pre-feasibility report · 6.22 p-bromo fluorobenzene 6.23 para nitro benzyl bromide 6.24 para bromo...

Pre-Feasibility Report

of

Neogen Chemicals Ltd Block No. 526A, Village: Karakhadi,

Taluka: Padra, Dist.: Vadodara, Gujarat-391450

Proposed Expansion for Manufacturing of Fine Chemicals and

Agro Intermediates (308 MTPM to 1800 MTPM)

Project Activity: 5(f) & 5(b), Category: A

PFR of Neogen Chemicals Ltd 1

1. INTRODUCTION

Neogen Chemicals Ltd proposes Expansion for Manufacturing of Fine

Chemicals and Agro Intermediates (308 MTPM to 1800 MTPM)

Manufacturing at Block No. 526A, Village: Karakhadi, Taluka: Padra,

Dist.: Vadodara, Gujarat-391450.

The area of the site is 160,528 m2.

Location of the proposed project and 10 km radius around the location

are shown below.

The estimated cost of the project is estimated around Rs. 300 crores.

2. LOCATION OF PROJECT

3. PRODUCTION CAPACITY

Production capacity is prescribe below:

List of Existing Products

Sr. No.

Name of Products Existing Quantity

MTPM

Proposed Quantity

MTPM

1 n-Propyl bromide 15 Existing products will be

added in following proposed groups

2 n-Butyl bromide 15 3 4-Bromo-Methyl - 2-Cyano bi phenyl 30 4 Ethyl 2-bromo Butyrate 40 5 p-Bromo Fluorobenzene 25.5 6 DECA bromo diphenyl ethane (DECA-DPE) 7 7 Bromo Proponyl bromide 15 8 1-Bromodecane (N Decyl Bromide) 10 9 Para Nitro Benzyl Bromide 5 10 Ethyl/Methyl bromo acetate 5 11 1,4-Dibromobutane 40 12 DECA 1 13 Para Bromo Phenol 5 14 Para Bromo Anisol 5 15 Tetrtiary Butyl Bromo Acetate (TBBA liq) 1 16 Bromo Acetyl Bromide 5 17 Allyl Bromide 5 18 Tetra Bromo bis phenol -A-Diglycidyl ether

(TBBA-DGE) 0.5

19 5-[4'-Bromomethyl - 1,1'-biphenyl 2- yl] - 1- triphenylmethyl - 2H- tetrazole

5

20 Acetyl Bromide 5 21 DEMBB 1 22 Ethylene dibromide 14 23 Tetra bromo Phthalic anhydride 1 24 Hexylbromide 15 25 Benzyl Bromide 35 26 Tetralone 2

Total 308 --


Proposed List of Product with quantity

Sr. No.

Name of Products Quantity Mt/Month

Category as per EIA Notification

1 Bromination and Chlorination of Alcohols 291.7 5(b) & 5(f)

1.1 Ethyl Bromide 1.2 n-Propyl Bromide 1.3 Iso Propyl Bromide 1.4 n-Butyl Bromide 1.5 Iso Butyl Bromide 1.6 Sec-Butyl Bromide 1.7 n-Hexyl Bromide 1.8 n-Heptyl Bromide 1.9 n-Octyl Bromide 1.10 n-Decyl Bromide 1.11 Lauryl Bromide 1.12 Cetyl Bromide 1.13 Myristyl Bromide 1.14 Stearyl Bromide 1.15 1,2 Dibromo Ethane 1.16 1,3 Dibromo Propane 1.17 1,4 Dibromo Butane 1.18 1,5 Dibromo pentane 1.19 1,6 Dibromo Hexane 1.20 1 Chloro 2 Ethyl Hexane 1.21 6 Chloro 1 Hexanol 1.22 3 Chloro Propanol 1.23 1,6 Dichloro Hexane 1.24 Cyclo Propyl Methyl Bromide 1.25 Cyclo Pentyl Bromide 1.26 Cyclo Pentyl Chloride 1.27 6-bromohexanol 1.28 8-bromooctanol 1.29 10-bromodecanol 1.30 Benzyl Bromide 1.31 Bromo Propinyl bromide 1.32 1-Bromodecane 1.33 Allyl Bromide 1.34 1-Bromo Octane 1.35 Iso-Octyl Chloride 1.36 1,3-Dichloro Propane

2 Bromination of Organic Acids and Esterification

291.7 5(f)


Sr. No.



2.1 2 Bromo propionic Acid 2.2 2 Bromo Propionyl Bromide 2.3 5 Bromo Valeric Acid 2.4 2 Bromo Hexanoic Acid 2.5 Sodium 2 Bromo Propionate 2.6 Ethyl 3 Bromo Propionate 2.7 Methyl 2 Bromo Butyrate 2.8 Ethyl 2 Bromo Butyrate 2.9 Ethyl 4 Bromo Butyrate 2.10 Methyl 2 Bromo Iso Butyrate 2.11 Ethyl 2 Bromo Iso Butyrate 2.12 Iso Propyl 2 Bromo Iso Butyrate 2.13 Ethyl 2 Bromo Valerate 2.14 Methyl 2 Bromo valerate 2.15 Ethyl 5 Bromo Valerate 2.16 Tert-Butyl 2 Bromo Iso Butyrate 2.17 Methyl 2 Bromo Caproate 2.18 2 Bromopentane dioic acid 2.19 2Bromopentane acid Di Butyl ester 2.20 4-Bromo-Methyl - 2-Cyano bi phenyl 2.21 Ethyl/Methyl Bromo Acetate 2.22 Bromo Acetyl Bromide 2.23 Acetyl Bromide 2.24 TBBA Liq 2.25 Methyl/Ethyl/tert-butyl/iso-propyl-2

bromoisobutyrate 2.26 2-bromopropionic acid or its sodium salt 2.27 Methyl 4-bromomethyl biphenyl 2

carboxylate 2.28 11-bromoundecoanic acid 3 Grignards Formation from Organic

Halides 83.3 5(f)

3.1 Methyl Magnesium Chloride 3M in THF 3.2 Methyl Magnesium Bromide 1.5M in THF 3.3 Ethyl Magnesium Chloride 2M in THF 3.4 Ethyl Magnesium Bromide 2M in THF 3.5 Vinyl Magnesium Bromide in 1M in THF 3.6 Isopropyl Magnesium Chloride 1M in THF 3.7 Phenyl Magnesium Bromide 2M in THF 3.8 n-Butyl Magnesium Chloride 1M in THF 3.9 Iso Propyl Magnesium Chloride–Li Cl Complex


Sr. No.



1.3M in THF 3.10 Iso Propyl Magnesium Bromide 1M in THF

4 Halogen Exchange Reactions 166.7 5(b)&5(f) 4.1 1 Bromo 2 Chloro Ethane 4.2 1 Bromo 4 Chloro Butane 4.3 1 Bromo 5 Chloro Pentane 4.4 1 Bromo 6 Chloro Hexane 4.5 Bromo Fluoro Methane 4.6 Methylene Dibromide 4.7 Bromo Chloro Methane 4.8 5 Iodo Valeric Acid Ethyl Ester 4.9 2 Bromo Hepta Fluoro Propane 4.10 2 Methyl Allyl Bromide

5 Addition of Halogen and Halogen Acids 208.3 5(b)&5(f) 5.1 Ethylene Dibromide 5.2 Phenyl Ethyl Bromide 5.3 1Bromo 3 Chloro Propane 5.4 n-Hexyl Bromide 5.5 n-Octyl Bromide 5.6 n-Decyl Bromide 5.7 Cyclo Pentyl Bromide 5.8 Cyclo Pentyl Chloride 5.9 1,2 Dibromo 3 Chloro Propane 5.10 1,2 Dibrmo hexa fluoro Propane 5.11 1,4 dibromo 2 butene 5.12 1,1 Dibromo 3 chloro Propane 5.13 Hexylbromide

6 Bromination or Chlorination of Cyclic and Aromatic Compounds with or Without Functional Groups

208.3 5(b)&5(f)

6.1 Bromo Benzene 6.2 Di Bromo Benzene 6.3 Ethyl 4 Bromo Methyl Benzoate 6.4 1 Bromo 4 Chloro Benzene 6.5 p- Bromo Toluene 6.6 4 Bromo O Xylene 6.7 2 Chloro 1,4 Naphthaquinone 6.8 1 Bromo 4 Fluoro Benzene 6.9 4 Bromo Methyl 2 Cyano Biphenyl (Bromo

OTBN) 6.10 1 Bromo 3,4 Dichloro Benzene


Sr. No.



6.11 Deca-DPE 6.12 Tribromophenol 6.13 1 Bromo 2 4 difluorobenzene 6.14 4 bromo benzyl bromide 6.15 2 bromo 4 fluoro aniline 6.16 4 nitrobenzyl bromide 6.17 Deca bromodiphenyl oxide 6.18 4 bromo phenol 6.19 4 bromo anisole 6.20 TBBE DGE 6.21 Tetra bromo phthalic anhydride 6.22 p-Bromo Fluorobenzene 6.23 Para Nitro Benzyl Bromide 6.24 Para Bromo Phenol 6.25 Para Bromo Anisol 6.26 5-[4'-Bromomethyl-1,1'-biphenyl 2- yl] - 1-

triphenylmethyl - 2H- tetrazole 6.27 DECA 6.28 Tetra bromo Phthalic anhydride

7 Dehydrohalogenation of Organic Halides with or without functional Group

83.3 5(f)

7.1 Vinyl Bromide 7.2 Vinyl Bromide in 25% THF 7.3 Vinyl Chloride 7.4 4 Bromo 1 Butene 7.5 6 Bromo 1 Hexene 7.6 7 Bromo 1 Heptene 7.7 8 Bromo 1 Octene 7.8 5 Bromo 1 Pentene 7.9 1 Bromo propene

8 Advance Intermediates 416.7 5(b)&5(f) 8.1 6 Methoxy 2 Naphthaldehyde 8.2 2 Fluoro 5 Bromo Benzonitrile 8.3 Ethyl 4- (dimethyl amino) Butyrate 8.4 Bromo Acetal 8.5 6 Bromo Hexyl Trimethyl Ammonium bromide 8.6 1 Bromo 3 Phenoxy Propane 8.7 6 Chloro 2 Hexanone 8.8 n-Octyl Amine 8.9 Bifenthrin Alcohol 8.10 Ethyl 7 Chloro 2 Oxo Heptanoate


Sr. No.



8.11 1 Bromo 6 Methyl Heptane 8.12 Methyl 3 Oxo Pentanoate 8.13 TBC 8.14 3,4 DFBA 8.15 Homophthal 8.16 L-valine OTBN 8.17 Tetrazole 8.18 DEMBB 8.19 Tetralone 8.20 6 Chloro hexanol tetra hydro pyran

derivative 8.21 3 bromo propyl trimethyl ammonium bromide 8.22 6 bromohexanol tetra hydro pyran derivative 8.23 8 bromohexanol tetrahydropyran derivative 8.24 10 bromo tetrahydro pyran derivative 8.25 2-amino-3’,4’-difluorobiphenyl 8.26 DFB 8.27 DEBB 8.28 2-Cyclopropyl 6-Methyl Phenol (from group

7) 8.29 Tetralone 8.30 DEMBB 8.31 TBBA-DGE 8.32 6-bromohexyltrimethyl ammonium bromide 8.33 N 2 Cyano 11 biphenyl 4-yl methyl valine

methyl ester 8.34 1,4,7,10 Tetrabenzylcyclen 8.35 2-Carboxymethyl-5-methoxy-benzoic acid or

intermediate 8.36 PFDF 8.37 KA(Nisso) 8.38 o-Nitrobenzaldehyde 8.39 RL-3 8.40 Diaxolone 8.41 IBA 8.42 LB-5

9 R&D 50 5(b)&5(f) Total 1800


4. MANPOWER REQUIREMENTS

Total manpower requirement at all level of plant will be 275.

5. ENERGY & FUEL REQUIREMENTS

• Energy requirement for the proposed project will be 2000 kVA, and

will be sourced from Madhya Gujarat Vij Company (MGVCL).

• Existing: Coal - 20 MT/day, HSD for DG Set (250 kVA) – 50 lit/hr.

• Proposed: FO - 102 KL/day, HSD – 220 lit/hr. per DG Set for 1000

kVA each

6. MANUFACTURING PROCESS

Detailed manufacturing process is given in Annexure-II of Form-I.

7. WATER REQUIREMENTS AND WASTEWATER GENERATION

The total fresh water requirement will be 480 KL/day, which will fulfill by

Borerwell water supply. The breakup of water consumption and

wastewater generation is given below.

Details of water consumption

Sr. No.

Sources Present m3/d

Proposed m3/d

Total m3/d

I Domestic 8 17 25 II Gardening 5 107 112 III Industrial

A Water treatment 0 40 40 B Processing 12 133 145 C Scrubber 3 32 35 D Boiler 17 128 145 E Cooling 92 158 250 F Washing - 30 30 Total Industrial 124 521 645

Total(I+II+III) 137 645 782 Less Recycle 0.0 302 302

Actual fresh water requirements

137 343 480

Details of waste water generation

Sr. No.

Sources Present m3/d

Proposed m3/d

Total m3/d

I Domestic 7 15 22 II Industrial A Water

treatment 0 40 40

Processing 11 139 150 Scrubber 01 4 5


B Boiler 3 12 15 C Cooling 12 38 50 D Washing - 30 30

Industrial 27 263 290 Total 34 278 312

8. SOURCES OF POLLUTION AND MITIGATION MEASURES

A. Air Pollution

Adequate stack height will be provided to control & disperse the air

pollutants within the satisfactory levels. Furthermore, facility for sampling

such as ladder and sampling point will be provided as per the GPCB

guidelines. The details of stacks with their APC measures & height are

given in below.

Sr. No.

Stack attached to Fuel Type

Stack Height,

in m

APC measures

Probable emission

Flue Gas Stacks Ø Existing

1 Boilers 3.0 TPH

Coal – 20 TPD

30 Cyclone separator, bag filter

SPM<150 mg/Nm3 SO2<100 ppm NOX<50 ppm

2 D G Set (250 kVA)

HSD –50 lit/hr.

4 Adequate Stack height

Ø Proposed

1 Boiler-1 6.0 TPH

FO – 17 KLD 32 Adequate Stack height

SPM<150 mg/Nm3 SO2<100 ppm NOX<50 ppm 2 Boiler-2

6.0 TPH FO – 17 KLD 32 Adequate

Stack height 3 Boiler-3








Stack height 7 D G Set - 1

(1000 kVA) HSD – 220

lit/hr. 11 Adequate

Stack height 8 D G Set - 2

(1000 kVA) HSD – 220

lit/hr. 11 Adequate

Stack height Ø Existing Process gas stacks

1 Bromine reactor

- 16 Two stage caustic

scrubber

HBr<30 mg/Nm3

Br2<2 mg/Nm3


Sr. No.


Stack Height,

in m

APC measures

Probable emission

2 Bromine storage tank


scrubber 3 Bromine

reactor - 16 Two stage

caustic scrubber

4 Bromine reactor


scrubber Ø Proposed Process gas stacks

1 Multipurpose plant-1

- 16 Water & Alkali

Scrubber

HBr<20 mg/Nm3 HCl<20 mg/Nm3 Br2<2 mg/Nm3 Cl2<9 mg/Nm3


- 16

Water & Alkali

Scrubber



- 16

Water & Alkali

Scrubber



- 16

Water & Alkali

Scrubber



- 16

Water & Alkali

Scrubber



- 16

Water & Alkali

Scrubber

SO2<40 mg/Nm3


7 Bromine scrubber

- 16 Two stage Alkali

Scrubber

HBr<20 mg/Nm3 Br2<2 mg/Nm3

8 Work area exhaust scrubber-1

- 16 Water & Alkali

Scrubber

SO2<40 mg/Nm3



- 16 Water & Alkali

Scrubber

SO2<40 mg/Nm3



Sr. No.


Stack Height,

in m

APC measures

Probable emission


- 16

Water & Alkali

Scrubber

SO2<40 mg/Nm3


B. Water Pollution

Industrial effluent will be treated in ETP having primary-secondary-

tertiary treatment units. Treated water will be further send to RO and

MEE to recover 230 KLD RO permeate and 60 KLD MEE condensate.

respectively. RO permeate and MEE condensate will be reused again and

ZLD will be achieved. Domestic wastewater will be treated in STP and will

be used for greenbelt development.

C. Hazardous Wastes

Entire quantity of hazardous waste will be handled & disposed as per

Hazardous & Other waste (Management & Transboundary Movement)

Rules, 2016. The unit will provided isolated area with impervious flooring

& roof cover for the storage of hazardous waste. Details of hazardous

waste and disposal are given below.

Sr.

No

Name of Waste Quantity, MT/month Method of Disposal

Existing Proposed Total

1 ETP waste 30 50 80 Collection, storage & disposal at TSDF site approved by GPCB. 2 MEE salt -- 52 52

3 Process/distillation

residue

41.5 1258.5 1300 Collection, storage & disposal at CHWIF or co-processing.

4 Discarded containers/ barrels/liners

120 200 320 Collection, storage, decontamination and disposal by selling to registered recyclers.

5 Used Lubricating Oil

0.1 Kl/year

0.9 Kl/year

1.0 Kl/year

Collection, storage & use within premises as lubricant/sell to registered recycler.

6 Liquor of HBr (<30%)

242 538 780

Collection, storage, sale to actual users/re -processors under Rule-9 of HAZ Rule-2016


7 Sodium hypochlorite 0 26

26


8 Spent H2SO4 20 240 260


9 Acetic acid 0 38 38 Collection, storage, sale to actual users/re -processors under Rule-9 of HAZ Rule-2016

10 Inorganic salts like (Sodium Bromide, Magnesium Bromide, Potassium Bromide, Calcium Bromide, Sodium Sulphate, Sodium Bisulfite, Ammonium Bisulphite, Potassium Bicarbonate)

1.4 498.6 500


9. GREEN BELT DEVELOPMENT

The unit proposes to earmarked space for development of green belt

along the plan periphery to arrest noise pollution and fugitive emissions

as well as to improve aesthetics.

10. FUNDS FOR POLLUTION CONTROL MEASURES

The management is quite conscious of its responsibility for maintaining

clear environment. Thus, around Rs. 30 crores will be provided for the

pollution control measures as a part of overall project financing.

11. MONITORING FACILITIES

Company is ready to carry out monitoring proposed by pollution control

board from time to time through outside agency.

12. CONCLUSION

On the basis of information presented here on pollution control measures

and its implementation, there will be no emission from the plant beyond

the norms specified by the Board as per the provisions of Water

(Prevention and Control of Pollution) Act, 1974 and Air (Prevention and

Control of Pollution) Act, 1981.

pre-feasibility report · 6.22 p-bromo fluorobenzene 6.23 para nitro benzyl bromide 6.24 para bromo...

Documents