list of annexures sr. no. name of annexure i list of...

1

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of products with their production capacity and raw materials

II Layout Map of the Plant

III Brief Manufacturing Process Description with Chemical and Mass Balance

IV Details of Water Consumption & Wastewater Generation

V Effluent Treatment Scheme

VI Details of Hazardous /Solid Waste Generation, Handling and Disposal

VII Details of Air pollution Control System (Stack & Vent)

VIII Socio‐economic Impacts

IX Proposed Terms of Reference for EIA studies

X Plot Allotment Letter

XI Water Supply Letter

XII CETP Membership Certificate

XIII TSDF Membership Certificate

XIV Toposheet

2

ANNEXURE – 1

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr. No.

Name of the Products

CAS no. QUANTITY

(MT/MONTH) End-use of products

GROUP-11 Cypermethrin 52315-07-8

200.00

Agro Chemical

2 Meta Phenoxy Benzyl Alcohol (MPBA) 13826-35-2 Agro Chemical

3 Meta Phenoxy Benzaldehyde (MPBD) 39515-51-0 Agro Chemical

4 Para Bromo fluoro Benzene 460-00-4 Agro Chemical

5 Permethrin 52645-53-1 Agro Chemical

6 Styrenated Phenol 61788-44-1 Rubber Chemical

7 Tri ethyl benzyl ammonium chloride 56-37-1 Agro Chemical

8 D V Acid Chloride /CMAC 52314-67-7 Agro Chemical

GROUP-2

9 Meta Bromo Anisole 2398-37-0

100.00

Specialty Chemical

10 Meta Bromo Nitro Benzene 585-79-5 Specialty Chemical

11 N-Butyl Bromide 109-65-9 Specialty Chemical

12 Tetra Butyl Ammonium Bromide 1643-19-2 Specialty Chemical

13 N-Propyl Bromide 106-94-5 Specialty Chemical

14 1-Bromo 3 Chloro Propane 109-70-6 Specialty Chemical

15 ISO-Butyl Bromide 78-77-3 Specialty Chemical

16 4-Amino, 1,2,4 Triazole 584-13-4 Specialty Chemical

17 Para Nitro Benzyl Bromide 110-11-8 Specialty Chemical

18 N-Pentyl Bromide 110-53-2 Specialty Chemical

19 1,2-di bromo ethane 106-93-4 Specialty Chemical

20 Ethyl Bromide 74-96-4 Specialty Chemical

21 Tri Phenyl Phosphine 603-35-0 Specialty Chemical

22 Ethyl tri phenyl Phosphonium Bromide 1530-32-1 Specialty Chemical

23 Mono Bromo Acetic Acid 79-08-3 Specialty Chemical

24 N-Bromo Succinimide 128-08-5 Specialty Chemical

25 Diethyl, Dipropyl Malonate 6065-63-0 Specialty Chemical

3

Sr. No.

Name of the Products

CAS no. QUANTITY

(MT/MONTH) End-use of products

26 Methyl Tri Phenyl Phosphonium Bromide 1779-49-3 Specialty Chemical

27 1H-1,2,4 Triazole 288-88-0 Specialty Chemical

28 1,3 Dichloro Acetone 534-07-6 Specialty Chemical

29 Bromo Benzene 108-86-1 Specialty Chemical

30 Iso Propyl Bromide 75-26-3 Specialty Chemical

31 Tetra Ethyl Ammonium Bromide 71-91-0 Specialty Chemical

32 Meta Chloro Propiophenone 34841-35-5 Specialty Chemical

Group 3 Inorganic Products

33 Bromine 7726-95-6

100.00

Specialty Chemical

34 Sodium Bromide 7647-15-6 Specialty Chemical

35 Calcium Bromide 7789-41-5 Specialty Chemical

36 Zinc Bromide 7699-45-8 Specialty Chemical

37 Hydrobromic Acid 48% 106-93-4 Specialty Chemical

38 Calcium Chloride 7440-70-2 Specialty Chemical

39 Lithium Bromide 7550-35-8 Specialty Chemical

400.00

LIST OF RAW MATERIALS:

Sr. No. Name of Raw Materials Capacity

(MT/Month)

GROUP‐1

1 Cypermethrin 200

CMAC 112.4

MPB 97

Hexane 410.6

Sodium Cyanide 28

Catalyst 3

Soda Ash 3

Acetic Acid. 0.6

Hypochlorite 8

2 Meta Phenoxy Benzyl Alcohol 200

M‐phenoxybenzaldehyde 198

Hydrogen 2.46

Raney Nickel 9.78

Iso PropylAlcohol (IPA) 204.82

3 Meta Phenoxy Benzaldehyde 200

Benzaldehyde 200

4


(MT/Month)

Aluminium Chloride 159.2

Chlorine 69.2

Bromine 154.2

EDC 1401.8

Sodium Thio‐Sulphate 4.4

Caustic Lye. 73

Mono Ethylene Glycol 106.6

Toluene 277.6

Resin (Cuprous Chloride) 7.2

Phenol 150.2

KOH 93

Sulfuric Acid 333

4 Para Bromo fluoro Benzene 200

Flouro Benzene 120.4

Liquid Bromine 209.2

Caustic Solution 8% 120.4

Catalyst 1.2

5 Permethrin 200

CMAC 116.6

MPBA 102.4

Hexane 410.6

Catalyst (Raney Nickel) 3

Soda Ash 3

Acetic Acid. 0.6

6 Styrenated Phenol 200

Styrenated Monomer 138.8

Phenol 61.2

7 Tri ethyl benzyl ammonium Bromide 200

TEA 114

Benzyl Chloride 138

IPA 15

Toluene 170.6

8 D V Acid Chloride/Cypermethric Acid Chloride 200

CMA hexane 295.35

Thionyl chloride 104.6

Dimethylformamide 0.9

GROUP ‐2

9 Meta Bromo Anisole 100

Meta bromo Nitro Benzene 105

Tetra Butyl Ammonium Bromide 31.4

Toluene 83.7

Caustic Potash (KOH) 68.6

Methanol 25

5


(MT/Month)

Sulphur 3.3

Hydrochloric Acid 58.4

Soda Ash 0.2

10 Meta Bromo Nitro Benzene 100

Nitro Benzene 125

Liquid Bromine 58.8

Oleum – 23% 375

Methanol 27

Soda Ash 3.8

11 N‐Butyl Bromide 100

N‐Butanol 58.8

Bromine 68.8

Sulphur Powder 5.1

Sulfuric Acid 5.9

Soda Ash 1.2

12 Tetra Butyl Ammonium Bromide 100

Tri Butyl Amine 64.5

N‐Butyl Bromide 59.3

Acetonitrile 67.7

Ethyl Acetate 69.5

13 N‐Propyl Bromide 100

N‐Propanol 55.5

Bromine 73.3

Sulphur Powder 4.8

Sulfuric Acid 16.6

Soda Ash 1.1

14 1‐Bromo 3 Chloro Propane 100

Aryl Chloride 124

HBr Gas 100

Sulfuric Acid 23

Soda Ash 3.5

Sodium Sulphate 1.5

15 ISO‐Butyl Bromide 100

ISO‐Butanol 58.8

Bromine 68.8

Sulphur Powder 3.5

Sulfuric Acid 5.9

Soda Ash 1.2

16 4‐Amino, 1,2,4 Trizole 100

Hydragine Hydrate 125

Formic Acid 85% 107.5

Mix. Xylene 6.2

6


(MT/Month)

17 Para Nitro Benzyl Bromide 100

Para Nitro Toluene 105

Acetic Acid 20

Liquid Bromine 32.5

Catalyst 4.4

18 N‐Pentyl Bromide 100

N‐Pentanol 62.5

Bromine 62.5

Sulphur Powder 20

Sulfuric Acid 6.2

Soda Ash 1.9

19 1,2‐Di bromo ethane 100

Mono Ethyl Glycol 37

Liquid Bromine 95.5

Soda Ash 1.1

Sulphur Powder 1.8

20 Ethyl Bromide 100

Ethylene Di bromide 100

Soda Ash 6.5

21 Tri Phenyl Phosphine 100

Mono Chloro Benzene 81

Trichloride Phosphorus 42.5

Mg. Turning 62.5

Toluene 105

22 Ethyl Triphenyl Phosphonium Bromide 100

Acetonitrile 80

Tri Phenyl Phosphine 88

Ethyl Bromide 40

23 Mono Bromo Acetic Acid 100

Mono Chloro Acetic Acid 125

Toluene 175

Hydrobromic Acid (48%) 260

24 N‐Bromo Succinimide 100

Succinimide 97.8

Bromine 2.8

Caustic Soda Flaks 3.2

Sodium Bromate 5

Sulphuric Acid 8

25 Diethyl Dipropyl Malonate 100

Di Ethyl Malonate 68.5

N‐Propyl Bromide 116.4

Caustic Soda Flaks 41

26 Methyl Tri Phenyl Phosnium Bromide 100

7


(MT/Month)

Hydrobromic Acid 44

Di methyl Sulphate 28.8

Tri Phenyl Phosphine 73.3

IPA 66.6

27 1H‐1,2,4 Trizole 100

Hydrazine Hydrate 96

Formamide 200

28 1,3 Dichloro Acetone 100

1,3 di 2‐chloropropenol 105

Sodium Di Chromate 150

Dilute Sulfuric Acid 230

29 Bromo Benzene 100

Benzene 66.6

Liquid Bromine 133.3

Catalyst Ferric Oxide. 3.3

Soda Ash 1.3

30 Iso Propyl Bromide 100

Iso‐Propanol 53

HBr (Hydrobromic Acid) 108.6

HCL 237

31 Tetra Ethyl Ammonium Bromide 100

Tri ethylamine 39

Ethyl bromide 45

Toluene 22

Iso propanol 39.2

32 Meta Chloro Propeophenone 100

Benzoic Acid/Benzene 102.6/98.5

Propionyl chloride 68.6

EDC 50

AlCl3 10.5

Chlorine gas 3

HCl 2.5

n‐Hexane 10

GROUP ‐3

33 Bromine 100

Sodium Bromide 750

Chlorine 43.75

34 Sodium Bromide 100

Sodium Hydroxide 38.85

Bromine 78.65

35 Calcium Bromide 100

Calcium Hydroxide 37

Hydrobromic Acid 81

8


(MT/Month)

36 Zinc Bromide 100

Zinc Oxides 36

Hydrobromic Acid 72

37 Hydro Bromic Acid in water (48%) 100

Liquid Bromine 34.2

Sulphur Powder 2.2

38 Calcium Chloride 100

HCL Acid 220

Calcium Oxides 90

39 Lithium Bromide 100

Formic Acid 54

Lithium Hydroxide 48

Liq. Bromine 184

NaOH 26

9

ANNEXURE – II

LAYOUT MAP OF THE PLANT

10

ANNEXURE – III

BRIEF MANUFACTURING PROCESS DESCRIPTION WITH CHEMICAL AND MASS BALANCE

1. CYPERMETHRIN:‐

BRIEF PROCESS:

A solution of sodium cyanide is prepared in SS reactor and further n‐hexane is charged along with

Catalyst and soda ash. In another reactor a mixture of Cypermethrin acid chloride, m‐phenoxy

Benzaldehyde and n‐hexane is prepared and kept at 10‐15oC. This mixture is added to the first

reactor keeping the temperature at room temperature and maintaining the same temperature for

1 hour. The organic layer is then washed successively with plain water, hypochlorite solution, and

aqueous acetic acid and again with plain water. It is then passed through sparkler filter and hexane

is distilled out first at normal pressure and then under vacuum to remove the traces to get

Cypermethrin tech. of purity 92% min.

CHEMICAL REACTION :‐

C8H9OCL3 + C13H10O2 + NACN ‐‐ C22H19NO3CL + NACL

CMAC + MPB + SODIUM CYNIDE CYPERMETHRIN + SODIUMCHLORIDE

(227.50) + (198) + (49) ‐ (416) + 58.50

11

MATERIAL BALANCE:‐

Sr.

No

Input material Name Qty (kg) Output material Name Qty (kg)

1 CMAC 562 CYPERMETHRIN 1000

2 MPB 485 Hexane Loss 61

3 Hexane 2053 Hexane recovered 1992

4 Water 1235 Waste Water 1495

5 Sodium Cyanide 140

6 Catalyst 15

7 Soda Ash 15

8 Acetic Acid. 3

9 Hypo Chlorite 40

TOTAL 4548 TOTAL 4548

Process Flow Diagram with Mass Balance

(CYPERMETHRIN)

2. META PHENOXY BENZYL ALCOHOL: ‐

BRIEF PROCESS:

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

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

Metaphenoxy Benzaldehyde (MPBA). The Slurry is filtered and Raney Ni is separated & recycled to next

12

batch, and the clear solution containing MPBA in Isopropyl alcohol is distilled to recover the solvent.

The pure product is collected in Drums.

CHEMICAL REACTION:‐

C6H5O‐C6H4‐CHO + H2‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐C6H5O‐C6H4‐CH2OH

MPB IPA SOLVENT/ RANEY NICKEL MPBA


Sr.

No

Input material Name Qty (kg) Sr.

No

Output material Name Qty (kg)

1 M‐phenoxy Benzaldehyde 990.0 1 Metaphenoxybenzyl Alcohol 1000.0

2 Hydrogen 12.30 2 Raney Ni (Recycled) 48.90

3 Raney Nickel 48.90 3 Isopropyl Alcohol (rec.) 813

4 Iso Propyl Alcohol (IPA) 1024.10 4 Isopropyl Alcohol (vap. loss.) 111.1

5 Water for washing 500 5 H2 excess gas venting 2.30

6. Wastewater generated 600.0

Total 2575.30 Total 2575.30


(Meta phenoxy benzyl Alcohol)

13

3. m‐ PHENOXY BENZALDEHYDE:‐

BRIEF PROCESS:

Stage‐I Benzaldehyde reacted with bromine and chlorine in presence of Aluminum Chloride, Ethylene di chloride as a solvent in above reaction, the Brominated mass quenched in water and washed. After washing organics mass is distilled and recovered ethylene di chloride is reused in Bromination. Distilled Meta bromo Benzaldehyde taken for second stage. CHEMICAL REACTION:‐

STAGE – I formation of m‐Bromo Benzaldehyde

C7H6O ALCL3/EDC C7H5OBr+C2H6O2 PTSA C9O2H9Br + H2O Br2/CL2 105 80 185 + 62 229 + 18 Stage‐II. Metabromo Benzaldehyde reacted with Mono Ethyl Glycol and produce Meta bromo benzal acetal, This meta bromo benzal acetal react with KOH and phenol in presence of Toluene Solvent and produce meta phenoxy benzalacetal which on hydrolysis with Sulphuric acid and water give meta phenoxy Benzaldehyde and MEG water is neutralized with caustic lye and recovered water and mono ethylene Glycol is recycle in next batch. STAGE – II. Formation of M‐ Phenoxy Benzaldehyde

C9O2H9Br + C6H6O Toluene + KOH C15O3H15 + Kbr + H2O 229 + 94 + 57 243 + 119 + 18 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Hydrolysis C13O2H10 + C2H6O2 198 + 62

14


Sr. No Input material Name Qty (kg) Output material Name Qty (kg)

Stage: I

1 Benzaldehyde 1000 m‐BB 1420

2 AlCl3 796 Fore cut ( Recycle) 121

3 Chlorine 346 Residue to Co‐process 23

4 Bromine 771 losses 14

5 EDC 7009 HCl,Cl2 as 30% HCL 1050

6 Water 850 HBr,Br2 as ( Recycle) 550

7 Sodium Thio‐Sulphate 22 AlCl3 in Water to ETP 786

8 Caustic Lye. 365 EDC (Reuse in Next Batch) 6909

Water and Thio. In Aq.Phase to ETP 286


Stage: II

1 m‐BB 1420 Bromo acetal 2066

2 Ethylene Glycol 533 Effluent to ETP 197

3 Toluene 1388 Toluene ( Recycle) 1033

4 Resin 36 Resin ( Recycle) 36

Losses 45

Total 3377 Total 3377

Stage: III

1 Phenol 751 m‐PB‐acetal in Toluene 3944

2 KOH 465 Losses 338

3 Toluene 3949 Toluene ( Recycle) 1643

4 Bromo acetal 2066 Bromine ( Recycle) 580

5 Water 300 KCl ( Recovery) 550

6 Chlorine 300 Water Vapor 776


15

Stage: IV

1 m‐PB‐acetal in Toluene 3944 m‐Phenoxy Benzaldehyde 1000

2 Sulfuric Acid 1665 Fore cut ( Recycle) 146

Residue 45

Losses 216

Toluene ( Recycle) 2136

Spent Sulphuric Acid 2066



(M‐Phenoxy Benzaldehyde)

16

4. PARA BROMO FLOURO BENZENE:‐

BRIEF PROCESS:

In the GLR ‐Capacity 3KL, Bromine is added in the fluoro benzene in presence of catalyst, at desired

temperature and atmospheric pressure. During reaction HBr gas is liberated which will be scrub in

presence Caustic solution , After reaction mass to unload in to SSR and wash with caustic solution

of 8%, after washing organics layer to separate and aqua’s layer solution is to send in to scrubber.

Organic layers are collected in to SSR and distilled out in the pack column, top cut is finish product

and bottom cut is ortho bromo fluoro Benzene as bye product.


C6H5F + Br2 ‐‐‐‐‐‐ Catalyst ‐‐‐‐‐ C6H4Fbr + HBr

96 + 160 175 + 80

Total input 256g/Mole Total output 256g/Mole


Sr.

No

Input material Name Qty

(kg)

Output material Name Qty

(kg)

1 Flouro Benzene 602 Para Bromo Flouro Benzene 1000

2 Liquid Bromine 1046 HBr in 10% Water for Bromine Recovery 1110

3 Caustic Solution 8% 602 Ortho Bromo Flouro Benzene – By

Product

140

4 Catalyst 6 Residue –incinerate 6

TOTAL 2256 Total 2256

17

5. PERMETHRIN:‐

BRIEF PROCESS:

In a Glass lined reactor, CMAC (DVACL) and catalyst are charged. Addition of MPBAL is started at

temperature of 20oC. The addition is completed within 3 to 4 hours and the same temperature is

maintained for 3 hours. The sample is checked for unreacted MPBAL. If not found, hexane is added and

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

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

vacuum. The material remaining in the reactor is Permethrin technical, which is packed suitably in

lacquered MS drums.


C8H9OCL3 + C13H12O2 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ C12H20O3CL2 + HCL

Cypermethric Acid Chloride + Meta Phenoxy ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Permethrin Tech +HCl.

(CMAC) (227.50) Alcohol (200.24) ‐‐‐‐‐‐‐‐‐‐ (391.0) + 36.50

18


Sr.

No

Input material Name Qty (kg) Output material Name Qty (kg)

1 CMAC 583 Permethrin 1000

2 MPBA 512 Hexane Loss 41

3 Hexane 2053 Hexane ( Recovered) 2010

4 Water 1000 HCL ‐ Recovered 393

5 Catalyst 15 Waste Water 737

6 Soda Ash 15

7 Acetic Acid. 3


19


(Permethrin)

6. STYRENATED PHENOL:‐

BRIEF PROCESS:

Charged Phenol Qty 1500Kgs in to SS Reactor under Agitation, Start slowly addition of Styrenated

Monomer Qty 3400Kgs for exothermic reaction, maintain temp up to 75 degree to 80 degree for 4 hrs.

For digestion, give sample for testing by Gas Chromatography. After gating purity pack in the mass in

HMHDPE Drums


C6H6O + 3C8H8 C30H30O

94 + 312 406


Sr.

No


No


1 Phenol 306 1 Styrenated Phenol 1000

2 Styrenated Monomer 694


20


(Styrenated Phenol)

7. TRI ETHYL BENZYL AMMONIUM BROMIDE:‐

BRIEF PROCESS:

In the S. S.Reactor ‐ Capacity 3KL, Charge Toluene, IPA, TEA and Benzyl Chloride, heat the mass up to

99 to 1020C, Reflux the material up to 9‐10 hrs. to recover the Toluene and IPA, than cool the mass up

to 100C, Separate the wet cake of finish product by centrifuge, dry the wet cake as per specification and

remain material M.L. having contain of Toluene, IPA and Second crop of product for next batch charge

for recovery.


H15NC6 + C7H7Cl Toluene C13NH22Cl

101 + 126.50 IPA 227.5

Input Total 227.50 gm/Mole Output Total 227.50gm/Mole


Sr.

No


(kg)


(kg)

1 Try Ethyl Amine. 570 Tri Ethyl Benzyl Ammonium Bromide. 1000

2 Benzyl Chloride 690 Recovered Toluene 800

3 Toluene 853 Recovered IPA 70

4 IPA 75 M.L. for Recycle. 318


21

8. CYPERMETHRIC ACID CHLORIDE:‐

24

9. META BROMO ANISOLE:‐

BRIEF PROCESS:

In the SS Reactor ‐Capacity 5KL, Charge MBNB and Toluene as per batch size than add Potassium

Hydroxide, as catalyst add TBAB, heat the mass up to 50 to 60 degree, Add methanol and maintain for

9 hrs. After maintain add sulphur as catalyst & maintain for 2 hrs., separate the aqua layer for ETP and

remain organics mass transfer to GLR cap – 5KL, and a the water, HCL and Soda Ash to complete

neutralization. Transfer the material in to SSR‐ Cap 5KL for distillation, after complete of distillation

finish comes out and residue to be unloaded in to drum for incineration.


C6H5NO2Br + KOH + CH3OH Toluene C7H7OBr + KNO2 + H2O

202 + 56 + 32 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 187 + 85 + 18

Sulphur& TBAB

Total 290g/Mole ‐‐‐‐ 290g/mole.


Sr.

No


No


1 Meta bromo Nitro Benzene. 1050 1 Meta bromo Anisole 1000

2 Tetra Butyl Ammonium Bromide. 314 2 Residue 195

3 Toluene. 837 3 Toluene ( Recovered) 2734

25

4 Caustic Potash (KOH). 686 4 Waste Water 245

5 Methanol 250

6 Sulphur 33

7 Hydrochloric Acid. 584

8 Soda Ash. 2

9 Water. 418


10. META BROMO NITRO BENZENE:‐

BRIEF PROCESS:

In the GLR ‐Capacity 5KL, Charge Oleum, slowly addition of Nitro Benzene at 10‐18 degree, after

complete of addition, start slowly addition of Liquid Bromine at same temp, Maintain the mass at RT.

Stat addition of water & maintain the temp up to 60 ‐ 70 degree, keep the mass to settle for separation,

Spent Sulphuric come out as a bye products and organics layer transfer to SSR‐5KL, wash the mass with

Soda Water and transfer to Crystallizer, after cooling the mass , separate the product in centrifuge and

remain material is M.L. of Nitro benzene for Re‐Cycle.

26


C6H5NO2 + ½ Br2 C6H5NO2Br.

123 + 80 203

Total 203g/Mole 203g/Mole


Sr.

No


(kg)


(kg)

1 Nitro Benzene. 1250 Meta bromo Nitro Benzene. 1000

2 Liquid Bromine. 588 M.L. of Nitro Benzene. ( Re‐Use) 259

3 Oleum – 23% 3750 Methanol – for ( Re‐Use) 208

4 Methanol. 270 Dilute Sulfuric Acid – 70%. 7283

5 Soda Ash. 38

6 Water. 2858


27

11. N‐BUTYL BROMIDE:‐

BRIEF PROCESS:

In the glass lined reactor ‐ Capacity 5KL, Charge N‐Butanol as per batch size than charge Sulphur Powder

in presence of Water. Slowly heat the mass 45 to 50 degree. Start addition Bromine up to 5 – 6 hrs.

Under temp of 50 to 60 degree. After addition of Bromine start distillation under reflux. Distilled mass

to be washed with Sulphuric Acid and Soda Water. Finish Product N‐Butyl Bromide is ready for packing

in HDPE Drums.


CH3CH2‐ CH2‐CH2+OH+S+H2O+ ½ Br2 ‐ CH3‐CH2CH2‐CH2‐Br + ½ H2SO4+H2O

74 + 32+ 18 + 80 137 + 49 + 18

204 gram mole ‐‐‐ 204 Gram mole.


Sr.

No

Input material Name Qty (kg) Output material Name Qty

(kg)

1 N‐Butanol 588 N‐Butyl Bromide 1000

2 Liquid Bromine 688 10% HBr Solution 633

3 Sulphur 51

4 Water 235

5 Sulphuric Acid. 59

6 Soda Ash. 12


28

12. TETRA BUTYL AMMONIUM BROMIDE:‐

BRIEF PROCESS:

In the SS‐Reactor –Cap‐5KL, Charge acetonitrile and tri butyl Amine, start addition of N‐Butyl Bromide

and heat the mass up to 80 to 82 degree . Maintain 36 hrs. To complete the reactions, cool down the

mass up to 50 degree than recover acetonitrile completely and degassing. Charge Ethyl Acetate and

cool the mass up to RT and chill. Than CF the material to get the wet cake, M.L. will be separate for

second crop and recovery of Basic RM (TBA)

Wet cake for drying at 70 to 75 degree centigrade.


C4H9Br + C12H27N C16NBrH36

137 + 185 322

Total 322g/mole 322g/mole.


Sr.

No


(kg)


(kg)

1 Tri‐Butyl Amine. 645 Tetra Butyl Ammonium Bromide 1000

2 N‐Butyl Bromide 593 Acetonitrile – for Recovery 637

3 Acetonitrile 677 Ethyl Acetate – for Recovery 645

4 Ethyl Acetate 695 M.L for Second Crop and recovery of

TBA ( Tri Butyl Amine)

318

Residue 10


32

13. N‐PROPYL BROMIDE:‐

BRIEF PROCESS:

In the glass lined reactor‐ Capacity 5KL, Charge N‐Propenol as per batch size than charge Sulphur

Powder in presence of Water. Slowly heat the mass 45 to 50 degree. Slowly start addition of

Bromine under reflux up to 10‐12 hrs. Under temp of 50 to 60 degree. After addition of Bromine

crude product to be distilled under reflux. Distilled mass to be washed with Sulphuric Acid and Soda

Water and make sure that the product is moisture free. Finish Product N‐Propyl Bromide is ready

for packing in HDPE Drums.


CH3CH2‐ CH2‐OH+S+ ½ Br2 CH3CH2‐ CH2‐Br + ½ H2SO4

60 + 32+ 80 123 + 49

172 gm/ Mole 172 gm/ mole

33


Sr.

No


(kg)

1 N‐Propanol. 555 N‐Propyl Bromide 1000


3 Sulphur 48

4 Water 222


6 Soda Ash. 11


34

14. 1‐BROMO 3‐CHLORO PROPANE:‐ BRIEF PROCESS:

In GLR –Cap‐5KL, Charge Aryl Chloride than pass HBr Gas slowly maintain chilling temp between 5

to 15 degree centigrade. Remove excess aryl chloride, wash the material with sulfuric acid, after

washing neutralize the mass with Soda water, and dry the material by Sodium Sulphate. Pack the

material in HDPE Drums.


CH2=CH‐CH2CL + HBr (Gas) BrCH2‐CH2‐CH2‐CL

76.5 + 81 157.50

Total = 157.5g/Mole 157.50g/Mole.


Sr.

No


(kg)

1 Aryl Chloride 1240 1‐Bromo ‐ 3 Chloro Propane 1000

2 HBr – Gas 1000 HBr 10% in Scrubber 1250

3 Sulphuric Acid 230 Effluents of Soda Water for

treatment

270

4 Soda Ash 35

5 Sodium Sulphate 15


35

15. ISO‐BUTYL BROMIDE:‐

BRIEF PROCESS:

In the glass lined reactor ‐ Capacity 5KL, Charge ISO‐Butanol as per batch size than charge Sulphur

Powder in presence of Water. Slowly start addition of Bromine up to 10‐12 hrs. Under temp of 55

to 65 degree, than distill the product under reflux for up to 8 to 10 hrs. Unload the Spent Sulphuric

in HBr 10% in other GLR, Wash the product with Sulphuric acid and Soda Water for neutralization.

Finish Product ISO‐Butyl Bromide is ready for packing in HDPE Drums.


CH3‐ CH2‐CH2‐ CH3+S+H2O+ ½ Br2 ‐ CH3‐CH2CH2‐CH3‐Br + ½ H2SO4+H2O

75 + 32+ 18 + 80 138 + 49 + 18

205 gram mole 205 Gram mole MATERIAL BALANCE:‐

Sr.

No


(kg)


1 ISO‐ Butanol 588 ISO‐Butyl Bromide 1000


36

3 Sulphur 35

4 Water 118


6 Soda Ash. 12


16. 4‐AMINO 1, 2, 4 TRIZOLE:‐ BRIEF PROCESS:

In the S. S.Reactor ‐ Capacity 5KL, Charge Hydragine Hydrate as per batch size, Slowly start addition

of Formic Acid 85% up to 10‐12 hrs. Under temp of 60 to 65 degree. After addition heat the mass

up to reflux, than charge mix xylene, and start azotopic distillation to remove the water completely.

Than cool the mass to 80 degree and unload the material in SS nudge filter and cool the mass up

to RT. After completely cooling take the material in S.S Centrifuge and dry the material in try dryer

and pack the finish product in fiber drum.


N4H12O2 + H4 C2 O4 Mix‐Xylene N4H4C2 + 6H2O

100 gm/Mole + 92 84gm/Mole + 108

Total 192 gm/Mole Total 192gm/Mole

37


Sr.

No


(kg)


(kg)

1 Hydrazine Hydrate 1250 4‐Amino 1,2,4 Triazole 1000

2 Formic Acid. 85% 1075 Distilled Water for Recycle 1331

3 Mix – Xylene 62 Mix‐ Xylene – Recovered 56


17. PARA NITRO BENZYL BROMIDE:‐

BRIEF PROCESS:

In the GLR ‐Capacity 5KL, Charge Para Nitro Toluene and Acetic Acid in presence of Catalyst ( Benzyl

Peraoxide) after charging slowly heat the mass up to 450C, and check mass should be water white

clear. Then slowly start addition of Bromine and maintain temp 45 to 600C. within 5‐6 hrs., and

maintain for 2‐3 hrs., after complete of reaction dump the entire mass in to HDPE Stirrer tank in

present of ICE Water under 5 to 100C for isolation the material. After getting chilled the mass

separate the material for drying in pp Tray. And remaining material is effluent to be sent to ETP for

suitable treatment.

38


C7H7NO2 + ½ Br2 C7H6BrO2N + H+

137 + 80 216 + 1

Total 217g/Mole 217g/Mole


Sr.

No


(kg)


(kg)

1 Para Nitro Benzene 1050 Para Nitro Benzyl Bromide. 1000

2 Acetic Acid 200 Acetic Acid with Water(Reuse in next Batch) 779

3 Liquid Bromine 325 Effluent 290

4 Catalyst 44

5 Ice Water. 450


39

18. N‐ PENTYL BROMIDE:‐

BRIEF PROCESS:

In the glass lined reactor ‐ Capacity 5KL, Charge Pentanol as per batch size than charge Sulphur

Powder in presence of Water. Slowly heat the mass up to 60 degree. Start addition Bromine up to

5 – 6 hrs. Than reflux 8‐10 hrs. To complete the distillation of product. Unload the Spent Sulphuric

in HBr 10% in other GLR, Wash the product with Sulphuric acid and Soda Water for neutralization.

Finish Product N‐Pentyl Bromide is ready for packing in HDPE Drums.


CH3CH2‐ CH2‐CH2‐ CH2‐OH+S+H2O+ ½ Br2 ‐ CH3‐CH2CH2‐CH2‐Br + ½ H2SO4+H2O

88 + 32+ 18 + 80 151 + 49 + 18

218 gram mole 218 Gram mole


Sr.

No


(kg)


(kg)

1 Pentanol 625 N‐Pentyl Bromide 1000


3 Sulphur 200

4 Water 125


6 Soda Ash. 19


40

19. 1‐2 DIBROMO ETHANE:‐

BRIEF PROCESS:

In the glass lined reactor ‐ Capacity 5KL, Charge mono ethyl Glycol in present of water, than charge

sulphur powder, heat the mass up to 500C, start addition of Liquid Bromine under reflux, after

addition maintain 2‐3 hrs., than start distillation, unload the Spent Sulphuric in 10% HBr for Resale

or Recovery of Bromine, after unloading wash the mass with Soda Water to neutralize the finish

products and pack after testing.


C2H6O2+S + Br2 + 2H2O C2H4Br2+ H2SO4+2H2

62 + 32 +160 + 36 188 + 98 + 4

290 g/mole 290g/mole


Sr.

No


(kg)


1 MEG 370 1,2 Di Bromo Ethane 1000


3 Sulphur Powder 18

4 Soda Ash. 11

5 Water 148


41

20. ETHYL BROMIDE:‐

BRIEF PROCESS:

In the glass lined reactor ‐ Capacity 5KL, Charge Ethylene Di Bromide as per batch size than charge

Soda Ash in present of Water. Start Hydrolysis under reflux up to 8 to 10 hrs. . Distill out the finish

product and pack the same, remain material is effluent and same to send it ETP.


CH2‐Br2

! + Na2CO3 2CH3‐CH2‐Br

CH2‐Br2 + H2O

188 + 18+ 12 218



Sr.

No


(kg)

1 Ethyl Di Bromide. 1000 Ethyl Bromide 1000

2 Water 225 Alkali Water for ETP 290

3 Soda Ash. 65


42

21. TRI PHENYL PHOSPHINE:‐

BRIEF PROCESS:

In SSR–Cap‐5KL, Charge MCB and Magnesium Turning, Start Addition of PCl3 and Maintain the

chilling temp 0‐50C, for 5‐6 hrs. Dump the mass in to HDPE tank under steering, separate the

organic layer and start distillation to separate excess MCB. And remain material is effluent, Charge

Toluene to Isolate the finish product, Separate the finish product by centrifuging, and pack after

drying.


C18H15Cl3 + PCL3 PC18H15 + 3Cl2

337.5 + 139.50 264 + 213

Input total 477g/mole‐ output total = 477g/mole

43


Sr.

No


(kg)


(kg)

1 Magnesium Turning 625 Tri Phenyl Phosphine 1000

2 Mono Chloro Benzene 810 Mono Chloro Benzene for Re‐Use 500

3 Toluene 1050 Toluene ( Recovered) 1625

4 Trichloride Phosphorus (PCL3) 425 Effluent 285

5 Chilled Water 500


22. ETHYL TRI PHENYL PHOSNIUM BROMIDE:‐

BRIEF PROCESS:

In the S. S.Reactor ‐ Capacity 3KL, Charge Acetonitrile, tri Phenyl Phosphine and Slowly charge

Ethyl Bromide, Heat the mass up to 700C, After exothermic reaction temperature will raise up to

80 to850C. Maintain the mass for 14‐15 under agitation, after maintain cool down the mass at RT.

Separate the product by Centrifuge, Remain material is M.L of Acetonitrile for Recycle in next

batch.

44


C18H15P + C2H5Br C20H20BrP

264 + 109 373

Input Total 373 gm/Mole Output Total 373gm/Mole


Sr.

No


(kg)


(kg)

1 Acetonitrile. 800 Ethyl Tri Phenyl Phosphium

Bromide

1000

2 Tri Phenyl Phosphine 880 Acetonitrile Recovered 780

3 Ethyl Bromide. 400 Second Crop Product to purify sale 300


23. MONO BROMO ACETIC ACID:‐

BRIEF PROCESS:

In the glass lined reactor ‐ Capacity 5KL, Charge Toluene, Mono Chloro Acetic Acid One by one and

also charge Hydrobromic Acid 48%, slowly heat to remove HCL Gas, Scrub the HCL Gas in water

media, Distill the material under high vacuum, Distilled material is finish product and remain

material is residue for incineration.

45


ClCH2‐COOH+Hbr Toluene BrCH2COOH + HCL

94.50 + 81 139 + 36.50

Input total 175.50g/Mole ‐ Output total 175.50g/Mole


Sr.

No


(kg)

1 Mono Chloro Acetic Acid 1250 Mono Bromo Acetic Acid. 1000

2 Toluene 1750 HBr 10% in Water for Resale. 2675

3 Hydrobromic Acid – 48% 2600 Toluene for Recovery 1625

4 Water in Scrubber. 2500 Hydro Chloric Acid 25% 2750

Residue. 50


46

24. N‐BROMO SUCCINIMIDE:‐

BRIEF PROCESS:

In the glass lined reactor Capacity 5KL, Charge Succinimide with water as per batch size ensure to

dissolve completely than slowly add Sulfuric acid at RT 45degree. After addition charge sodium

bromate in presence of 2 hrs. steering than add Liquid Bromine under temp of 55 to 60 degree,

thereafter charge ICE Water make the work up by charging caustic Soda Flaks to isolate the mass ,

use centrifuge to separate finish products from liquid and mother liquor goes to ETP and finish

products to dry in try dryer between 100 to 105 degree. After testing of the moisture material is

ready for packing.


C4H10N + ½ Br2‐‐ C4NBrH8+2H+

72 + 80 ‐ 150 + 2

Total 152g/Mole‐ 152g/Mole MATERIAL BALANCE:‐

Sr.

No


(kg)


(kg)

1 Succinimide 978 N‐Bromo Succinimide 1000

2 Liquid Bromine 28 ETP – Effluent 268

3 Caustic Soda Flaks 32

4 Sodium Bromate 50

5 Sulphuric Acid‐98% 80

6 Water 100


47

25. DI‐ETHYL DI‐PROPYL MALONATE:‐

BRIEF PROCESS:

In SSR–Cap‐5KL, Charge N‐Propyl Bromide and start Di Ethyl Malonate, 70 0C, after addition, also

start addition caustic 35% soda solution, add the fresh water to cool down the temp at RT. Separate

the Organics layer (upper) for distillation, lower layer is Sodium Bromide solution of 30% to 33%

for Resale or Bromine Recovery.


C6H14Br 2+ C7O4H12 + 2NAOH 2NABR +2H2O +C13H24O4

246 + 160 + 80 206 + 36 + 244

Input total 486g/mole‐ output total = 486g/mole


Sr.

No


(kg)

1 Di Ethyl Malonate. 685 Di ethyl Di propyl Malonate 1000

2 N‐Propyl Bromide. 1164 Sodium Bromide Solution ‐35% 2517

3 Caustic Soda Flaks 410 Residue. 34

4 Water 1292


48

26. METHYL TRI PHENYL PHOSNIUM BROMIDE:‐

BRIEF PROCESS:

In the GLR ‐Capacity 5KL, Charge Hydrobromic Acid and Dimethyl Sulphate, to produce gas methyl

Bromide, in SSR‐ 3KL charge TPP and IPA, start passing of Gas Methyl Bromide at RT, for 5‐6 hrs.,

after complete of reaction bring down the temp. Up to 15‐180C, Separate the wet cake of finish

product by centrifuge, remain material is M.L. of IPA and second crop of product which to be distill

and isolate. Dry the wet cake and pack.


C18H15P + C1H3Br C19H18PBr

264 + 95 359

Input Total 359g/Mole Output Total 359g/Mole


Sr. No Input material Name Qty (kg) Output material Name Qty (kg)

1 Hydrobromic Acid 48% 440 Methyl tri phenyl Phosnium Bromide. 1000

2 Di methyl Sulphate. 288 HBr 10% in Spent Sulphuric Acid. 517

3 Tri Phenyl Phosphine. 733 IPA ( Recovered ) 600

4 IPA 666 Residue 10


49

27. 1‐H‐1, 2, 4 TRIZOLE:‐

BRIEF PROCESS:

In the S. S.Reactor ‐ Capacity 3KL, Charge Formamide, Slowly start addition of Hydragine Hydrate

to remove clean water from process, this water is ready for recycle in utility. After removal of water

unload the mass in to SS crystallizer for solidification, separate the wet cake of finish product by

process through centrifuge, Remain M.L. will recycle for next batch. Dry the material as per finish

product specification, and pack in fiber drums of 25Kgs.


N4H12O2 + H6 C2 O2N2 N6C12H6 + H2O + NH3OH

100 gm/Mole + 90 138 + + 18

Input Total 190 gm/Mole Output Total 190gm/Mole


Sr.

No


(kg)


(kg)

1 Formamide 2000 1H‐ 1,2,4 Trizole 1000

2 Hydragine Hydrate 960 Water using for Cooling Tower 1000

M.L. for Reuse. 960


50

28. 1, 3 DI‐ CHLORO ACETONE:‐

BRIEF PROCESS:

In GLR –Cap‐5KL, Charge 1,3 Dichloro propanol and Sodium di chromate, start addition of diluted

Sulphuric Acid, under temp of 5‐100C, Maintain the reaction up to 10 hrs., after complete of

addition separate wet cake by centrifuge. After getting wet cake charge the material in SSR – 3KL

for distillation and purification in water.


H H H H H H

! ! ! ! ! !

Cl‐C‐‐‐C‐‐‐ C‐‐‐Cl + Na2Cr2O7 + H2SO4 = Cl‐C‐‐‐C‐‐‐ C‐‐‐Cl +Na2Cr2 (OH) 3 SO410H2O+3H2

! ! ! ! ! !

H OH H H H H

129 + 280 + 98 = 128 + 373 + 6

Total Input 507g/Mole = Total Output 507g/Mole


Sr.

No


(kg)


(kg)

1 1, 3 di Chloro 2 propanol. 1050 1,3 di Chloro Acetone 1000

2 Sodium di chromate 1500 Sodium di chromate – 10% for Sale. 1000

3 Water 1400 Effluents to ETP 250

4 Dilute Sulphuric Acid– 70%

2300 Water Evaporation (Drying Loss) 4000


51

29. BROMO BENZENE:‐

BRIEF PROCESS:

In the GLR ‐ Capacity 5KL, Charge Benzene as per batch size in present of Catalyst Fe (Iron), heat

the mass up to 75 to 800C, Slowly start addition of Liquid Bromine within 10‐12 hrs., during addition

HBr gas generate which is to be scrub in scrubber, Maintain the same temp for fractional

distillation, 01st cut is Benzene and 2nd cut is Bromo Benzene (FG) which is to be neutralize with

Soda Ash, After neutralize material is ready for packing in HDPE Drums.


C6H6 + Br2 Fe (Iron) C6H5Br + HBr

78 + 160 157 + 81

Input Total 238g/Mole Output Total 238gm/Mole


Sr.

No


(kg)

1 Benzene 666 Bromo Benzene 1000

2 Liquid Bromine 1333 Recovered Benzene 133

3 Water 666 HBr in Water – 48% for Bromine recovery 1511

4 Fe( Iron) 33 Residue for incinerator/Co‐process 66

5 Soda Ash 13


52

30. ISO PROPYL BROMIDE:‐

BRIEF PROCESS:

Isopropyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after

passing required amount of HBr acid over a given period of time the mass is analyzed for

completion of reaction on GC. When unreacted ISO Propyl alcohol is less than 1% HBr acid

addition is stopped and taken for Water washing. The Organic is taken in to the Glass lined

reactor and water is added. This mass was stirred at room temperature. Organic layer

taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer

is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the

Product is fractionated. Pure Iso‐Propyl Bromide thus obtained is packed in 200 lit Drums.



Sr.

No


(kg)


(kg)

Stage‐I

1 Iso Propyl Alcohol 530 Iso Propyl Bromide 1086

2 HCL 2370 Rec. HBr 23% 1813

53

Stage‐II

3 Iso Propyl Bromide 1086 Iso Propyl Bromide 1082

4 Water 482 ETP 487

Stage‐III

5 Iso Propyl Bromide 1082 PRODUCT 1000

Residue 82


31. TETRA ETHYL AMMONIUM BROMIDE:‐

BRIEF PROCESS:

The TOLUENE + ISOPROPANOL and Tri ethyl amine taken in the reactor. At 500C Ethyl bromides

charged in to it. Those mixture is stirred well for about 24 hr. temperature is maintained 70c in

the reactor this mixture is cooled to 200C. Chilled and stirred for about 3 hrs.at 20° C. The final

mass filtered in basket filter. The powder is dried for 8 hrs. In the dryer at 50° C and then packed

it in the drum. The Mother liquor from the filter is collected and Distilled then reused it for next

batch of reactions.


TOLUENE + ISOPROPANOL

TRI ETHYL AMINE + ETHYL BROMIDE TETRA ETHYL AMMONIUM BROMIDE

[C6H15N] [C2H5Br] [C8H20NBr]


Sr.

No


(kg)


(kg)

1 TRI ETHYLAMIN

390

TETRA ETHYL AMMONIUM

BROMIDE 1000

2 ETHYL BROMIDE 450 REC SOLVENTS 452

3 TOLUENE 220

4 ISO PROPANOL 392

TOTAL 1452 Total 1452

54

32. META CHLORO PROPIOPHENONE:‐

BRIEF PROCESS:

Stage‐1:

Friedel Craft Reaction – Charge Benzoic Acid or Benzene and catalyst AlCl3 in GLR and cool at

10‐120C. Add Propionyl chloride slowly keep temperature at <12 0C.

Distillation – Apply vacuum and distill Propiophenone.

Stage‐2:

Chlorination – Charge required quantity of solvent (EDC) cool to 10 0C then charged reactant

Propiophenone and again chilled to 4 0C then start slow addition of catalyst AlCl3 with

controlling temperature after completion of catalyst charging purged chlorine with control rate

and temperature then quench the reaction in dilute HCl maintaining temperature below 20 °C.

Solvent recovery & Fraction Distillation – Washed neutral organic layer to be taken for

atmosphere solvent recovery after completion of solvent recovery start & complete high

vacuum, high temperature fraction distillation to get dilute MCPP.

Centrifugation – Dilute MCPP is centrifuge to get wet cake of crude MCPP and after drying get

pure product.


55


Sr. No.

Input Qty. per Batch (Kg)

Output Qty. per Batch (Kg)

STAGE:‐1

1 Benzoic Acid / Benzene 1026 / 985 Propiophenone 1092

2 Propionyl chloride 686 HCL gas 322

3 Aluminum chloride 50 CO2 gas 388/0

4 Chilled water 240 Water 250/545

5 Recover Catalyst (Aluminum chloride)

50

Total 2052/2051 Total 2052/2051

STAGE:‐2

1 Propiophenone 1092 m‐Chloropropiohenone 1000

2 Ethylene dichloride 500 HCL gas 217

3 Aluminum chloride 55 Recover Catalyst (Aluminum chloride )

55

4 Chlorine gas 30 Recover Ethylene dichloride

475

5 Chilled water 70 Ethylene dichloride loss 25

6 HCL 25 Recover Hexane 98

7 Hexane 100 Hexane loss 2


33. BROMINE:‐

BRIEF PROCESS

Take necessary quantity of Bromide Solution as per concentration in Glass lined reactor and distill out

the organic impurity. After impurity removal acidify the mass with HCl and then transfer the reaction

mass into feed tank for distillation of Bromine after passing chlorine gas and steam.

56

CHEMICAL REACTION

2NaBr + Cl2 → Br2 + 2NaCl

Sodium Bromide Chlorine Bromine Sodium Chloride


Input Quantity Kg

Output Quantity Kg

Sodium Bromide 20% Solution 7500 Bromine 1000

Chlorine 437.5 Sodium Chloride with effluent water 6937.5

TOTAL 7937.5 TOTAL 7937.5

Heating in GLR

Hydrochloric Acid

Chlorine and Steam

34. SODIUM BROMIDE:‐

BRIEF PROCESS:

Sodium bromide is produced by neutralization method, in which sodium hydroxide is neutralized using

Hydrobromic acid. For neutralization process, Hydrobromic acid was introduced into the reactor having

stirrer where it was treated with Sodium Hydroxide at ambient temperature. After neutralization steps

reaction mass was transferred to evaporating tank where water vapour was removed to form Sodium

Bromide of desired concentration

Bromide Solution 6000 Ltr in GLR for

organic impurity removal

Acidification of feed

Distillation in Glass assembly

Finished Product

57


NaOH + HBr NaBr + H2O

Sodium Hydrobromic Sodium Water Hydroxide Acid Bromide

MATERIAL BALANCE

Material Input Quantity (Kg)

Material Output Quantity (Kg)

Sodium Hydroxide 388.5 Sodium Bromide 1000

Hydrobromic acid 786.5 Waste Water 175


35. CALCIUM BROMIDE:‐

BRIEF PROCESS:

Calcium bromide is produced by neutralization method, in which calcium hydroxide is neutralized using

Hydrobromic acid. For neutralization process, solution of Hydrobromic Acid was introduced into the

reactor having stirrer where it was treated with Calcium Hydroxide at ambient temperature. After

neutralization steps reaction mass was transferred to evaporating tank where water vapour was

removed to form Calcium Bromide of desired concentration


Ca (OH) 2 + 2HBr CaBr2 + 2H2O

Calcium Hydrobromic Calcium Water Hydroxide Acid Bromide

58




Calcium Hydroxide 370

Calcium Bromide 1000

Hydrobromic acid 810

Waste Water 180

Total 1180

Total 1180

36. ZINC BROMIDE:‐

BRIEF PROCESS:

Zinc bromide is produced by neutralization method, in which Zinc Oxide is neutralized using

Hydrobromic acid. For neutralization process, solution of Hydrobromic acid was introduced into the

reactor having stirrer where it was treated with Zinc Oxide at ambient temperature. After neutralization

steps reaction mass was transferred to evaporating tank where water vapour was removed to form Zinc

Bromide of desired concentration


ZnO + 2HBr ZnBr2 + H2O

Zinc Hydrobromic Zinc Water Oxide Acid Bromide




Zinc Oxide 360 Zinc Bromide 1000

Hydrobromic acid 720 Waste Water 80


59

37. HYDROBROMIC ACID‐48%:‐

BRIEF PROCESS:

In the glass lined reactor, charge water as per batch size then charge Sulphur Powder. Heat the

mass up to 50 to 60 degree, start addition of Bromine under the same temperature. After addition

heat up to reflux, and distill the material purity 48% as a finish product and pack the same,

remaining material is Spent Sulphuric Acid in 10% HBr which is be used back for Bromine recovery.


4H2O + S + 3Br2 6 HBr (100%) + H2SO4

72 + 32 + 480 486 + 98



Sr. No Input material Name Qty

(kg)


1 Liquid Bromine. 342 Hydrobromic Acid – 48% 1000

2 Water 703 10% HBr Solution 67

3 Sulphur Powder 22


60

38. CALCIUM CHLORIDE

BRIEF PROCESS:‐

In brick lined reaction vessel 900 kg calcium carbonate is taken and then 2200 kg 30%

hydrochloric acid is added slowly and reaction will start automatically. After the completion of

reaction calcium chloride solution will be dried to produce solid 1000 kg calcium chloride.


CaCO3 + 2HCl CaCl2 + H2O + CO2

Calcium Hydrobromic Calcium Water Carbon Carbonate Acid Chloride Dioxide


Sr. No

Raw Materials / Items Kg/Batch Product / By Product Qty/Batch

1 Calcium Carbonate 900 Calcium Chloride 1000

2 HCl (30%) 2200 Process Sludge 40

3 Drying Loss 1664

4 CO2 396


61

39. LITHIUM BROMIDE:‐

BRIEF PROCESS:‐

Charge lithium hydroxide and formic acid into MSGL reactor with stirring at 25 °C. Start

addition of liquid bromine by controlling temp 10 °C for 30 minutes. Transfer the same mass

into SS reactor and heat up to 100 °C. Filter it through sparkler filter. Cooled the same mass

at 100 °C. Centrifuge it, dry it & packed it.



Sr.

No


(kg)


(kg)

1 Formic acid 540

Final Product 1000

2 Lithium Hydroxide

480

Waste Water

830

3 NaOH

260

Evaporation Loss

100

4 Liq. Bromine

1840

NaBr/HBr solution

1190


63

ANNEXURE – IV

DETAIL OF WATER CONSUMPTION & WASTEWATER GENERATION

Water consumption:

Sr.No. Types Of Activity Fresh Water required KL/Day‐Proposed

1 Group ‐ I ‐ Process 8.23

2 Group ‐ II ‐ Process 8.52

3 Group ‐III‐ Process (Inorganic Products) 2.34

4 Boiler 14.91

5 Cooling ( Make ‐ up) 10.00

6 Washing 1.00

7 Gardening 5.00

8 Domestic use 5.00

Total 55.00

Note: Product No – 1, 10, 37 from Group I,II and III respectively are considered as it will going to

consume Maximum Fresh water

Waste water generation:

Sr.No. PRODUCT NAME Waste Water Generation KL/Day

1 Group ‐ I ‐ Process 9.96

2 Group ‐ II ‐ Process 1.81

3 Group ‐III‐ Process (Inorganic Products) 23.12

4 Boiler Blow down 2.61

5 Cooling Blow Down 2.00

6 Washing 0.50

7 Domestic use 4.5

Total 44.50

Note: Product No – 1, 32, 33 from Group I, II and III respectively are considered as it going to

generate Maximum Effluent Water.

64

ANNEXURE – V

EFFLUENT TREATMENT SCHEME

PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)

M/s. MALVIS INDUSTRIES shall have an Effluent treatment plant consisting of primary, Secondary & Tertiary units with the capacity of treating effluent up to 45 KLD. The effluent will be brought within the limits prescribed by the CETP of Saykha. The details of ETP are as follows.

Effluent generated from the Process, Washing as well as Boiler blow-down will be neutralized with lime in neutralization tank and further treatment in Secondary & tertiary Treatment Plant. After that the treated effluent is discharged to CETP of Saykha as per CETP inlet norms through tankers. Effluent Treatment Plant (Dimension):

FLOW DIAGRAM OF PROPOSED ETP

Sr. No. Name of the units Size (m)

1. Collection tank cum Neutralization Tank 3.0 x 3.0 x 4.0

2. Aeration Tank 3.0 x 3.0 x 4.0

3. Tertiary Tank 3.0 x 3.0 x 4.0

4. Sludge Drying Bed 2.0 x 2.0 x 1.0

5 Final Discharge Tank 3.0 x 3.0 x 2.0

65

EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT

Sr.No. Parameter of Waste Water Before Treatment Final Treated Effluent

1. pH 1.50 – 11.00 5.50 – 8.00

2. COD (mg/l) 2200-3000 Below 100

3. BOD (mg/l) 700-1000 Below 30

4. TDS (mg/l) 2500-15000 2500-5000

5. TSS (mg/l) 250-300 Below 50

66

ANNEXURE – VI

DETAILS OF HAZARDOUS / SOLID WASTE GENERATION, HANDLING AND DISPOSAL

Sr. No Hazardous waste Cat. No. Total

Quantity (MT/Annum)

Method of disposal

1 Used Oil Sch‐I/ 5.1

16.66 Kgs/Month

Collection, Storage, Reuse or sell toRegistered Refiners.

2 Discarded/Containers/ Barrels/ liners

Sch‐I/ 33.1

1.66 MT/Month

Collection, Storage, Reuse or sell to GPCB authorized vendor.

3 ETP sludge Sch‐I/35.3

16.00MT/Month

Collection, Storage & send tocommon TSDF site BEIL Dahej.

4 Process Waste Sch‐I/ 28.1

4.00 MT/Month

Collection, Storage & send tocommon TSDF site BEIL Dahej. To be Consider Group ‐3(Product No: 38)

5 Distillation Residue Sch‐I/ 36.1

33.1 MT/Month

Collection, Storage & send toCHWIF or Co‐process BEIL‐Ankleshwar. To be Consider Group ‐1(Product No: 3) & Group ‐2(Product No: 9)

6 HCL Solution Sch‐II/ B‐15

485.00 MT/Month

Collection, Storage & CaptiveConsumption or sell to enduser/s having Rule 9 Permission. To be Consider Group ‐1(Product No: 3) & Group ‐2(Product No: 23)

7 HBr Solution Sch‐II/ B‐15

806.5 MT/Month

Collection, Storage & CaptiveConsumption or sell to enduser/s having Rule 9 Permission. To be Consider Group ‐1(Product No: 4), Group ‐2(Product No: 23) & Group ‐3(Product No: 39)

8 H2SO4 Solution Sch‐II/ B‐15

1142.0 MT/Month

Collection, Storage & CaptiveConsumption or sell to enduser/s having Rule 9 Permission. To be Consider Group ‐1(Product No: 3) & Group ‐2(Product No: 10)

9 Ortho Bromo Flouro Benzene

‐ 28.00

MT/Month

Collection, Storage & CaptiveConsumption or sell to enduser/s. having Rule 9 Permission. To be Consider Group ‐1(Product No: 4)

10 Sodium Di Chromate

‐ 100.00

MT/Month

Collection, Storage & CaptiveConsumption or sell to enduser/s. having Rule 9 Permission. To be Consider Group ‐2(Product No: 29)

67

ANNEXURE – VII

DETAILS OF AIR POLLUTION CONTROL SYSTEM (STACK & VENT)

DETAILS OF FUEL CONSUMPTION

Sr. No.

Name of fuel

Quantity of Fuel

1. Coal/ Bio Coal 2 MT/Day

2. Diesel 10 Liter/Hr.

FLUE GAS EMISSION THROUGH STACK:

Sr. No.

Stack Attached to

Stack Height (meter)

Fuel UsedAir Pollution

Control MeasureParameter

Permissible Limit

1. Steam Boiler

(Capacity ‐2 MT) 22

Coal/Bio coal

Mechanical Dust Collector

PM SOX NOX

150 mg/Nm3 100 ppm 50 ppm

2. Hot Air Generator 22 Coal/Bio coal

Cyclone & Bag Filer

3. D.G.Set (Capacity

‐250 KVA) 11

Diesel Adequate Stack

Height

PROCESS GAS EMISSION DETAILS:

Sr NO. Stack Attached To Stack Height

(meter)

Parameter

Permissible

Limit (mg/Nm3) APCM

1 Process Vent‐I

(attached to Drier & Cooler)

11 PM 150 Multicyclone Separator/Bag

Filter

2

Process Vent‐II (attached to Reaction Vessel)

11

Cl2,

HCl,

HBr

9 20 5

Alkali Scrubber

68

ANNEXURE – VIII SOCIO- ECONOMIC IMPACTS

1) Employment Opportunities

The manpower requirement for the proposed Expansion project is being expected to generate some permanent jobs and secondary jobs for the operation and maintenance of plant. This will increase direct / indirect employment opportunities and ancillary business development to some extent for the local population. This phase is expected to create a beneficial impact on the local socio-economic environment.

2) Industries

Required raw materials and skilled and unskilled laborers will be utilized maximum from the local area. The increasing industrial activity will boost the commercial and economic status of the locality, to some extent.

3) Public Health

The company regularly examines, inspects and tests its emission from sources to make sure that the emission is below the permissible limit. Hence, there will not be any significant change in the status of sanitation and the community health of the area, as sufficient measures have been taken and proposed expansion under the EMP.

4) Transportation and Communication

Since the existing factory is having proper linkage for the transport and communication, the development of this project will not cause any additional impact. In brief, as a result of the proposed expansion project there will be no adverse impact on sanitation, communication and community health, as sufficient measures have been proposed expansion to be taken under the EMP. The proposed expansion project is not expected to make any significant change in the existing status of the socio -economic environment of this region.

5) Corporate Social Responsibility As per government guideline generally 2% of the profit is reserved for Corporate Social Responsibility.

6) Corporate Environmental Responsibility As this is Greenfield project 2% of project cost is reserved for Corporate Environmental Responsibilities.

69

ANNEXURE – IX

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

Project Description

Justification of project.

Promoters and their back ground

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

industries, surface water bodies, forests etc.

Project cost

Project location and Plant layout.

Water source and utilization including proposed water balance.

Product spectrum (proposed products along with production capacity) and process

List of hazardous chemicals.

Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 10

km area.

Existing environmental status Vis a Vis air, water, noise, soil in 10 km area from the project

site.

For PM10, PM2.5, SO2, NOx.

Ground water quality at 8 locations within 10 km.

Complete water balance.

3. Socio Economic Data

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

study area were surveyed.

4. Impacts Identification and Mitigatory Measures

Identification of impacting activities from the proposed expansion project during construction

and operational phase.

Impact on air and mitigation measures including green belt.

Impact on water environment and mitigation measures.

Soil pollution source and mitigation measures.

Noise generation and control.

Solid waste quantification and disposal.

70

5. Environmental Management Plan

Details of pollution control measures.

Environment management team.

Proposed schedule for environmental monitoring including post project.

6. Risk Assessment

Objectives and methodology of risk assessment.

Details on storage facilities.

Process safety, transportation, firefighting systems, safety features and emergency

capabilities to be adopted.

Identification of hazards.

Consequence analysis through occurrence & evaluation of incidents.

Disaster Management Plan.

7. Information for Control of Fugitive Emissions.

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.

9. Information on Rain Water Harvesting.

10. Green Belt Development plan.

71

ANNEXURE – X

PLOT ALLOTMENT LETTER

78

ANNEXURE – XI

WATER SUPPLY LETTER

79

ANNEXURE – XII

CETP MEMBERSHIP CERTIFICATE

80

ANNEXURE – XIII

TSDF MEMBERSHIP CERTIFICATE

81

ANNEXURE – XIV

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