m/s. awake chemicals pvt. ltd.environmentclearance.nic.in/writereaddata/online/tor/0_0...1....

PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed Synthetic Organic Chemicals

Manufacturing Unit of

M/s. AWAKE CHEMICALS PVT. LTD. Survey No. : 610, Sayla-Muli By-pass Road, Bh. Sarvoday Jin Mill,

Sayla-363430, Taluka: Sayla, District: Surendranagar, Gujarat.

Himanshubhai Mesvaniya: 90675 72622 E-mail: [email protected]

Prepared By:

T. R. ASSOCIATES

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S. G. Highway, Ahmedabad.

Mo. No.: 98253 71099 Email ID: [email protected]; [email protected]

February 2016

1. Introduction M/s. Awake Chemicals Pvt. Ltd. is a proposed new project to be located at Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin Mill, Sayla-363430, Ta: Sayla, Dist: Surendranagar, Gujarat for manufacturing of synthetic organic chemicals including pharmaceutical and dyes and intermediates with total production capacity of 62 MT/Month.

It may be noted that Proponent had obtained Consent To Establish for manufacturing inorganic products with the company name Shree Sarvasiddhi Chemicals at above stated location and constructed shed but the production never started and now the proponent intends to obtain EC for new above stated organic chemical products. Proposed production details are given below:

Sr. No. Product Capacity

( MT/Month)

1. Diethyl Safranine 5

2. Safranine-O 5

3. Janus Green B 5

4. Methylene Blue Zn free 5

5. Titan Yellow 5

6. Succinimide 5

7. N-Bromo Succinimide 2

8. N-Chloro Succinimide 2

9. Bromohexine HCl (BP) 2

10. Bronopol 2

11. Niclosamide 4

12. Oxo-O-Tolyl Acetonitrile 5

13. 4 Nitro 3,5 Dimethyl Pyridine 7

14. Dichloro Pyrimidine 5

15. 2-Amino 5-Methyl Thiozole 2

16. Oil Mustard (Allyal Isothlocyanate) 1

By-Product

1. Zn Carbonate 1.6

2. Sodium Bromide 0.2

3. Sodium Bromide Solution 2.1

4. Sodium Acetate 1.2

5. Ammonium Chloride 0.6

The proposed products fall under Category 5(f) as stated in Environment Impact Assessment Notification Published on 14th September, 2006. Further, the location of the proposed project is outside the notified industrial estate. Hence, the project proponent has to obtain the EC from

the Ministry of Environment & Forests, New Delhi. M/s. T. R. Associates has been appointed to carry out EIA/EMP studies for Environmental Clearance.

The total land area of company is 11,129 Sq. Mt. out of which 3,680 Sq. Mt. (33.1% of total land) area will be used for greenbelt development. The estimated cost of the proposed project is 3 Crores. Total budget allocation towards Environmental Management Facilities will be Rs. 50 Lacs. Total 30 persons will be employed including skilled persons, unskilled persons and office staff.

2. Project Proponent and their back ground

Company is promoted by its directors namely Mr. Himanshubhai Mesvaniya having enough experience in field of manufacturing of inorganic and organic chemicals.

3. Brief description of nature of the project: It is a small scale project for production of synthetic organic chemicals including pharmaceutical and dyes and intermediates which will be sold in domestic market as well exported.

Need for the project and its importance to the country and or region:

Looking to the product profile, it is required to take Environmental Clearance. In India, good quality raw materials are available at cheap rates, enabling the manufacturing at low cost. This increases the profit margin as compared to other players in the world. To meet the current and future market demand, the project proponent intends to start a new unit. Looking to the market demand, the proposed project is feasible at stated location.

Imports v/s Indigenous production:

Indian market is open and big that is why every kind of import is booming. Indian industrialist must understand the fact that its no more a regional shift, it is a global shift. Indian technology should be upgraded an updated at par with international standards.

The working environment in India has changed tremendously. Earlier the trade fairs were hardly participated by foreign chemical manufacturing companies where as now it is flooded with global suppliers.

Export Possibility:

There is good possibility for export. But currently we are focused on local sale market for distribution.

Employment Generation (Direct and Indirect) due to the project:

This project will provide direct employment to 30 people whereas it will provide employment to many others indirectly.

4. Project Description

(i) Type of project including interlinked and interdependent projects: Chemicals, Dyes & stains are frequently used in biology and medicine to highlight structures in biological tissues for viewing, often with the aid of different microscopes. So it is an individual Industry having no direct dependency on others.

(ii) Location Proposed project is to be located at Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin Mill, Sayla-363430, Ta: Sayla, Dist: Surendranagar, Gujarat at Latitude: 22° 32' 56.51" N and Longitude: 71° 29' 43.57" E Google image showing proposed project site is given below; Google Image of Proposed Location:

Proposed Project Site

SH 21

NH 8A

0.3 km

Nearest Residential Area of Sayla

0.9 km

0.3 km

Salient features in the surroundings area of the proposed site within 10 km radius are as follows:

Sr. No.

Important Features Description

1 Location Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin Mill, Sayla-363430, Ta: Sayla, Dist: Surendranagar, Gujarat.

2 GPS Coordinates

3 Mean Sea Level 127 m 4 Nearest power station Paschim Gujarat Vij Company Ltd., Sayla 5 Proponent Name Mr. Himanshubhai Mesvaniya (Director)

Contact No. 09067572622 6 Corporate office address Survey No.: 610, Sayla-Muli by-pass road, Bh.

Sarvoday Jin, Sayla-363430, Ta: Sayla, Dist: Surendranagar.

7 Temperature range 120 C to 450 C 8 Annual Rain fall 803 mm 9 Nearest Road SH21 @ 0.3 Km, West

NH 8A @ 0.9 Km, South 10 Nearest Railway station Nearest Railway station: Muli Road Railway

station @ 15.3 Km, NNW 11 Nearest city Sayla @ 0.3 Km, West 12 Nearest village Sayla @ 0.3 Km, West 13 National Highway NH 8A @ 0.9 Km, South 14 State Highway SH21 @ 0.3 Km, West 15 Nearest River/water body 1) Bhogava River (Seasonal) @ 5.3 Km, SE

2) Nibhani River (Seasonal River) @ 7.0 Km, SE 3) Check dam on Bhogava River @ 9.0 Km, SSW,

Near Village Juna Jashapar 16 Seismic Zone Zone-III (Less Active) 17 National Parks / Sanctuary None within 10 Km radius.

(iii) Project description with process details

List of Products & By-products

Sr. No. Name of Product Quantity (MT/Month)

1 Diethyl Safranine 5 2 Safranine-O 5 3 Janus Green B 5 4 Methylene Blue Zn Free 5 5 Titan Yellow 5 6 Succinimide 5 7 N-Bromo Succinimide 2 8 N-Chloro Succinimide 2 9 Bromohexine HCL(BP) 2 10 Bronopol 2 11 Niclosamide 4 12 Oxo-O-Tolyl Acetonitrile 5 13 4 Nitro 3,5 Dimethyl Pyridine 7 14 Dichloro Pyrimidine 5 15 2 Amino 5 Methyl Thiozole 2 16 Oil Mustard 1

By-product 1 Zn Carbonate 1.6 2 Sodium Bromide 0.2 3 Sodium Bromide Solution 2.1 4 Sodium Acetate 1.2 5 Ammonium Chloride 0.6

List of raw materials

Sr. No. Name of the product Name of Raw Materials Quantity in

KG/Month

1 Diethyl Safranine

Diethyl Aniline 4445HCL 2223Sodium Nitrite 1600Zn Dust 1556Calcium Carbonate 2223Aniline 2223Sodium Dichromate 1778Salt 6667

2 Safranine - O

Garnet GB 3572HCl 1786Sodium Nitrite 1286Fe Dust 1608ICE 7143Calcium Carbonate 715Aniline 1786Sodium Dichromate 1072Salt 5000


KG/Month

3 Janus Green B

Safranine 5000HCl 2500Sodium Nitrite 1750Sodium Acetate 1750Dimethyl Aniline 2500Soda Ash 1500Salt 5000

4 METHYLENE BLUE ZN FREE

Methylene Blue 2B 6250Soda Ash 1000EDTA 313ICE 25000Salt 625

5 Titan yellow

Dehydro Thio Para Toludine Sulphonic Acid 5264

HCl 1579Sodium Nitrite 922ICE 5264Sodium Carbonate 2106Salt 7895

6 Succinimide Succinic acid 5960Ammonia 860

7 N bromo succinimide Succinimide 1116Caustic 449Bromine 1794

8 N CHLORO SUCCINIMIDE Succinimide 1480Sodium hypochloride 1100Acetic acid 900

9 Bromohexine HCL (BP)

2Nitro N Cyclohexyl Methyl Benzyl Amine 1600

Hydrogen 11Methanol 5334Carbon 27Bromine 1734HCl 240Ethanol 3734

10 Bronopol

Nitro Methane 667Methanol (Fresh) 500Caustic 467Formaldehyde 1467Carbon 34Bromine 1767

11 Niclosamide

Xylene 11429Ortho Chloro para nitro aniliine 2058Thiohyl chloride 15435 Chloro salicylic acid 2000

12 Oxo-O-Tolyl Acetonitrile Xylene (Fresh) 3334


KG/Month

Ortho toluic acid 4584Thionyl chloride 3750Sodium cyanide 1667

13 4 Nitro 3,5 Dimethyl Pyridine

3,5 lutidine 6731Sulphuric acid 11005Acetic acid (Fresh) 1347Nitric acid 7337Ammonia Gas 6512Hydrogen Peroxide 4712

14 Dichloro pyrimidine

Di hydroxyl Pyridimine 5233MDC (Fresh) 5070Phosphorus Oxochloride 9303TEA (Fresh) 1675Caustic 7256

15 2 amino 5 methyl thiozole

Propenaldehyde 2400Sulphuryl Chloride 6000Methanol 5300Caustic 2700Toluene 6000Thiourea 2000HCL 400

16 Oil Mustard Allyl Chloride 820Ammonium Thiocyanate 824

Detailed Manufacturing Processes

1. DIETHYL SAFRANINE: Manufacturing Process

Charge Diethyl Aniline, conc. HCl and water in open watt. Charge ice for chilling. Charge sodium nitrite for diazotized it. Charge Zn-powder & Aniline into it then complete reaction by addition of sodium dichromate & calcium carbonate then heat & filter product. Take clear filtrate & charge salt. Pure Diethyl Safranine is isolate then dry & pulverized to get finished product.

Reaction Chemistry

Process Flow Diagram

Mass Balance

Sr. No. Input Qty Per

Batch (Kg) Output Qty Per Batch (Kg)

1. Diethyl Aniline 200 Zn powder (To be reused in next batch)

2

2. Water 200 Wastewater (To be treated in ETP)

900

3. HCl 100 Drying loss (To atmosphere through vent)

95

4. Sodium Nitrite 72 Diethyl Safranine 225 5. Zn Dust 70 6. Calcium Carbonate 100 7. Aniline 100 8. Sodium Dichromate 80 9. Salt 300

Total 1222 1222 2. SAFRANINE-0:

Manufacturing Process Charge Garnet GB, Conc. HCl and water in open watt. Charge ICE for chilling. Charge sodium Nitrite for diazotised it. Charge Fe-Powder & Aniline into it then complete reaction by addition

Chilled up to 0⁰C

Zn-Powder 2 kg to be reused in next batch

Filtration

Heat Mass 90°C

900 kgs wastewater Centrifuge

95kgs Drying loss Drying

Pulverizing

Packing 225kgs

Diethyl aniline 200 KGS

D M WATER 200KGS OPEN WATT

Stir mass under chilling for 4-5 hrs

Sodium nitrite 72 kgs Zn-dust 70kg

Calcium Carbonate 100 kgs

Aniline 100kgs

Salt 300kgs

of sodium Dichromate & Calcium Carbonate then heat & filter product. Take Clear filtrate & Charge Salt. Pure Diethyl Safranine is isolate then dry & pulverised it. Reaction Chemistry

Process Flow Diagram with Mass Balance

Chilled upto 0°C

Fe-Powder 12kg Filtration

Heat Mass at 90°C

1990 kgs Wastewater Centrifuge

60kgs Drying loss Drying

Pulverising

Packing 280kgs (25 kgs *11 drum)

Garnet GB 200 KGS D M WATER 1000KGS

HCl 100kg OPEN WATT

Stir mass under chilling for 4-5hrs

Sodium nitrite 72 kgs Fe-dust 90kg

Ice 400kgs

Calcium Carbonate 40 kgs Aniline 100kgs

Sodium Dichromate 60kgs

Salt 280kgs

Mass Balance

SR. NO. INPUT QTY PER

BATCH (KG) OUTPUT QTY PER BATCH (KG)

1. Garnet GB 200 Fe powder (To be reused in next batch) 12

2. Water 1000 Wastewater (To be treated in ETP) 1990

3. HCl 100 Drying loss (To atmosphere through vent) 60

4. Sodium Nitrite 72 SAFRANINE 0 2805. Fe Dust 90 6. ICE 400 7. Calcium Carbonate 40 8. Aniline 100 9. Sodium Dichromate 60 10. Salt 280

TOTAL 2342 2342

3. JANUS GREEN B: Manufacturing Process Safranine, conc. HCl and water charge in open watt. Charge ice for chilling. Charge sodium nitrite for diazotised it. Charge Dimethyl Aniline into it then complete reaction by addition of Sodium Acetate & soda ash heat & filter product. Take clear filtrate & charge salt. Pure Janus Green-B is isolate then dry & pulverised it. Reaction Chemistry


Mass Balance



1. Safranine 200 Wastewater (To be treated in ETP)

700

2. Water 200 Drying loss (To atmosphere through vent)

100

3. HCl 100 Janus Green B 2004. Sodium Nitrite 70 5. Sodium Acetate 70 6. Dimethyl Aniline 100 7. Soda Ash 60 8. Salt 200 TOTAL 1000 1000

Chilledupto0⁰C570KGS

Stirfor2hrs800kgs

Heat800kgsR. Mass90°C

700kgsWaterCentrifuge1000KGS

100kgsdryinglossDrying300kgs

Pulverising200kgs

Packing200kgs(25kgs*8drum)

Safranine200KGSDMWATER200KGS

HCl100kg

Openwatt500kgs

StirR .massunderchillingfor4‐5hrs800kgs

Sodiumnitrite70kgs

SodiumAcetate70kgsDimethylAniline100kgs

SodaAsh60kgs

Salt200kgs

4. METHYLENE BLUE ZN FREE: Manufacturing Process Methylene Blue to be charged in open watt & purify it by Soda ash & EDTA. Then filter & Salt Out done by pure salt. The purified material is isolated which is Methylene Blue Zn Free.

Reaction Chemistry


Mass Balance



1. Methylene Blue 2B 200 Zn carbonate (by-product) 502. Water 1000 Wastewater (To be

treated in ETP) 1662

3. Soda Ash 32 Drying loss (To atmosphere through vent) 190

4. EDTA 10 Methylene Blue Zn Free 1605. ICE 800 6. Salt 20

TOTAL 2062 2062

Salt20kgs

HEATupto90⁰C1242KGS

Zn‐CARBONATE50kg

Filtration1242kgs

2012kgsR. Mass

1662kgsWaterCentrifuge 350KGS

190kgsdryinglossDrying160kgs

Pulverising160kgs


Methylblue‐2b200kgs

Dmwater1000kgs

Openwatt1200kgs

StirR. massunderchillingfor1‐2hrs1992kgs

SODAASH32kgsEDTA10kg

800KGSICE

5. TITAN YELLOW:

Manufacturing Process Dehydro Thio is diazotised in the presence of sodium nitrite under Conc. HCl & chilling condition, the reaction mixture is then coupled with the Dehydro Thio. The final product is filtered & centrifuged. Before packing material is dried in tray dryer & pulverised. Reaction Chemistry


Chilledupto0⁰C695KGS

StirR. massunderchilling875Kgs

HeatR.Mass

795kgsWaterCentrifuge380KGS

190kgsDryinglossDrying190kgs

Pulverising190kgs


Dehydrothioparatoluedenesulphonicacid(DTPT)100KGS

DMWATER300KGSHCl60kg

Openwatt460kgs

StirR. massunderchillingfor4‐5hrs875kgs

Sodiumnitrite35kgsIce200kgs

100kgsDTPTSodiumCarbonate80kgs

Salt300kgs

Mass Balance SR. NO. INPUT QTY PER


1. Dehydro Thio Para Toludine Sulphonic Acid (DTPT)

200Wastewater (To be treated in ETP) 795

2. Water 300 Drying loss (To atmosphere through vent) 190

3. HCl 60 Titan Yellow 1904. Sodium Nitrite 35 5. ICE 200 6. Sodium Carbonate 80 7. Salt 300

TOTAL 1175 1175 6. SUCCINIMIDE

Manufacturing Process Charge Recycle water with Succinic acid in to reactor, then slowly purge Ammonia gas

& heat to 200⁰C and maintain for 2 hours. After 100⁰C collect he water and same will be use in to next batch as raw water. Cool to 70-80⁰C unload the molten mass in to trays. This material will become solidifying after Cooling.

Reaction Chemistry

Process Flow Diagram:

ChargeIntoreactor&HeatUpto200⁰Cfor2Hrs.

TrayDryer 500kg

FinishedProduct

Succinicacid596kg

Ammonia86kg

182 Kg.Wastewater

364Kg.

H

HOOCCH2CH2COOH + NH3

Succinicacid

MolWt:118g/Mol

Ammonia

MolWt:17g/Mol Succinimide

MolWt:99g/Mol

Water

MolWt:36g/Mol

NO O

Mass Balance:

SR. NO. INPUT BATCH (KG) OUTPUT QTY PER

BATCH (KG)1 Succinic acid 596 Wastewater (To be

recycled in next batch) 182

2 Recycled Water 182 Wastewater (To be treated in ETP)

182

3 Ammonia 86 Succinimide (Product) 500 Total 864 864

7. N BROMO SUCCINIMIDE

Manufacturing Process Charge water with succinimide in the reactor. In this solution add caustic and bromine

solution. In second reactor prepare sodium hypo bromide solution and transfer in to 1st reactor

to dissolve succinimide (slowly at 20⁰C) and maintain it for 1 hr at 10 ⁰C. Centrifuge the solution after reaction take place. Glue water wash & dry in to try dryer

@ 65⁰C temp. Finish product is ready for packing. Reaction Chemistry


Chargeintoreactor1704kg

Centrifuge1704kg

SodiumBromide‐34kgWastewater–1150kgSodiumBromideSolution190Kg(SendtoBromineRecoveryplant)

Product330kg

Succinimide184kgWater1000kg

Caustic74kg+Water150litBromine296Kg

Mass Balance



1. Succinimide 184 Sodium Bromide Solution (by-product) 190

2. Water 1150 Waste water 11503. Caustic 74 Sodium bromide (by-product) 34 4. Bromine 296 N Bromo Succinimide 330

TOTAL 1704 1704 8. N CHLORO SUCCINIMIDE

Manufacturing Process Charge water & Succcinimide in the reactor. Add acetic acid to the solution. Maintain temperature up to 20⁰C. Further sodium hypo chloride is added slowly to make pH 8.5. Precipitation observed. Stir for 1 hr and then centrifuge & dry it for packing.

Reaction Chemistry

N N

O O O O + NaOCl + CH3COOH +CH3COONa + H2O

Succinimide Sodium Hypo chloride Acetic acid N Chloro Succinimide Sodium acetate Water Mol Wt: 99 g/Mol Wt: 74 g/Mol Mol Wt: 60 g/Mol Mol Wt: 134 g/Mol Mol Wt: 82 g/Mol 18 g/Mol Process Flow Diagram Mass Balance SR. NO.

INPUT QTY PER BATCH (KG)

OUTPUT QTY PER BATCH (KG)

1 Succinimide 148 Waste water 542 Water 27 Sodium acetate (by-product) 1213 Sodium hypo chloride 110 N Chloro Succinimide 2004 Acetic acid 90

TOTAL 375 375

Succinimide148kg Water27Lit

SodiumHypochloride110kgAceticAcid90kg

ChargeintoReactor375kg

Centrifuge375kg

Product200kg

WasteWater–54litSodiumAcetate–121kg

9. BROMOHEXINE HCL (BP) Manufacturing Process Charge methanol in reactor then charge nitro cyclohexyl methyl benzyl amine in reactor,

then charge catalyst. Then hydrogen gas is introduced to the reactor at 60C. After the reaction catalyst is filtered. To the filtrate bromine is added slowly at 15C

after complete addition, reaction mass is stirred for 6 hours at room temperature. This is again chilled to 20C and centrifuged ml is collected for recycle.

The centrifuge cake is charged in reactor in ethanol to this dissolved mixture carbon is added and is stirred for 2 hours. This is then filtered. To the filtrate HCl is added at 10C and stirred for 3 hours, this is then centrifuged and ml is recycled after distillation. Then product is dried and packed.

Reaction Chemistry

NO2

NCH2

CH3

NCH2

CH3

NH2

NCH2

CH3Br

Br NH2

+ HCl NCH2

CH3Br

BrNH2

•HCl

•HCl

C14H20ClN2O2HCl

288

216534

H2

C14H20ClN2O2HCl C14H20ClN2O2HCl

C14H21N2

+ HCl + 2H2O

NH2

NCH2

CH3Br

Br 2Br2

C14H20Br2N2 + 36 + 36

+ 4 284.78

36.5

260

412

412.5

+ 158

+ 2HBr

376.13

316

Process Flow chart 2 Nitro n Cyclohexylmethyl Benzylamine HCL – 300 Kg Methanol – 1000 kg Hydrogen Gas- 2 Kg Catalyst Ranickel Bromine – 325 Kg 1000 Kg Mother Liquor Recycle Ethanol 700 lit Carbon 5 Kg 812 Kg Mother Liquor HCL 45 Kg Recycle

Mass Balance

SR. NO. INPUT

QTY PER BATCH (KG)


1. 2 Nitro N Cyclohexyl Methyl Benzyl Amine

300 Mother liquor (To be recycled)

1000

2. Hydrogen 2 Drying Loss 1903. Methanol 1000 Mother liquor (To be

recycled) 812

4. Carbon 5 Bromohexine HCl 3755. Bromine 325 6. HCL 45 7. Ethanol 700

TOTAL 2377 2377

Reactor

Filter

Drying and packing 375 Kg

Centrifuge

Reactor

Centrifuge

10. BRONOPOL (BP)

Manufacturing Process Charge methanol in Reactor then charge nitro methane, formaldehyde, caustic lye

slowly to the mixture. This is maintained for 3 hours at 20C, after that charge bromine and maintain for 4 hours at 60C, then methanol is recovered.

After total methanol recovery, charge water& Carbon this is then stir for 1 Hr. Then carbon is filtered & water is distilled. The reaction mixture is chilled to 10C & centrifuge & dry. Ml is sodium bromide solution & is collected separately.

Reaction Chemistry

Process Flow chart

CH3NO2 + 2HCHO + Br2 + NaOH

61 + 2*30 + 79*2 + 40

61 + 60 + 158 + 40 119 + 101 + 18

+ NaBr + H2O

+ NaBr + H2O

Br NO2 OH HO

C3H6O4NBr

318 318

Filter

Centrifuge

Dryer

Water Recycle 500 Kg

Sodium Bromide

Solution 130 kg

Product 300 Kg

Nitro Methane 100 kgs

Methanol 500 kgs

Caustic 70 kgs

Methanol 425 kg

Water 500 Kgs

C b 5 k

Reactor

Drying loss 105 Kg

Distillation Residue 50 kg Distillation loss 150 kg

Mass Balance SR. NO.



1. Water 500 Wastewater 5002. Nitro Methane 100 Methanol (Recovered) 4253. Methanol 500 Sodium Bromide Solution 1304. Caustic 70 Distillation residue 505. Formaldehyde 220 Distillation loss 1506. Carbon 5 Drying Loss 1057. Bromine 265 Bronopol (BP) 300

TOTAL 1660 1660 11. NICLOSAMIDE-BP Manufacturing Process Charge xylene in reactor and then add 5 nitro salicyclic acid at room temperature. This is stir for 1 hour and chilled to 10C. then slowly charge thionyl chloride at 15C

and maintain for 3 hours. Then slowly charge orthochloro para nitro aniline then stir for 6 hours at 85C. This is

then cooled to room temperature and centrifuged. ML is collected and recycled. Then extra water is drained to ETP and product is dried

and packed.

Reaction Chemistry

+

C7H5ClO3 + 2SOCl2

2NaOH

C7H4O2Cl2 C6H5N2O2Cl

C7H4O2Cl2 + NaCl + H2O + NaHSO3

+ NaCl + H2O + NaHSO3

172.57 + 118.57 + 80

363.5 363.5

OH

COCl

Cl

+ 2SOCl2

OH

COCl

Cl

2 * 40

371 371

191 + 58 + 18 + 104

OH

COOH

Cl

NHOC

Cl

Cl

OH

O2N H2N NO2

Cl

+ C13H8Cl2N2O4

191 + 172.5 172.57 + 36

+ HCl

+ HCl

Process Flow chart

Mass Balance



1. Water 600 Waste Water 440 2. Xylene 1000 Water ML Re Use 1200 3. Ortho Chloro Para Nitro

Aniline 180 Drying loss 100

4. Thionylchloride 135 Niclosamide BP 3505. 5 Chloro Salicyclic Acid 175

TOTAL 2090 2090 12. OXO-O-TOLYL ACETONITRILE

Manufacturing Process Charge Xylene to the reactor then charge orthotoulic acid. Add thionyl chloride at 15C

with controlled temperature. To this solution sodium cyanide and water is added at room temperature. Then stirred for 8 hours and separated. Then xylene is recovered and reused and a

finished product is packed in drums.

Centrifuge

Dryer

ML Recycle

1200 Kg

Wastewater 440 kg

Product 350 Kg

Xylene 1000 kgs

O.C.P.N.A 180 kgs

Thionylchloride 135 kgs

Reactor

Drying loss 100 Kg

Reaction Chemistry

Process Flow chart

+

+ NaCl + H2O + NaHSO3

136.2 + 118.57 + 80

203 203

+ 2SOCl2 + 2NaOH

334 334

154 + 58 + 18 + 104

NaCN

154 + 49 145 + 58

+ NaCl

OH

CH3

C=O

OH

CH3

C=O

OH

CH3

C=O

CN

CH3

C=O

Reactor

Final Product 300 kgs.

Stirring and Separation

Xylene 700 Kg O Toluic acid 275 Kg Thionylchloride 225 Kg

Sodium Cyanide 100 Kg Water 700 Kg

Xylene (Recovered & reused in next batch) 500 Kg Wastewater 500 Kg Drying & distillation loss 550 Process waste 100 Kg Distillation residue 50 kg

Mass Balance



1. Water 700 Waste Water 5002. Xylene (Recovered+ Fresh) 700 Xylene (Recovery) 5003. Ortho toluic acid 275 Drying & distillation loss 550

4. Thionyl chloride 225 Distillation residue 50

5. Sodium cyanide 100 Process waste 100

OXO-O- Tolyl Acetonitrile

300

TOTAL 2000 2000 13. 4 NITRO 3, 5 DIMETHYL PYRIDINE :

Manufacturing Process Charge Acetic acid and 3,5 lutidine .This mixture is stir for 1 hr. After this in prepared solution hydrogen peroxide is added. Then acetic acid is recovered. This is unloaded into drums. Sulphuric acid and Nitric acid mixture is prepared. In the same nitrating mixture above N-oxide mixture is added between the temperature 65 ˚C .This is then stir for 3 hrs. Then slowly water is added at room temperature .After maintaining is to be neutralized by ammonia gas. This is then centrifuged and dry. Reaction Chemistry

Process Flow chart 3, 5 Lutidine 400 Kg Acetic acid 380 Kg Hydrogen Peroxide 280 Kg Sulphuric Acid 654 Kg Nitric acid 436 Kg Ammonia gas 387 Kg Water 1150 lit Water 200 Lit

H2O2 HNO3 H3C N

H3C CH3

H3C N

H3C CH3

O

H3C N

H3C CH3

O

NO2

H2SO4 Acetic Acid

Reactor

Reactor Mixing

Centrifuge 1350 Kg wastewater

Dried & Packing 416 Kg

Acetic Acid Recovery 300 kg

1821 Kg wastewater




1. 3,5 lutidine 400 Aqueous layer (wastewater to ETP) 13502. Sulphuric acid 654 Acetic Acid recovery 3003. Acetic Acid 380 Emission and Drying Loss 18214. Nitric acid 436 4 Nitro 3,5 Dimethyl Pyridine 4165. Ammonia gas 387 6. Hydrogen Peroxide 280 7. Water 1350

TOTAL 3887 3887 14. DICHLORO PYRIMIDINE

Manufacturing Process In a glassline reactor Di hydroxy pyrimidine is dissolved in phosphorous oxychloride and

MDC as a solvent. This mixture is treated with tri ethyl amine.The above mixture is maintained at

40˚C for 6 hrs. This is then chilled to 10˚C, then water is added slowly. Then the mixture is stir

for 1 hr. Then layer is separated, organic layer is taken for MDC recovery and final product is

packed in drums. Aqueous layer contains TEA, which is recovered by treating with caustic flakes.

Reaction Chemistry

N

HO OH

N + 2POCl3 + 8 NaOH

N

Cl Cl

N + 2Na2PO4 + 8H2O + 4NaCl

146 + 142 *02 + 8 * 2 + 4 * 58.5 112.13 + 307 + 320

735 735

Process Flow chart




1. Di hydroxyl Pyridimine 225 Aqueous Effluent 9252. MDC 1218 MDC Recovery 10003. Phosphorous Oxychloride 400 Mother liquor + TEA (To

be recycled innext batch) 462

4. TEA 72 Dichloro Pyridimine 2155. Caustic 312 Distillation Loss 5506. Water 1000 Distillation residue 75

TOTAL 3227 3227

15. 2-AMINO 5-METHYL THIOZOLE

Manufacturing Process In a glassline reactor sulphuric chloride is charged .It is chilled to 20˚C then propenaldehyde is added in 5 hours. Then addition of 265 lit of Methanol in to solution. For adjusting pH there is addition of caustic for 10 pH. Then two layers separated aqueous layer send to ETP and organic layer treated with thiourea and HCL mixture. This is then reflux for 3 hour. Then cooled and adjust ph to 9 by dilute caustic solution. It is then centrifuge and dry.

Reactor

MDC Layer

1840 kgs

MDC Distillation

Aqueous Layer

TEA 1075 kgs

Reactor

Pack 215 kg

Phosphorous Oxichloride 400 kgs Di Hydroxy Pyrimidine 225 kgs

Water 1000 kgs

MDC Recovery 1000

Distilation loss 400

MDC 1218 kgs

TEA 72 kgs

Aqueous effluent 925 kg

Mother liquor + TEA 462kg

Caustic 312 kg

Reaction Chemistry

Process Flow chart

Reactor

SEPARATION

Reactor

CENTRIFUGE

DRYER

WATER 200 LITS

400 lits

Aqueous

190 lits

Aqueous

Product 100 Kg

Propenaldehyde 120 kgs

Sulphuryl chloride 300 kgs

Methenol 265 kgs

Caustic 85 kgs + 200 lits water

Caustic 50 kgs + 120 lits water

Toluene 300 kgs

HCl 20 kgs

Thiourea 100 kgs

Drying Loss

1070

CH3CH2CHO + 2SO2Cl2 + CH3OH + 5NaOH CH3CHClCOOCH3 + 2NaHSO3 + 3NaCl + H2O

315 315

122 + 2 * 104 + 3 * 58 + 5 * 18

CH3CHClCOOCH3 + H2N‐C‐NH2

S N

S H2N CH3

558

+ 2NaOH + 2NaCl + NaOOH3 + 2H2O

558

122.5 + 76 + 2 * 40 114 + 2 * 49.5 + 70 + 2 * 18

122.5 + 2 * 134 + 76 + 2 * 40



1. Propenaldehyde 120 Aqueous layer Effluent 5902. Sulphuryl Chloride 300 Emission and Drying Loss 10703. Methanol 265 4. Caustic 135 5. Toluene 300 6. Thiourea 100 7. HCL 20 8. Water 520 2 amino 5 methyl

thiozole 100

TOTAL 1760 1760 16. ALLYAL ISOTHIOCYANATE ( ALLYAL MUSTARD OIL) Manufacturing Process Charge water and ammonium thiocynate in reactor with continuous stirring. Stir for 4 hours at maintained temperature between 10˚C to 15˚C. add slowly Allyl chloride within 1 hour. Then reflux for 4 hours at 45˚C to 50˚C. cool to room temperature and then stop stirring and separation for 3 hours. Separate two layers. Upper layer is product (crude) and lower layer is wastewater. Take crude product in glass distillation unit and start distillation under vaccum. Distilled out pure allyl isothiocynate. Reaction Chemistry CH2=CHCH2Cl + NH4SCN → CH2=CHCH2NCS + NH4Cl Allyl Chloride Ammonium Allyl Iso Ammoinium Thiocyanate thiocynate Chloride (76.5) + (76.0) → ( 99 ) + (54) Process Flow chart

Condensation

Separation

Distillation

Final Product

Ammonium Thiocyanate 206 kg

Water 386 kg

Allyl Chloride 205 kg

Crude Allyl Thiocyanate

Ammonium Chloride 148 kgs

Wastewater 387 kgs

Ammonium Thiocyanate 2 kgs

Distillation residue 10 kgs



1. Allyl Chloride 205 Allyl Iso Thiocyanate 2502. Ammonium Thiocyanate 206 Ammonium chloride 1483. Water 386 Ammonium Thiocyanate

(To be reused in next batch)

2

Wastewater (To be treated in ETP)

387

Distillation residue 10 TOTAL 797 797

5. Resource optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined.

Latest Process technology will be adopted as available in market with optimum resources requirement with highest yield and less waste and pollution generation. Treated industrial effluent will be reused in cooling activities. In addition to this, all the feasible cleaner production technologies will be adopted.

6. Availability of water its source, Energy/ power requirement and

source should be given. Energy/power requirement will be 150 KVA which will be procured through Paschim Gujarat Vij Company Limited. The total water requirement will be 30 KL/day which will be fulfilled by own Open well. Water balance diagram is given here under;

Water balance diagram

Source of Water Supply: Open well Total: 30 KL/day

Domestic 1.5 KL/day

Greenbelt Development

8 KL/day

Industrial 26.5 KL/day

To Septic Tank & Soak pit 1.3 KL/day

Cooling 20 KL/day

DM Plant 7 KL/day

Washing 0.5 KL/day

Process 6 KL/day

Effluent Treatment Plant followed by Evaporator and condenser system 17 KL/day

ZERO DISCHARGE

0.5 KL/day

RO Plant 21 KL/day

0.2 KL/day 9

KL/day

Permeate 9.5 KL/day

Sludge to TSDF

Scrubbing 0.5 KL/day

Scrubbed Ammonia to be Recycled

Boiler 2.5 KL/day

15.5 KL/day

2 KL/day

Reject 1

KL/day

Reject 5.5

KL/day

6 KL/day

Reject 11.5

KL/day

0.8 KL/day

4.5 KL/day

7. Quantity of wastes to be generated (liquid and solid) and scheme for their Management/disposal.

HAZARDOUS WASTE GENERATION AND DISPOSAL

Sr. No.

Description CategoryQuantity

(MT/Annum)Management

1 ETP Sludge & Evaporation Residue

34.3 150 Collection, storage and

disposal at approved TSDF Site

2 Used / Spent Oil 5.1 0.1 Collection, storage and used

within premises as a lubricant / sold to registered recycler.

3 Discarded bags/ drums/ containers

33.3 65 Collection, storage & sell to

authorized vendor 4 Distillation residue 20.3 36 Collection, storage and

disposal at approved CHWIF Site

5 Process waste 28.1 20

WASTEWATER GENERATION AND DISPOSAL FACILITY Industrial Wastewater:

Waste water having Ammonical Nitrogen content (about 300 liters/day having Ammonical Nitrogen 200-300 mg/l) will be collected separately and given Ammonia stripping. Ammonia water will be recycled in process.

Wastewater after Ammonical nitrogen removal and other Industrial wastewater generated from manufacturing process and washing activities will be collected in Collection tank.

Then this wastewater will be given chemical treatment. Then it will be then pumped to filter press from where the sludge separated will be sent to

TSDF site. The filtrate separated from the filter press will be then collected in intermediate holding

tank. Boiler & Cooling Tower blow-down and R.O & DM reject will be added in this holding tank. Reverse osmosis will be provided to this water and will be reused in cooling tower, washing

and gardening purpose Reject from this R.O will be evaporated in evaporator.

Name of the units Volume (m3) No. of Unit Collection tank and stripper system Capacity 500 liters/day 1 set Collection cum Neutralization Tank 10 1 Chemical (Fenton) Treatment Tank 10 1 Filter Press 2 m3/hr 1 Intermediate Water Collection Tank 20 1 Evaporator followed by Condenser 1 m3/hr 1 Treated Water Storage Tank 20 1

ETP Flow Diagram:

Stream-wise Quality of Effluent:

Particular Unit Process WashingComposite

Effluent (Before Treatment)

After Chemical Treatment &

Sludge RemovalQuantity KL/day 9.0 0.5 9.5 9.5

pH -- 3.0-5.0 6.0-7.0 3.0-6.0 6.5-8.0

Total Suspended Solids mg/l 100-200 200-300 100-200 40-50

Total Dissolved Solids mg/l 3000-4000 1100-1200 3000-4000 3500-4500

Chemical Oxygen Demand mg/l 3000-4000 100-150 3000-4000 200-300

Particular Unit

Process & washing effluent

after chemical treatment

Cooling & Boiler blow

down

RO & DM Reject

Composite Effluent

After evaporation (Condensate

water) Quantity KL/day 9.5 1.0 6.5 17 15.5

pH -- 6.5-8.0 6.5-7.5 6.5-7.5 6.5-7.5 6.5-7.5

TSS mg/l 40-50 70-80 20-30 30-40 <10

TDS mg/l 3500-4500 2000-2500 6000-8000 4000-5000 <500

COD mg/l 200-300 40-50 10-20 100-150 <100

Evaporatorand

condenser

ChemicalTreatment(10KL)

IntermediateHoldingTank

(20KL)

HighAmmonicalNitrogeneffluent

HoldingTankforReuse(20KL)

SludgeandevaporationresiduetoTSDF

FilterPress(2m3/Hr)

Pump

CollectionTank(10KL)

AmmoniaStripper(0.5KL)

Wastewaterfrom

Processandwashing

blowdownandreject

8. Schematic representations of the feasibility drawing which give information of EIA purpose.

9. Site Analysis

(i) Connectivity Nearest Railway station Muli road railway station 15.3 Km Nearest National highway NH 8A 0.9 Km Nearest Airport Rajkot 77.4 Km Nearest State highway SH 21 0 km

(ii) Existing Infrastructure

(1) Power: 150 KVA from Paschim Gujarat Vij Company Limited, Sayla. (2) Water: Source of the water will be own Open well. (3) Basic amenities; Good Road connectivity with state and National highway. (4) Post Office: at Sayla which is 1.2 km away from project site

(iii) Land Form, Land use and Land ownership. Proposed project site has already been procured by proponent and it is having an existing shed in one corner and other is an open area which is presently not being used for any purposes. (iv) Soil classification of Surendranagar In this region, major area falls into 'very deep' soil. However, ‘deep’ soil is in major area of Surendranagar district. There are 'moderately deep' soils in few area of Surendranagar. There are 'very shallow' to 'shallow' soil in North-East part (Surendranagar district) and South West (Surendranagar district) part of the region. Rocky outcrops are also found in some part of the region especially in South - West (Surendranagar District) of the region. A major texture of the soil in the region is 'Loamy'. However, in South-West part (in Ahmedabad and Surendranagar district) a soil texture in few area is found to be 'Clayey'. Major area of the region is having 'Well’ drained soil. However, in some area of region especially in central part and Western part of Surendranagar district is representing 'Some what excessively' drained soil. A very few area of southern part of the region (Adjoining area of Ahmedabad and Surendranagar district) is showing 'moderately well' drained soil. In few area in Eastern part of Surendranagar district is 'Slightly Saline'. Also Slight sodicity is found in North-East part of Surendranagar district. In west part of the Surendranagar region 'Moderate’ to ‘strong‘ sodicity of the soil is found in the region.

(v) Social Infrastructure available. Sayla is the nearest residential area from the project site which is at only 0.3 km far. This Sayla is a Taluka place which is having all the social and infrastructure facilities.

(vi) Climate data from Indian Meteorological Department

Month

Air Temperature oC Humidity % Monthly Rainfall

Total, mm

Mean Wind Speed kmphDaily Max. Daily Min. Max. Min.

March 2015 42.9 12.2 100.0 11.0 16.7 9.9 April 2015 44.3 22.0 92.0 6.0 0 14.5 May 2015 44.4 24.7 93.0 7.0 6.0 17.7 Source: IMD, Rajkot 10. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and

Country Planning/Development authority Classification.

Proposed Project site is located near to the State highway 21 and National Highway 8A which is well connected to the Rajkot and Ahmedabad having all the infrastructural and transportation facilities. There is no any similar type of industry in nearby area.

(ii) Land use planning (breakup along with green belt etc).

Sr. No.

Particular Area (Sq. Mt.)

1 Built Up Area 2791.0 2 Green belt area 3680.0 3 Open/ Road area 4658.0

Total 11129.0

Plant Lay-out is given hereunder; Plant Lay-out

(iii) Assessment of Infrastructure Demand (Physical & Social). Sayla is the nearest residential area from the project site which is at only 0.3 km far. This Sayla is a Taluka place which is having all the social and infrastructure facilities.

(iv) Amenities/Facilities. Sayla is the nearest residential area from the project site which is at only 0.3 km far. This Sayla is a Taluka place which is having all the social and infrastructure facilities.

(v) Proposed Infrastructure a. Industrial Area

Industry will provide 2791 Sqmt. built up area for industrial process activity. Which provide all needed facility including proper ventilation, safe handling system, etc.

b. Residential Area There will not be any provision of labor quarters within the premises.

c. Green Belt. 3,680 Sqmt. (33.1%) area will be proposed for greenbelt development. In addition to this, project proponent will participate in greenbelt development programs in nearby areas under their CSR.

d. Social Infrastructure The Project proponent Industry will contribute annually 2% of total profit towards CSR (Corporate Social Responsibility) activity like following in nearby villages;

Education Facilities:- Facilities for village schools like game kits, drawing kits, table-chairs; school construction (classroom/toilet/school boundary), ceiling fans or books for school library

Health Facilities:-to provide assistance to existing health facilities in Nearest Hospital, for improvement in health facilities or services.

11. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion Start construction work: 1st September, 2016 Completion of construction work: 15th October, 2016

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

Total project cost is around 3 Crores

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