Reaction of TBA with Thionyl Chloride in presence of Dimethyl Formamide at 60°C gives tetra ChloroButyric Acid Chloride (TBAC), During reaction SO2 and HCI gas is evolved which is scrubbed in scrubber. Crude TBAC is further distilled under high vacuum. The purity of Distilled TBAC is 98 %.

Stage‐4:‐ Preparation of 2 ‐ ChlorqCycIo Butanone Derivative ( 2 CB )

TBAC is reacted with Jsobutylene in presence of Tri Ethyl Amine (TEA) at 70°C under 5.0 Kg/cm2 pressure, n‐Hexane is used as solvent. After reaction excess Isobutylene is recovered. The whole mass is washed with water to remove TEA. The organic mass is neutralized with Sodium bi carbonate and organic mass is transferred for further process.

Stage ‐ 5:‐ Preparation of Sodium Salt of Cypermerhric Acid (Na‐CMA)

2 CB is isomerised to 4 CB in presence of catalyst and then directly reacted with caustic lye solution which gives Na‐CMA.

Stage ‐ 6:‐ Preparation of Cypermerhric Acid (CMA)

Na‐ CMA is acidified with dilute Sulphuric Acid at room temperature. CMA is extracted in n‐Hexane. Aqueous layer (sodium sulphate + sodium chloride + organic impurities) is drain to ETP

Stage ‐ 7:‐ Preparation of Cypenmerhric Acid Chloride (CMAC)

Reaction of CMA with Thionyl Chloride in presence of Dimethyl Formamide at 60X gives Cypermethric Acid Chloride (CMAC). During reaction SO,, and HCI gas is evolved which is scrubbed in scrubber. Crude CMAC is further distilled under high vacuum. The purity of Distilled CMAC is 98 %.



Chemical reaction of Cyper methric Acid Chloride:

Stage ‐ 1 Cl

CCl4 CH2 CH CN CCl3 CH2 CH CN154 53 207CTC Acrylonit rile Tetra Chloro Butyronitrile

Stage ‐ 2

Cl Cl

CCl3 CH2 CH CN 2H2O + HCl CCl3 CH2 CH COOH NH4Cl207 18 36.5 226 53.5

Tetra Chloro Butyronitrile Water Hydrochloric Acid

Tetra Chloro Butyric Acid

Ammonium Chloride

Stage ‐ 3

Cl Cl

CCl3 CH2 CH COOH SOCl2 CCl3 CH2 CH COCl SO2 + HCl226 119 244.5 64 36.5

Tetra Chloro Butyric Acid Thyonil Chloride Tetra Chloro Butyric Acid Chloride Sulphur Di oxide

Hydrochloric Acid

Stage ‐ 4

Cl ClH3C

CCl3 CH2 CH COCl C CH2 CCl3 CH2 C C O + HClH3C

H3C C CH2

H3C244.5 56

264 36.5Tetra Chloro Butyric Acid Chloride Isobutylene 2 - Chloro Cyclobutanone Derivat ive Hydrochloric

Acid

Preperation of Tetra Chloro Butyronitrile TBN

Preperation of Tetra Chloro Butyric Acid

Preperation of Tetra Chloro Butyric Acid Chloride

Preperation of 2 ‐ Chloro Cyclobutanone Derivative



Stage ‐ 5

Cl

CCl3 CH2 C C O CCl3 CH2 CH C O

H3C C CH2 H3C C CH Cl

H3C H3C264 264

2 - Chloro Cyclobutanone Derivative 4 - Chloro Cyclobutanone Derivat ive

Stage ‐6

CCl3 CH2 CH C O + 2 NaO H CCl3 CH2 CH CH C OONa + NaClC

H3C C CH Cl H3C CH3

H3C264 80 267.5 58.5

4 - Chloro Cyclobutanone Derivative Sodium Hydroxide Sodium Salt of Saturated Cypermethric Acid Sodium Chloride

Stage ‐7

CCl3 CH2 CH CH C OONa + NaOH CCl2 CH CH CH C OONa + NaClC C

H3C CH3 H3C CH3

267.5 40 231 58.5

Sodium Salt of Saturated Cypermethric Acid Sodium Hydroxide Sodium Salt of Cypermethric Acid Sodium Chloride

Preperation of Sodium Salt of Saturated Cypermethric Acid

Preperation of Sodium Salt of Cypermethric Acid

Preperation of 4 ‐ Chloro Cyclobutanone Derivative

Stage ‐ 8

CCl2 CH CH CH C OONa + 1/2 H2SO4 CCl2 CH CH CH C OOH 1/2 Na2SO4C C

H3C CH3 H3C CH371

231 49 209Sodium Sulphate

Sodium Salt of Cypermethric AcidSulphuric Acid

Sodium Salt of Cypermethric Acid

Stage ‐ 9

CCl2 CH CH CH C OOH + SOCl2 CCl2 CH CH CH C OCl + SO2 + HClC C

H3C CH3 H3C CH3

209 119 227.5 64 36.5Sodium Salt of Cypermethric Acid Thyonil Chloride Cypermethric Acid chloride Sulphur Di oxide

Hydrochloric Acid

Preperation of Cypermethric Acid

Preperation of Cypermethric Acid Chloride



Mass Balance of Cyper methric Acid Chloride:

Forcut 380Acrylonytrile 500CTC 1550 22 Evaporattion LossAcetonytrile 22 380 Forcut recovery Catalyst 10 328 Waste Water to ETPDEA‐HCl 11Water 230 730

27031973

30 % HCl 1800 1753 29 % Ammonium Water 333 Chloride Solution

4106

2353Water 281 837 Waste Water Water from 2 CB 610 To ETP

32442407

DMF 20 286 Distilled Water recycle stage 2ATC 1067 174 Evaporation LossWater for HCl 763 5058 22.3 % Na2SO3 Caustic Lye 48 % 1495 1090 30 % HCl recycle in stage 2Water for Scrubber 2989 68 Organic Residue

8741 66762065

n‐ Hexane 5140IB 594 137 IB Recivered 824 TEA recoveredTEA 824 300 Evaporation LossWater for TEA HCl 500 1622 TEA‐HCl +764 C.S. lye Soda Ash 5 4840 n‐Hexane RecoveryWater for Soda Ash 505 610 Soda Wash Aq.

9633 7509 1562 aq. Mass to MEE

Catalyst 10 2124TEA 10n‐Hexane 1000 1405 n‐Hexane Caustic 100 % 971Water 5141

92567851

Sulphuric Acid 1199Water 514 8519 (6889 (20%) Sodium Sulphate soln.)n‐Hexane 3000 (1630 sent to MEE)

125644045

DMF 10 2667 n‐ Hexane RecoveryTC 606 2976 22.3 % Na2SO3 Soln.Ct. Lye 48% 849 620 30 % HCl recycle in stage 2Water for scrubber 1697 333 Evaporation LossWater for HCl 434

7641 1045 6596

45 Organic Residue

Process Flow Diagram of (Cypermethric Acid Chloride)

Stage : 1TBN

Stage : 2

CMA

1000 KG CMAC

2 CB

CMAC

CMAC Distillation

Stage : 7

TBA Washing

Stage : 3 TBAC

Stage : 4

TBA

Stage : 2A

Na‐CMAStage : 5

Stage : 6



Mole balance of Cyper methric Acid Chloride:

Sr.No Raw Material Mole.Wt. As is kg Purity% Real(100 % basis)

No. of Mole

Theo. Actual Excess Mole

% Excess Excess Qty Kgs

Remark

In put1 Fore Cut 154 380 85 323 2.10 Conta ins CTC and Acrylonitri le recycle from Sr.No 22

2 Acrylonitrile 53.00 500 99 495 9.34 1.00 2.17 1.17 53.9 61.9 Recovered in Fore cut at Sr.No 223 CTC 154.00 1550 99 1535 9.96 1.00 2.31 1.31 56.8 202.2 Recovered in Fore cut at Sr.No 224 Acetonitrile 41.00 22 99 22 0.53 0.00 0.00 0 0.0 22.0 To Effluent at Sr.No 325 Catalyst 134.50 10 98 10 0.07 0.00 0.02 0.02 0.0 10.0 To Effluent at Sr.No 326 DEA - HCl 109.64 11 98 11 0.10 0.02 0.02 0.00 0.0 11.0 To Effluent at Sr.No 327 Hydrochloric Acid 36.50 1800 30 540 14.79 1.00 3.43 2.43 70.9 88.9 Ammonium Chloride Aquous Sr.No 248 Dist. Water recycle 18.00 286 100 286 15.89 0.00 286.0 Recycle from Sr.No. 25 for washing9 DMF 73.00 30 99 30 0.41 0.00 0.09 0.09 0.0 30.0 To residue Sr.No 3410 Thyonil Chloride 119.00 1673 99 1656 13.92 1.00 3.23 2.23 69.1 265.5 To Scrubber in form of SO2 and HCl11 Sodium Hydroxide (CS Lye) 40.00 2344 48 1125 28.13 2.00 6.53 4.53 69.4 181.2 To scrubber 12 Na2SO3 ML recycle 126.00 4686 80 3749 29.75 6.91 6.91 0.00 0.0 0.0 Recycle from Sr.No 2813 n-Hexane 86.18 9140 99 9049 105.00 1.00 24.37 23.37 95.9 2014.4 Used as solvent and recovered in Sr.No 3114 Isobutelene 56 594 99 588 10.50 1.00 2.44 1.44 59.0 80.5 Recovered and recycle from Sr.No 2915 Triethylamine 101 834 98 817 8.09 1.00 1.88 0.88 46.8 88.7 Recovered and recycle from Sr.No 3016 Sodium Carbonate 142 5 99 5 0.03 0.01 0.01 0.0 5.0 To Effluent at Sr.No 3217 Catalyst 142 10 47 5 0.03 0.01 0.01 0.00 0.0 10.0 To Effluent at Sr.No 3218 Sodium Hydroxide( Flakes) 40 971 99 961 24.03 3.00 5.58 2.58 46.2 103.2 To Effluent at Sr.No 3219 Sulphuric Acid 98 1199 98 1175 11.99 0.50 2.78 2.28 82.0 223.8 To Effluent at Sr.No 3220 Water 18 9025 100 9025 501.39 9025.0 Used for washing

Total 35070

Out Put21 Cypermethric Acid Chloride 227.5 1000 98 980 4.31 1.0 0.46

22 Fore Cut 154 380 85 323 Recycle to Sr.No 123 Evaporation Losses 272 27224 Ammonium Chloride Soln. 53.5 1753 29 50825 Dist. Water recycle 18.00 286 286 Recycle to Sr.No 826 Na2SO3 wet cake 126.00 2240 80 179227 Hydrochloric Acid 36.50 1710 30 513 Recycle to Sr No 728 Na2SO3 ML recycle 126.00 4686 30 1406 Recycle to Sr No 1229 Recovered Isobutelene 56.00 137 95 130 Recycle to Sr No 1430 Recovered Triethylamine 101.00 824 95 783 Recycle to Sr No 1531 Recovered n-Hexane 86.18 8912 95 8466 Recycle to Sr No 1332 Waste water to ETP 2573 2573 To effluent treatment Plant33 Waste water to ETP + TEE 8519 851934 Organic Residue 113 11335 Water Evaporation losses 1665 1665

Total 35070

Qty. Kg Mole / Mole ratio



(2.0) Process of Deltamethrin Technical: High cis cypermethric acid is react with catalyst in alkaline condition to separate RR & SS‐ cypermethric acid. Solution of RR‐ Cypermethric acid is reacted with HBr gas in presence of AlCl3 to obtain Tribromo Cypermethric acid. Tri bromo Cypermethric acid is converting into Di bromo Cypermethric acid in alkaline condition Di bromo Cypermethric acid is reacting with methanol in acidic condition to form Di bromo Cypermethric ester. This Di bromo Cypermethric ester is taken for fraction distillation and makes pure Di bromo Cypermethric ester. Di bromo Cypermethric ester is hydrolyzed under alkaline condition at elevated temperature to form Di bromo Cypermethric acid. Di bromo Cypermethric acid is reacting with Thionyl chloride in presence of catalytic amount of DMF to form Di bromo Cypermethric acid chloride.. During the reaction SO2 and HCl in generate, which is scrub in NaOH solution. Di bromo Cypermethric acid chloride is condensed with m‐phenoxy Benzaldehyde and sodium cyanide in presence of phase transfer catalyst and toluene as solvent. Separated organic layer and distilled out toluene to obtain RS‐Deltamethrin crude. Make solution of crude RS‐Deltamethrin in isopropyl alcohol and add triethyl amine and maintain for 20 hrs to obtain S‐Deltamethrin which is filtered and wash with IPA to obtain wet cake of Deltamethrin. This wet cake is dry to obtain pure Deltamethrin technical.

Chemical reaction of Delta Methrin technical:

Stage‐1 Resolution (Reaction chemistry)

Cl2C=CH-CH-C(CH3)2

CHCOOH

Stage-1

2,2-dichloro vinyl -2,2-dimethyl cyclopropane carboxylic acid M.F.=C8H10O2Cl2M.wt.=209

+ NaOH

Sodium hydroxideM.F.=NaOH M.wt.=40

Cl2C=CH-CH-C(CH3)2

CHCOONa

Sodium salt of 2,2-dichloro vinyl -2,2-dimethyl cyclopropane carboxylic acid M.F.=C8H9O2Cl2NaM.wt.=231+

C6H5-CHOH-CHCH3-NH-CH3 HCl

Ephedrine HydrochlorideM.F.= C10H16NOClM.wt.=201.5

Cl2C=CH-CH-C(CH3)2Cl2C=CH-CH-C(CH3)2

CHCOO-N+CH3-CH-CH3-CHOH-C6H5

H H1R,3R 2,2-dichloro vinyl -2,2-dimethyl cyclopropane carboxylic acid ComplexM.F.=C18H25NCl2O3M.wt.=374

+

Cl2C=CH-CH-C(CH3)2

CHCOO-N+CH3-CH-CH3-CHOH-C6H5 + HCl

Hydrochloric acid M.F.=HClM.wt.36.5

Complex Breaking

Cl2C=CH-CH-C(CH3)2

CHCOOH1R,3R 2,2-dichloro vinyl-2,2-dimethyl cyclopropane carboxylic acid M.F.=C8H10O2Cl2M.wt.=209

+ C6H5-CHOH-CHCH3-NH-CH3 HCl

Ephedrine HydrochlorideM.F.= C10H16NOClM.wt.=201.5

H H1R,3R 2,2-dichloro vinyl -2,2-dimethyl cyclopropane carboxylic acid ComplexM.F.=C18H25NCl2O3M.wt.=374

CHCOOH

SS 2,2-dichloro vinyl -2,2-dimethyl cyclopropane carboxylic acid M.F.=C8H10Cl2O2M.wt.=209



Stage‐2 Bromination

Cl2C=CH-CH-C(CH3)2

CHCOOH

Cypermethric acid M.F.=C8H10O2Cl2M.wt.=209

+ Br2

Benzene M.f.= C6H6M.wt.=78

Bromine M.F.=Br2M.wt.=160

Br

+ HBr

Bromo Benzene M.F.=C6H5BrM.wt.=157

M.F.=HBrM.wt.=81

+

HBr M.F.=HBrM.wt.=81

HBr+

32HCl

Hydrochloric acidM.F.=HClM.wt.=36.5

Br2HC-CH-CH-C(CH3)2

CHCOOH

TribromoCypermethric acid M.F.=C8H11O2Br3M.wt.=379

Br

FeCl3

Stage‐3 Dehydro halogenation & acidification

Br2HC-CH-CH-C(CH3)2

CHCOOH

TribromoCypermethric acid M.F.=C8H11O2Br3M.wt.=379

NaOH

Dehydrohalogenation

Br2C=CH-CH-C(CH3)2

CHCOOH

DibromoCypermethricacid M.F.=C8H10O2Br2M.wt.=298

Br

+ H2SO41/2

+ HBr

Hydrobromic acid M.F.=HBrM.wt.=81

+ 1/2 Na2SO4 + H2O

+

Sodium sulphate M.F.=Na2SO4M.wt.=142

water M.F.=H2OM.wt.=18

Sodiumhydroxide M.F.=NaOHM.wt.=40

sulphuricacid M.F.=H2SO4M.wt.=98



Stage‐4 Esterification

Br2C=CH-CH-C(CH3)2

CHCOOH

DibromoCypermethric acid M.F.=C8H10O2Br2M.wt.=298

+ CH3OH

MethanolM.F.=CH3OHM.wt.=32

H2SO4

Br2C=CH-CH-C(CH3)2

CHCOOCH3

DibromoCypermethric esterM.F.=C9H12O2Br2M.wt.=312

+ H2O

Stage‐5 Ester Hydrolysis

Br2C=CH-CH-C(CH3)2

CHCOOCH3

DibromoCypermethric esterM.F.=C9H12O2Br2M.wt.=312

+ NaOHBr2C=CH-CH-C(CH3)2

CHCOONa

Sodium salt ofDibromoCypermethric acidM.F.=C8H9O2Br2NaM.wt.=320

+ CH3OH

Hydrolysis

Br2C=CH-CH-C(CH3)2

CHCOOH

DibromoCypermethric acidM.F.=C8H10O2Br2M.wt.=298

+ NaCl

Stage‐6 Dibromo acid chloride

Br2C=CH-CH-C(CH3)2

CHCOOH

DibromoCypermethric acidM.F.=C8H10O2Br2M.wt.=298

+ SOCl2

Thionyl chlorideM.F.=SOCl2M.wt.=119

Br2C=CH-CH-C(CH3)2

CHCOCl

DibromoCypermethric acid chlorideM.F.=C8H9OBr2 ClM.wt.=316.5

+ SO2 + HCl



Stage‐7 Condensation

Br2C=CH-CH-C(CH3)2

CHCOCl

DibromoCypermethric acid chlorideM.F.=C8H9OBr2 ClM.wt.=316.5

+ O CHOm-Phenoxy Benzaldehyde M.F.=C13H10O2M.wt.=198

+ NaCN

Sodium CyanideM.F.=NaCNM.wt.=49

O CHCNOOC-CH-C(CH3)2

CH-CH=CBr2

RS DeltamethrinM.F.=C22H19NO3Br2M.wt.=505

Stage‐8 Epimerization & purification

O CHCNOOC-CH-C(CH3)2

CH-CH=CBr2

RS DeltamethrinM.F.=C22H19NO3Br2M.wt.=505

(C2H5)3N

O C OOC-CH-C(CH3)2

CH-CH=CBr2

S DeltamethrinM.F.=C22H19NO3Br2M.wt.=505

Epimerisation

H

CN



Mass Balance for Deltamethrin:

Preparation of RR-Cypermethrin acid

(Stage : 1)(Isomer Seperation)

Water : 2.752Caustic Soda Flakes : 0.509

Cypermethric acid : 2.8715% aqueous solution of CAT-V : 7.964

Reaction mass : 14.042

RR-Cypermethric acidComplex breaking

15% aq. Soln. of catalyst recover & recycle: 5.848

Methylene Dichloride : 2.510HCl (30%) : 0.398

Water : 3.116

Organic mass : 4.01

Brominationof

Benzene Bromination of RR-Cypermethric acid

(stage : 2)

HBr gas : 2.148Aluminum Chloride : 0.868

Methylene Dichloride : 3.186

Benzene : 2.68FeCl3 : 0.044

Bromine : 4.836Loss:0.045

0.15 HBr scrub in NaOHfor bromine recovery

Bromination mass washing

HCl (30%) : 1.42

Water : 3.72 6.15 aqueous mass contains HCl & Hbr for bromine recovery

Acid water washing(Stage : 3)

Water: .1.2HCl (30%): 0.172

Water wash: 1.2

Aq. Mass to ETP: 1.45

Hot Filtration & washing

Loss: 0.048

•Aqueous mass for Cypermethric acid •& catalyst recovery : 14.543

Hot water washing: 3.975

Methylene di chloride washing: 0.413

Wet cake RR CMA complex: 3.839

Loss: 0.005

DehydrationMethylene di Chloride recover: 1.29Loss: 0.05

Crude Bromo Benzene: 5.412

Washing

HBr: 2.148

Sod. Thio Sulphate: 0.05

Aq. Mass for Bromine recovery: 1.64

Aq. Mass to ETP: 1.064

Water: 2.5

Crude Bromo Benzene: 5.258

Distillation

Residue: 0.448

Loss: 0.05

Benzene: 0.360 recycle

Bromo Benzene: 4.40

Organic mass : 2.67


Loss:0.030


Organic mass : 7.145

Dehydro haloginationWater: .4.09

C S flakes: 0.186C S lye (47%): 0.258

Loss: 0.226MDC recover: 4.675


Acidification & layer SeparationMDC: 1.910

H2SO4: 0.295

Loss: 0.025Aq. Mass: 5.858

Organic mass 3.100

Washing & layer SeparationWater: .0.725Loss: 0.005Aq. Mass: 0.77

Organic mass 3.05

MDC RecoveryMethanol: 0.455Loss: 0.021MDC recovered: 1.610MDC + traces of methanol: 0.209

Organic mass 1.665

EsterificationMethanol: 0.175

Reaction mass 1.971

Sulphuric acid: 0.131



0.096 Loss 4.71 Toluene recover Crude Deltamethrin 1.429Isopropyl alcohol 4.290 4.204 Isopropyl alcohol recover Triethyl amine 0.232 0.086 Isopropyl alcohol Loss 98% sulphuric acid 0.054 0.220 Triethyl amine recover 0.012 Triethyl amine loss wet cake 1.483Isopropyl alcohol 2.160 1.67 Isopropyl alcohol recover Carbon 0.005 0.040 Isopropyl alcohol loss Hyflow 0.005 0.002 Carbon + hyflow 0.450 DM ML wet cake 1.491 0.450 Isopropyl alcohol recover 0.041 Isopropyl alcohol loss 1.00 Deltamethrin technical

Toluene recovery under 750 mm/hg vacuum at 75°C

Epimerization & filtration & washing

Purification, Filter & washing

Dry



Recovery of Catalyst & product (deltamethrin)

Total aqueous mass for CMA & Ephedrine hydrochloride recovery

14.543 0.020 Loss

MDC 1.300 2.300 Organic mass contain CMA + Ephidrine HClHCl(30%) 0.920 Aqueous mass 14.443 0.025 Loss MDC for extraction 2.10 2.886 Organic mass contain CMA + Ephidrine HCl Aqueous mass 13.632MDC 0.790 0.020 Loss HCl (30%) 0.660 1.000 Organic mass contain CMA+ Ephidrine HCl Aqueous mass 14.062 to ETP

SS CMA Recovery and adjust pH 6.5

MDC Extraction

MDC Extraction pH=2

Total Organic mass 6.186 0.020 Loss Water 1.200 1.525 15% Ephedrine HCl Solution recycle in

reaction HCl (30%) 0.175 Organic mass 5.996 0.010 Loss Water 0.400 0.491 15% Ephedrine HCl Solution recycle in

reaction Organic mass 5.895 0.12 MDC loss 4.070 MDC recover 0.84 water Reaction mass 1.907Thionyl chloride 1.175 0.360 HCl gasDMF 0.006 0.021 Loss 1.2 30% HCl solu. 0.632 SO2 gas 3.590 22 NaOH solu. 2.075 Cypermethric acid chloride 4.22 22% Na2SO3 Solution

Water wash & adjust pH=2

Water wash & adjust pH=2

Solvent recovery

Chlorination Water scrubber

NaOH scrubber



Mole Balance of Deltamethrin:

Sr.NoRaw Material Mole.Wt. As is kg Purity%

Real(100 % basis)

No. of Mole Theo. Actual

Excess Mole % Excess

Excess Qty Kgs Remark

In put1 Cypermethric acid 209 2.8 98 2.761 0.0132 1.00 1.20 0.20 16.9 42.62 C.s.Flakes 40.00 0.889 98 0.871 0.0218 1.00 1.99 0.99 49.6 39.4 To ETP Sr. No. 453 20% aq. Soln. of Cat‐V 201.70 7.9 20 1.580 0.0078 0.40 0.71 0.31 44.0 63.3 Recoverd & Recycle sr. No. 314 methylene dichloride 84.90 13.524 99 13.389 0.1577 0.20 14.38 14 98.6 1203.5 Recoverd & Recycle sr. No. 345 HCl (30%) 36.50 4.295 30 1.289 0.0353 1.00 3.22 2.22 68.9 81.0 To ETP Sr. No. 456 Benzene 78.00 2.68 99 2.653 0.0340 1.50 3.10 1.60 51.6 124.9 Recoverd & Recycle sr. No. 477 FeCl3 162.00 0.044 99 0.044 0.0003 0.02 0.02 100.0 4.0 To ETP Sr. No. 458 Bromine 80.00 4.836 99 4.788 0.0598 1.50 5.46 3.96 72.5 316.4 Recoverd & Recycle sr. No. 329 Aluminium chloride 133.00 0.868 98 0.851 0.0064 0.35 0.58 0.23 40.0 31.0 To ETP Sr. No. 4510 C.S.lye 40.00 0.273 48 0.131 0.0033 0.20 0.30 0.10 33.0 3.9 To ETP Sr. No. 4511 sulphuric acid 98.00 0.5 98 0.470 0.0048 0.25 0.44 0.19 42.9 18.4 To ETP Sr. No. 4512 Sodium Bicarbonate 84.00 0.015 98 0.015 0.0002 0.02 0.02 100.0 1.3 To ETP Sr. No. 4513 Methanol 32 0.63 99 0.624 0.0195 0.50 1.78 1.28 71.9 40.9 To ETP Sr. No. 4514 toluene 92 4.805 99 4.757 0.0517 4.71 4.71 100.0 433.6 Recoverd & Recycle sr. No. 3715 thionyl chloride 119 1.6 99 1.549 0.0130 0.75 1.19 0.44 36.8 52.0 To scrubber in the form of SO2 & HCl16 DMF 73 0.013 99 0.013 0.0002 0.02 0.02 100.0 1.2 To Residue sr. no. 49 17 m‐phenoxy benzaldehyde 198 0.6 99 0.565 0.0029 0.18 0.26 0.08 30.8 15.9 To ETP Sr. No. 4518 sodium cyanide 49 0.22 99 0.218 0.0044 0.18 0.41 0.23 55.6 11.0 after treatment To ETP Sr. No. 4519 soda ash 106 0.018 98 0.018 0.0002 0.02 0.02 100.0 1.6 To ETP Sr. No. 4520 TEBA 227.7 0.024 98 0.024 0.0001 0.01 0.01 100.0 2.1 To ETP Sr. No. 4521 Acetic acid 60 0.005 98 0.005 0.0001 0.01 0.01 100.0 0.4 To ETP Sr. No. 4522 Hypo 74.5 1.820 10 0.182 0.0024 0.22 0.22 100.0 16.6 For treatment Sr. No. 18 & To ETP sr. no 45 23 Isopropyl alcohol 60.1 6.450 99 6.386 0.1062 9.69 9.69 100.0 582.1 Recoverd & Recycle sr. No. 3924 TEA 101 0.232 99 0.230 0.0023 0.21 0.21 100.0 20.9 Recoverd & Recycle sr. No. 4125 Activated carbon 12 0.005 99 0.005 0.0004 0.04 0.04 100.0 0.004 To ETP sludge as per sr. no. 43 26 hypo super cell 0.005 99 0.005 0.004 To ETP sludge as per sr. no. 43 27 22% c.s.lye 40 4.790 22 1.054 0.0263 1.00 2.40 1.40 58.4 56.1 as per sr. no. 3528 water 18 31.827 100 31.827 1.7682 161.18 161.18 100.0 2901.2 To ETP Sr. No. 4529 Sodium thiosulphate 0.050 99 0.050 0.00 0.0 For HBr Scrubber

Total 91.65

Out Put

30 Deltamethrin technical 505 1.000 98 0.98 0.00194 0.5 0.15 Final product

3116% Aq. Soln of Cat‐V recover & recycle

201.7 7.864 16 1.25824 0.00 Recoverd & Recycle sr. No. 332 HBr solun. 81 7.94 20 272 0.00 For Bromine recovery Sr. No.8

33Methylene dichloride recover & recycle 84.9 13.059 0 0.00 Recoverd & Recycle sr. No. 4

34 MDC loss 0.465 286 0.0035 22% sodium sulphite solution 142.00 5.629 22 1 0.00 TO TEE36 30% HCl 36.50 1.597 30 0 0.00 Reover & recycle 37 toluene Recover & recycle 92.00 4.8 0 0.00 Reused for other product38 Toluene loss 0.096 0 0.00

39iso propyl alcohol recover & recycle

60.10 6.324 0 0.00 Recoverd & Recycle sr. No. 2340 IPA loss 0.166 0 0.0041 TEA recover & recycle 101.00 0.22 0 0.00 Recoverd & Recycle sr. No. 2442 TEA loss 0.012 0 0.0043 Hyflow + carbon waste 0.002 0 0.00 To ETP and removed as ETP sludge44 DM ML 0.45 0 0.0045 Aqueous mass 33.9 0 0.0046 ss CMAC 227.5 2.075 99 2 0.0090 0.5 3.16 Secondary Product for Sale47 Benzene recycle 78 0.36 Recoverd & Recycle sr. No. 648 Bromo benzene 157 4.4 By product49 Residue 0.55850 1st cut 0.274 Recoverd & Recycle sr. No. 651 Loss 0.454

91.65

Qty. Kg Mole / Mole ratio

(3) Process of Diclorovos Technical:

Flush the reactor with Nitrogen & Charge the Chloral in Reactor. Add TMP (Trimethyl Phosphate) by maintaining the temperature 45‐500c by circulating the chilled water. During the reaction methyl Chloride gas generated will be removed through vent condense and sent to Incinerator. Finally maintain the Temperature 900c and stripped the methyl Chloride traces by N2 purging. Cool the mass to room temperature and check the quality of Product and pack the material.



Chemical Reaction of Diclorovos Technical:

Cl3C-CHO + (OCH3)3P Tri Chloro Acetaldehyde Tri Methyl Phosphite M. Wt. : 147.5 M.wt. 124 Cl O OCH3 C=CHO-P + CH 3Cl Cl OCH3 DDVP Methyl Chloride (2,2 Di- Chloro Vinyl Di Methyl Phosphate) M. Wt. : 221 50.5

Mass Balance of Diclorovos Technical:

Dichlorvos technical material balance

Chloral 0.642 0.228 Methyl Chloride gas to incinerationTMP 0.586

1.0 Dichlorvos technical

Preparation of Dichlorvos technical

Mole Balance of Diclorovos Technical:

Qty. Kg Mole/Mole ratioRaw Material Mole.

Wt.As is kg

Purity%

Real(100 %

basis)

No. of Mole


% Excess

Excess Qty Kgs

Remarks

Sr. No. In put1 Chloral 147.5 0.642 99 0.636 0.00 1.00 1.00 0.00 0.24 02 TMP 124.00 0.586 99 0.580 0.00 1.00 1.09 0.09 8.12 11

Total 1.228

Out Put3 Dichlorvos 221 1.000 95 0.95 0.0043 1.0 1.004 Effluent 50.5 0.228 TO Incineration

Total 1.228



(4) Glyphosate Technical: Stage I

Manufacturing of Di Sodium salt of Imino Di Acetic Acid Di Ethanol Amine is reacted with Sodium Hydroxide in presence of Catalyst under pressure of nitrogen at an elevated temperature. This results into formation of Di Sodium Salt of Imino Di Acetic Acid along with liberation of hydrogen. The product is isolated and Catalyst is Recycled back in the next batch. The recycling of Catalyst is done ten times. Stage II

Manufacturing of Phosphono Methyl Imino Di Acetic Acid Di Sodium salt of Imino Di Acetic Acid is reacted with Formaldehyde and Phosphorus Trichloride at elevated temperature resulting into Phosphono Methyl Imino Di Acetic Acid. The product is isolated by filtration wet cake of PMIDA used for next stage. Stage III Manufacturing of Phosphono Methyl Glycine (Glyphosate) Phosphono Methyl Imino Acetic Acid slurry is prepared by addition of ammonia solution and Ammonia salt of ‐ Phosphono Methyl Imino Di Acetic Acid is further oxidized by molecular oxygen to Ammonia salt of Phosphono methyl Imino Acetic acid. Followed by pH adjustment by HCl addition & followed by further drying.

Chemical Reaction of Glyphosate:

Reaction chemistry C2H4OH Catalyst CH2COONa HN + 2NaOH HN +4H2 C2H4OH CH2COONa DEA DSIDA O CH2COONa HO CH2COOHNH + PCl3 +HCHO +3H2O P CH2N CH2COONa HO CH2COOH DSIDA PMIDA + NaCl + H2O



Mass Balance of Glyphosate:

P CH2 N

OHO

HO

CH2COOH

CH2COOH

PMIDA M.F=C5H10PO7NM.wt.=227

+ 1/2 O2catalyst

+NH3P CH2 NH

OHO

HOCH2COOH

Glyphosate M.F.=C3H8O5NPM.wt.=169



Mole Balance of Glyphosate:

(5) Process of Lamdacyhalothrin technical: Lambda acid is reacted with Thionyl chloride in presence of DMF as a catalyst to form lambda acid chloride which is further react with m‐phenoxy Benzaldehyde in presence of sodium cyanide ,phase transfer catalyst & n‐Hexane . The reaction mass is wash with soda ash solution and water. Finally n‐hexane is stripped off to get crude lambda cyhalothrin. Crude lambda cyhalothrin is epimerized to get lambda cyhalothrin technical.



Chemical reaction of Lamdacyhalothrin technical:

C=CH CH CH

CH3CH3

Cl

CF3

C

O

OH

lambda acid M.F.=C9H10O2F3ClM.wt.=242.5

+ SOCl2

thionyl chloride M.F.=SOCl2M.wt.=119

C=CH CH CH

CH3CH3

Cl

CF3

C

O

Cl

lambda acid chloride M.F.=C9H9OF3Cl2M.wt.=261

C=CH CH CH

CH3CH3

Cl

CF3

C

O

Cl

lambda acid chloride M.F.=C9H9OF3Cl2M.wt.=261

+ NaCN +

sodium cyanide M.F.=NaCNM.wt.=49

O

CHO

m-Phenoxy Benzaldehyde M.F.=C13H10O2M.wt.=198

n-Hexane catalyst

C=CH CH CH

CH3CH3

Cl

CF3

C

O

O C

H

CN

O

lambda cyhalothrin M.F.=C23H19O3NClF3M.wt.=449.5

+ NaCl



Mass Balance of Lamdacyhalothrin technical:



Mole Balance of Lamdacyhalothrin technical:

(6) Process of Permethrin technical: Cypermethric Acid Chloride (CMAC) reacts with Meta Phenoxy Benzyl Alcohol (MPBAL) at 70°C to 80°C to give Permethrin. The evolved HCL gas during reaction is scrubbed in water. The reaction mass is washed with Potassium Carbonate solution to remove the dissolve HCl gas. Permethrin is dehydrated under high vacuum to remove traces of water. The purity of the Technical product Permethrin obtained will be minimum 92 %.



Chemical reaction of Permethrin technical:

Mass balance of Permethrin technical:

233 Water

CMAC 620MPBAL 520Water 1250Potassium Carbonate 15

2638

333 HCl 30 %1260 Waste Water

1045 Crude Permethrin

45 Distilled Water

1000 Kg Permethrin

Stage ‐ 2 Dehydration

Stage ‐ 1 Reaction & Washing

Scrubber 30 % HCl

All quantities are in Kgs



Mole balance of Permethrin technical

Sr.No Raw Material Mole.Wt As is kg Purity% Real(100 % basis)

No. of Mole


% Excess Excess Qty Kgs

Remark

In put1 CMAC 227.5 620 98 607.6 2.67 1.00 1.14 0.14 11.9 30.7 To Effluent at Sr.No 82 MPBAL 200.00 520 98 509.6 2.55 1.00 1.08 0.08 7.7 16.6 To Effluent at Sr.No 83 Pottasium Carbonate 138.2 15 99 14.85 0.11 0.04 0.05 0.01 0.0 0.0 To Effluent at Sr.No 84 Water 18 1250 100 1250 69.44 29.51 29.51 100.0 531.3 Used for washing5 Water for scrubber18 18 233 100 233 12.94 5.2 5.50 0.30 5.5 5.4 To Scrubber for HCl scrubbering

Total 2638

Out Put6 Permethrin 391 1000 92 920 2.35 1.0 0.927 HCl (30%) 36.5 333 30 99.9 2.74 1.0 1.16 0.16 14.0 6.0 To effluent treatment Plant8 Effluent 18.00 1305 1305 72.50 To effluent treatment Plant

Total 2638

Qty. Kg Mole/Mole ratio

(7) Process of Temephos: Thiodiphenol is react with O,O‐Dimethyl thiophosphoryl chloride in basic condition in presence of Solvent to form Temephos technical. Then wash with water & recover solvent to get Temephos technical .

Chemical reaction of Temephos:

Thio di phenol O,O‐Dimethyl thiophosphoryl chloride M.F.=C12H10SO2 M.F.=C2H6ClPSO2M.wt.=218 M.wt.=160.5

Temephos sodium chloride water M.F.=C16H20O6P2S3 M.F.=NaCl M.F.=H2OM.wt.=466.5 M.wt.=58.5 M.wt.=18

SHO OH + POCH3

OCH3Cl

S

2

2 NaOH/MDCTEBA

SO O POCH3

OCH3

S

P

SH3CO

H3CO+ 2NaCl + 2H2O



Mass Balance of temephos:

C.s. lye (47%) 0.436 Water 1.470 Thio di phenol 0.490 DMTC 0.779 TEBA 0.0245 Methylene dichloride 0.828 4.027 reaction mass Water 0.980 2.199 Aqueous mass Sodium dithionite 0.0024 0.982 Aqueous mass 1.828 organic mass 0.745 MDC recover 0.083 Loss 1.000 Temephos

technical

Preparation of Temephos technical at 30‐34°C

Layer separation & water washing

Solvent recovery

Mole balance of temephos:


Raw Material Mole.Wt.

As is kg

Purity%

Real(100 % basis)

No. of Mole


% Excess

Excess Qty Kgs

Remarks

Sr. No. In put1 Thiodiphenol 218 0.49 98 0.480 0.00 1.00 1.08 0.08 7.55 18 To ETP Sr. No. 92 DMTC 160.50 0.779 99 0.771 0.00 2.00 2.36 0.36 15.24 58 To ETP Sr. No. 93 C.S.lye 40 0.436 47 0.205 0.01 2.00 2.52 0.52 20.50 21 To ETP Sr. No. 94 water 18 2.450 99 2.426 0.13 66.17 66.17 100 1191 To ETP Sr. No. 95 TEBA 0.025 To ETP Sr. No. 96 Methylene

dichloride0.828 Recover & recycle In sr.

No.107 Sodium dithionate 0.002 To ETP Sr. No. 9

Total 5.01

Out Put8 Temephos 466.5 1.000 95 0.95 0.0020 1.0 0.929 Effluent 18 3.181 TO ETP10 Methylene

dichloride 0.745 Recover & recycle In sr.

No.611 loss 0.083

Total 5.01



(8) Process of Tricyclozole: 4 HMBT is react with formic acid at elevated temperature to form precipitated of Tricyclozole. Then filter precipitated & wash with water followed by drying to obtain Tricyclozole.

Chemical Reaction of Tricyclozole:

CH3

N

S

C NHNH2

2-Hydrogeno-4-Methyl Benzothiazole M.F.= C8H9SN3M.wt.=179

+ HCOOH

Formic acid M.F.=CH2O2M.Wt.=46

CH3

N

S

C

Tricyclazole M.F.= C9H7SN3M.wt.=189

CHN

N + 2H2O

Mass Balance of Tricyclozole:

4‐HMBT 1.000 Formic acid 0.760 Reaction mass 1.760 Water 7.660 NaOH (20%) solution 0.406 Reaction mass 8.826 Water 2.000 0.100 Loss 10.216 Aqueous mass to

MEE Wet cake 1.510 0.510 Evaporation loss Tricyclazole 1.00 (95%)

Preparation of Tricyclazole at 110°C

Water dumping & adjust pH 4‐4.5

Filtration & washing

Drying at 100°C



Mole balance of Tricyclozole:

Qty. Kg Mole/Mole ratioRaw Material Mole.

Wt.As is

kgPurity

%Real(10

0 % basis)

No. of Mole


% Excess

Excess Qty Kgs

Remarks

Sr. No. In put1 4-HMBT 179 1.00 98 0.980 0.01 1.00 1.09 0.09 8.19 16 To ETP Sr. No. 62 Formic acid 46.00 0.76 99 0.752 0.02 1.00 3.25 2.25 69.27 104 To ETP Sr. No. 63 Sodium hydroxide 40 0.406 47 0.191 0.00 0.80 0.95 0.15 15.71 6 To ETP Sr. No. 64 water 18 8.660 99 8.573 0.48 94.76 94.76 100 1706 To ETP Sr. No. 6

Total 10.826

Out Put5 Tricyclazole

technical 189 1.000 95 0.95 0.0050 1.0 0.92

6 Effluent 18 9.216 TO TEE7 Evaporation loss 0.610

Total 10.826

(9) Process of Acephate:

DMPAT in MDC as solvent is ‘Isomerizes’ by aid of Di methyl Sulphate (DMS) to give Methamidophos (MMP). This MMP is then further ‘Acetylated’ by Acetic Anhydride to yield Acephate. This reaction generates Acetic Acid, which is neutralized by Ammonia solution. The neutralized mass is then further extracted repeatedly with MDC. The aqueous layer generated contains ‘Ammonium Acetate and is incinerated. The organic mass obtained is fed to MDC recover unit. MDC is recovered by atmospheric and vacuum distillation. This recovered MDC is recycling back in the process. The residual mass of the distillation is carried forward for Acephate recovery by crystallization. Ethyl Acetate is added to the residual mass and crystallized to get Acephate. The wet Acephate thus obtained from filtration is further dried in rotary vacuum dryer. The mother liquor obtained from filtration is further used to recover Ethyl Acetate under vacuum. The Ethyl Acetate recovered is recycled back in the process. The residue obtained after Ethyl Acetate recovery is incinerated.

Chemical reaction of Acephate: Chemical Reaction :

Isomerism :

DMS

(CH3O)2P(S)NH2 (CH3O)(CH3S)P(O)NH2

DMPAT Methamidophos

Acetylation :

(CH3O)(CH3S)P(O)NH2+ (CH3CO)2O (CH3O)(CH3S)P(O)NHCOCH3 +CH3COOH Methamidophos Acetic Anhydride Acephate Acetic Acid

Neutralization:

CH3COOH + NH3 CH3COONH4

Acetic Acid Ammonia Ammonium Acetate



Mass Balance of Acephate:

Mole Balance of Acephate:

Raw Material Mole.Wt. As is kg Purity%Real(100 % basis)



Excess Qty Kgs Remarks

Sr. No. In put1 DMPAT 141 1.18 95 1.121 0.01 1.00 1.50 0.50 33.40 71 To ETP Sr. No. 102 AC2O 102.00 0.96 99 0.950 0.01 1.00 1.76 0.76 43.17 77 To ETP Sr. No. 103 DMS 126 0.12 98 0.118 0.00 0.18 0.18 100.00 22 To ETP Sr. No. 104 Sulphuric acid 98 0.04 98 0.039 0.00 0.08 0.08 100.00 7 To ETP Sr. No. 105 ammonia 17 0.22 99 0.218 0.01 2.42 2.42 100.00 41 To ETP Sr. No. 106 Methylene dichloride 85 11.535 99 11.420 0.1 25.37 25.37 100.00 2157 Recover & Recycle Sr. No. 127 Ethyl acetate 88 1.96 99 1.942 0.0221 4.17 4.17 100.00 367 Recover & Recycle Sr. No. 138 water 18 1.240 99 1.228 0.07 12.88 12.88 100 232 To ETP Sr. No. 10

Total 17.26

Out Put9 Acephate 183.2 1.000 97 0.97 0.0053 1.0 0.67 Main product10 Effluent 18 2.510 To ETP Sr. No. 1011 Organic residue 0.330 incinerator 12 Methylene Dichloride R 10.946 Recover & Recycle Sr. No. 613 Ethyl acetate R 1.577 Recover & Recycle Sr. No. 714 Evaporation loss 0.900

17.26




(10) Process of Hexaconazole:

2,4‐dichloro valerophenone is made to react with dimethyl sulphate and potassium hydroxide in presence of dimethyl sulphide to give Oxirane. Solvent dimethyl sulphide is recovered by distillation and the Oxirane is separated from the reactor. Then water is adding to the reactor to dissolve salt from during the reaction and transferred to ETP. In dimethyl formamide, potassium carbonate, 1,2,4‐triazole is added and then the above prepared Oxirane is added at reflux temperature. After completion of the reaction the mass is filtered and then solvent DMF is distilled out. Then the product Hexaconazole is isolated by adding water . the slurry is filtered, centrifuge and dry. The filtered potassium carbonated is washed with DMF to recovered product.

Chemical reaction of Hexaconazole:

Stage‐1 preparation of Oxirane

2,4‐dichloro valerophenone 2‐Butyl‐(2,4‐Dichloro phenyl) Oxirane M.F.=C11H12Cl2O M.F.=C12H14Cl2O M.wt.=231 M.wt.=245

Stage‐2

Preparation of Hexaconazole

Cl

Cl

C

O

(CH3)2S/(CH3)2SO4(CH3)2S/

/KOH

Cl

Cl

CO

K2SO4+H2O

CCl

Cl

+

K2CO3

2-Butyl-2-[2,4 Dichloro Phenyl] OxiraneM.F.=C12H14Cl2OM.wt.=245

O

1,2,4-Triazole M.F.=C2H3N3M.wt.=69

Hexaconazole M.F.=C14H17Cl2ON3M.wt.=314

Cl

Cl

COH

CH2

N

NN

(CH2)3CH3

N

N N



Mass Balance of Hexaconazole:

2,4‐Dichloro valerophenone

0.950

Dimethyl sulfite (DMS) 1.577 1.262 DMS Recover & recycle Water 0.081 0.275 Loss Dimethyl sulphate (DMSO4)

0.836

Potassium hydroxide 0.913 Reaction mass 2.820 Water 5.712 Reaction mass 8.532 0.035 Loss 7.500 Aqueous mass Oxirane 0.997 (95%) DMF 3.488 Anhydrous K2CO3 0.082 1,2,4‐Triazole 0.327 Reaction mass 4.894 . 0.095 K2CO3 wet cake 0.030 Loss Reaction mass 4.769 3.138 0.170 Loss Residual mass 1.461

Methanol 0.985 1.526 Mother liquorMethanol for washing 0.140 0.060 Loss 0.045 loss methanol rec.1.08 Hexaconazole 1.00 (purity=92%) Residue 0.404

Preparation of Oxirane

Water dumping at 65‐70°C

Filtration and layer separation at 65‐70°C

Preparation of Hexaconazole at 135‐138°C

Filtration at 50°C

DMF recovery under vacuum

Heat to 60°C and Crystallization at 10°C

Methanol recovery



(11) Process of Imidacloprid: Imidacloprid is prepared by reaction of 2‐Chloro‐5‐chloromethylpyridine in presence of solvent and Nitroiminoimidazolidine with anhydrous potassium carbonate. After the completion of reaction to remove the formed salt by adding water. Then cool the reaction mass to 15‐20°C and filter it to obtain Imidacloprid.

Chemical reaction of Imidacloprid:

NC l

C H 2 C l

2 - C h l o r o - 5 - C h l o r o m e t h y l P y r i d i n e

M o l . W t . 1 6 2

+NH N H

N NO 2

N i t r o i m i n o i m i d a z o l i d i n e

M o l . W t . 1 3 0

N

CH 2

C l

N N H

N NO 2

I m i d a c l o p r i d

M o l W t . = 2 5 5 . 5

+

K 2 CO 3

KCl + KHCO 3

M e t h y l E t h y l K e t o n e

Mass Balance of Imidacloprid:

Methyl ethyl ketone 6.400

Nitro imino imidazolidine 0.840

Anhydrous K2CO3 1.200

2‐chloro‐5‐chloro methyl pyridine

1.000

Reaction mass 9.44

Water washing 5.000 6.450 Aqueous mass

Reaction mass 7.99

3.150 Methyl ethyl ketone

Preparation of imidacloprid

Water washing

Distillation of Methyl ethyl ketone



recover

0.050 Distillation Loss

Reaction mass 4.79

0.01 Loss

3.58 Mother liquor

3.10 MEK (r)

1.2 Wet cake of imidacloprid 0.100 loss

0.38 Residue

1.0 Imidacloprid technical

Mole Balance of Imidacloprid:





Sr. No. In put1 2-chloro-5-chloro methyl pyridine 162 1.000 99 1.0 0.01 1.00 1.66 0.66 39.8 107 To ETP sr. no. 72 Nitro imino imidazolidine 130.00 0.84 99 0.8 0.01 1.00 1.74 0.74 42.5 96 To ETP sr. no. 73 anhydrous pottasium carbonate 138 1.2 98 1.176 0.01 1.00 2.32 1.32 57 182 To ETP sr. no. 74 Methyl ethyl ketone 72 6.4 26 1.664 0.02 1.00 6.28 5.28 84 380 Recover & recycle in sr. no. 45 water 18 5.000 99 4.95 0.28 74.75 74.75 0 1345 To ETP sr. no. 7

Total 14.440

Out Put6 Imidacloprid Technical 255.5 1.000 94 0.94 0.00368 1.0 0.60 Main Product7 Effluent 18 6.45 TO ETP sr. no.78 Methyl ethyl ketone 6.45 12 Recover & Recycle in sr. no.49 loss 0.1610 Residue 0.38 incineration

Total 14.44


(12) Process of Profenophos: O‐Chloro Phenol is reacting with Bromine to give 4‐Bromo‐2‐Chloro Phenol and Hydrogen bromide is Liberated as by‐product which is scrub in water.4‐bromo‐2‐chloro phenol is further reacting with O,O‐diethyl thio phosphoryl chloride in alkaline media to give O,O‐diethylthiophosphor ‐2‐chloro‐4‐Bromo Phenol.

O,O‐diethylthiophosphor ‐2‐chloro‐4‐Bromo Phenol is reacting with trimethyl amine to form Q‐salt, which is further react with n‐propyl bromide to form Profenophos and solvent n‐propyl bromide is recovered to give pure profenophos.

Crystallization & filtration

Solvent rec.

Drying



Chemical reaction of Profenophos:

OHCl

2-Chloro Phenol M.F= C6H5OClM.wt.=128.5

+ Br2

BromineM.f.=Br2M.wt.=160

OHCl

Br

+ HBr

4-bromo 2-ChloroPhenol M.F.=C6H4OClBrM.wt.=207.5

Cl

Br4-bromo 2-ChloroPhenol M.F.=C6H4OClBrM.wt.=207.5

OH

+ P-(OC2H5)2

S

Cl

Diethyl thio phosporyl Chloride M.F. =C4H10O2ClSM.wt.=188.5

Cl

Br

M.F.=C10H13O3ClBrPSM.wt.=359.5

OP-(OC2H5)2

S

O,O-Diethyl thio phosphor-2-Chloro-4-Bromo Phenol



Br

ClO P

SOC2H5

OC2H5

O,O-Diethylthio phosphoro-2-chloro-4-bromo phenolM.F.:-C10H13O3ClBrPSM.wt.:-359.5

+ N(CH3)3

Trimethyl amineM.F.:-C3H9NM.wt.:-59

Br

ClO P

O

OC2H5

SN(CH3)3

C2H5

Q-Salt M.F.:-C13H22NSO3PBrClM.wt.:-418.5

Br

ClO P

O

OC2H5

SN(CH3)3

C2H5

Q-Salt M.F.:-C13H22NSO3PBrClM.wt.:-418.5

+ C3H7Br

n-Propyl BromideM.F.:-C3H7BrM.wt.:-123

Br

ClO P

O

OC2H5

Profenophos M.F.:-C11H15SO3PBrClM.wt.:-373.5

SC3H7

+N(CH3)3HBr

M.wt.:-140

Trimethyl amine Hydrogen bromide

+C2H5OH

ethanol

M.wt.:-46

+ H2O

Mass balance of Profenophos:



1.24 water 2‐chloro phenol 0.535 0.310 HBr gas ZnCl2 0.007 0.006 loss Bromine 0.660 1.51 20% HBr solution Reaction mass 0.866Water 0.300 0.330 Aqueous mass to ETPDETC 0.784 0.006 Loss Reaction mass 1.634TEBA 0.0057 26% C.S. solution 0.650 Reaction mass 2.290 Water washing 1.000 1.840 Aqueous mass to MEE Reaction mass 1.450 30% Trimethyl amine solution

1.000

HCl (30%) 0.050 Reaction mass 2.500 n‐propyl bromide 1.540 TEBA 0.0006 reaction mass 4.040 Water 1.000 3.730 Aqueous mass Reaction mass 1.310 0.300 n‐propyl bromide recover 0.010 Loss 1.00 Profenophos Technical

ScrubberPreparation of 4‐Bromo‐2‐chloro phenol

Preparation of 4‐Bromo‐2‐chloro phenol

Preparation of O,O‐Diethyl thio phosphoro‐2‐chloro‐4‐bromo phenol

Water washing & layer separation

Preparation of Q‐salt

pH adjustment

Preparation of profenophos

Water washing

n‐propyl bromide recovery under vacuum



Mole Balance of Profenophos:





Sr. No. In put1 2-chloro phenol 128.5 0.535 99 0.5 0.00 1.00 1.62 0.62 38.3 80 To ETP sr. no. 12 2 bromine 160.00 0.66 99 0.7 0.00 1.00 1.61 0.61 37.7 97 To ETP sr. no. 12 3 DETC 188.5 0.784 70 0.5488 0.00 1.00 1.14 0.14 13 27 To ETP sr. no. 12 4 C.s. lye 40 0.65 26 0.169 0.00 1.00 1.66 0.66 40 26 To ETP sr. no. 12 5 Zinc chloride 0.007 99 0.00693 0.00 0.00 0 0 To ETP sr. no. 12 6 TMA solution 59 1.000 30 0.3 0.0 1 2.00 1.00 50 59 To ETP sr. no. 12 7 n-Propyl bromide 123 1.540 99 1.5246 0 1 4.87 3.87 79 476 To ETP sr. no. 12 8 water 18 3.540 99 4 0 76.55 76.55 100 1378 Recover & recycle in sr. no. 79 HCl 30 0.050 99 0.0495 0 0.5 0.65 0.15 23 4 To ETP sr. no. 12 10 TEBA 0.006 99 0.006237 0.00 0.00 0 To ETP sr. no. 12

Total 8.772

Out Put11 Profenophos Technical 373.5 1.000 95 0.95 0.00254 1.0 0.62 Main Product12 Effluent 18 5.91 TO ETP sr. no.1213 HBr Solution 1.51 12 for Bromine recovery14 Handling loss 0.02215 N-propyl Bromide 1 0.3 Recover & Recycle in sr. no.7

Total 8.742




ANNEXURE: 4

Water requirement letter from Notified industrial estate:



ANNEXURE: 5

Quantity of waste water (liquid waste) generated and its management:

Sr. No.

Particulars Existing Proposed After Proposed expansion

1 Domestic 2.0 8.0 10.0 2 Processing , washing &

scrubber 4.039 79.96 84.0

3 Cooling 1.0 1.0 2.0 4 Boiler 1.0 19.0 20.0 5 Floor/equipment/container

washing 10.0 10.0 20.0

6 Others 0 3.0 3.0 7 Total 18.039 120.96 139.0 8 Total industrial 16.039 112.96 129.0 9 Mode of Disposal 10 Septic tank/soak pit 2.0 8.0 10.0 11 ETP to CETP 15.387 53.812 69.2 12 MEE 0.652 37.048 37.7 13 Proposed Incineration

system 0 22.1 22.1

Note: The generated waste water will segregated, concentrated (high TDS) effluent will be treated in MEE, High COD/NH3 will be incinerated in proposed incineration system & normal effluent will be treated in the primary, secondary & tertiary ETP and will be discharged through GIDC underground drainage to CETP. The details of the same is given below;



Details of Effluent Treatment Plant • Design Criteria : • Product : Pesticides technical • Source of Effluent : Process, washing & Utilities. • Design Flow of Effluent : 70 KL/day Max. • Design Parameters : As under • Effluent Characteristics:

No Parameters Concentrated effluent (High COD/NH3‐N)

Concentrated effluent

(High TDS)

Combined Normal effluent

Treated effluent

CETP inlet norms

EPA norms

1 pH 4‐5 7‐8 6.0‐7.0 7.5 6.5‐8.5 6.5‐8.5 2 Color pt. Co 500 200 600 50 <100 <100 3 TDS mgl 8% 20% 4000‐5000 4000‐

5000 ‐ ‐

4 S/S mgl 150‐200 300‐400 300‐400 70‐80 <100 <100 5 Oil/grease mgl 1.3 2‐3 5.6 1‐2 <10 <106 BOD mgl 5000 3000 3000 70‐80 <400 <100 7 COD mgl 2,00,000 15000‐20000 9500 200‐250 <1000 <250 8 NH3‐N mgl 20,000 70‐80 50‐60 10‐12 <50 <509 Phenolic

compound mgl 0.6 2‐3 1.2 0.16 <1 <1

10 Sulphide mgl 5‐6 3‐4 1‐2 ND <2 <2 12 Mode of treatment Incineration MEE PST ETP

Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install:

Sr.No. Name of the unit Dimensions in meter Capacity in m3

1. Oil and grease trap 5.04 x 1.7x 1 8.568 2. Collection tank.1 3.26 x 2.4 x 2.47 19.3 3. Collection tank.2 3.3 x 2.35 x 2.43 18.8 4. Collection tank.3 3.2 x 2.33 x 2.44 18.3 5. Collection tank.4 3.2 x 2.38 x 2.39 18.6 6. Effluent transfer pump 15 hp 50 7. Equalization cum neutralization tank. 3.8 x 3 x 2.5 28.5

8. Primary settling tank. 3.8 x 3 x 1.461/3 x 3.8 x 3 x1.90

16.647.37

9. Bio‐reactor 12.5 x 7.7 x 5.7 548 10. Secondary settling tank. 3.8 x 3 x 1.46

1.3 x 3.8 x 3 x 1.94 16.64 7.3

11. Holding tank.1 Holding tank.2

2.1 x 1.75 x 1.85 2.84 x 1.76 2.7

13.4 6.7

12. Floculator 0.63 Ø x 1.5 ht 1.8 13. Lamella settling tank. 1.4 Ø x 1.3 x 1.6 2.9 14. Pressure sand bed filter 1 m Ø x 2 m ht. 1.5 16. Activated carbon filter 1 m Ø x 2 m ht. 1.5 17. Final outlet tank. Sintex tank 5kl



EFFLUENT TREATMENT SCHEME FOR NORMAL EFFLUENT

1. PRIMARY TREATMENT: UNITS: Oil & Grease removal Tank Collection cum Neutralization Tank Primary settling and sludge removal The effluent coming from the plant is initially passed through the Oil & Grease removal system. The oil free effluent is then collected into the collection cum reaction tank. In the collection cum reaction tank various chemicals like None Ferric Alum, Caustic soda/acid and polyelectrolyte (coagulant) are added to ensure proper settling which reduces the suspended solid concentration, colour and COD in the effluent. The treated effluent is then fed into the primary clarifier. Clear effluent from primary settling tank is charged into the secondary treatment tank (Aeration tank) and settled sludge is discharged into the sludge drying beds and leached of the sludge drying beds is going back to collection tank. 2. SECONDARY TREATMENT (BIOLOGICAL TREATMENT): UNITS: Aeration Tank Secondary settling The primary treated clear effluent is passed through the aeration tank where the biodegradation of the organic matter is taken place in presence of active microorganism and required Dissolved Oxygen level. During the biological treatment BOD Value and COD Value are reduced. After the biological treatment (aeration tank) the effluent with the biomass is passed through secondary settling tank where biomass is settled and settled biomass is recycle back to aeration tank or if excess is discharged into the sludge drying beds. And clear effluent is collected into the holding tank. 3. TERTIARY TREATMENT: UNIT: Sand and Carbon Filter (Mixed bed) After secondary treatment the effluent is passed through the mixed bed filter for further reduction of COD Value, BOD Value and Colour. Treated water is collected into the treated water tank above the roof. Finally the treated effluent confirming the treated water discharge norms laid down by board will be discharged for plantation or into the drainage to CETP as and when permitted.



FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT FOR NORMAL EFFLUENT STREAM



PROCESS OF SOLVENT STRIPPER & MULTI EFFECT EVAPORATOR FOR HIGH TDS EFFLUENT STREAM

Plant Configuration Part – A: Stripper Unit with Flash Condenser, Re‐boiler and Recirculation Pump Part – B: Forced Circulation Evaporation Plant with Thermo Compressor Part – C: Agitated Thin Film Dryer PROCESS DESCRIPTION (Part – A) • Feed will enter a series of Pre-heaters of Evaporator: P4, P3, P2 and then P1 using Feed Pump.

From discharge of feed pump, feed will be heated through series of preheater using vapour from jacket of respective Calandria. Feed will be heated to the boiling point and will enter to the recirculation loop of Stripper.

• Recirculation Loop of Stripper will comprise of Flash Vessel, Recirculation Pump and Reboiler. • Feed coming out from Preheater of Evaporation Plant will be recirculated through reboiler and

heated up using Steam. • Heated Feed will be allowed to flash in Flash Vessel and by flashing high volatiles and water will

convert in vapour. Vapour will travel from bottom to top of Stripping column where feed liquid will flow from top to bottom. Random packing inside the stripping column shall provide mass transfer surface to vapor liquid interface.

• Rich organic vapour with some water vapour will come out from the top of Stripper column. This vapour will be condensed in Flash Condenser at the top of Stripper column.

• Condensed organic rich liquid will be collected in Reflux pot from condenser. From Reflux pot partly it will be withdrawn according to the desired Water Vapour/ Organic ratio and remaining will enter to the column as reflux.

PROCESS DESCRIPTION (Part ‐ B)

• Feed will enter to the Evaporation Plant from Discharge of recirculation pump of stripper. • First Effect is a Forced Circulation Type comprising of Calandria‐1, Vapour Separator‐1 and

Recirculation Pump – 1. Liquid will recirculate continuously through Calandria Tubes at high velocity and will get heated using Heat of Condensation of First Effect Jacket. This Heated Mass will be allowed to flash in Vapour Separator and Water Vapour will be generated.

• This Flash Vapour will be partly recompressed to the Jacket of First Effect using Thermo compressor which will convert high pressure motive steam to low pressure and will create suction and take a part of the generated water vapour from Vapour Separator ‐1.

• Condensate from Jacket of First Effect will travel to 2nd Effect using pressure difference available between these two Jackets.

• Concentrate coming out from 1st Effect will be sent to Balance Tank‐2 which will be placed between 1st and 2nd Effect.

• Second Effect also is a Forced Circulation Type comprising of Calandria‐2, Vapour Separator‐2 and Recirculation Pump – 2. Liquid will recirculate continuously through Calandria Tubes at high velocity and will get heated using Heat of Condensation of Second Effect Jacket. This Heated Mass will be allowed to flash in Vapour Separator and Water Vapour will be generated.

• Flash Vapour will come out from Vapour Separator ‐2 and will be utilize as



heating media for 3rd Effect. • Condensate from Jacket of 2nd Effect will travel to 3rd Effect using pressure

difference available between these two Jackets. Condensate will be taken out from plant using condensate outlet pump and send for storage.

• Concentrate coming out from 2nd Effect will be below saturation level and there will not be any crystallization taking place in 2nd effect.

• Concentrate from Evaporation will be taken out from the Plant using Concentrate Outlet Pump and send to Settler.

• Water Vapor from Last Effect will be condensed in surface type condenser using Cooling Water as condensing media. Steam Jet Ejectors/ Water ring Vacuum Pump will maintain vacuum in the plant back to the condenser.

Process Description (Part – C)

• Treated Feed will enter the Storage Tank. • Feed will not be required to preheat as it will come from the tank. • Feed will enter the Vertical ATFD first for initial evaporation and then it will be

splashed to the Heat Transfer Surface of ATFD using liquid distributor. • V‐ATFD will be a hollow cylindrical Jacketed Vessel having Agitator

and specially designed Scrapper blades to wipe out the Surface of ATFD to keep it clean. This will maintain consistent performance of ATFD for a long time.

• ATFD Scrapper will rotate at medium RPM using Gear Box for reduction of RPM which will be govern by Variable Frequency Drive.

• ATFD Heat Transfer Surface will be heated through Steam in Jacket. Vapour outlet will be connected with Entrainment Separator to avoid product contamination in Condensate.

• Vapour will be condensed in Condenser and Negative draft will be maintained by Water Ring Vacuum Pump.

• Product will come out from bottom of Vertical ATFD. Steam will be applied in Jacket of same to allow the product dry.

Conclusion :‐ In general when Dried Feed comes out from the entire system, it shall be a cumulative mixture of all Solid Separated Mass, with content of moisture level less than 4%. The Solid Mass achieved will be in Lumps and Powdered form after the gelling and binding of the Solids.



DETAILS OF SOLVENT STRIPPER & MEE INSTALLED AT UNIT: I

Average hydraulic load, m3/day : 58.0 (38.0 from Unit: I + 20.0 from Unit: II)

Design hydraulic load, m3/day : 75.0

Sr. No. Particulars Size in meters Capacity in M3 MOC

1 Oil/Grease trap 1 x 1 X 0.2 0.2 m3 MS/Epoxy

2 Collection cum pH correction tank with air

diffuser

5 x 5 x 4.0 100 m3 RCC

3 Di. Acid/alkali dosing tank - 200 lits HDPE

4 Solvent stripper 0.3 Ø x 2.0 ht. 75 KLD SS 316

5 MEE Calndria:I 0.356 Ø x 0.844 Ht. 75 KLD SS 316

6 MEE Calndria:II 0.273 Ø x 0.836 Ht.

7 MEE Calndria:III 0.273 Ø x 0.836 Ht.

8 Agitated Thin Film Dryer (ATFD)

0.3 Ø x 2.7 ht. 7 TPD SS 316

9 Final holding tank for water from MEE

condensate & ATFD

5 x 5 x 4.0 100 m3 RCC

FLOW DIAGRAM OF MULTI EFFECT EVAPORATOR



DETAILS OF PROPOSED INCINERATION SYSTEM

Effluent quantity: 22.1 M3/day + Process Residue: (2.67 TPD from Unit: I + 0.670 TPD from Unit: II)

Capacity of Incinerator: 1500 Liters / hr liquid, 250 kg/hr residue.

Process: Thermal destruction of organic matter by heat transfer

Design Temperature: 1200oC

Operation temperature in primary chamber: 850oC

Applied HP : 21 HP

Control : manual with digital temperature digital indicator

Fuel consumption: 129 Kg/hr (LDO/FO) or 175 SCM/hr Natural gas

Combustion chamber:

(a) Primary chamber:

Material of construction: MS

Installation: Vertical Fired, Circular Refractory lined

Lining: Inside portion of chamber duly lined with fire bricks and fire insulation bricks

Maintenance & Ash Door: 01 no each

Combustion Burner: low air pressure burner, manually operated (03 nos.)

Operating Temperature‘: 8500C

(b) Secondary Chamber

Material of Construction: Mild Steel

Installation: Vertical Fired, Circular Refractory lined

Lining: Inside portion of chamber duly lined with fire bricks and fire insulation bricks .

Maintenance & Ash Door: 01 no each

Combustion Burner: low air pressure burner, manually operated (03 nos.)

Operating Temperature: 1100 0C

Liquid Spray Nozzle: Air atomized, external mix (03 Nos.)

Blower : 02 Nos. direct drive, 1400 to 1600 cfm

ID Fan: 01 No., 7000‐8000 cfm

Holding Tank: 16000 liters

Ventury Scrubber:

Type: Pressure Shower



Throat Diameter: 1140 mm X 1500 X 3300 Tower Height: 7000 mm Bottom Discharge: 500 mm Dia.

Stack: Conical Base, Guy Support, 30 m height 400 mm dia.

Measuring Equipment: Waste Water meter, Fuel meter, Power meter.

Sampling Port: 100 mm dia

FLOW DIAGRAM OF INCINERATION SYSTEM



ANNEXURE: 6

MEMBERSHIP CERTIFICATE OF CETP, VAPI



ACCEPTANCE LETTER OF CETP VAPI FOR ADDITIONAL EFFLUENT



MEMBERSHIP CERTIFICATE OF TSDF, VAPI & CHWIF, SEPPL, KUTCH



ANNEXURE: 7



ANNEXURE: 8

Copy of plot allotment letter issued by GIDC



COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA



ANNEXURE: 9

A Schematic Representation of the feasibility drawing



ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED

EXPANSION The utility emissions will be from the Steam Boiler of 5 Tons/Hr & 2 Tons/Hr. Natural gas (green fuel)/FO as fuel will be used in the Steam Boiler. Also we have installed a D.G. Set of 380 KVA & 620 KVA capacities to use in case of power failure and HSD shall be used as a fuel. From the existing plant SO2 & HCl gases are generated. For the scrubbing of these process gases, two stage water followed by alkali scrubber are provided to recover the valuable by products. After proposed expansion additional, two numbers are scrubbing system will be provided to scrub SO2, Br2 & HCl. Also we will provide ventury scrubber to the proposed incineration system. Details of which are as under;

Sr. No. Particulars Existing After Proposed

Expansion Remarks

1.0 Capacity of Steam boiler

5 TPH 5 TPH + 2 TPH One additional

1.1 Fuel Used Furnace oil/Natural gas

Furnace oil/Natural gas 1.2 Fuel Consumption 0.5 kl/hr

/650 SCM/hr 0.7 kl/hr

/910 SCM/hr 1.3 APC provided Chimney Chimney 1.4 Height/dia of

chimney 30 meters 30 meters x 2

2.0 Capacity of D G set

380 KVA (Standby) 1000 KVA (Standby) 2.1 Fuel Used HSD HSD 2.2 Fuel Consumption 15 liters/hr 40 lits/hr 2.3 APC provided Exhaust Exhaust 2.4 Height/dia of

Exhaust 11 meters 11 meters

3.0 Stack attached to Reactor of CMAC ( Chlorination of TBA with SOCl2)

Reactor ( Chlorination of TBA

with SOCl2)

Existing one

scrubber &

additional two

scrubber 3.1 APC provided Water followed by

alkali & ventury scrubber

Water followed by alkali & ventury scrubber

3.2 Height of vent 11 meters 11 meters 3.3 Expected emission SO2: < 40 mg/Nm3

HCl:<20 mg/Nm3 SO2: < 40 mg/Nm3 HCl:<20 mg/Nm3

4.0 Stack attached to 0 Reactor of Deltamethrin ( Bromination of RR-CMA with HBr gas &

reaction with TC)

4.1 APC provided 0 Water followed by alkali & ventury scrubber



4.2 Height of vent 0 11 meters 4.3 Expected emission 0 HBr: < 5 mg/Nm3

HCl: <20 mg/Nm3 SO2: < 40 mg/Nm3

5.0 Stack attached to 0 Reactor of Lamdacyhalothrin

( Chlorination with TC & reactor of Permethrin )

5.1 APC provided 0 Water followed by alkali & ventury scrubber

5.2 Height of vent 0 11 meters 5.3 Expected emission 0 HCl:<20 mg/Nm3

SO2: < 40 mg/Nm3 6.0 Stack attached to 0 Incinerator 6.1 Fuel used 0 Furnace oil/natural gas 6.2 Fuel Consumption 0 129 kgs/hr or 175 SCM/Hr 6.3 APC provided 0 Ventury alkali scrubber 6.4 Height of vent 0 30 meters 6.5 Expected emission 0 PM: < 100 mg/Nm3

HCl:<20 mg/Nm3 SO2: < 40 mg/Nm3

NOx: < 25 mg/Nm3 NH3: < 175 mg/Nm3



DETAILS OF AIR POLLUTION CONTROL EQUIPMENTS

Sr. No. Name of the unit Size Nos.

1 Height of Scrubber (Packed column) 3 meter 22 Size of Scrubber 600 mm dia 23 MOC of Scrubber MS Graphite 24 Type of Packing Paul /ring 1 5 Height of Packing 2.5 meters 6 Height of Scrubber (Falling Film) 2.5 meters 67 Size of Scrubber 400 mm dia 8 MOC of Scrubber MS graphite lined 9 Size of Vacuum catch pot 630 lits 210 MOC of Scrubber MS graphite lined 211 Capacity of water circulation tank 15 KL 212 MOC Tank MS FRP 413 Capacity of water circulation Pump 6 m3/hr 414 Size of ventury 200 kgs/hr 215 MOC of condenser PP/FRP 216 Size of condenser 20 m2 217 MOC of condenser MS 18 Size of caustic circulation tank 15 KL 119 Capacity of circulation pump 54 m3/hr 220 Size of nutsch to filter sodium sulphite 2x2x1.5 meter 221 MOC of filter nutsch MS 2



FLOW DIAGRAM OF SCRUBBING SYSTEM

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