m/s. anu products ltd. -...
TRANSCRIPT
FORM-1
for
PROPOSED PESTICIDE MANUFACTURING UNIT IN
SARIGAM IND. ESTATE
of
M/s. ANU PRODUCTS LTD.
C-1B/3206, 3208, 3210, 3212,
Chemical Zone, GIDC Sarigam-396 155,
Dist: Valsad, Gujarat
Prepared by:
APPENDIX I
(See paragraph - 6)
FORM 1
(I) Basic Information
Name of the Project : M/s. Anu Products Ltd.
Location f site alternatives under
consideration
: M/s. Anu Products Ltd.
C-1B/3206, 3208, 3210, 3212,
Chemicals Zone, GIDC Sarigam-396 155,
Dist.: Valsad (Gujarat)
Size of the Project : Please refer Annexure –I.
Expected cost of the project : Rs. 5 crores
Contact Information : Mr. M. R. Narayanan
(General Manager)
M/s. Anu Products Ltd.
C-1B/3206, 3208, 3210, 3212,
Chemicals Zone, GIDC Sarigam-396 155,
Dist.: Valsad (Gujarat)
Phone No.: (0260) 2781414
Mobile No.: 9924106799, 9321092191
e-mail: [email protected]
Screening Category : A-5(b)
• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,
mining lease area and production capacity for mineral production, area for mineral exploration,
length for linear transport infrastructure, generation capacity for power generation etc.,)
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions,
which will cause physical changes in the locality (topography, land use, changes in
water bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of with approximate
quantities frates, wherever possible)
with source of information data
1.1 Permanent or temporary change in land use,
land cover or topography including increase
intensity of land use (with respect to local land
use plan)
No Proposed project activity is within the
Sarigam GIDC Industrial Estate.
1.2 Clearance of existing land, vegetation and
Buildings?
Yes Minor site clearance activities shall be
carried out to clear shrubs and weed.
1.3 Creation of new land uses?
No The Project site is located on level
ground, which does not require any
major land filling for area grading
work.
1.4 Pre-construction investigations e.g. bore
Houses, soil testing?
No
1.5 Construction works?
Yes Please refer Annexure – II.
1.6 Demolition works? No
1.7 Temporary sites used for construction works
or housing of construction workers?
No
1.8 Above ground buildings, structures or
earthworks including linear structures, cut and fill or excavations
Yes Please refer Annexure – II.
1.9 Underground works mining or tunneling?
No
1.10 Reclamation works?
No
1.11 Dredging?
No
1.12 Off shore structures?
No
1.13 Production and manufacturing processes?
Yes Please refer Annexure –III.
1.14 Facilities for storage of goods or materials?
Yes Raw material storage area & Finished
products area will be developed for
proposed project activity.
1.15 Facilities for treatment or disposal of solid waste
or liquid effluents ?
Yes Effluent generated shall be given
primary, secondary & tertiary
treatment and send to CETP of M/s.
Perfect Enviro Control System Ltd.,
Sarigam for further treatment and final
disposal.
Hazardous waste will be send to TSDF
of M/s. Vapi Waste Effluent
Management Company Pvt. Ltd.
(VWEMCL), Vapi for final disposal
and organic waste will be send to M/s.
GEPIL, Surat for incineration.
For details please refer Annexure – IV
& V.
1.16 Facilities for long term housing of operational workers?
No
1.17 New road, rail or sea traffic during Construction
or operation?
Yes Addition of very few trucks per day.
1.18 New road, rail, air waterborne or other transport
infrastructure including new or altered routes and stations, ports, airports etc?
No
1.19 Closure or diversion of existing transport routes
or infrastructure leading to changes in Traffic
movements?
No
1.20 New or diverted transmission lines or Pipelines?
No
1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of
watercourses or aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water form ground
or surface waters? Yes Water requirement will be met through
GIDC water supply.
1.24 Changes in water bodies or the land surface
Affecting drainage or run-off? No
1.25 Transport of personnel or materials for
construction, operation or decommissioning?
Yes Transportation of personnel or raw
material and products will be primarily
by road only.
1.26 Long-term dismantling or decommissioning or
restoration works? No
1.27 Ongoing activity during decommissioning
which could have an impact on the
environment?
No
1.28 Influx of people to an area either temporarily
or permanently? No
1.29 Introduction of alien species?
No
1.30 Loss of native species or genetic diversity?
No
1.31 Any other actions? No
2. Use of Natural resources for construction or operation of the Project (such as land, water,
materials or energy, especially any resources which are non-renewable or in short supply):
Sr.
No.
Information/checklist confirmation Yes/No Details thereof (with approximate
quantities /rates, wherever possible)
with source of information data
2.1 Land especially undeveloped or agricultural land
(ha)
No Proposed project activity will be within
Chemicals Zone, Sarigam GIDC Industrial
Estate, Dist: Valsad.
2.2 Water (expected source & competing users)
unit: KLD
Yes Water Source: GIDC Water Supply
For details please refer Annexure – VI.
2.3 Minerals (MT) No
2.4 Construction material - stone, aggregates,
and / soil (expected source - MT)
Yes Construction materials, like steel, cement,
crushed stones, sand, rubble, etc. required
for the proposed project shall be procured
from the local market of the region.
2.5 Forests and timber (source - MT) No
2.6 Energy including electricity and fuels (source,
competing users) Unit: fuel (MT), energy (MW)
Yes Please refer Annexure – VII.
2.7 Any other natural resources (use appropriate
standard units)
No
3. Use, storage, transport, handling or production of substances or materials, which could be
harmful to human health or the environment or raise concerns about actual or perceived
risks to human health.
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
3.1 Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
health or the environment (flora, fauna, and
water supplies)
Yes Please refer Annexure –VIII.
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by changing
living conditions?
No
3.4 Vulnerable groups of people who could be
affected by the project e.g. hospital patients,
children, the elderly etc.
No
3.5 Any other causes No
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
4.1 Spoil, overburden or mine wastes No
4.2 Municipal waste (domestic and or commercial
wastes)
No
4.3 Hazardous wastes (as per Hazardous Waste
Management Rules)
Yes Please refer Annexure – V.
4.4 Other industrial process wastes Yes Please refer Annexure – V.
4.5 Surplus product No
4.6 Sewage sludge or other sludge from effluent
treatment Yes
Please refer Annexure – V.
4.7 Construction or demolition wastes No
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes Yes
Please refer Annexure – V.
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
5.1 Emissions from combustion of fossil fuels
from stationary or mobile sources
Yes Please refer Annexure – IX.
5.2 Emissions from production processes Yes Please refer Annexure – IX.
5.3 Emissions from materials handling storage or
transport
No
5.4 Emissions from construction activities
including plant and equipment
No
5.5 Dust or odours from handling of materials
including construction materials, sewage and
waste
No
5.6 Emissions from incineration of waste No
5.7 Emissions from burning of waste in open air e.g. slash materials, construction debris)
No
5.8 Emissions from any other sources No
6.Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data with
source of information data
6.1 From operation of equipment e.g. engines,
ventilation plant, crushers
Yes The Noise level will be within the
prescribed limit. At noisy areas adequate
preventive & control measures will be
taken. No significant noise, vibration or
emission of light & heat from the unit.
6.2 From industrial or similar processes Yes - Do-
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational traffic No
6.6 From lighting or cooling systems No
6.7 From any other sources No
7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
7.1 From handling, storage, use or spillage of
hazardous materials
Yes Please refer Annexure – VIII.
7.2 From discharge of sewage or other effluents to
water or the land (expected mode and place of
discharge)
Yes • The final treated effluent from the
industry shall go to CETP for further
treatment and final disposal.
• Effluent generation from the domestic
will be send to septic tank/soak pit.
7.3 By deposition of pollutants emitted to air into
the and or into water
No
7.4 From any other sources No
7.5 Is there a risk of long term build up of
pollutants in the environment from these
sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect human
health or the environment
S.No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
8.1 From explosions, spillages, fires etc from
storage, handling, use or production of
hazardous substances
Yes Please refer Annexure – X.
8.2 From any other causes No
8.3 Could the project be affected by natural
disasters causing environmental damage (e.g.
floods, earthquakes, landslides, cloudburst
etc)?
No
9. Factors which should be considered (such as consequential development) which could lead to
environmental effects or the potential for cumulative impacts with other existing or planned
activities in the locality
(II) Environmental Sensitivity
Sr.
No.
Areas Name/
Identity
Aerial distance (within 15km.) Proposed
project location boundary
1 Areas protected under international
conventions, national or local legislation for their ecological, landscape, cultural or other
related value
- Proposed project site is within the Sarigam
GIDC Industrial Estate, Dist.: Valsad
2 Areas which important for are or sensitive Ecol
logical reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres,
mountains, forests
Daman
Ganga
River
Daman Ganga River - 13 km away from
Project Site.
3 Area used by protected, important or sensitive
Species of flora or fauna for breeding, nesting,
foraging, resting, over wintering, migration
Dadra
Nagar
Haveli
Reserve
Forest
Dadra Nagar Haveli Reserve Forest – 15
km away from Project Site.
4 Inland, coastal, marine or underground waters - No inland, costal or marine within 15 km
from the proposed project
5 State, National boundaries - N.A. 6 Routes or facilities used by the public for access
to recreation or other tourist, pilgrim areas
- Public transportation
Sr. No.
Information/Checklist confirmation
Yes/No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
9.1 Lead to development of supporting. utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.
• Supporting infrastructure (roads, power
supply, waste or waste water treatment, etc.)
• housing development
• extractive industry
• supply industry
• other
Yes Please refer Annexure – XI.
9.2 Lead to after-use of the site, which could have an impact on the environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to proximity to
other existing or planned projects with similar
effects
No
7 Defense installations - N.A.
8 Densely populated or built-up area Vapi Vapi is around 18 km away from the
proposed project site.
9 Area occupied by sensitive man-made land uses Hospitals, schools, places of worship,
community facilities)
No
10 Areas containing important, high quality or
scarce resources (ground water resources,
surface resources, forestry, agriculture, fisheries, tourism, minerals)
No
11 Areas already subjected to pollution
environmental damage. (those where existing
legal environmental standards are exceeded)or
- N.A.
12 Areas susceptible to natural hazard which could cause the project to present environmental
problems (earthquake s, subsidence ,landslides,
flooding erosion, or extreme or adverse climatic conditions)
- N.A.
IV). Proposed Terms of Reference for EIA studies: N.A.
LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE
I List of Products along with their Production Capacity
II Plant Layout
III Brief Manufacturing Process Description
IV Details of Effluent Treatment Plant
V Details of Hazardous Waste Generation and Disposal
VI Details of water consumption & waste water generation
VII Details of Fuel & Energy Requirements
VIII Details of Hazardous Chemicals Storage & Handling
IX Details of Stacks and Vents
X Risk Scenario
XI Socio-economic Impacts
ANNEXURE-I
_______________________________________________________________________
LIST OF PROPOSED PRODUCTS ALONG WITH THEIR PRODUCTION
CAPACITY WITH RAW MATERIALS
SR. NO. NAME PROPOSED QUNTITY
(MT/MONTH)
Pesticide Products
1 Glyphosate
100
2 PMIDA (Intermediate)
3 Acephate
4 Cypermethrin
5 Permethrin
6 Lambda Cyhalothrin
7 Alphamethrin
8 Imidaclorpid
9 Acetamipid (Acetamiprid)
10 Thioclorpid
11 Temephos
12 Dichlorovos
13 Thiomethoxan (Thiomethoxam)
14 Metsulfuron Methyl
15 Paraquat
16 Imazethapyr
17 2-4 D-Ethyl Ester
18 Copper Oxy Chloride
19 Ziram
20 Carbendazim
21 Butachlor
22 Chloropyriphos
23 Tricyclozole
24 Bifenthrin
25 Chodinofop
26 4-Amino 1,2,4 Triazole (Intermediate)
By Products
27 Ammonium Acetate Solution (44.92 %) 179.4
28 Sodium Sulfide (Sulfit)e 110.7
29 HCl (30 %) 92
ANNEXURE-II
_______________________________________________________________________
PLANT LAYOUT
HO
HOP
O
CH2 NCH2COOH
CH2COOH
++
O2CH2COOH
NCH2
O
PHO
HO
HCO2 HCHO+
ANNEXURE-III
_______________________________________________________________________
MANUFACTURING PROCESS
1. GLYPHOSATE
1.1 Process Description
PMIDA is oxidize under pressure at 50 oC in presence of carbon catalyst. The mass is
concentrated, crystallize, filter and dried to get Glyphosate technical.
1.2 Chemical Reaction
1.3 Material Balance
Stage - 1: Preparation of IDA.HCl
Cl - CH
2
- COOH + NH
4
OH + Ca(OH)
2
+ HCl + H
2
O
Monochloro
Acetic Acid
Ammonium
Hydroxide
Calcium
Hydroxide
Hydrochloric
Acid
Water
HCl
NH
CH
2
- COOH
CH
2
- COOH
+ CaCl
2
+ H
2
O
IDA.HCl
Calcium Chloride
Water
Stage - 2: Preparation of PMIDA
IDA.HCl
CH2 - COOH
CH2 - COOH
NH
HCl
+ H
3
PO
3
+ HCHO + H
2
O
Phosphorus Acid
Formaldehyde
Water
P - CH
2
- N
OHO
HO
CH
2
- COOH
CH
2
- COOH
+ H
2
O + HCl
PMIDA
Water Hydrochloric Acid
(Phosphono Methyl Imino Diacetic Acid)
2. PMIDA (Intermediate)
2.1 Process Description
MCA (Monochloro acetic acid) is reacted with Ammonia in presence of Calcium hydroxide
forming hydrochloric salt of IDA (Imino di acetic acid). The reaction is carried out at 45°C
under atmospheric condition. After reaction the mass is chilled to below 10°C & filtered. Wet
cake of IDA.HCl is further reacted with phosphorus acid & Formaldehyde at 110 to 115°C to
give PMIDA.
PMIDA is reacted with Ammonia solution to make Ammonium salt of PMIDA, which further
with oxygen in presence of carbon catalyst to give Ammonium salt of Glyphosate. During
reaction CO2 & Formaldehyde gas is evolved which is scrubbed in water scrubber followed by
caustic scrubber. The mass is acidified with Sulphuric acid & crystallized it as 0 to 5°C to get
Glyphosate acid.
2.2 Chemical Reaction
H2O 1300 Kg
MCA 1332.15 kg
20% Amm. Sol. 119.82 kg
Ca(OH)2 522.21 kg
HCl 30% 257.26 kg
22.48% CaCl2 solution 2337.03 kg
H3PO3 577.97 kg
37% HCHO 211.4 kg
H2O 380.6 kg
IDA.HCl 1194.71 kg
Evaporation loss 18.6
Kg
Waste water 2156.14 kg
PMIDA 1600 kg
HCl 1410 kg
2.3 Material Balance
Stage : 1
IDA. HCl
Reaction
Stage : 2
PMIDA
Reaction
3. ACEPHATE
3.1 Process Description
Dimethyl Phosphoro Amido Thioate (DMPAT) is isomerizes to Methamediphos catalytic
reaction at 30oC and atmospheric pressure. After Isomerization, the mass is reacted with
acetic anhydride at 40oC in the presence of Dichloro methane as solvent. It is neutralized with
aqueous ammonia. The layers are separated and aqueous layer containing Ammonium acetate
is sold as by product. The organic layer is taken in another reactor for dichloromethane
recovery and Acephate separation.
Recovered dichloromethane is recycled in the next batch and Acephate solution. It is
centrifuged at 50oC. Ethyl acetate is recovered from the mother liquor of crude Acephate cake
and it is recycled. The residue is incinerated. The cake is dried in rotary vacuum dryer. The
dry acephate is filled in bags as final packing.
3.2 Chemical Reaction
CH3O S CH3S O
P NH2 P NH2
CH3O CH3O
Dimethyl phosphoro amido thioate Methamidophos
CH3S O CH3 CO CH3S O
P NH2 + O P NHCOCH3 + CH3COOH
CH3O CH CO CH3O
Methamidophos Acetic anhydride Acephate Acetic acid
CH3COOH + NH4OH CH3COONH4 + H2O
Acetic acid Ammonium hydroxide Ammonium Acetate water
3.3 Material Balance
4. CYPERMETHRIN
4.1 Process Description
The reaction mixture of Cypermethric acid chloride & metaphenoxybenzaldehyde is reacted
with sodium cyanide in presence of hexane. The reaction is carried under controlled
temperature conditions in presence of phase transfer catalyst.
The reaction mass is then washed with water. After completion of washing the organic mass is
taken up for recovery of the excess hexane, to get Cypermethrin technical.
The Aqueous waste with traces of sodium cyanide is de
Sodium Hypochlorite 8% concentrated solution. The solution is treated such that the treated
waste contains sodium cyanide up level of < 0.2 ppm.
4.2 Chemical Reaction
The reaction mixture of Cypermethric acid chloride & metaphenoxybenzaldehyde is reacted
with sodium cyanide in presence of hexane. The reaction is carried under controlled
ence of phase transfer catalyst.
The reaction mass is then washed with water. After completion of washing the organic mass is
taken up for recovery of the excess hexane, to get Cypermethrin technical.
The Aqueous waste with traces of sodium cyanide is detoxified by treating the aqueous with
Sodium Hypochlorite 8% concentrated solution. The solution is treated such that the treated
waste contains sodium cyanide up level of < 0.2 ppm.
The reaction mixture of Cypermethric acid chloride & metaphenoxybenzaldehyde is reacted
with sodium cyanide in presence of hexane. The reaction is carried under controlled
The reaction mass is then washed with water. After completion of washing the organic mass is
toxified by treating the aqueous with
Sodium Hypochlorite 8% concentrated solution. The solution is treated such that the treated
4.3 Material Balance
5. PERMETHRIN
5.1 Process Description
Meta Phenoxy Benzyl Alcohol is reacted with Cypermethric Acid Chloride (CMAC) to
give the Permethrin mass.
Hydrochloric acid gas is generated during the reaction which is scrubbed in water to get
30% solution of hydrochloric acid. The resu
carbonate solutions as well as water. And finally the remnesant water is dehydrated off &
to get the pure Permethrin Tech.
5.2 Chemical Reaction
Meta Phenoxy Benzyl Alcohol is reacted with Cypermethric Acid Chloride (CMAC) to
Hydrochloric acid gas is generated during the reaction which is scrubbed in water to get
30% solution of hydrochloric acid. The resulting mass is then washed by potassium
carbonate solutions as well as water. And finally the remnesant water is dehydrated off &
to get the pure Permethrin Tech.
Meta Phenoxy Benzyl Alcohol is reacted with Cypermethric Acid Chloride (CMAC) to
Hydrochloric acid gas is generated during the reaction which is scrubbed in water to get
lting mass is then washed by potassium
carbonate solutions as well as water. And finally the remnesant water is dehydrated off &
5.3 Material Balance
6. LAMBDA CYHALOTHRIN
6.1 Process Description
Crysanthanic Acid is chlorinated with thionyl chloride as the chlorinating agent using hexane
as the solvating media. Sulphur di Oxide and hydrochloric acid gas which is evolved is
scrubbed in a two stage scrubber.
The reaction mass Tri Fluoro Propenyl Acid Chloride (TFP Acid Chloride) is then condensed
with Meta Phenoxy Benzaldehyde, Sodium Cyanide to form the Product Cyhalothrin. In this
process n - Hexane is used as solvent along with phase transfer Catalyst.
The reaction mass of Cyhalothrin is washed with water. The aqueous is separated for
detoxification. Solvent- n-Hexane is stripped off to get pure Cyhalothrin oil. Finally Cyhalothrin
oil is epimerized in Isopropyl Alcohol to give Lambda Cyhalothrin of 85 % (Min.)
An aqueous layer which contains traces of Sodium Cyanide is detoxified by the treatment of
Sodium Hypochlorite Solution (8 - 10%) up to < 0.2 ppm Level. Then it is mixed up with main
ETP stream for further treatment & finally discharged to CETP System.
6.2 Chemical Reaction
6.3 Material Balance
Cl2 HC
CH3 CH3
C
O
O CH CN
O
Epimerisation
Cypermethrin Alphamethrin
O
CNCH
CH3CH3
HCCl2 CO2
7. ALPHAMETHRIN
7.1 Process Description
The cypermethrin is subjected to epimerization at 25 oC in the presence of triethyl amine in
solvent hexane to obtain alphamethrin. Then it is filtered and dried under vacuum. Hexane and
TEA are recovered and recycled. The purity of Alphamethrin obtained will be minimum 95 %.
7.2 Chemical Reaction
7.3 Material Balance
INPUT QTY
(KG)
OUTPUT QTY
(KG)
Cypermethrin 1250 Alphamethrin 1000
Triethylamine 300 Triethylamine (Recovered) 285
Water 500 n-Hexane (Recovered) 552
n-Hexane Cypermethrin 250
n-Hexane (Recovered) 552 Waste water 563
n-Hexane (Fresh) 48
Total 2650 Total 2650
N N NH
N-NO
2
N
Cl.CH
2
+
Cl
2-Chloro5-Chloro Methyl Pyridine
NaOH
DMF
N
Cl
2
N NH
N-NO
2
CH
2
I Mida Cloprid
8. IMIDACLORPID
8.1 Process Description
(A) dimethylformamide is charged into the reactor to which is added 2-nitroimidazolidine.(B)
2-chloro-5-chloromethylpyridine is charged into the reactor to form solution. (C) Solution in
reactor (B) is charged to reactor mass of (A) to which is added sodium hydroxide. It is stirred
for 6 hrs. After reaction is complete the reaction mass is filtered to remove Nacl formed in the
reaction. The filtrate is distilled to remove DMF. The concentration filtrate is reacted with
hydrochloric acid to precipitate imidacloprid which is filtered and dried.
8.2 Chemical Reaction
8.3 Material Balance
BASIS: 1MT/day
Reactor
Reactor
Filter
Reactor
Filter
600 Kg 2-Chloro-5-Chloromethyl Pyridine
2000 Liter DMF
1500 Liter DMF
510 Kg 2-Nitroiminoimidazolidine
160 Kg Caustic Soda
DMF
Cake sodium chloride to solid
waste
40 Liter Hydrochloric acid
Imidacloprid for drying
Filtrate to Effluent
N
Cl
CH
2
Cl
+
HN - C - CH
3
CH
3
N
CN
CH
2
Cl
N
N
CH
3
CH
3
N
CN
DMF
K
2
CO
3
2-Chloro 5-Chloromethyl Pyridine
2-Cyanoimino
2-methylamino Ethane
Acetamiprid
9. ACETAMIPID
9.1 Process Description
(A) 2-Chloro 5- chloro methyl pyridine is charged to a reactor containing dimethylformalmide.
It is stirred for 1hr to form solution. (B) Dimethylformamide is charged to the reactor to which
is added 2-cyanoimino 2-methylamino ethane and stirred for 1 hrs. (C) Solution in (A) is
charged to solution (B) followed by potassium carbonate. It is stirred for 4.5hrs. After reaction
is complete the reaction mass is filtered to remove potassium chloride formed during the
reaction. DMF which is recycled to the concentration reaction mass is added 30% hydrochloric
acid to precipitation out acetamiprid which is filtered and dried
9.2 Chemical Reaction
9.3 Material Balance
BASIS: 1 MT/day
Reactor
(A)
Reactor
Filter
Reactor
(B)
Filter
770 Kg 2-Chloro-5-Chloromethyl Pyridine
2000 Liter DMF
1500 Liter DMF
460 Kg 2-Cynoimino 2-Methylamino Ethane
340 Kg Potassium Carbonate
DMF
Cake of Potassium chloride
60 Liter Hydrochloric acid (30%)
Acetamiprid for drying
Filtrate to rectification
HN S
N
CN
+
N
Cl
ClCH2
K
2
CO
3
DMF
N
Cl
CN
N
N S
2-Cyanoimino Thiazole
2-Chloro 5-Chloromethyl Pyridine
Thiacloprid
10. THIOCLORPID
10.1 Process Description
(A) dimethylformamide is charged into the reactor to which is added 2-chloro 5-chloromethyl
pyridine and stirred to form solution. (B) Dimethylformamide is charged into the reactor to
which is added 2-cyanoimino thiazole. It is stirred to form solution. (C) Solution in reaction
(A) is charged to solution in (B) followed by potassium carbonate. It is stirred for 6hrs. After
reaction is complete, the reaction mass is filtered to remove potassium chloride formed during
the reaction. The filtrate is concentrated by distilled DMF which is recycled to the concentrated
mass is now added, hydrochloric acid to precipitate out THIACLOPRID which is filtered and
dried.
10.2 Chemical Reaction
10.3 Material Balance
BASIS: 1 MT/day
675 Kg 2-Chloro-5-Chloromethyl Pyridine
Cake of Potassium chloride
50 Liter Hydrochloric acid
Reactor
Reactor
Filter
Reactor
Filter
1800 Liter DMF
1500 Liter DMF
530 Kg 2-Cynoimino Thiazole
290 Kg Potassium Carbonate
DMF
Thiacloprid for drying
Filtrate to rectification
11. TEMEPHOS
11.1 Process Description
TDS is condensed with DMTC in presence of a phase transfer catalyst. MDC is used as
solvent. Caustic Lye is added to the mass for pH maintaining. After complete reaction, the
mass is heated & water is added for the purpose of washing. Aqueous is separated and
discharged to ETP for further treatment. MDC is then recovered to 95% (min) to give
Temephos Tech. (90%) as final product.
End Use
Pesticide formulation & as an Insecticide.
11.2 Chemical Reaction
11.3 Material Balance
12. DICHLOROVOS
12.1 Process Description
Dichlorovos Technical is manufactured by condensing Chloral and trimethyl Phosphate. After
condensation Methyl Chloride is removed by deg
The Dichlorovos thus obtained is packed in HMHDPE drums and dispatched.
12.2 Chemical Reaction
Dichlorovos Technical is manufactured by condensing Chloral and trimethyl Phosphate. After
condensation Methyl Chloride is removed by degassing.
The Dichlorovos thus obtained is packed in HMHDPE drums and dispatched.
Dichlorovos Technical is manufactured by condensing Chloral and trimethyl Phosphate. After
12.3 Material Balance
HN
O
N
N- NO
2
-CH
3
+
N
S
Cl
CH
2
Cl
DMF
K
2
CO
3
Cl
N
S
N
O
N-CH
3
N
NO
2
4-Nitroimino 3-methyl Isoxazole
2-Chloro 5-Chloro
mthyl Tiazole
Thiamethoxam
13. THIOMETHOXAN
13.1 Process Description
(A)Dimethylformamide is charged into the reactor, to which is added of 2-chloro 5-
chloromethyl thiazole. (B) 4-Nitroimino 3-methyl isoxazole is charged into
Dimethylformamide take into the reactor. It is stirred for 1 hr to form solution. (C) Solution in
(B) is charged into reaction mass of solution (A) to which is added potassium carbonate. It is
stirred for 5 hr. After reaction is over the reaction mass is filtered to remove potassium chloride
formed in the reaction. The filtrate is distilled to remove DMF. The concentrated filtrate is
reacted with 30 % Hydrochloric acid to precipitate Thiamethoxam.
13.2 Chemical Reaction
13.3 Material Balance
BASIS: 1 MT/day
Reactor
(B)
Reactor
Filter
Reactor
(A)
Filter
600 Kg 4-Nitroimino-3-methyl Isoxazole
2000 Liter DMF
2000 Liter DMF
638 Kg 2-Chloro-5-Chloromethyl Thiazole
270 Kg Potassium Carbonate
DMF
Thiamethoxam for drying
Filtrate to rectification
50 Liter Hydrochloric Acid (30%)
Cake of Potassium Chloride to
Solid wast
C
S NH
2
O
O
O
O - C - H
+ O
C
O-CH
2
-CH
3
Cl
Na
2
CO
3
O-Sulfamoyl Methyl Benzoate
Ethyl Chloro Formate
CH
3
CH
2
O
C
NHS
CH
3O
C
O
+
N
N
N
NH
2
H3
CO
CH
3
2 Amino 4methoxy 6 methyl 1,3,5 triazine
O
C
O
CH
3
O
C
O
O
C
O
S NH
C N
N
N
CH
3
OCH
3
Metsulfurun-Methyl
14. METSULFURON METHYL
14.1 Process Description
O-Sulfamol methyl benzoate is charged into the reactor to which xylene is charged this is
further reacted with Ethylcloroformate and soda ash is added slowly. After reaction is over the
reaction mass is filtered to remove sodium chloride. The filterate is taken into another reactor
to which is added 2, amino 4- methyl 1,3,5triazine. The mass is stirred for 4 hrs. After reaction
is over Xylene is distilled out which is recycled,, the mesulfuron methyl formed is filtered and
dried.
14.2 Chemical Reaction
14.3 Material Balance
BASIS: 1MT/day
Reactor
Filter
Reactor
Filter
1500 Liter Xylene
160 kg Soda Ash
650 kg o-Sulfomoyl methyl benzoate
330 kg Ethylchloro formate
Wet cake to Solid
Waste Filtrate
425 kg 2-amino 4-methoxy 6-methyl
1,3,5 triazine
Filtrate
Xylene Distilled
Metsulfuron Methyl for Drying
N
N
+ 2 CH
3
Cl
H
3
CN
N
+ CH
3
. 2Cl
-
Bipyridyl Methyl Chloride
15. PARAQUAT
15.1 Process Description
Bipyridyl is added to water to which is added methyl chloride gas. The mass is stirred,
concentrated and filtrate is recycled.
15.2 Chemical Reaction
15.3 Material Balance
BASIS: 1 MT/Day
Reactor
Filter
1650 Liter Water
650 Kg Water Bipyridyl
420 Kg Methyl Chloride
Wet Cake for Paraquat Drying
Filtrate
N
C
2
H
5
C
C
O
O
O
+
H
3
C
CH
2
CH
CH
3
NH
2
CH
3
C
O
NH
2
O
O
C
C
N
C
2
H
5
N
C
CH
3
H
2
C-CH
3
C
CH
3
O
NH
2
+
NaOH
N
N
C
2
H
5
C
O
OH
O
CH
3
CH
2
CH
2
CH
2
2,3 Dicarboxylic acid anhydride,
5-methyl pyridine
2-amino 2,3 dimethyl butyramide
Imazethapyr
16. IMAZETHAPYR
16.1 Process Description
Xylene is charged in to the reactor to which is added dicarboxylic acid anhydride, 5-methyl
pyridine followed by 2-amino 2, 3,dimethyl butyramide. The mixture is stirred for 6hrs. After
completion of reaction 25% sodium hydroxide is charged. After reaction is over aqueous layer
is separated, xylene is distilled out which is recycled and reaction mass is filtered to give
imazethapyr.
16.2 Chemical Reaction
16.3 Material Balance
BASIS: 1 MT/day
Reactor
Reactor
Filter
1500 Liter Xylene
650 kg 2,3 dicarboxylicacidanhydride 5-ethyl pyridine
480 kg 2-amino 2,3 dimethyl butyramide
584 Kg
Caustic Soln. (25%)
Aqueous Layer
Aqueous Layer
Xylene Distilled
Effluent
Imazethapyr to Drying
O.CH 2COONa.H 2O
Cl
Cl
H2SO4 C2H5OH+ +
Cl
Cl
O-CH2-C-O-CH2-CH3
O
NaHSO 4 2H2O+ +
17. 2-4 D-ETHYL ESTER
17.1 Process Description
Sodium Salt is charged into the reactor along with Ethyl Alcohol to from Homogenous
mixture.
Sulphuric acid is added slowly into the reactor. The mass is continuously stirred for 3 hrs.
Bottom layer separated from organic mass and sent for neutralization and recovery. Mother
liquor is washed, neutralized and heated to about 70 oC to make it moisture free and packed in
200 kg barrels.
17.2 Chemical Reaction
100 kg S S
558 kg Sulphuric
Acid (98%)
327 kg Alcohol (90%)
Mother Liquor
Spent
954.8 kg
930.2 kg
To next stage
To Detoxificaation
Mother Liquor 954.8 Kg
800 Ltr Water
+
30 kg TEA
879 kg Ester
40 kg
821.85 kg Effluent
44 kg Water atm.
loss
Final product
Recycled
To Detoxificaation
821.85 kg
+ +
930.2 kg
+
65 kg NaOH
665.4 kg Na2SO4 By Product
1151.65kg Effluent
To ETP
17.3 Material Balance
Stage : 1
Condensatio
n
879.4 kg Ester
40 kg untreated
acid
20 kg water
8.4 kg H2So4
125.25 kg Alcohol (100
%)
159.44 kg Sulphuric (100
%)
468.40 kg Na So4
Stage : 2
Neutralizatio
n & Recovery
125.25 kg
Alcohol (100
%)
+
Stage : 3
Detoxification 125.25 kg
Alcohol (100
%)
+
2Cu + 2HCl CuCl2.Cu(OH) 2
O2
18. COPPER OXY CHLORIDE
18.1 Process Description
Copper scrap is charged into a reactor and HCl added. Air is continuously purged into the
reactor till Copper Oxy Chloride technical is formed. Mother liquor is discharged and
neutralized to obtain 7 pH. Copper Oxy Chloride is centrifuged to obtain wet cake which is
further dried for final product.
18.2 Chemical Reaction
Copper Scrap Fresh 622 kg
HCL (30%) 591 kg
Water 800 kg
Air
Recycled Copper Scrap 2387
kg Recycled HCl (3%) 1000 kg
Water (Air Scrubber) 800 kg
1000 kg. 3% HCl Soln.
from Air Scrubber
2387 kg. Copper Scrap
1056 kg.COC Tech.
2000 kg. Water
19.5 kg. HCl (100%)
Recycled
Recycled
2813
slurry COC
pH-6-6.5
to next stage
Slurry 6161
+
Water 500 kg.
+
NaOH 21.40 kg
1500 kg COC cake
+ 5176.15 kg. water
+ 31.25 kg. NaCl
+ 5 kg.
5212.40 kg
To
effluent
treatment
1500 kg by cake
1051 kg COC
449 kg Water
Final Product
Loss of atmosphere
18.3 Material Balance
Stage : 1
Air
Oxidation
Stage : 2
Neutralizatio
n
+
Filtration
Stage : 3
Drying
+
Filtration
(A)
NH
CH
3
CH
3
+ CS2 + NaOH
N - C -S Na
+ H
2
O
Dimethyl
Amine
Carbon
Disulphide
CH
3
Sodium Dimethyl Dithio Carbamate
(B)
N
CH
3
CH
3
- C - S Na + ZnSO
4
S
CH
3
S
CH
3
N - C -S Zn
CH
3
-S -C -N
CH
3
CH
3
S
Zinc Dimethyl Dithio Carbamate
2
19. ZIRAM
19.1 Process Description
(A) Caustic soda solution is charged to the reactor to which added water and dimethylamine
solution (40%). Then carbondisulfide is added slowly to complete the reaction to give of
sodium dimethyl dithiocarbamate solution(40%). (B) Above solution is charged into the reactor
to which added water and zinc sulphate heptahydrate solution in water. The reaction mass is
stirred for two hours and filtered, washed to give ziram.(C) Water is charged into the reactor to
which added ziram wet cake. The reaction mass is stirred for 2-3 hrs and packed ziram 27% cs.
19.2 Chemical Reaction
19.3 Material Balance
BASIS: 5000 Liter/day
Reactor
Reactor
Filter
Reactor
850 Liter Water
1200 Kg DMA
905 kg C. S. Lye
850 kg Carbon Disulfide
7000 Liter Water 1520 Kg Zinc Sulphate Heptahydrate Soln.
1500 Liter Water
To Packing
Filtrate
Wet
Cake
S = C
H
3
C - O
NH
2
NH
2
S
O
O
O
H
3
C
+
Thiourea
Dimethyl Sulphate
H
3
C - S
- C
NH
2
NH
2
+(SO
4
)
-
Y
2
+ O = C
Cl
O - CH
3
Methyl Chloroformate
+ NaOH
H
3
C - S - C
NH
2
N
C
O
O - CH
3
+
NH
2
NH
2
O-Phenylene Diamine
Methanol
NH
N
C
- N - C
O
OCH
3
Carbendazim
20. CARBENDAZIM
20.1 Process Description
(A) Thiourea is mixed with water and to is dimethyl sulphate. It is refluxed and cooled to room
temperature (B) This is added to another reactor to which is added Methyl clorofomate, water
and 25% caustic soda solution. This is stirred for 2 hrs and filtered. (C) The wet cake is reacted
with O-Phynylene diamine and methanol.The reaction mass is stirred for 3 hrs and then
methanol is distilled out and carbendazim formed is filtered and dried.
20.2 Chemical Reaction
20.3 Material Balance
660 kg o-Phenylene
diamine
Reactor
Reactor
Reactor
Filter
Filter
420 kg Thiourea
200 Liter Water
600 kg Dimethyl Sulphate
520 kg Methyl Chloroformate
3000 Liter Water
880 Kg NaOH soln. (25%)
1000 Liter Methanol
Filtrate to Effluent
Carbendazim
Methanol distilled and
recycled
N
C2H5
C2H5
CH2Cl
COCH 2ClC4H9OH+
COCH 2Cl
C2H5
C2H5
N
CH2OC4H9
NH3
CH2OC4H9N
C2H5
C2H5
COCH 2Cl
Butachlor
21. BUTACHLOR
21.1 Process Description
MRM is reacted with Butanol to get Butachlor Technical under controlled temperature.
Ammonia gas is purged to neutralize the hydrochloric acid formed. Mother Liquor is washed to
remove ammonium chloride and taken for concentration to get Butachlor Technical.
21.2 Chemical Reaction
21.3 Material Balance
Reactor + Neutralizer
SS Reactor
(Washing)
Distillation
Filtration
MRM (900 Kg)
Butanol (650 Kg Recycle +
350 Kg = 1000 kg)
Ammonia Gas (50-60 Kg)
Water (1000 Kg)
Butanol (650 Kg) Recycle to
Reactor + Neutralizer
Butachlor (1050 Kg) for packing
Water (1000 Kg)
NH4Cl (175 Kg)
To ETP
&
Recovery
CCl3COCl CH2 CH.CN+
OH
Cl
Cl
Cl
N
N
Cl
Cl
Cl
OH
+ NaOH
Cl
Cl
Cl
N
ONa
+ H2O
ONa
N
Cl
Cl
Cl
+ Cl P
OC2H5
OC2H5
SCl
Cl
Cl
N
S
OC2H5
OC2H5PO
NaCl+
22. CHLOROPYRIPHOS
22.1 Process Description
NaHTCP is reacted with DETC in presence of phase transfer catalyst at room temp. EDC is
used as solvent. After reaction aqueous phase in separated and sent to ETP for treatment.
Organic mass is concentrated under vacuum to get CPP technical.
25.2 Chemical Reaction
400 KGS
450 KGS
401Kgs
2000 KGS
12 KGS CATALYST
TCAC
DRUM
2900 KGS
310 KGS 3000 KGS
5272 KGS
400 KGS
1962 KGS HTCP MASS
5400 KGS WATER
3000 KGS CAUSTIC LYE
(47-48%)
UTILITY
BRINE WATER 1010-15 C
UTILITY
LPS -4 KGS
CH-WATER
10362 KGS Na-HTCP MASS
5217 KGS 4145 KGS
5834 KGS 4557 KGS
UTILITY
CHILD WATER
3500 KGS
1391 KGS
7781 KGS
Utility CW
22.3 Material Balance
V-9022 ACN DAY
TANK 5 S 316, 2.2 KL 15 MTR.
ACN TANK
V- 9001A SS 316, 12
KL 0 MTR
HTCP REACTOR
R-9003 C MSGL
6.3 KL 5 MTR
HTCP REACTOR
R-9003 B MSGL
8.3 KL 5 MTR
HCL SCRUBBER
FRB 10 Mtr
TCAC DAY
TANK MSLL, 2.5
KL 10 MTR
HTCP REACTOR
R-9004 B MSGL
8 KL 5 MTR
CPN TANK
R-9004B
MSLL,KL
0 MTR
HTCP DISTILATION
R-9005 A MSGL 6.3
KL 15 MTR
N3 - HTCP PREPARATION
R-9001 SS-316, 10 KL 10
MTR PRESSURE REACTOR
R-9008 SS-316, 7.5 KL
15 MTR
PRESSURE REACTOR
R-9008 SS-316, 6 KL 10
MTR
CPN ®TANK, ICU
V-
MSGL, 1 KL
0 MTR
CPN (RS) TANK, II CUT
V- 5101A
MSLL, 6 KL
0 MTR
SLURRY HOLD TANK
PP+FRP 10 KL
10 MTR
SLURRY COOLER MS
14 KL + 10 MTR
ML HOLD TANK
MS CARBON 10 KL
9 MTR
SLURRY FILTRATION
PP FILTER PRESS
5 MTR WAT CAKE
SLURRY PREPARATION V- 9013 A MS FRP, 5 KL 5 MTR
SLURRY PREPARATION V- 9013 A MS FRP, 5 KL 5 MTR
TOXIFICATION REACTOR R- 9002 A SS FRP, 6.5 KL 10 MTR
FILTRATION WOODEN FILTER PRESS NOs OF PLATE
1 st
SEPRATOR
SS 316 10 MTR
2 nd
SEPRATOR
SS 316 5 MTR
ML TANK V- 9010 MA CARBON 12 KL 0 MTR
EMUISON TANK V-43 S SS 31 B KL 0 MTR
ORGANIC HOLD TANK SS 316, 5 KL 0 MTR
EDC RECOVERY R-9007 A SS 316, 6 KL 15 MTR
CRYSTALISER CR-1, SS 316 10 MTR
CRYSTALISER CR-2, SS 316 10 MTR
METHANOL RECOVERY R- 9006 SS 316, 6 KL 5 MTR
7762.4 KGS MASS FOR FILTRATION 7752.4 KGS MASS FOR FILTRATION
3400 KGS SLURRY
500 KGS WATER (2 TIMES)
7552.4 KGS CLEAR FILTARATE (ORG +AQ) 200 KGS WAT CAKELUT
EMULSION
352.4 KGS
4400 KGS URG
3800 KGS Aqu
1000 KGS WASH
PRODUCT CPP TECH GRADE 3500 KGS
ML FOR 2 nd
CROP 1775.6 KGS FOR 2 nd
CROP
500 KGS AS 2 nd
CROP
1275.6 KGS
RESIDUE
795.6
4500 KGS ORGAN MASS FOR EDC RECOVERS
4860 KGS CRUDE (6 EDC LOTS)
1820 KGS
EDC LOSS
16200 KGS
EDC RECOVER
50 KGS METHANOLE RECOVER
50 KGS
METHANOLE RECOVER
3800 KGS EDC 35 KGS NaCl 59 KGS HCl 7 KGS TEBA 0.4 KGS 4-DMAP 636 KGS DETC 120 KGS Na2Co3 10KGS MOREWAT
1800 KGS WET CARE
1600 KGS WATER
1800 KGS WET CARE
1600 KGS WATER
PART –B PART –A
23. TRICYCLOZOLE
23.1 Process Description
2 Hydrazino -4- Methyl Benzo Thiozole is reacted with Formic Ac
reaction at 110 degree Centigrade. The reaction mass is maintained for about 8
completion of the reaction the mass is drowned in Chilled water. Subsequently it is filtered in a
nutche. The massed is centrifuged and dried
23.2 Chemical Reaction
Methyl Benzo Thiozole is reacted with Formic Acid; this is a cyclzation
reaction at 110 degree Centigrade. The reaction mass is maintained for about 8
completion of the reaction the mass is drowned in Chilled water. Subsequently it is filtered in a
nutche. The massed is centrifuged and dried to get in a tray drier for Tricyclozole (technical).
id; this is a cyclzation
reaction at 110 degree Centigrade. The reaction mass is maintained for about 8-10 hrs. On
completion of the reaction the mass is drowned in Chilled water. Subsequently it is filtered in a
to get in a tray drier for Tricyclozole (technical).
23.3 Material Balance
F
F
F
c c c cc
Cl
Cl
Cl
CH2CH2
CH3
CH3
OCH 3
O
H
+ CH3 CH3
CH3
OK
C
CH3
Cl
cc
F
F
F CH
CH3O
OCH 3
c+SOCl2
c
OCH3
CHc
Cl
CH3
F3C
Cl
+
HOH 2C CH3
F3C
CH3
Cl
c CH
CH3O
c
CH3
O
CH2
Bifenthrin
24. BIFENTHRIN
24.1 Process Description
Hexane is charged into reactor to which is added cyhalothrin followed by potassium t-butoxide.
It is stirred for 4 hrs. after reaction is complete, the reaction mass is cooled. Water is added to
remove potassium chloride formed in the reaction. Aqueous layer is separated and hexane is
distilled out. After that thionyl chloride is charged. Hydrochloric acid gas and sulfur dioxide is
scrubbed in caustic solution. After reaction is over again hexane is added and excess of thionyl
chloride is recovered by distillation. This is followed by addition of 2-methyl 3-methylhydroxy
bipyridyl. It is stirred for 6 hrs. after reaction is over hexane is distilled out and after cooling
Bifenthrin is filtered and dried.
24.2 Chemical Reaction
24.2 Material Balance
BASIS: 1 MT/Day
Reactor
Filter
815 Kg Cyhalothrin
3000 Liter Hexane
480 Kg 2-methyl
3-methylhydroxy bipyridyl
276 Kg Potassium t-butoxide 300 Liter SOCl2
SO2 + HCl to scrubber
Hexane distilled recycled
Solvent
Bifrnthrin
N
Cl
Cl
Cl
F2+
F
FCl
Nsolvent
OH
OH
+
N
OH O Cl
F
+H3C CH C
OC2H5
OHCl
O
N
F
Cl O CH
CH3
COOH
Clodinofop
25. CLODINOFOP
25.1 Process Description
2,3,5 Trichloro pyridine is reacted with fluorine in a vessel to give 2,3 Difluoro 5-chloro
pyridine which is further reacted with hydroquinone solvent is distilled out and reaction mass is
cooled and filtered. The product is further reacted with ethyl ester of 2-chloro propionic acid in
presence of toluene. After reaction is over, the toluene is distilled out. The reaction mass is
cooled and filtered to give Clodinofop which is dried.
25.2 Chemical Reaction
25.2 Material Balance
BASIS: 1 MT/Day
Reactor
Filter
375 Kg Hydroquinone
260 Kg 2,3,5 Trichloro pyridine 130 Kg F2
Solvent
Solvent
Solvent
Reactor
Filter
3000 Liter Toluene 470 Kg ethyl ester of 2-chloro propionic acid
Toluene
Toluene distilled
Filter Cake Clodinofop for drying
H.NH.NH 2.H2O HCHO H C
O
N
H
NH2+
Hydrazene Hydrate Formic Acid
2H2O+
NH2
H
N
O
CH
Reflux
140 oC
H
H
NH2
+ 2H2ONC
N
N
C
4-Amino 1,2,4 Thiazole
26. 4-AMINO 1,2,4 TRIAZOLE
26.1 Process Description
Hydrazene Hydrate is charged in reactor followed by formic acid at 45 oC. The mass is
refluxed at 140 oC for 24 hrs. Mass is cooled to 50
oC and dried atmospherically. Finally
powder is dried in a drier and packed.
26.2 Chemical Reaction
26.3 Material Balance
Reactor
Hydrazene Hydrate (80 %) 1800 kg
Formic Acid (85 %) 1548 kg
Methanol 105 kg
Effluent 2453 kg
4-amino 1,2,4 Triazole 1000 kg
ANNEXURE - IV
DESCRIPTION OF EFFLUENT TREATMENT PLANT WITH FLOW DIAGRAM
M/s. Anu Products Ltd. is proposing a new ETP of consisting of primary, secondary and
tertiary treatment units. A detail of the proposed ETP plant with unit dimensions is given
below.
PROCESS DESCRIPTION OF PROPOSED ETP
Raw effluent from all the plants will be transferred by means of effluent transfer pumps to Oil
& Grease Trap. The oily scum will be removed here and then effluent will be allowed to enter
into Collection cum Equalization Tank. The fixed type diffusers will be provided at the bottom
& air will be supplied by Air Blowers. This tank will take care of shock loading. The equalized
effluent will be pumped to Neutralization Tank where acid/alkali solution will be dosed by
dosing pumps.
The neutralized effluent will be transferred to Flash Mixer by effluent transfer pumps, where
polyelectrolyte will be added as a coagulation aid. The effluent from Flash Mixer will be
overflowed to Flocculation Tank, where flocs will be formed and will taken to Primary
Lamella type Settling tank for separation of solids as primary sludge. The clarified effluent
from Primary settling tank will overflowed to two stage aeration tank, where Urea & DAP will
be dosed.
The effluent in the Aeration Tank will be treated in extended type activated sludge process.
Retrievable type fine bubble membrane diffusers will be provided at the bottom of tank for
supply of air into the system. The overflow of Aeration Tank will be taken Holding Tank. The
settled biomass from bottom will be recirculated by recirculation pumps to Aeration Tank to
maintain required biomass level.
The effluent from Holding Tank will be pumped to Pressure Sand Filter to remove TSS and
will be passed to Activated Carbon Filter, to remove the color and polish the effluent to meet
the GPCB norms. The outlet of Activated Carbon Filter will be enter to underground GIDC
drainage by means of HDPE pipe laid from Activated Carbon Filter to GIDC Chamber.
The sludge will be drained into Sludge Thickner. The sludge consistency will be increased in
Sludge Thickner. The sludge from the bottom of Sludge Thickner will be fed to Decanter to get
sludge cake having more consistency of solids. The overflow from Sludge Thickner will go
into Overflow chamber, from where it will be pumped to Collection Sump for further
treatment. High COD stream will be segregated and send to Common Incinerator facility for
incineration.
Proposed Effluent treatment plant flow diagram is given in Figure and list of units of ETP with
their size are given in Table.
LIST OF ETP UNITS AND SIZE:
Sr.
No.
Unit Dimensions
1 Oil & Grease Trap 1 x 1.5 x 1.2
2 Collection Tank 3.2 x 3.2 x 2.5 (2 nos.)
3 Effluent transfer pump 1 HP
4 Neutralization tank 2.9 x 2.9 x 2 (2 nos.)
5 Flash mixer/ Flocculater 1.2 x 1.2 x 1.5
6 Primary Lamella type settling tank with tube
deck packing
3.2 x 3.2 x 2.5
7 Filter press 28 x 28
8 Two Stage Aeration tank with in built Clarifier 9.6 x 6.4 x (4.5 + 0.5)
9 Activated sludge recirculation pump 1 HP
10 Treated Effluent collection tank 3.16 x 3.16 x 2.5
11 Filter pump -
12 Pressure san filter 1.6 x 2.5
13 Activated carbon filter 1.6 x 2.5
EFFLUENT TREATMENT PLANT
ANNEXURE - V
HAZARDOUS WASTE GENERATION AND DISPOSAL
SR.
NO.
TYPE OF WASTE TOTAL PROPOSED
QUANTITY
CATEGORY NO. DISPOSAL
1 ETP Sludge 5 MT/Month 34.3
To TSDF, Vapi for land filling
2 Used Oil 0.01 KL/Month 5.1 Reuse/recycle for lubrication
3 Discarded Containers/bags 920 nos./Month 33.3 Decontamination, detoxification and sold to GPCB
approved vendors
4 Distillation residue 0.85 MT/Month 29.1 To common Incinerator of M/s. PECS, Sarigam for
incineration
5 Filter Aids 0.09 MT/Month 35.1 To common Incinerator of M/s. PECS, Sarigam for
incineration
6 Contaminated cotton waste 0.042 MT/Month - To TSDF, Vapi for land filling
7 Waste insulation material 0.09 MT/Month - To TSDF, Vapi for land filling
8 Fly Ash 0.5 MT/Month - To Proposed Ash dump facility with premises or Sold to
Cement Brick Manufacturer or send to TSDF, Vapi for
land filling
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 72 of 100
ANNEXURE – VI
DETAILS OF WATER CONSUMPTION AND WASTEWATER GENERATION
SR.
NO.
CATEGORY WATER
CONSUMPTION
LITERS /DAY
EFFLUENT
GENERATION
LITERS /DAY
1 Process 32,000 22,000
2 Boiler 16,000 11,000
3 Cooling 15,000 2,500
4 Washing/Floor/Equip.
/drum washing
3,500 3,200
5 Others/
Gardening
1,500 1,500
6 Domestic 2,000 1,800
Total 70,000 42,000
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 73 of 100
ANNEXURE-VII
_______________________________________________________________________
FUEL & ENERGY REQUIREMENT
TOTAL POWER REQUIREMENT (KVA)
Sr.
No. Scenario
Project
(KVA) Total (KVA)
1 Proposed 500 500
SOURCE OF POWER (KW)
Sr. No. Scenario Source
1 Proposed DGVCL
DG set (750 KVA)
(as emergency used only)
FUEL REQUIREMENT
Sr.
No.
Fuel Total Proposed
Consumption
1 FO 45 KL/Month
2 Diesel 200 Liter /Month
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 74 of 100
ANNEXURE-VIII
___________________________________________________________________________________________________________________
STORAGE DETAILS OF HAZARDOUS CHEMICALS
Sr.
No
Name of
Hazardous
Quantity
stored
(Including in
process
& handling)
(MT/Month)
Places of
its
Storage
State &
Operating
Pressure &
Temp.
Type of Hazards
Possible (Fire, explosive,
toxic release, spillage etc.
Control measures
provided
1 Sulphuric Acid 15 Tank Ambient Corrosive, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
2
MDC 10 Tank Ambient Fire, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
3
DMS
10 Drum Ambient Fire, Spillage
• Drum will be stored on pallet with the
suitable trap.
• Fire Extinguishers & Hydrant points
will be provided.
4
Ethyl Acetate 15 Tank Ambient Fire, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
5 Acetic
anhydride 10 Tank Ambient Corrosive, Toxic
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
6
Iso Propyl
Alcohol
15 Tank Ambient
Fire, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 75 of 100
7 Hexane 15 Tank Ambient Fire, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
8 HCl (30%) 15 Tank Ambient Corrosive, Toxic
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
9 Toluene 15 Tank
Ambient Fire, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
10 DMF 10 nos.
(250 kg) Drum Ambient Fire, Spillage
• Drum will be stored on pallet with the
suitable trap.
• Fire Extinguishers & Hydrant points
will be provided.
11 Xylene 10 nos.
(200 kg each) Drum
Ambient Fire, Spillage • Drum will be stored on pallet with the
suitable trap.
• Fire Extinguishers & Hydrant points
will be provided.
12 Thiourea 5 Bag Ambient
Corrosive, Toxic • Bags will be stored on pallet with the
suitable trap.
• Fire Extinguishers & Hydrant points
will be provided.
13 Ethanol 10 Tank
Ambient Corrosive, Toxic • Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
14 Formaldehyde 10 nos.
(200 kg each)
Drum
Ambient Fire, Spillage • Drum will be stored on pallet with the
suitable trap.
• Fire Extinguishers & Hydrant points
will be provided.
15 Butanol 10 nos. Drum Ambient Fire, Spillage • Drum will be stored on pallet with the
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 76 of 100
(170 kg each) suitable trap.
• Fire Extinguishers & Hydrant points
will be provided.
16 Ammonia Soln.
(20%) 15 KL Tank Ambient Fire, Spillage
• Dyke around the tank will be provided.
• Fire Extinguishers & Hydrant points
will be provided.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 77 of 100
ANNEXURE-IX
_______________________________________________________________________
DETAILS OF STACKS & VENTS (PROPOSED)
Sr.
No.
Stack/Venatt
ached to
Type of
Emission
Stack
Height
(meter)
Stack
Diameter
(meter)
Pollution Control
Equipment
Fuel name and
Quantity/hour
1 Boiler SPM
Sox
NOx
30 1.23
-
Furnace Oil
45000 Liter/Month
2 Chlorination
of acid to
acid chloride
with Thionyl
Chloride-
Process Vent
HCl
SO2
11 0.076 Water scrubber
followed by alkali
scrubber & ventury
scrubber
-
4 D. G. Set SPM
SO2
NOx
11 0.1
-
Diesel
200 Liter/Month
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 78 of 100
ANNEXURE-X
_______________________________________________________________________
RISK SCENARIO
Scenario MCL Scenario Pressure Temp. Quantity
1. Pool fire due to release of Methylene
Dichloride
Ambient Ambient 10 MT
2. Pool fire due to release of Ethyl
Acetate
Ambient Ambient 15 MT
3. Release of Acetic Anhydride - toxic
effect
Ambient Ambient 10 MT
4. Pool fire due to release of Iso Propyl
Alcohol
Ambient Ambient 15 MT
5. Pool fire due to release of Hexane Ambient Ambient 15 MT
6. Pool fire due to release of Toluene Ambient Ambient 15 MT
7. Pool fire due to release of Ethanol Ambient Ambient 10 MT
8. Release of Ammonia Soln. (20 %) -
toxic effect
Ambient Ambient 15 m
3
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 79 of 100
Detailed Summary of Results:
Detailed Results of the consequence analysis of above-mentioned scenarios have been given
below:
Scenario # 1: Pool fire due to Release of Methylene Dichloride (MDC)
A release from the Methylene Dichloride storage Tank
Temperature & Pressure - Ambient
Capacity - 10 MT
Results indicate:
Effective diameter of the pool - 4.45 m
(100 % fatality within the pool area)
Fatality Zone radius - 16.76 m
Injury Zone radius (First degree burns) - 24.08 m
Preventative / Mitigation Measures:
Storage: Store in a tightly closed container. Keep from contact with oxidizing materials. Store in
a cool, dry, well-ventilated area away from incompatible substances. Store below 40C. Keep
away from active metals.
Handling: Wash thoroughly after handling. Remove contaminated clothing and wash before
reuse. Use with adequate ventilation. Loosen closure cautiously before opening. Avoid contact
with eyes, skin, and clothing. Do not get in eyes, on skin, or on clothing. Keep container tightly
closed. Avoid contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not ingest
or inhale.
Protection: Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described
by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard
EN166. Skin: Wear appropriate protective gloves to prevent skin exposure. Clothing: Wear
appropriate protective clothing to prevent skin exposure.
Small spills/leaks: Absorb spill with inert material, (e.g., dry sand or earth), then place into a
chemical waste container. Avoid runoff into storm sewers and ditches which lead to waterways.
Clean up spills immediately, using the appropriate protective equipment. Remove all sources of
ignition. Provide ventilation
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 80 of 100
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 81 of 100
LA
YO
UT
FO
R S
CE
NA
RIO
# 1
= FATALITY ZONE
= INJURY ZONE
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 82 of 100
Scenario # 2: Pool fire due to Release of Ethyl Acetate
A release from the Ethyl Acetate storage Tank
Temperature & Pressure - Ambient
Capacity - 15 MT
Results indicate:
Effective diameter of the pool - 4.88 m
(100 % fatality within the pool area)
Fatality Zone radius - 15.85 m
Injury Zone radius (First degree burns) - 22.56 m
Preventative / Mitigation Measures:
Storage: Keep away from heat, sparks, and flame. Keep away from sources of ignition. Store in a
tightly closed container. Store in a cool, dry, well-ventilated area away from incompatible
substances.
Handling: Wash thoroughly after handling. Use with adequate ventilation. Ground and bond
containers when transferring material. Avoid contact with eyes, skin, and clothing. Empty
containers retain product residue, (liquid and/or vapor), and can be dangerous. Keep container
tightly closed. Avoid contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not
pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat, sparks or open
flames.
Protection: Wear appropriate protective gloves, clothing and goggles.
Small spills/leaks: Avoid runoff into storm sewers and ditches which lead to waterways. Remove
all sources of ignition. Absorb spill using an absorbent, non-combustible material such as earth,
sand, or vermiculite. Provide ventilation. A vapor suppressing foam may be used to reduce
vapors. Water spray may reduce vapor but may not prevent ignition in closed spaces.
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 83 of 100
LA
YO
UT
FO
R S
CE
NA
RIO
# 2
= FATALITY ZONE
= INJURY ZONE
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 84 of 100
Scenario # 3: Release of Acetic Anhydride- toxic effect
Release of Acetic Anhydride from storage tank:
Storage Temperature: - Ambient
Storage Pressure: Ambient
Results indicate:
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 5.38 kilograms/min
(averaged over a minute or more)
Total Amount Released: 186 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
Footprint Information:
Dispersion Module: Gaussian
Red LOC (200 ppm = TEEL-3) Max Threat Zone: 19 meters
Note: Footprint was not drawn because effects of near-field patchiness make dispersion
predictions unreliable for short distances.
Yellow LOC (5 ppm = TEEL-1) Max Threat Zone: 119 meters
Orange LOC (5 ppm = TEEL-2) Max Threat Zone: 119 meters
Preventative / Mitigation Measures:
Storage: Keep away from heat, sparks, and flame. Keep away from sources of ignition. Do
not store in direct sunlight. Keep container closed when not in use. Keep from contact with
oxidizing materials. Store in a cool, dry, well-ventilated area away from incompatible
substances. Keep away from water. Flammables-area.
Handling: Remove contaminated clothing and wash before reuse. Do not allow water to get
into the container because of violent reaction. Ground and bond containers when transferring
material. Use spark-proof tools and explosion proof equipment. Do not breathe dust, vapor,
mist, or gas. Do not get in eyes, on skin, or on clothing. Empty containers retain product
residue, (liquid and/or vapor), and can be dangerous. Avoid contact with heat, sparks and
flame. Use with adequate ventilation. Discard contaminated shoes. Do not pressurize, cut,
weld, braze, solder, drill, grind, or expose empty containers to heat, sparks or open flames.
Keep from contact with moist air and steam.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 85 of 100
Protection: Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as
described by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European
Standard EN166. Skin: Wear appropriate protective gloves to prevent skin exposure.
Clothing: Wear appropriate protective clothing to prevent skin exposure.
Small spills/leaks: Absorb spill with inert material, (e.g., dry sand or earth), then place into a
chemical waste container. Avoid runoff into storm sewers and ditches which lead to
waterways. Clean up spills immediately, using the appropriate protective equipment. Remove
all sources of ignition. Use a spark-proof tool. Provide ventilation. Do not expose spill to
water. Spill may be neutralized with lime. Cover with material such as dry soda ash or
calcium carbonate and place into a closed container for disposal. A vapor suppressing foam
may be used to reduce vapors.
Fire fighting: Wear a self-contained breathing apparatus in pressure-demand,
MSHA/NIOSH (approved or equivalent), and full protective gear. Vapors may form an
explosive mixture with air. Vapors can travel to a source of ignition and flash back. During a
fire, irritating and highly toxic gases may be generated by thermal decomposition or
combustion. Water Reactive. Material will react with water and may release a flammable
and/or toxic gas. Use water spray to keep fire-exposed containers cool. Wear appropriate
protective clothing to prevent contact with skin and eyes. Wear a self-contained breathing
apparatus (SCBA) to prevent contact with thermal decomposition products. Containers may
explode in the heat of a fire. Flammable Liquid. May ignite or explode on contact with steam
or moist air. Extinguishing media: Use dry sand or earth to smother fire. If water is the only
media available, use in flooding amounts. DO NOT USE WATER! Do NOT use straight
streams of water. Contact profession
Scenario # 3: Release of Acetic Anhydride- toxic effect
Source strength (Release rate)
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 87 of 100
Scenario # 4: Pool fire due to Release of Iso Propyl Alcohol
A release from the Iso Propyl Alcohol storage Tank
Temperature & Pressure - Ambient
Capacity - 15 MT
Results indicate:
Effective diameter of the pool - 4.88 m
(100 % fatality within the pool area)
Fatality Zone radius - 15.24 m
Injury Zone radius (First degree burns) - 21.95 m
Preventative / Mitigation Measures:
Storage: Keep away from sources of ignition. Store in a cool, dry place. Store in a tightly closed
container.
Handling: Wash thoroughly after handling. Wash hands before eating. Use only in a well
ventilated area. Use spark-proof tools and explosion proof equipment. Empty containers retain
product residue, (liquid and/or vapor), and can be dangerous. Do not get on skin or in eyes. Avoid
ingestion and inhalation. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty
containers to heat, sparks or open flames.
Protection: Wear appropriate protective gloves, clothing and goggles.
Small spills/leaks: Absorb spill with inert material, (e.g., dry sand or earth), then place into a
chemical waste container. Clean up spills immediately, using the appropriate protective
equipment. Scoop up with a nonsparking tool, then place into a suitable container for disposal.
Remove all sources of ignition.
Fire fighting: Use water in flooding quantities as fog. Use foam, dry chemical, or carbon dioxide.
Cool all affected containers with flooding quantities of water. Apply water from as far a distance
as possible. Use water spray to knock-down vapors. Keep run-off water out of sewers and water
sources.
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 88 of 100
LA
YO
UT
FO
R S
CE
NA
RIO
# 4
= FATALITY ZONE
= INJURY ZONE
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 89 of 100
Scenario # 5: Pool fire due to Release of Hexane
A release from the Hexane storage Tank
Temperature & Pressure - Ambient
Capacity - 15 MT
Results indicate:
Effective diameter of the pool - 4.88 m
(100 % fatality within the pool area)
Fatality Zone radius - 16.46 m
Injury Zone radius (First degree burns) - 23.47 m
Preventative / Mitigation Measures:
Storage: Keep away from heat and flame. Keep away from sources of ignition. Store in a tightly
closed container. Keep from contact with oxidizing materials. Store in a cool, dry, well-ventilated
area away from incompatible substances.
Handling: Wash thoroughly after handling. Remove contaminated clothing and wash before
reuse. Use only in a well ventilated area. Ground and bond containers when transferring material.
Avoid contact with eyes, skin, and clothing. Do not breathe dust, vapor, mist, or gas. Empty
containers retain product residue, (liquid and/or vapor), and can be dangerous. Take precautionary
measures against static discharges. Avoid contact with heat, sparks and flame. Do not ingest or
inhale. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat,
sparks or open flames.
Protection: Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described
by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard
EN166. Skin: Wear appropriate protective gloves to prevent skin exposure. Clothing: Wear
appropriate protective clothing to prevent skin exposure.
Small spills/leaks: Absorb spill with inert material, (e.g., dry sand or earth), then place into a
chemical waste container. Avoid runoff into storm sewers and ditches which lead to waterways.
Clean up spills immediately, using the appropriate protective equipment. Scoop up with a
nonsparking tool, then place into a suitable container for disposal. Remove all sources of ignition.
Provide ventilation. A vapor suppressing foam may be used to reduce vapors.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 90 of 100
Fire fighting: Wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH
(approved or equivalent), and full protective gear. Vapors may form an explosive mixture with
air. Vapors can travel to a source of ignition and flash back. During a fire, irritating and highly
toxic gases may be generated by thermal decomposition or combustion. Use water spray to keep
fire-exposed containers cool. Extremely flammable liquid. Water may be ineffective. Material is
lighter than water and a fire may be spread by the use of water. Vapors may be heavier than air.
They can spread along the ground and collect in low or confined areas. Will be easily ignited by
heat, sparks or flame. Containers may explode if exposed to fire. Extinguishing media: For small
fires, use dry chemical, carbon dioxide, water spray or alcohol-resistant foam. Water may be
ineffective. Water may spread fire. If water is the only media available, use in flooding amounts.
For large fires, use water spray.
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 91 of 100
LA
YO
UT
FO
R S
CE
NA
RIO
# 5
= FATALITY ZONE
= INJURY ZONE
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 92 of 100
Scenario # 6: Pool fire due to Release of Toluene
A release from the Toluene storage Tank
Temperature & Pressure - Ambient
Capacity - 15 MT
Results indicate:
Effective diameter of the pool - 4.88 m
(100 % fatality within the pool area)
Fatality Zone radius - 12.8 m
Injury Zone radius (First degree burns) - 18.29 m
Preventative / Mitigation Measures:
Handling & Storage: Protect against physical damage. Store in a cool, dry well-ventilated
location, away from any area where the fire hazard may be acute. Outside or detached storage is
preferred. Separate from incompatibles. Containers should be bonded and grounded for transfers
to avoid static sparks. Storage and use areas should be No Smoking areas. Use non-sparking type
tools and equipment, including explosion proof ventilation. Containers of this material may be
hazardous when empty since they retain product residues (vapors, liquid); observe all warnings
and precautions listed for the product.
Protection: Eyes: Immediately flush eyes with plenty of water for at least 15 minutes, lifting
lower and upper eyelids occasionally. Get medical attention immediately. Skin: In case of contact,
immediately flush skin with plenty of soap and water for at least 15 minutes while removing
contaminated clothing and shoes. Wash clothing before reuse. Call a physician immediately.
Fire fighting: Dry chemical, foam or carbon dioxide. Water may be used to flush spills away
from exposures and to dilute spills to non-flammable mixtures. In the event of a fire, wear full
protective clothing and NIOSH-approved self-contained breathing apparatus with full facepiece
operated in the pressure demand or other positive pressure mode. Water spray may be used to
keep fire exposed containers cool.
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 93 of 100
LA
YO
UT
FO
R S
CE
NA
RIO
# 6
= FATALITY ZONE
= INJURY ZONE
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 94 of 100
Scenario # 7: Pool fire due to Release of Ethanol
A release from the Ethanol storage Tank
Temperature & Pressure - Ambient
Capacity - 10 MT
Results indicate:
Effective diameter of the pool - 4.45 m
(100 % fatality within the pool area)
Fatality Zone radius - 14.33 m
Injury Zone radius (First degree burns) - 20.42 m
Preventative / Mitigation Measures:
Handling & Storage: Store in a segregated and approved area. Keep container in a cool, well-
Ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all possible
sources of ignition (spark or flame). Do not store above 23 oC.
Protection: Eyes: Check for and remove any contact lenses. Immediately flush eyes with running
water for at least 15 minutes, keeping eyelids open. Cold water may be used. Get medical
attention.
Small spills/leaks: Dilute with water and mop up, or absorb with an inert dry material and place
in an appropriate waste disposal container.
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 95 of 100
LA
YO
UT
FO
R S
CE
NA
RIO
# 7
= FATALITY ZONE
= INJURY ZONE
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 96 of 100
Scenario # 8: Release of Ammonia Soln. (20%)- toxic effect
Release of Ammonia Soln. (20%) storage tank:
Storage Temperature: - Ambient
Storage Pressure: Ambient
Results indicate:
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 314 grams/min
(averaged over a minute or more)
Total Amount Hazardous Component Released: 18.5 kilograms
Footprint Information:
Dispersion Module: Gaussian
Red LOC (750 ppm = ERPG-3) Max Threat Zone: < 10 meters
Note: Footprint was not drawn because effects of near-field patchiness make dispersion
predictions unreliable for short distances.
Orange LOC (150 ppm = ERPG-2) Max Threat Zone: 14 meters
Note: Footprint was not drawn because effects of near-field patchiness make dispersion
predictions unreliable for short distances.
Yellow LOC (25 ppm = ERPG-1) Max Threat Zone: 34 meters
Note: Footprint was not drawn because effects of near-field patchiness make dispersion
predictions unreliable for short distances.
Preventative / Mitigation Measures:
Storage: Keep in a cool, dry, dark location in a tightly sealed container or cylinder. Keep away
from incompatible materials, ignition sources and untrained individuals. Secure and label area.
Protect containers/cylinders from physical damage.
Handling: All chemicals should be considered hazardous. Avoid direct physical contact. Use
appropriate, approved safety equipment. Untrained individuals should not handle this chemical or
its container. Handling should occur in a chemical fume hood.
Protection: Wear appropriate protective gloves, clothing and goggles.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 97 of 100
Small spills/leaks: Keep material out of water sources and sewers. Attempt to stop leak if without
undue personnel hazard. Use water spray to knock-down vapors. Vapor knockdown water is
corrosive or toxic and should be diked for containment. Land spill: Dig a pit, pond, lagoon,
holding area to contain liquid or solid material. Dike surface flow using soil, sand bags, foamed
polyurethane, or foamed concrete. Absorb bulk liquid with fly ash or cement powder. Neutralize
with vinegar or other dilute acid. Water spill: Neutralize with dilute acid. Use mechanical dredges
or lifts to remove immobilized masses of pollutants and precipitates.
Fire fighting: Wear positive pressure breathing apparatus and full protective clothing.Small fires:
dry chemical or carbon dioxide. Large fires: water spray, fog or foam. Apply water gently to the
surface. Do not get water inside container. Move container from fire area if you can do it without
risk. Stay away from ends of tanks. Cool containers that are exposed to flames with water from
the side until well after fire is out. Isolate area until gas has dispersed.
Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives
only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of
given radius.
Source strength (Release rate)
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 99 of 100
ANNEXURE-XI
_______________________________________________________________________
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
During construction phase, skilled and unskilled manpower will be needed. This will
temporarily increase the employment opportunity. Secondary jobs are also bound to be
generated to provide day-to-day needs and services to the work force. This will also
temporarily increase the demand for essential daily utilities in the local market.
The manpower requirement for the proposed expansion is expected to generate some
permanent jobs and secondary jobs for the operation and maintenance of plant. This will
increase direct / indirect employment opportunities and ancillary business development to
some extent for the local population.
This phase is expected to create a beneficial impact on the local socio-economic environment.
2) INDUSTRIES
During construction of the project, the 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 economical status of the locality, to some extent.
3) PUBLIC HEALTH
During construction period, workers will be provided with basic amenities like safe water
supply, low cost sanitation facilities, first aid, required personal protective equipment, etc.
Otherwise, there could be an increase in diseases related to personal hygiene.
Emission, if uncontrolled from process and utility stacks may cause discomfort, burning of
eyes to the recipients in the down wind direction. This may be caused due to the failure of
control equipment / process. 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 under the EMP.
C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx Page 100 of 100
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 expansion there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be taken
under the EMP. The proposed expansion is not expected to make any significant change in
the existing status of the socio - economic environment of this region.