pre-feasibility report for establishment of synthetic...

Pre-Feasibility Report Reshmika Minerals and Chemicals Private limited

Pre-feasibility report for

Establishment of Synthetic organic chemicals and intermediates to serve agrochemicals, pharmaceuticals,

polymer, and specialty chemicals etc. industries

By

Reshmika Minerals and Chemicals Private limited PROJECT TERMED UNDER SCHEDULE 5 (B) & 5 (F)

CATEGORY - A

Prepared By

M/s Reshmika Minerals & Chemicals Private Limited (RMCPL)

Plot No. 23, Panoli GIDC, District - Bharuch,

Gujarat – 394 116

Web: www.reshmika.com

http://www.reshmika.com/


Table of Contents

1. Executive Summary .................................................................................................................................. 1

1.1 Introduction ......................................................................................................................................... 1

2. Introduction of the Project .................................................................................................................... 3

2.1 Identification of the project and Project Proponent ............................................................ 3

2.2 Brief Description of nature of the Project ................................................................................ 3

2.3 Need of project and its importance to the country or region ........................................... 3

2.4 Demand Supply Gap .......................................................................................................................... 3

2.5 Imports vs indigenous production .............................................................................................. 4

2.6 Export Possibility ............................................................................................................................... 4

2.7Domestic / Export Markets ............................................................................................................. 4

2.8Employment Generation due to Project (Direct and indirect) due to the project ..... 4

3. Project Description ................................................................................................................................... 5

3.1 Type of Project: ................................................................................................................................... 5

3.2 Location of the Project ..................................................................................................................... 5

3.3 Details of alternative site considered ......................................................................................... 5

3.4 Size or magnitude of operation .................................................................................................... 5

3.5 Project Description with Processes Details ............................................................................. 6

3.6 Raw Material required ..................................................................................................................... 6

3.6.1 Manpower Requirement ................................................................................................... 8

3.7 Resource Optimization / recycling ............................................................................................. 8

3.8 Availability of Water, energy, power, its source .................................................................... 8

3.8.1 Water ........................................................................................................................................ 8

3.8.2 Power ........................................................................................................................................ 8

3.8.3 Steam and other energy .................................................................................................... 9

3.9 Waste Generation and its treatment, disposal ..................................................................... 11

3.10 Schematic representation of the feasibility for EIA ......................................................... 12

4. Site Analysis ............................................................................................................................................... 13

4.1 Connectivity ....................................................................................................................................... 13

4.2 Land form, Land use and Land ownership ............................................................................. 13

4.3 Topography ........................................................................................................................................ 13

4.4 Existing Land use pattern ............................................................................................................. 14

4.5 Existing Infrastructure ................................................................................................................... 14

4.6 Soil Classification ............................................................................................................................. 14

4.7 Climate data from secondary source ........................................................................................ 14

4.8 Social Infrastructure available .................................................................................................... 15

5. Planning Brief ........................................................................................................................................... 16

5.1 Planning Concept ............................................................................................................................. 16

5.2 Population Projection ..................................................................................................................... 16


5.3 Land use planning ............................................................................................................................ 16

5.4 Assessment of Infrastructure Demand (Physical and Social) ......................................... 16

5.5 Amenities and Facilities ................................................................................................................ 16

6. Proposed Infrastructure ....................................................................................................................... 18

6.1 Industrial area (Processing area) ............................................................................................. 18

6.2 Residential Area (non processing area) .................................................................................. 18

6.3 Green Belt............................................................................................................................................ 18

6.4 Social Infrastructure ....................................................................................................................... 18

6.5 Connectivity ....................................................................................................................................... 18

6.6 Drinking Water Management ...................................................................................................... 18

6.7 Sewage System .................................................................................................................................. 19

6.8 Industrial waste management .................................................................................................... 19

6.8.1 Waste water generation, Treatment and disposal ................................................ 20

6.9 Solid waste management .............................................................................................................. 21

6.10 Power requirement supply and source ................................................................................ 21

Rehabilitation and Resettlement (R & R Plan) ............................................................................. 21

7. Project schedule and cost estimates ................................................................................................ 22

7.1 Time schedule of the Project ....................................................................................................... 22

7.2 Estimated project cost ................................................................................................................... 22

8. Analysis of proposal ............................................................................................................................... 23

8.1 Financial and Social Benefits ....................................................................................................... 23

List of Annexures

Annexure No Description

I Plot allotment / ownership record

II Google image of site & study area

III Proposed Layout plant of the

IV Proposed production process block diagram

V Waste management

VI Proposed effluent treatment scheme


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1. Executive Summary

1.1 Introduction

M/s Vansum Industries is a group of companies having head quarter at Pune, Maharashtra. We

are a group of experienced Chemical Industry professionals providing original manufacturing

services on Manganese products. We carry out rigorous and immense production with the help

of our extensive in-house knowledge base and our highly qualified staff of chemical engineers.

We manufacture quality manganese products in bulk quantity. The chemical manufacturing

operations are simultaneously managed at two locations viz.

1) M/s. Kemtech Solutions Pvt. Ltd.(KSPL) at Pune, Maharashtra and

2) M/s. Reshmika Minerals & Chemicals Pvt. Ltd. (RMCPL) at GIDC Panoli, Gujarat.

Company is regularly producing chemicals from raw Ore Manganese compounds at both

locations and has increased its market share over last 47 years.

RMCPL started its operations in the year 2010 by acquiring a 89,632.72 square meter land in

the year 2008 at GIDC Panoli, Gujarat.

As of today, RMCPL has occupied/utilized 8,739 square meter of land to meet market

requirements.

RMCPL is now producing ~ 60,000 TPA of Manganese Sulphate Solution to customers in and

around Panoli.

RMCPL wish to establish its manufacturing operation of Organic Chemicals and intermediates

at its site at GIDC, Panoli, Gujarat.

RMCPL has developed in-house green technologies for same. The initial lab and pilot scale

studies are successfully completed and company is ready to undertake commercial operations.

The products identified are not only based on green technologies but also have potentials to

substitute imports, which are sourced at present from China. Also, some of the intermediates

in-spite of imports shows a gap in demand against supply and hence the market potentials for

products are very encouraging. These observations are based on data obtained by RMCPL by

conducting market survey from reputed agencies.


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This proposal envisages the details required in order to obtain environmental clearance from

authorities so that the stablishment activities at Panoli can be undertaken.

The google image of the plant site is attached at Annexure – I.

Proposed Layout Plan for new establishment is attached as Annexure–II.

The project brief is summarized in the table below

Project summary

Sr. No.

Particulars Details

1 Name of Company Reshmika Minerals & Chemicals Pvt. Ltd. 2 Proposed Product & By

products Refer Section 3.4 for details

3 Location Plot No.23, GIDC Industrial Estate, Panoli, Gujarat 394 116.

4 Name of the project Establishment of synthetic organic chemicals and intermediates to serve agrochemicals, pharmaceuticals, polymer, and specialty chemicals etc. industries

5 Total land area of the plot 89,632.72 square meter 6 Total proposed built up area 16,500 sq.mtr. 7 Major raw material o-Xylene, Nitric Acid, Sulphuric Acid, m-Xylene,

Hydrogen Gas, Propionic Acid, Phenol, Acetaldehyde-oxime, Toluene, Salicylic acid, Ammonia solution (Liquor ammonia), 1-Octanol / 1-Octene, Styrene, Hydrogen peroxide, Caustic lye, Lime

8 Water Existing water requirement: 405.5 KL/day Proposed water requirement for Project: 261 KL/Day

9 Power Existing Power requirement: 275 KVA Proposed power requirement for project: 1000 KVA

10 Proposed Manpower Refer Chapter 3 11 Waste water quantity

(estimate) and disposal pathway

Refer Chapter 3

12 Air emissions Refer Chapter 3

13 Solid Waste Refer Chapter 3 14 Project cost estimate ~ Rs. 3000 Lacs


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2. Introduction of the Project

2.1 Identification of the project and Project Proponent

This proposal envisages establishment of current activities of RMCPL at Panoli, Gujarat. RMCPL

has conducted a market survey and based on recommendations thereof it is proposed to

undertake an establishment project wherein manufacture of organic intermediate can be

produced.

2.2 Brief Description of nature of the Project

RMCPL over last 2 years is rigorously working on developing greener technologies for some of

the organic intermediates. The selection of products is based on market survey conducted

exclusively for RMCPL by a professional market agency. The project involves development, scale

up and commercialization of developed technologies for products as mentioned in project

summary above. The project will be implemented at existing site at GIDC Panoli. All liquid,

solid, gases discharges are appropriately managed as explained in Annexure - V.

2.3 Need of project and its importance to the country or region

India is leading manufacturer of technical material for Agro / Pharma / Polymer / Specialty

chemical etc. industry. Most of the chemical industry in India is dependent on intermediate

supplies through imports particularly from China. In spite of that industry has faced severe

shortages for chemical intermediates due to factors beyond local controls. RMCPL has identified

organic intermediates imported in country in large quantities in-spite of some local production.

Some of the technical intermediates are short in supply since timely imports cannot be managed.

The intermediates identified by RMCPL will be mainly produced to bridge the gap between

demand and supply. Also, the innovative technologies when commercialized will also give an

opportunity to substitute imports so that valuable foreign exchange can be saved. The proposal

will also generate job opportunities for locals. The initiative taken up by RMCPL is mainly due

to strategic direction of Govt. of India viz. Make in India.

2.4 Demand Supply Gap

RMCPL has conducted market survey to identify the organic intermediates to be produced in-

house so that not only the demand supply gap is adequately covered but also, to ensure that

import substitution can be achieved. The market survey conducted clearly shows a gap of

almost 20-30% of Indian requirement. In addition to this, considering the potentials of import

substitution and further export opportunities the project looks attractive.


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2.5 Imports vs indigenous production

Some of the intermediates identified by RMCPL for production are totally imported in the

country whereas, for others the dependency for imports is upto 70-80%. Only one or two

intermediates are locally produced and it is observed that production capacities over last 5 years

are stagnant and not increasing.

2.6 Export Possibility

At present country is not exporting intermediates identified by RMCPL mainly due to non-

availabilities of production capacities. RMCPL objective is initially to meet local demand and

export opportunities are not explored at this juncture. However, RMCPL will create in future

more capacities if export opportunities are available.

2.7 Domestic / Export Markets

As above explained in 2.4 to 2.6

2.8 Employment Generation due to Project (Direct and indirect) due to the project

Project envisaged by RMCPL is from basic stage involving procurement of raw material, storage,

commercial production in-house analytical backup, finished products warehousing and supply

chain management. Since present activities are running at its peak wherein no existing

manpower can be released for new project, RMCPL proposes to recruit additional manpower for

all the functions explained above. The head count will cover skilled as well as unskilled labour

which will be managed by a highly experienced and talented seniors. The operations at Panoli

will also generate job opportunities for indirect labour to support activities such as transport,

maintenance, fabrication, civil jobs at site, canteen and food suppliers and security etc. RMCPL

foresees around 100 to 110 jobs for direct employment.


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3. Project Description

3.1 Type of Project:

Project involves manufacturing of synthetic organic intermediates. The proposed project will be

established in existing unit. (Details given in summary table)

3.2 Location of the Project

Project shall be located at Plot no P-30, GIDC Panoli. Refer Annexure II for location and

surrounding area details.

3.3 Details of alternative site considered

No alternative site considered. Project is envisaged at existing site, GIDC Panoli.

3.4 Size or magnitude of operation

Initially RMCPL will produce at least 2 products at a time as given in project summary table

depending upon market needs. The tonnage involved could be 200 – 400 TPM which may go

upto 1000 TPM. The project is envisaged on 16,500 sq.mtr. of area out of 89632.72 sq.mtr. of

total plot area.

Proposed product and by product details are as follows,

No Product / By Product CAS No Proposed

Capacity, TPM Products

1 Di-Ethyl Ketone (DEK) 96-22-0 250 2 Propiophenone 93-55-0 50 3 4-Nitro-o-Xylene 99-51-4 500 4 3-Nitro-o-Xylene 83-41-0 600 5 1,3-Dimethyl-2-Nitrobenzene 81-20-9 20 6 2,4-Dimethyl-1-Nitrobenzene 89-87-2 80 7 3,4-Xylidine (3,4 –Dimethyl Aniline) 95-64-7 100 8 2,6-Xylidine (2,6 –Dimethyl Aniline) 87-62-7 10 9 2,4-Xylidine (2,4 – Dimethyl Aniline) 95-68-1 40

10 N-(1-Ethylpropyl)-3,4-Xylidine 56038-89-2 500 11 2-Cynophenol 611-20-1 100 12 1-Octanoic acid 124-07-2 300 13 Styrene oxide 96-09-3 200 14 Phenyl ethyl alcohol 60-12-8 200 15 Phenyl ethyl alcohol methyl ether 3558-60-9 50


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Currently RMCPL is having CCA No 75308 from GPCB manufacturing inorganic chemicals Manganese dioxide (2000 Mt/Month), Manganese Oxide (700 Mt/Month) and Manganese sulphate solution (12000 Mt/month), Bricks (using own nonhazardous waste generated from manufacturing process) (36,00,000 Nos/Month). The existing activity does not falls underEIA notification, 2006.

3.5 Project Description with Processes Details

Refer Annexure IV (Chemical Reaction, process stepwise block diagram, process description,

indicating RM, Products and by products formed, emission details, waste generated…)

3.6 Raw Material required Following raw material shall be required for the manufacturing of proposed products.

No Raw Material

Estimated

Quantity

Ton/Month

source of supply

Mode of transport of Raw

material to site.

(Tanker/Drums/Carboys/…

1 Propionic acid 510 Imported ISO Tank

2 o-Xylene 850 - 875 Local Tanker

3 Fuming HNO3 700 - 725 Local Tanker

3 n-Hexane 20 Local Tanker

4 m - Xylene 75 Local Tanker

5 Conc. Sulphuric acid 75 Local Tanker

6 Conc./ Dilute Nitric

acid (60% acid) 75 Local Tanker

7 4-Nitro-o-Xylene 525 Indigenous Tanker

8 Hydrogen Gas 35 Local Trolley

9 Methanol 75 Local Tanker

10 1,3-Dimethyl-2-

Nitrobenzene 13 Indigenous Drum / Tanker

11 2,4-Dimethyl-

Nitrobenzene 52 Indigenous Drum / Tanker

12 Diethyl Ketone (DEK) 225 Indigenous Drum / Tanker

16 Phenyl acetaldehyde 122-78-1 20 17 Phenyl acetaldehyde di-methylacetal 101-48-4 20 18 Phenyl ethyl acetate 103-45-7 20

Total 3060 By Products

19 Methyl Ethyl Ketone 78-93-3 5 20 Dilute Sulfuric acid 7664-93-9 230 21 Dilute nitric acid 7697-37-2 800

Total 4095


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13 Salicylic acid 165 Local Drum

14 Liquor ammonia, 25% 90 Local Tanker

15 Toluene 20 Local Tanker / Drum

16 1-Octanol 310 Imported ISO Tank

17 Oxygen 85 Local Cylinder

18 Benzoic acid 50 Local Bags

19 Styrene 500 Imported Tanker

20 Hydrogen peroxide,

70%/50%/30% 400 Local ISO Tank / Tanker

21 Acetic acid 20 Local Tanker / Drums

22 Di-methyl sulfate 20 Local Tanker / Drums

Marketing area of Final Products

No Product /By Products Marketing area

(Local / Export)

Mode of transport

(tanker /Drums/ Carboys)

1 Di-Ethyl Ketone (DEK) Both Drum / Tanker

2 Propiophenone Both Drum / Tanker

3 4-Nitro-o-Xylene Local Drum / Tanker

4 3-Nitro-o-Xylene Both Drum / Tanker

5 1,3-Dimethyl-2-Nitrobenzene Both Drum / Tanker

6 2,4-Dimethyl-1-Nitrobenzene Both Drum / Tanker

7 3,4-Xylidine (3,4 –Dimethyl Aniline) Both Drum / Tanker

8 2,6-Xylidine (2,6 –Dimethyl Aniline) Both Drum / Tanker

9 2,4-Xylidine (2,4 – Dimethyl Aniline) Both Drums

10 N-(1-Ethylpropyl)-3,4-Xylidine Both Drums

11 2-Cynophenol Both Drums

12 1-Octanoic acid Both Drums

13 Styrene oxide Both Drum / Tanker

14 Phenyl ethyl alcohol Both Drum / Tanker

15 Phenyl ethyl methyl ether Local Drums

16 Phenyl ethyl acetate Local Drums

17 Phenyl acetaldehyde Local Drums

18 Phenyl acetaldehyde di-methyl acetal Local Drums

19 Methyl ethyl ketone - MEK Local Drums

20 Dilute Sulfuric acid Local Tanker

21 Dilute nitric acid Local Tanker


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3.6.1 Manpower Requirement

Expected manpower requirement for the proposed project (during operation phase) shall be as follows:

Description Existing at site

(Nos) Proposed for the

Project (Nos) Total, (Nos)

Permanent Staff 23 25 48 Contract workmen 35 75 110

Total 58 100 158

3.7 Resource Optimization / recycling

The technologies developed at RMCPL addresses issues such as recycle of solvents, recovery of

crops to obtain maximum yields, conservation of energies, recycle of aqueous stream Annexure

V shows process recycles whereas utilities recycles will be a part of engineering design.

3.8 Availability of Water, energy, power, its source

3.8.1 Water

RMCPL at present has an approval of 405.5 cmd of water consumption whereas present

consumption per day is maximum upto 130 cmd. The present production of Manganese

Sulphate solution is expected to grow and hence available quota of water will be just adequate.

For proposed project, fresh water requirement will be an additional 261 cmd.

The additional water requirement will be sourced by GIDC.

Water requirement for Existing Quantity in cmd

(as per CTO)

Proposed Quantity in

cmd

Total

Domestic 7 9 16

Industrial Process 374.5 252 626.5

Gardening 24 - 24

Total 405.5 261 666.5

3.8.2 Power

RMCPL at present has sanctioned quota of 275 KVA of electrical supply which is just adequate.

The proposed project will require additional 1000 KVA. Since the technologies envisaged high

temperature for some of the processes. The additional power requirement will be provided by

DGVCL.


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3.8.3 Steam and other energy

• Steam generation Boiler

Boiler required to produce steam for heating / reactions / product distillation / to operate MEE

for ETP, steaming jet ejectors, supporting other utility machinery.

3 TPH of steam with dryness fraction >0.97, steam pressure at 10 kg/cm2 and temperature

1800C. 2 operational and 1 as standby Gas fired boiler is proposed.

• General Hot oil unit

Hot oil unit required for heating / reactions / product distillation / to operate MEE for ETP /

ZLD unit having ATFD.

2.5 million kcal/h unit capable of producing Hot oil at 300o C. Hot oil circulation rate at 150 m3/h.

2 operational and one as standby Gas fired hot oil unit is proposed.

• High temperature hot oil unit

Hot oil unit required for heating / carrying out reactions using fixed bed catalytic reactors.

1 million kcal/h unit capable of producing Hot oil at 360o C. Hot oil circulation rate at 100m3/h.

2 operational Gas fired hot oil unit is proposed.

Estimated fuel requirement shall be as follows:

Fuel for No of units Type of

Fuel

Estimated fuel

quantity

Steam generation boiler (3 TPH each at 10 barg) 2 operation &

1 standby

Natural Gas 2 x 214 Nm3/hr

General Hot oil generator (2.5 Million Kcal/hr

each) (Hot oil at 300 deg C with 150 m3/hr

circulation)

2 operation &

1 standby

Natural Gas 2 x 346 Nm3/hr

High temperature Hot oil generator (1.0 Million

Kcal/hr each) (Hot oil at 360 deg C with 100

m3/hr circulation)

2 Operational Natural Gas 2 x 138 Nm3/hr

Emergency power generation set (750 KVA x 2

Nos)

2 Natural Gas 2 x 200 Nm3/hr

Other utilities shall be as follows,

Type of Utility Machinery

Service Ratings / Capacity Quantity

Chilled water generation unit

Chilled water generator required for controlling reactions, for controlling losses in organics, for providing cooling to vent

500 TR unit capable of producing Chilled Water at +5o C. Chilled water circulation rate could be 300 m3/h. Electrically operated.

Two in Operation


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coolers in distillation operations.

Chilled brine generation unit

Chilled brine generator required for controlling reactions.

200 TR unit capable of producing Chilled Water at - 15o C. Chilled brine circulation rate could be 125 m3/h. Electrically operated or VAM.

Two in Operation

Hot Molten Salt circulation unit

Molten salt unit required for heating / carrying out reactions using fixed bed catalytic reactors.

500000 kcal/h capacity molten salt circulation unit. Salt temperature at 400o C. Unit should be electrically heated with submersible pumps for circulation of molten salt.

One in Operation + One standby

Solar electric power generation system

For providing electrical power to molten salt heating system (during day time only)

750 KVA electrical generator with possible PV based silicon solar cell collectors.

One system

Cooling towers

Cooling towers required to control reaction, required for distillation, cooling for chilled water generators, chilled brine generators, Electrical Generators etc.

2000 TR unit capable of producing Cooling Water at +32o C. Cooling water circulation rate could be 750 m3/h. Electrically operated.

Two in Operation + One Standby unit

Nitrogen generator

PSA based Nitrogen generation set-up required for providing inert atmosphere in reactions, hydrogenation section, distillation and tank farm sections.

50 m3/h capacity nitrogen generation plant having nitrogen purity > 99.9%, pressure 7 kg/cm2, and with the dew point < -40o C.


Compresses air generator

Compressed air generation set-up required for providing instrument quality air required for controlling process in

50 m3/h capacity dry generation plant , having pressure 7 kg/cm2, and with the dew point < -30o C.



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reactions, distillation and tank farm sections.

DM water plant

DM Water plant required for generation of steam for boilers, process etc.

The water quality needs to be DM suitable for boiler quality, 10 m3/h capacity, with resin beds and mixed bed system to eliminate all the ionic impurities and silica, with bed regeneration facility etc.


Vacuum systems

Steam jet ejectors and dry vacuum pumps

Triple stage steam jet ejectors capable of giving vacuum 1 torr, as well as dry type vacuum pumps capable of giving vacuum to 1 torr level.

5 steam jet ejectors and 10 vacuum pump dedicated for distillation sections.

Note: Above is estimated requirement, shall be detailed during EIA stage.

3.9 Waste Generation and its treatment, disposal Please refer section 6.8.


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3.10 Schematic representation of the feasibility for EIA

-


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4. Site Analysis

4.1 Connectivity

This proposed Project site shall be located at Plot P-23, Panoli GIDC in Bharuch district, Gujarat. The Site is about 13 km from Ankleshwar city and is about 0.6 km away from National highway No 8. Nearest railway station is Ankleshwar. 4.2 Land form, Land use and Land ownership

Land is for industrial use. Its ownership is with M/s Reshmika Minerals & Chemicals Private

Limited (RMCPL). The surplus land within the site shall be utilized for proposed establishment.

4.3 Topography Bharuch district is located in the Sourthern part of Gujarat, near the Gulf of Khambhat in Arabian

Sea. In 1997, Bharuch district is bifurcated into Two parts (1) Narmada District and (2) Bharuch

District. The newly formed Bharuch District has 5253.30 Sq.km. area and situated between

21.30’ to 22.00’ North Latitude and 72.45’ to 73.15’ East Longitude

Bharuch District comes under Seismic Zone- III. Bharuch District is bounded by Baroda and

Anand District on the North, Narmada District on the East, Surat District is on the South and on

its west lies the gulf of Cambay. The Eastern strip of the district is a hilly and forest area. Main

rivers in Bharuch District are Narmada, Dhadhar and Kaveri. The rivers flow throughout the

year.


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4.4 Existing Land use pattern

It is industrial plot allocated by GIDC to M/s RMCPL.

4.5 Existing Infrastructure

The project is located in a well-developed zone, which have all essential facilities such as well-connected road network with ease of transportation, arrangement for supply of water and power to industries, effluent disposal facilities etc.

4.6 Soil Classification

The soils of the Bharuch district are derived from the Deccan trap which is main rock formation of the district. The soil of the district can be classified as light, medium and heavy according to depth, texture and location. There is sandy loam to loamy in texture, brownish black in color.

4.7 Climate data from secondary source

The climate of region is moderate with greater humidity on its coastal side. The average rainfall

in the district is 750 mm to 800 mm.

The weather of Bharuch district is hot and dry-starting from mid-march till mid-June, mid-

during summer season weather remains hot and dry. While from mid-June till end of September


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weather remains humid and can be considered pleasant. From October-November weather is

bit hot. From December to February climate remains cool. 4.8 Social Infrastructure available

Nearest town is Ankleshwar which is about 13 km from site. Social infrastructure such as schools, Hospitals, market place and other amenities are easily available. Transport facilities by rail and road are available.


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5. Planning Brief

5.1 Planning Concept Ankleshwar is largely an industrial area dominated by large scale industries, especially chemical plants & Pharmaceutical plants. Now the unit has proposed for establishment At Panoli GIDC Tal. Ankleshwar in Gujarat which has an industrial area with common effluent treatment plant; common incinerator and land fill sites. Govt. agencies provide many basic facilities like uninterrupted water supply, power and road network.

5.2 Population Projection

Bharuch district covers 3.32% of total area of Gujarat State. Sub-district Bharuch has the highest population (452517) whereas sub-district Hansot has the lowest (61268). Among villages, Dahej village of Sub-district Vagra is the most populated villages (13495) and Kakadpada village of the sub district Jhagadia has the lowest population of 47. Population density and sex ratio of Bharuch District was reported 238 persons/sq.km and 925 females per 1000 males respectively in 2011 census report. Total literacy of Bharuch District was found 81.51% for male and 75.09% for Females. The basic amenities like primary and secondary education schools, community health workers, primary health sub centre, private practitioners, primary health centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre, hospital, drinking water, transportation facilities, electricity , telephone etc. are available. 5.3 Land use planning

The proposed project is in the well-established GIDC industrial area. The land is year marked for industrial use.

5.4 Assessment of Infrastructure Demand (Physical and Social)

No major infrastructure demand is envisaged as the proposed site is in well-developed Panoli GIDC area.

5.5 Amenities and Facilities The available basic amenities are as under: Education Facilities: All the villages have a minimum of one primary school. Medical Facilities: All the surrounding villages have medical facilities.


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Drinking water Facilities & Power Supply: All the villages have potable water supply and in 100% area the drinking water is supplied through taps, wells and tube wells. All the villages have power supply facilities in the study region.

Transport Facilities: Bus services are available in all the villages of the study region within 5 km area and are the most preferable mode of transport in the region. Auto-rickshaw is also used as transport facility. Villages are connected with paved roads.


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6. Proposed Infrastructure

6.1 Industrial area (Processing area) Since the Project is planned at site owned by company in well-developed industrial area (GIDC Panoli), no special/specific development is anticipated. Company will have to do site development only.

6.2 Residential Area (non-processing area) No Residential area is proposed within the plant site.

6.3 Green Belt Green belt of adequate area within and around the project site shall be carried out as per industries norms and requirement.

6.4 Social Infrastructure Local people will be given preference wherever found suitable for all the jobs in the plant, direct as well as indirect. Thus, the project shall have a positive impact on the employment pattern of the region. Economic status of the local population will improve due to increased ancillary/business opportunities, thereby making positive impact. Educational, medical & housing facilities will improve due to the proposed project.

6.5 Connectivity This proposed project facility shall be located at GIDC Panoli in Bharuch, Gujarat. The Site is 0.6 km away from National highway no 8 and about 9 km away from Ankaleshwar city. The infrastructure is made available by GIDC and the raw material is easily available through the easy transport via road connectivity.

6.6 Drinking Water Management Existing water supply is from GIDC. Proposed water shall be procured from GIDC. The existing

& Proposed water requirement is as below

Water requirement for Existing Quantity in cmd

(as per CTO)

Proposed Quantity in

cmd

Total

Domestic 7 9 16

Industrial Process 374.5 252 626.5

Gardening 24 - 24

Total 405.5 261 666.5


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6.7 Sewage System The sewage will be treated at combined ETP.

6.8 Industrial waste management The hazardous waste like ETP waste, Spent Oil, Spent solvent, process organic residue and discarded containers will be generated from the proposed activity. The hazardous waste management and disposal is shown in Table below.

No Waste Type

Category Existing quantity as per CCA No AWH 75308

Proposed quantity

Quantity after establishment

Mode of disposal

1 Used Oil 5.1 1000 Kg/Year

1000 Kg/Year

2000 Kg/year

Disposal by sale to registered refiners

2 Discarded container bags /Liners

33.3 6.03 MT/Year

10.0 MT/Year

16.03 MT/Year

Collection, storage, reuse and decontamination.

3 Used Catalyst

29.5 - 1.25 Ton/Month

1.25 Ton/Month

Used catalyst will be sent to solid waste disposal facility or can be used for preparation of bricks.

4 Used / Spent Catalyst (Transition metal)

29.5 - 5000 Kg/year

5000 Kg/year

Used catalyst will be send to supplier for re-activation of catalyst.

5 Distillation column residue

29.1 - 95 Tons/Month

95 Tons/Month

Will be sent to common hazardous waste incineration facility

6 ETP sludge 35.3 - 100 MT/Year

100 MT/Year

CHWTSDF

7 Used Empty Barrels / Liners

33.1 - 1000 Nos/Year

1000 Nos/Year

Sale to Authorized party


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Note: Above waste figures are preliminary estimates, will be firmed up and detailed in EIA

report

6.8.1 Waste water generation, Treatment and disposal

Current scenario

Currently there is no trade effluent generated at site. Domestic effluent quantity is treated at

soak pit.

There is no liquid effluent generation in the process. RMCPL existing unit is zero liquid discharge

unit. Solid waste is generated in the form of sludge. Total quantity of Non Hazardous sludge is

~ 1800 MT per month. The entire quantity of sludge is used for manufacturing cold pressed

bricks.

Proposed scenario

Waste water is expected from proposed establishment from following sources

o Domestic sewage

o Plant processing / washings

o Reaction water

o Cooling Tower blow down

o Boiler blow down

o DM / Water softening plant – Backwash and regeneration water

It is proposed to treat above effluent in combined effluent treatment plant.

It is proposed to treat organic effluent and sewage water in conventional primary, secondary

and tertiary treatment followed by sand filtration and AC filtration and disinfection.

The treated effluent from above will be equalized with CT blow down, Boiler blow down, DM /

Water softening plant – Backwash and regeneration water which is expected to be having TDS

and negligible BOD/COD.

Equalized and homogenized effluent shall be passed through suitably designed UF/RO system.

Permeate shall be recycled to cooling tower and reject from this unit shall be subjected to

evaporation either by MEE or ATFD system so as to recover maximum condensate and reject the

accumulated salts.

Recovered condensate from this will be reused / recycled within site to cooling tower / other

usage. Removed salts shall be disposed to CHWTSDF site.

Expected waste water generation quantity shall be as follows,


21

Waste water Generation (For establishment)

No. Description Proposed generation (cmd)

Disposal

1 Domestic effluent 12 It will be treated onsite and reused. There will be no

discharge outside. 2 Trade effluent 54 Total 66

Proposed ETP scheme is given at Annexure VI.

6.9 Solid waste management

Solid waste generated during construction shall be managed / disposed as per industrial norm. There is no specific infrastructure is required for the proposed establishment for solid waste management. Refer 6.8 above for additional waste generation and its disposal management. 6.10 Power requirement supply and source

Existing power requirement for the plant site is 275 KVA, which is supplied by DGVCL. There is

500 KVA DG set at site for emergency requirement.

For proposed project, power requirement shall be 1000 KVA, which also will be sourced from

GGVCL.

There will addition of two DG set of 750 KVA each for emergency power requirement.

6.11 Rrehabilitation and Resettlement (R & R Plan)

The proposed Project shall be at plot of the company which is located at GIDC Panoli (which is notified industrial area). It does not require acquisition of Land and the Infrastructure so there is no any kind of activity of Rehabilitation and Resettlement carried out.


22

7. Project schedule and cost estimates

7.1 Time schedule of the Project It is expected that the project shall be completed within 6 – 18 months from date of grant of environmental clearance.

7.2 Estimated project cost

Total estimated project cost is around 3000 Rs. Lacs.


23

8. Analysis of proposal

8.1 Financial and Social Benefits

Proposed manpower shall be utilized from local region around Ankleshwar. Company shall also try to provide indirect employment opportunities by availing local contract services during transportation during operational phase. The proposed manufacturing project envisages - For the growing domestic market and as Import substitution - Direct employment to locals and will prompt ancillary business - Export benefits


24

Annexure I

Plot allotment / ownership record


25


26


27

Annexure II

Site & surrounding study area of 1 km

Site & surrounding study area of 10 km


28

Annexure III

Proposed Layout Plan for the project


29

Annexure IV

Product wise, Chemical Reaction, process block diagram and Brief process description

1) Di-ethyl-ketone Reaction

Process Block diagram

Brief Process Description

The fixed bed or stirred tank reactor having solid catalyst is heated to 375 to 400o C. The

propionic acid is fed through the hot catalyst bed continuously. The reaction products (DEK,

water vapor and carbon di-oxide) are fed to the distillation column in a continuous mode.

2

Catalyst , Heat

+ +

H2O

Propionic acid De-Ethyl ketone Carbon di-

oxide

Water

Process Block Diagram : Diethyl Ketone (DEK)

Reactor

Distillation - I

Propionic acid

Distillation bottom recycle

Distillation - II Distilled water recycle / reuse

Product DEK

Carbon dioxide


30

The top of distillation column water and DEK are condensed, whereas the excess propionic acid

is collected at distillation column bottom. The excess propionic acid is recycled to the catalytic

reactor.

The DEK and water are subjected to distillation to separate water and pure DEK. The water is

used for gardening purpose. The carbon di-oxide generated is passed through the scrubber.

2) Diethyl Ketone and Propiophenone

Reaction



Catalyst , Heat

H2O

Benzoic acid Propionic acid De-Ethyl

ketone

Propiophenone Carbon

di-oxide

Water

Process Block Diagram : PROPIOPHENONE AND DEK

Reactor

Distillation - I

Propionic acid& Benzoic acid

Distillation bottom

Distillation - II Distilled water recycle / reuse

Product DEK

Carbon dioxideDistillation - III

Product

Propiophenone

Propionic acidrecycle


31

The fixed bed or stirred tank reactor having catalyst is heated to 375 to 400o C. Mean time

propionic acid and benzoic acid solution (around 10 to 20% by wt of benzoic acid) is prepared

as a feed stock. The propionic and benzoic acid solution is fed through the hot catalyst bed

continuously. The reaction products (DEK, Propiophenone, water vapor and carbon di-oxide)

are fed to the distillation column.

The top of column water and DEK are condensed, whereas; propiophenone with the excess

propionic acid is collected at distillation column bottom. The bottom product containing excess

propionic acid and propiophenone is subjected to distillation. Initially excess propionic acid is

collected, which is recycled to reactor. Then the pure propiophenone is collected as product.

The DEK and water are subjected to distillation to separate water and pure DEK. The water is

used for gardening purpose. The carbon di-oxide generated is passed through the scrubber.

3) 4-Nitro-o-xylene (4 NOX) and 3-Nitro –o – xylene (NOX)

Reaction


Catalyst, Stir

o-Xylene Nitric acid 3-NOX 4-NOX


32


In a stirred reactor n-hexane / or suitable solvent (n-hexane and catalyst are stirred at room

temperature). The jacket of reactor is supplied with cooling / chilled water. Then to it O-Xylene

and nitric acid is added continuously over the period of 6 to 8 hours. The addition is done slowly

with careful control of temperature. The addition is completed in 6 to 8 hours and then stirred

further for 8 hours. The reaction mixture is filtered, the catalyst is recovered. The reaction

mixture is washed with water. The aqueous layer contains dilute nitric acid.

The organic layer is subjected to fractional distillation initially under atmospheric pressure to

recover n-hexane, which is recycled to reaction zone. Then the fractional distillation under

vacuum is carried out to recover un-converted o-Xylene, which is recycled to reaction zone. The

3-NOX is first distilled out and recovered as product. The material in the distillation still is finally

recovered using short path distillation unit to recover 4-NOX product. At the bottom of short

path distillation heavies are collected, which are send for disposal

Process Block Diagram : 4-NOX AND 3-NOX

Reactor

Distillation - I

3 NOX Product /Incineration

o Xylenerecycle

Distillation - II

Short path distillation

Filtration

Extraction with water

Distillation III

Distillation IV 4 NOX Product

Residue & Others

Discard - For Incineration

n Hexane recycle

catalyst

o Xylene + n HexaneCatalyst + Nitric acid

water Spent acid


33

4) 1,3-Dimethyl-2-nitrobenzene and 2,4-Dimethyl-1-nitrobenzene

Reaction


Nitric acid

Sulfuric acid

Di-Nitro Isomers

m- Xylene 1,3-Dimethyl-2-

Nitrobenzene

2,4-Dimethyl-1-

Nitrobenzene

Process Block Diagram : 1,3-DIMETHYL-2-NITRO BENZENE AND 2,4-DIMETHYL-1-NITROBENZENE

Reactor

Decantation / water wash

Distillation - I

Sulphuric acid+ Nitric acid

M Xylene

WaterAqueous layerstorage

Distillation - II

Distillation column residue

2,4-Dimethyl-1-Nitrobenzene

Recovered M Xylene

Short path distillation



34


In a stirred reactor 80% sulfuric acid solution in water along with m-Xylene is charged. The

jacket of reactor as well as the internal cooling coil of reactor is supplied with cooling / chilled

water. The reaction mixture is cooled to 20 to 22o C. Then to this reaction mixture 50 to 55%

dilute nitric acid is added continuously over the period of 4 to 6 hours. The addition is done

slowly with careful control of temperature. The addition is completed in 4 to 6 hours and then

stirred further for 1 hour. The reaction mixture is allowed to settle and separate in two layers.

Two layers are separated, lower heavy layer of dilute sulfuric acid is separated and stored in

dilute sulfuric acid. Then to the crude nitro mass, DM water is charged and stirred, allowed to

settle in two layers. The heavier crude nitro mass is separated and stored in crude nitro-mass

storage tank. The water washing is transferred and mixed with dilute sulfuric acid. This

aqueous layer contains dilute sulfuric acid which is sold in market or used elsewhere in the

existing plant.

The organic layer is subjected to fractional distillation initially under vacuum to recover un-

reacted m-Xylene, which is recycled to reaction zone in next batch. Then the fractional

distillation under vacuum is carried out to recover product 1,3-Dimethyl-2-Nitro benzene is first

distilled out and recovered at boiling point of product. The material in the distillation still is

finally recovered using short path distillation unit to recover 2,4-Dimethyl-1-Nitrobenzene as

the top distilled product. At the bottom of short path distillation heavies / higher boiler are

collected, which are sent for disposal.

5) Amino Compounds like 2,6 –Dimethyl Aniline, 2,4 Dimethyl Aniline, 3.4 Dimethyl Aniline

Reaction

2,6-DIMETHYLANILINE

Methanol, Hydrogen

gas

Catalyst, Heat

2 H2O

1,3-Dimethyl-2-

Nitrobenzene

2,6-Dimethylaniline Water of reaction


35


2,4-DIMETHYLANILINE

Methanol, Hydrogen

gas

Catalyst, Heat

2 H2O

2,4-Dimethyl-1-

Nitrobenzene


3, 4-DIMETHYLANILINE

Methanol, Hydrogen

gas

Catalyst, Heat

2 H2O

3,4-Dimethyl-1-

Nitrobenzene


Process Block Diagram : 2,6 -DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I


Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle

Distillation - II Distilled water for reuse

Product

Solvent Recycle


36

Process Block Diagram : 2,4-DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I

Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle


Product

Solvent Recycle


Process Block Diagram : 3,4-DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I

4 NOX Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle


Product

Solvent Recycle


37

General brief Process Description (to reduce nitro compounds to corresponding amino

compound)

In a stirred high pressure hydrogenation reactor having good mixing, internal cooling coil and

external limpet coil for heating is first thoroughly checked for tightness by applying nitrogen at

high pressure. Once this testing is done, transfer dry methanol to the reactor. Then transfer the

corresponding nitro mass (viz. 1, 3-Dimethyl-2-Nitrobenzene or 2, 4-Dimethyl-1-Nitrobenzene

or 3, 4-Dimethyl-1-Nitrobenzene). The agitator of reactor is started. Then the reaction mass is

flushed with nitrogen. Once the nitrogen flushing is over, then solid catalyst viz. Pd/C or Pt/C is

charged in the reaction mixture under nitrogen environment and mixing of reaction mass. Once

all the raw materials are charged, the reactor is evacuated with the help of vacuum pump. The

vacuum is released by nitrogen gas and the reactor is pressurized to 3 kg-g/cm2 with nitrogen

and the excess nitrogen pressure is vented after holding the pressure for 5 minutes. The

operation is repeated for five times to expel out air completely. Reactor is completely closed, all

safety gadgets are checked like pressure control loop, safety relief valve, rupture disc, hydrogen

gas leak sensors etc.

Then the reaction mixture is heated to desired temperature by passing medium pressure steam

pressure through the limpet coil of the reactor. Once the reaction temperature is attained, the

reactor is pressurized to the desired pressure with the help of hydrogen gas through auto

loading loop through hydrogen gas mass flow controller. Once the desired hydrogen gas

consumption attains desired value, the reactor is cooled by passing cooling tower water through

the internal cooling coil of the reactor. The reaction mass is further digested so that no nitro-

mass is left unconverted and the minimum hydrogen gas is present in the reactor. The excess

hydrogen is gas vented along with low pressure steam and nitrogen gas diluent.

The reaction mixture is filtered through the catalyst filter. The catalyst filter cake is washed with

methanol followed by DM water. The washings are taken in the reaction mixture. The catalyst is

recycled in next batch. The filtrate is subjected to recovery by distillation. Initially the methanol

and reaction water are recovered by distillation at atmospheric pressure. The recovered

methanol is recycled in next batch. The distilled water partly send to cooling water make-up.

The finished product is (amino compounds) recovered by distillation under vacuum. The

product is stored in nitrogen atmosphere. The distilled product is packed in the drums.

6) 4 NAX - N-(1-Ethyl propyl)-3,4-Dimethyl aniline

Reaction


38



In a reactor, the reactor is first flushed with nitrogen for three to four times. Then to the reactor

enough quantity of IPA or Methanol solvent is charged followed by hydrogenation catalyst

Catalyst, Stir

Hydrogen , Heat

H2O

4-NOX DI-ETHYL

KETONE

N-(1-ETHYL

PROPYL)-3,4-

XYLIDINE

Process Block Diagram : N-(1-ETHYL PROPYL)-3,4-DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I

DEK + 4 NOX Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle


Product

Solvent Recycle


39

(Pd/Carbon). Then to this mixture 4-NOX and DEK are charged to desired quantity. The reactor

is closed and the reactants are flushed thoroughly with nitrogen gas. The reaction mass is heated

under agitation till 75 to 80o C. Then to it the hydrogen gas is passed to reactor, hydrogen gas is

allowed to consume. If required the reaction mass is occasionally cooled by passing water

through the jacket of the reactor. Hydrogenation is continued till no more hydrogen gas is

consumed. After the reaction is over reaction mixture is digested for further 30 to 45 minutes.

Then the reaction mixture is cooled and the catalyst is filtered through sparkler filter. The

catalyst is washed with small quantity of solvent. The catalyst is preserved for recycle in next

hydrogenation batch.

The filtrate and washings are charged to distillation vessel. The product is subjected to complete

solvent recovery under vacuum. The product is cooled and is taken in drum. The product drum

is flushed with nitrogen.

The distillate obtained in the above-mentioned flash distillation operation is subjected to

solvent recovery to recover and recycle the solvent. The water recovered by distillation is

subjected to gardening application or cooling tower application.

7) 2-Cynophenol Reaction


Ammonia solution ,

Toluene, Heat

2H2O

Salicylic acid Salicyl amide Water of reaction

Vapor phase ,

Catalyst

H2O

Salicyl amide 2-Cynophenol Water of reaction


40


The reactor is flushed with nitrogen, then reactor is charged with toluene. Desired amount of

salicylic acid is then charged to the reactor followed by desired amount of liquor ammonia

solution is charged. The reaction mixture is stirred for 1 hour. The reaction mixture is slowly

heated till the boiling point, the excess water and reaction water is removed by azeotropic

distillation with toluene. The distilled water is send for disposal. The toluene is recovered by

distillation. The salicyl amide is stored in molten condition.

The molten salicyl amide is continuously charged to fixed bed catalytic reactor along with small

amount of nitrogen. The reaction product 2-cyanophenol and reaction water is collected by

cooling. This product i.e. crude 2-cyanophenol and reaction water is charged along toluene to

the azeotropic distillation facility. The reaction water is recovered by azeotropic distillation,

which is send for treatment. The dehydrated 2-cyanophenol is cooled by applying chilled water

through the jacket of reactor. The crystallized purified 2-cyanophenol is centrifuged in the

centrifuge. The crystalline 2-cyanophenol is then dried in a vacuum drier. The mother liquor is

subjected to recovery of second crop 2-cyanophenol. Finally the toluene is recovered by

distillation and recycled. The residue of distillation column is send for solid waste disposal

facility.

Process Block Diagram : 2 Cyanophenol

Reactor-Neutralizer

Dehydration Reactor

Catalytic Reactoration

Toluene + Salicylic acidLiquor Ammonia

Distilled water with ammoniaTraces - disposal

Solvent Distillation

Distilled solvent recycle

Dehydration ReactorDistilled water- disposal

Crystallization

CentrifugeVacuum

DryerProduct

Mother Liquor Distillation

Distilled Toluene recycle

Residue -Disposal

Toluene

Toluene


41

8) 1-Octanoic acid

Reaction



The reactor is charged with desired amount 1-Octanol. Then to the reactor is charged with the

catalyst. The agitator of the reactor is started with high intensity for better mixing of catalyst

and 1-Octanol. Then the reactor is heated to desired temperature by passing steam through the

jacket of reactor. Then the reactor is pressurized with oxygen gas to the desired pressure and

allowed to consume the pressure. The operation is repeated by pressurizing with oxygen till

Oxygen, Catalyst

Heat

Water & Residue

1-Octanol 1-Octanoic acid

Process Block Diagram : 1- Octanoic acid

Reactor

Catalyst Filter

Vacuum Distillation

Filtrate and washing

Catalyst Cakerecycle

Reaction WaterResidue/Polymeric bodies

Product1- Octanoic acid

1 Octanol

1 Octanol + CatalystOxygen

1 Octanol

1 OctanolRecycle


42

desired consumption takes place. The reaction temperature is continuously maintained by

cooling the reaction mixture by passing cooling water through the jacket of reactor.

Once the reaction is complete, the reaction mass is cooled, depressurized and filtered through

the filter. The crude 1-Octanoic acid distilled under reduced pressure, the water of reaction is

recovered and disposed followed by excess 1-Octanol is recovered and recycled. Finally 1-

Octanoic acid is recovered and the distillation residue is subjected to incineration.


43

Annexure V

Waste Management

The waste generation and waste disposal pathways are shown as per the project as

follows:

Project: Diethyl ketone (DEK)

Product / By products Quantity , ton/month Remarks / Disposal pathways

Products

Diethyl ketone Refer section 3.4 above Product

Propiophenone Refer section 3.4 above Product

Methyl-Ethyl ketone Refer section 3.4 above By-Product

Emissions

Carbon dioxide 145 to 150 TPM This carbon di-oxide is washed

with water and released in air. The

water used for scrubbing is send

for recovery of volatiles if any and

recycled in a scrubber. This is

completely close loop system.

Liquid waste / distilled water

Distilled water 52 to 55 TPM The water generated in reaction is

distilled water and free of organic.

Will be recycled to cooling water

and partly recycled in the reaction

zone.

Solid waste / waste catalyst

Used catalyst 3.00 to 3.50 TPM The DEK / Propiophenone / MEK

manufacturing is catalytic process,

where modified clay is used. In a

process the catalyst gets

deactivated. The deactivated

catalyst will be send to solid waste

disposal facility.

Note:

• All the above quantities are estimated figures and are likely to change as per the

production capacity / production.

Project: 4-Nitro-o-Xylene (4-NOX) and 3-Nitro-o-Xylene (3-NOX)


44

Product / By products Quantity ,

ton/month

Remarks / Disposal pathways

Products

4-Nitro-o-Xylene Refer section 3.4

above

Product

3-Nitro-o-Xylene Refer section 3.4

above

By-Product. This product is a

distilled and pure product. This

product has limited market. The

excess product over the market

demand will be send to common

disposal facility for incineration or

it will be send for co-processing to

cement plant.


Distillation column residue 100 to 110 TPM By-Product. This product is

distillation column residue. This

product will be send to common



cement plant.


Dilute nitric acid 750 to 800 TPM 50% dilute nitric acid.

Out of this 80 to 100 TPM will be

used in the m-Xylene nitration to

produce mixture of Nitro-m-

Xylenes.

700 to 720 TPM of dilute nitric acid

will be sold in market.

Note:


production capacity / production. Dilute nitric acid strength will also depend on the

water used for washings.

Project: 1,3-Dimethyl-2-Nitrobenzene and 2,4-Dimethyl-1-Nitrobenzene


ton/month



45

Products

1,3-Dimethyl-2-

Nitrobenzene

Refer section 3.4

above

Product

2,4-Dimethyl-1-

Nitrobenzene

Refer section 3.4

above

By-Product. This product is a

distilled and pure product.


Distillation column residue 2.6 to 3.0 TPM By-Product. This product is

distillation column residue. This

product will be send to common



cement plant.


Dilute sulfuric acid 210 to 230 TPM 30% dilute sulfuric acid with

minor amount of nitric acid.

This will be used as the raw

material in the existing facility or

will be sold in the market.

Note:



• Dilute sulfuric acid strength and quantity is likely to change depending upon water

washings

Project: Xylidines - 1, 3-Dimethylaniline (2, 6-Dimethylaniline), 2, 4-Dimethylaniline, 3,

4-Dimethylaniline


ton/month


Products

1,3-Dimethylaniline

(2,6-Dimethylaniline)

Refer section 3.4

above

Product

2,4-Dimethylaniline Refer section 3.4

above

Product

3,4-Dimethylaniline Refer section 3.4

above

Product



46

Distilled water 45 to 48 TPM This will be used for gardening and

cooling tower make-up.

Note:



Project: N-(1-Ethylpropyl)-3,4-Dimethyl aniline


ton/month


Products

N-(1-Ethylpropyl)-3,4-

Dimethyl aniline

Refer section 3.4

above

Product


Distilled water 36 to 38 TPM This will be used for gardening and

cooling tower make-up.

Note:



Project: 2-Cynophenol


ton/month


Products

2-Cyanophenol Refer section 3.4

above

Product

Solid waste - Solvent distillation and Crystallization residue

Residue 35 to 45 TPM This product will be send to

common disposal facility for

incineration or it will be send for

co-processing to cement plant.

Liquid waste / distilled water with trace ammonia

Distilled water 90 to 110 TPM This will be treated by

neutralization and will be fed to

water recovery facility.

Note:




47

Project: 1-Octanoic acid

Note:



Project: 1-Octanoic acid


ton/month


Products

1-Octanoic acid Refer section 3.4

above

Product


Distillation column residue 36 to 45 TPM This product is distillation column

residue. This product will be send

to common disposal facility for




Distilled Water 39 to 40 TPM This is distilled water and

proposed to use in cooling water

make-up


ton/month


Products

1-Octanoic acid Refer section 3.4

above

Product


Distillation column residue 36 to 45 TPM This product is distillation column

residue. This product will be send

to common disposal facility for





48

Note:



Project: Styrene Based products

Distilled Water 39 to 40 TPM This is distilled water and

proposed to use in cooling water

make-up


49

Note:



Annexure VI


ton/month


Products

Styrene Oxide Refer section 3.4

above

Product

Phenyl ethyl alcohol Refer section 3.4

above

Product

Phenyl acetaldehyde Refer section 3.4

above

Product

Phenyl acetaldehyde

dimethyl acetal

Refer section 3.4

above

Product

Phenyl ethyl alcohol methyl

ether

Refer section 3.4

above

Product

Phenyl ethyl acetate Refer section 3.4

above

Product



for Styrene Oxide / Phenyl

ethyl alcohol / related

products

20 to 50 TPM This product is distillation column

residue. This i.e. distillation

column bottoms goes to agarbatti

industry or else this product will

be send to common disposal

facility for incineration or it will be

send for co-processing to cement

plant.

Phenyl ethyl alcohol salt

after reaction

10 to 20 TPM It will be send to Solid Hazardous

waste Disposal facility or else it

will be sold as product.


Distilled Water 200 to 300 TPM This is distilled water recovered

after styrene oxide aqueous layer

processing and proposed to use in

cooling water make-up


50

Proposed Effluent Treatment scheme

Proposed ETP Scheme

Process Effluent + Reaction Water

Equalization tank

Aeration tank

Settling tank

Acid/ Alkali dosage

Polyelectrolyte

Neutralization tank

Cooling tower blowdownBoiler BD / DM Plant backwash/ Regeneration water

Sewage Effluent

Excess Sludge Settling tank

Sand / AC Filter

Equalization tank

pH Correction

UF / RO Unit

MEE / ATFD System

Permeate and Condensate

recycle / reuseRO Reject

Salts for disposal

Sludgerecycle

pre-feasibility report for establishment of synthetic...

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