PRE-FEASIBILITY REPORT - …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/20_Jan... · Unit Process: Formylation with Vilsmeier Haack Reagent Such as ... CMA 3-chloro-2-methyl

PRE-FEASIBILITY REPORT

For

EXPANSION OF DYES INTERMEDIATE UNIT

[Schedule 5 (f) Category “B” as per EIA notification 2006 and its amendment thereof]

At

Plot No. 1708, A-2/1715, Phase-III, Notified Industrial Area,

GIDC Vapi, Dist- Valsad (Gujarat).

Land/Plot Area: 8219 m2

Production Capacity: 608.34 TPM to 1673.35 TPM

APPLICANT CONSULTANT SARNA CHEMICALS PVT. LIMITED

(UNIT: II) ECO CHEM SALES & SERVICES

Plot No. 1708, A-2/1715, Phase-III Office Floor, Ashoka Pavilion - A Notified Industrial Area, New Civil Road, Surat, 395001

GIDC Vapi, Dist- Valsad (Gujarat) NABET/EIA/1720/RA 051 E-mail: [email protected] E-mail: [email protected]

Mo. No.: +91-9825886564 Tel No. +91 261 2231630

Prefeasibility Report Sarna Chemicals Pvt. Limited (Unit: II)

Expansion project- Dyes intermediates Page 1

Project pre-feasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification – 2006

1 Executive Summary:

Name & Location

Name of the Project: M/s Sarna Chemicals Pvt. Limited (Unit: II)

Location : Plot No: 1708, A-2/1715, Phase:III, G.I.D.C, Vapi

Ta: Pardi. Pin Code: 396195.

Dist. - Valsad (Gujarat).

Project M/s Sarna Chemicals Pvt. limited (Unit: II) is located in notified industrial area GIDC

Vapi, falling under medium Scale category manufacturing products as mentioned under

for which the company had obtained Consent To Establish and Operate from Gujarat

pollution Control Board.

The company proposes to enhance the capacity of existing products as well introduce

new similar group of products under the category “Dyes Intermediates”.

Existing project cost is Rs.6.19 Crore. Proposed expansion Project Cost: Rs. 14.13

Crore. Total cost after proposed expansion will be Rs. 20.32 Crore.

Applicability of EIA notification – 2006 Category as per the amended EIA notification-2006: as existing and proposed products

(i.e. Dyes Intermediates) are covered under the Category-5(f). Hence, Environmental

clearance is required.

Project Proponent

The company in India comprises of 2 directors

Medium scale unit

LIST OF EXISTING PRODUCTS WITH MONTHLY CAPACITY

S. No. Product Quantity (TPM)

Group: A

A1 AEC. HCl or 35

A2 MNBC or

A3 Chloro ester or

A4 Schwander Acid Chloride or

A5 NMT Chloride or

A6 Acridon – III or

A7 Schwander Acid or

A8 Ether Amine or

A9 B base

Group A Maximum 35

Group: B

B1 Basic Blue or 10



B2 m Nitro Anisole or 10

B3 DDD or 20

B4 CJD or 40

B5 AHD or 40

B6 MIHQ or 30

B7 GBL Condensed or 35

B8 Acridon – II or 02

B9 NMT Amide or 25

B10 1:2/1:4 DMB or 10

B11 DEAB or 20

B12 DMAB or 10

B13 NEL or 10

B14 MBL or 10

B15 AMAS 10

Group B Maximum 40

Group: C

C1 OJD 25

Group C Maximum 25

Group: D

D1 ONBSC or 20

D2 NDMT or 50

D3 FJD or 50

D4 AEE HCl or 50

D5 DCPC 50

Group D Maximum 50

Group: E

E1 M-Anisidine or 05

E2 VJD 20

Group E Maximum 20

Group: F

F1 MNCB + (ONCB/PNCB) 170 + (21)

Group F Maximum 170

Group: G

G1 MCA 100

Group G Maximum 100

Group : H

H1 Sodium Sulphite Crystal 28.34

Group :I

I1 Sodium Thio Sulphate Crystal 140

Total Group A, B, C, D, E, F,G, H, I 608.34

By product

1. 30% HCl 243.765

2. NaCl Salt Direct recovery from ANF 34.640

3. Spent Acid 78% 186.830

4. NaBr Soln. 28% 167.205

5. NaNO2 Soln. 25% 33.510

6. AlCl3 Soln. 30% 138.750



LIST OF PRODUCTS AFTER PROPOSED EXPANSION

S. No.

Name of the Products Capacity

(TPM)

1 Unit Process for Chlorination

(A) Chlorination with Chlorine such as MNCB + (PNCB & ONCB) 200 + 38.4

(B) Chlorination with Thionyl Chloride/Sulfuryl Chloride Such as MNBC;

NMT-Cl; Chloroester; SACl, AEC.HCl, 5-ClABTF; ITC 100

(C) Chlorination with Phosphorus Trichloride (PCl3) and condensation

such as N-OPLA 10

2 Unit Process condensation such as CJD; AHD; GBL-condense;

DDD; Samba-3, Triazolone; 1,3-DAU, DPI; NOXSA 100

3 Unit Process: Deamination Such as Semicarbazide HCl; MBI; BI 20

4 Unit Process: Alkylation with DMS/DES Such as 1,2/1,3/1,4-DMB;

NEL; 2HMB 10

5 Unit Process: Nitration with Dilute Nitric Acid Such as NDMB

[2,4/3,4/2,5]; NBI; NMBI; Ac-DCPNA; NABT; NIPA 15

6 Unit Process: Formylation with Vilsmeier Haack Reagent Such as

DEAB; DMAB; DMBA; DHB 20

7 Unit Process: Amidation Such as NMT-amide; p-Nitro benzamide;

DSA, ONCBPSA 20

8 Unit Process: Acylation using Aluminium Trichloride Such as

DCPC; 2HMB 10

9 Unit Process: Reduction

(A) Reduction with sodium hydrogen sulfide (NaSH) Such as MCA; 4-

NAPSA; MSMAA 100

(B) Reduction with Iron and acid in water Such as MA; VJD; AOX;

OPSAMIDE 10

(C) Reduction by hydrogenation Such as AMBI; AM3; MOPDA; ABI;

AMBA; MPBA; AIPA; DABA, Ortho Phenoxy aniline 100

10 Unit Process: Chloroxidation/oxidation

(A) Such as SA; Ether amine; ONBSC; PNBSC; 40

(B) Such as sodium hypochlorite 36.8

11 Unit process for dehydration

(A) Dehydration using phosphorus oxychloride (POCl3) Such as Nitrile 5

(B) Dehydration by evaporation Such as sodium thiosulfate 141

12 Unit process for chloro Sulfonation Such as NOXSC; DSC;

ONCBPSC 25

13 Unit process for hydrolysis Such as ONCBPSAH; DCPNA 15

14 Unit process for Sulfonation Such as DCASA, FJD 20

15 Unit process for Crystallization Such as sodium sulfite 217.15

16 Unit process for purification Such as HCl (30%) 400

17 Unit process for Methoxylation Such as CMA 20

Total 1673.35



FULL NAME OF THE PRODUCTS

S. No. Short Name Full Name CAS No.

1. MNCB/ONCB/PNCB m/o/p-Nitrochlorobenzene 121-73-3/88-73-

3/100-00-5

2. MNBC m-Nitrobenzoyl chloride 121-90-4

3. NMTCl 3-Nitro-4-carbomethoxy Benzoyl chloride 64152-10-9

4. Chloroester isopropyl 4-chlorobutanoate 3153-34-2

5. SACl Scwander Acid Chloride or 4-(2-chloro

ethyl sulfonyl)-butyryl chloride 24352-85-0

6. AEC.HCl [2-(2-aminoethoxy) ethyl chloride]

hydrochloride 55265-25-3

7. 5ClABTF 5-chloro-2-amino-benzotrifluoride 445-03-4

8. ITC Isophthaloyl chloride 99-63-8

9. NOPLA 4-Carbomethoxy-3-nitro-2,5-

dichlorobenzanilide 99-63-8

10. CJD N-{2-[(2-hydroxyethyl)thio]ethyl}-3-

nitrobenzamide Not Available

11. AHD 2-{[2-(aminoethoxy)ethyl]thio}ethane al Not Available

12. GBL 4-[(2-hydroxyethyl)thio]butanoic acid Not Available

13. DDD 2,2'-Dinitro diphenyl disulfide 1155-00-6

14. SAMBA-3 2-Amino-2-hydroxy-diethyl sulfide 24304-84-5

15. Triazolone 1,2,4-TRIAZOL-3-ONE 930-33-6

16. 1,3-DAU Carbohydrazide or 1,3-Diaminourea 497-18-7

17. DPI Diphenyl isophthalate 744-45-6

18. NOXSA 5-Nitro-N-(2-hydroxyethyl)-2,3-dimethylbenzenesulfonamide

25959-70-0

19. Semicarbazide HCl Semicarbazide Hydrochloride 563-41-7

20. MBI 5-methylbenzimidazolone 5400-75-9

21. BI Benzimidazolone 615-16-7

22. 1,2/1,3/1,4-DMB 1,2/1,3/1,4-Dimethoxybenzene 91-16-7;151-10-

0;150-78-7

23. NEL N-ethyl-1,8-naphtho lactum 130-00-7

24. 2HMB 2-Hydroxy-4-methoxy benzaldehyde 673-22-3

25. NDMB [2,4/3,4/2,5] 2,4/3,4/2,5-Dimethoxy Nitrobenzene 709-09-1

26. NBI 5-Nitrobenzimidazolone 93-84-5

27. NMBI 5-Nitro-6-methylbenzimidazolone 83573-62-0

28. Ac-DCPNA 2,5-Dichloro-4-nitroacetanilide 6627-34-5

29. NABT 5-Acetomino-2-Nitro-Benzotrifluoride 393-12-4

30. NIPA 5-Nitro-Isophthalic acid 618-88-2

31. DEAB 4-Diethyl amino benzaldehyde 120-21-8

32. DMAB 4-Dimethyl amino benzaldehyde 100-10-7

33. DMBA 1,3-Dimethoxybenzaldehyde 86-51-1

34. DHB 1,3-Dihydroxybenzaldehyde 24677-78-9

35. NMT-Amide 3-Nitro-4-carbomethoxy Benzamide Not Available

36. P-Nitro benzamide Para-Nitro-benzamide 619-80-7

37. DSA 5-Chloro-2,4-disulfamylaniline 121-30-2

38. ONCBPSA 3-Nitro-4-chlorobenzenesulfonamide 17691-19-9

39. DCPC 2,4-Dichloro phenacylchloride 4252-78-2

40. 2HMB 2-Hydroxy-4-methoxy benzaldehyde 673-22-3

41. MCA m-Chloroaniline 108-42-9

42. 4-NAPSA 3-amino-2-hydroxy-5- 74525-32-9



nitrobenzenesulfonic acid Sodium salt

43. MSMAA 3-Amino-4-methylamino-phenyl methyl

sulfone 73097-51-5

44. MA m-Anisidine 536-90-3

45. VJD 3-amino-N-{2-[(2-

hydroxyethyl)sulfonyl]ethyl}benzamid 107294-87-1

46. AOX 5-amino-N-(2-hydroxyethyl)-2,3-

dimethylbenzenesulfonamide 25797-78-8

47. OPSAMIDE 3-Amino-4-hydroxy-benzenesulfonamide 98-32-8

48. AMBI 5-amino-6-methyl benzimidazolone 67014-36-2

49. AM3 5-acetamino-2-amino benzotrifluoride 1579-89-1

50. MOPDA 4-methyl-2-amino-aniline 496-72-0

51. ABI 5-amino benzimidazolone 95-23-8

52. AMBA (4-aminobenzyl)methylamine 38020-69-8

53. MPBA m-phenoxy-benzylalcohol 13826-35-2

54. AIPA 5-Amino-Isophthalic acid 91-36-0

55. DABA 3,5-Diamino-benzoic acid 535-87-5

56. O-Phenoxy aniline Ortho-phenoxy aniline 1131-60-8

57. SA Scwander Acid or 4-(2-chloro ethyl

sulfonyl)-butyric acid 121315-24-0

58. Ether amine 2(2-amino ethoxy)-2'-chloro-

diethylsulfone hydrochloride solution 98231-71-1

59. ONBSC o-Nitrobenzene sulfonyl Chloride 1694-92-4

60. PNBSC p-Nitrobenzene sulfonyl Chloride 98-74-8

61. Sodium hypochlorite Sodium hypochlorite 7681-52-9

62. Nitrile 3-Nitro-4-carbomethoxy-benzonitrile Not Available

63. Sodium thiosulfate Sodium thiosulfate 10102-17-7

64. NOXSC 5-Nitro-N-(2-hydroxyethyl)-2,3-

dimethylbenzenesulfonyl chloride 68631-04-9

65. DSC 4-Amino-6-chlorobenzene-1,3-disulfonyl

chloride 671-89-6

66. ONCBPSC 3-Nitro-4-chlorobenzenesulfonyl chloride 1694-92-4

67. ONCBPSAH 3-Nitro-4-hydroxy-benzenesulfonamide 24855-58-1

68. DCPNA 2,5-dichloro-4-nitro-aniline 6627-34-5

69. DCASA 3,4-Dichloro-aniline 6-sulfonic acid 6331-96-0

70. FJD 2-(3-Aminobenzamido) ethyl sulfonyl

ethyl hydrogen sulphate 121315-20-6

71. Sodium sulfite Sodium sulfite 7757-83-7

72. HCl (30%) Hydrochloric acid (30%) 7647-01-0

73. CMA 3-chloro-2-methyl anisole 3260-88-6

Manufacturing process is attached as Annexure-3.



Resource Requirement:

Components Existing

Proposed Total after proposed expansion

Resources availability

Power, KVA 350 550 900 sourced from Dakshin Gujarat Vij Co. Ltd.

Fresh Water, kL/day

87.99 118.87 206.86 Will be sourced from GIDC water supply Dept.

Coal for Boiler (7 TPH), Kg/h

1050 0 1050 Sourced from local dealer

Fuel (HSD) for D.G.Set, kg/h (Capacity: 250 KVA)


Fuel (HSD) for D.G.Set, kg/h (Capacity: 250 KVA)


Fuel (HSD) for D.G.Set, kg/h (Capacity:500 KVA)


Cooling Tower, TR

250 250 500 In-house

Chilling plant, TR

40 120 160 In-house

Raw material Consumption after proposed expansion:

S. No. Raw Materials CAS No. Consumption in MT

Per Ton of Product

Per month

1. Unit Process for Chlorination

(A) Chlorination with Chlorine such as ;

For MNCB/ONCB/PNCB

i Nitrobenzene 98-95-3 0.94 188

ii Chlorine 7782-50-5 0.56 112

iii Ferric Chloride 7705-08-0 0.07 14

(B) Chlorination with Thionyl Chloride/Sulfuryl Chloride Such as;

For MNBC

i Meta-Nitrobenzoic acid (MNBA) 121-92-6 0.90 90

ii Thionyl Chloride (Recovered) -- 0.13 13

iii Thionyl Chloride (Fresh) 7719-09-7 0.67 67

For NMT-Cl

i Nitro-Monomethyl-terphthalate (NMMT) 35092-89-8 0.93 93





For Chloroester

i Gamma-Butyrolactone (BTL) 96-48-0 0.51 51



iv Isopropyl alcohol (IPA) 67-63-0 0.38 38

For SACl

i Scwander Acid or 4-(2-chloro ethyl sulfonyl)-butyric acid (S-acid)

121315-24-0 0.92 92



For AEC HCl

i 2-aminoethoxyethanol (AEE. HCl) 929-06-6 0.88 88

ii Thionyl Chloride (Recovered) -- 0.059 5.9


For 5-ClABTF

i 3-aminobenzotrifluoride (ABTF) 98-16-8 0.85 85

ii Sulfuryl chloride (Sul. Chloride) 7791-25-5 0.57 57

iii Recovered MCB -- 1.91 191

iv Fresh MCB 108-90-7 0.04 4

For ITC

i Isophthalic acid (ITA) 121-91-5 0.81 81.0

ii Thionyl Chloride (TC) (Recovered) -- 0.13 12.0

iii Thionyl Chloride (TC) (Fresh) 7719-09-7 1.20 120.0

(C) Chlorination with Phosphorus Trichloride (PCl3) and condensation

such as

For N-OPLA

I Nitro-Monomethyl-terphthalate (NMMT) 35092-89-8 0.67 6.7

ii Phosphorus Trichloride 7719-12-2 0.23 2.3

iii MCB ML -- 3.22 32.2

iv MCB (fresh) 108-90-7 0.09 0.9

v 2, 5-dichloro aniline (2,5 DCA) 95-82-9 0.48 4.8

vi Soda ash 497-19-8 0.18 1.8

2. Unit Process condensation such as;

For CJD

i m-Nitrobenzoyl chloride (MNBC) 121-90-4 0.67 67

ii Caustic lye 1310-73-2 0.31 31

iii 2-Amino-2-hydroxy-diethyl sulphide (SAMBA-3)

24304-84-5 0.44 44

iv HCI 7647-01-0 0.03 3

For AHD

i [2-(2-aminoethoxy) ethyl chloride] hydrochloride (2-AEC HCl)

55265-25-3 0.97 97

ii Methanol 67-56-1 1.66 166

iii Caustic lye 1310-73-2 0.54 54

iv 2-mercaptoethanol (ME) 60-24-2 0.47 47

v Hydrochloric acid (HCI) 7647-01-0 0.19 19

For GBL-condense

i isopropyl 4-chlorobutanoate (Chloroester) 3153-34-2 0.78 78

ii Caustic lye 1310-73-2 0.64 64

iii 2-mercaptoethanol (ME) 60-24-2 0.37 37

iv Hydrochloric acid (HCI) 7647-01-0 0.03 3

For DDD



i Ortho-Nitro chlorobenzene (ONCB) 88-73-3 1.02 102

ii Sodium hydrogen sulphide (NaSH) 16721-80-5 0.60 60

iii Caustic lye 1310-73-2 0.28 28

iv Sulfur 7704-34-9 0.11 11

v 5% HCl Wash -- 0.76 76

For Samba-3

i 2-mercaptoethanol (ME) 60-24-2 0.65 65

ii 2-chloroethanol amine hydrochloride (CEA) 870-24-6 0.66 66

iii Caustic lye 1310-73-2 0.34 34

iv Methanol 67-56-1 0.77 77

For Triazolone

i Semicarbazide ‎75-75-5 0.90 90

ii Fresh Formic Acid 64-18-6 0.56 56

iii Recovered Formic Acid -- 0.71 71

For 1,3-DAU

i Dimethyl carbonate (DMC) 616-38-6 1.00 100

ii Hydrazine hydrate (HH) (80%) 10217-52-4 0.81 81

iii Recovered HH 0.36 36

For DPI

i Isophthaloyl chloride (ITC) 99-63-8 0.66 66.0

Ii Caustic lye 1310-73-2 0.56 56.0

Iii Phenol 108-95-2 0.62 62.0

Iv 1,2-dichloroethane EDC (Recovered) -- 2.87 287.0

v 1,2-dichloroethane (EDC) (fresh) 107-06-2 0.09 9.0

For NOXSA

i 2,2-dimethyl-5-nitro-benzenesulfonyl chloride (NOXSC)

68631-04-9 0.56 56

ii Monomethyl ethanol amine (MEA) 141-43-5 0.11 11

iii NaOH 1310-73-2 0.15 15

3. Unit Process: Deamination Such as;

For Semicarbazide HCl

i Urea 57-13-6 0.27 5.4

ii Hydrazine hydrate (HH) (80%) 10217-52-4 0.14 2.8

iii Recovered HH 0.06 1.2

iv Recovered Methanol -- 0.94 18.8

v Fresh Methanol 67-56-1 0.04 0.8

vi Hydrochloric acid (HCl) 7647-01-0 0.16 3.2

For MBI

i Urea 57-13-6 0.12 2.4

ii 3,4-Diaminotoluene (MOPDA) 496-72-0 0.24 4.8

iii Recycle Mono-chlorobenzene MCB -- 0.96 19.2

iv Fresh Mono-chlorobenzene MCB 108-90-7 0.02 0.4

For BI

i Urea 57-13-6 0.46 9.2

ii O-phenelyenediamine (OPDA) 95-54-5 0.81 16.2

iii Recycle Mono-chlorobenzene (MCB) -- 3.34 66.8

iv Fresh Mono-chlorobenzene (MCB) 108-90-7 0.08 1.6

4. Unit Process: Alkylation with DMS/DES Such as;

For 1,2/1,3/1,4-DMB

i Resorcinol 108-46-3 0.84 8.4

ii Dimethyl sulphate (DMS) 77-78-1 1.03 10.3

iii Caustic Lye 1310-73-2 1.38 13.8



For NEL

i Lactum 130-00-7 0.84 8.4

ii Diethyl sulphate (DES) 64-67-5 0.73 7.3

iii Caustic lye 1310-73-2 0.60 6

iv Recovered Ortho-Dichlorobenzene (ODCB) 95-50-1 1.97 19.7

v Fresh Ortho-Dichlorobenzene (ODCB) -- 0.04 0.4

For 2HMB

i 2,3-Dihydroxybenzaldehyde (DHB) 24677-78-9 0.95 9.5

ii Dimethyl sulphate (DMS) 77-78-1 0.49 4.9

iii Pot. Carbonate (K2CO3) 584-08-7 0.57 5.7

iv Recover Acetone -- 2.87 28.7

v Fresh Acetone 67-64-1 0.09 0.9

5. Unit Process: Nitration with Dilute Nitric Acid Such as;

For NDMB [2,4/3,4/2,5]

i 1,2/1,3 dimethoxybenzene (1,2/1,3-DMB) 91-16-7/151-10-0 0.78 11.7

ii Nitric acid (DNA) 7697-37-2 3.38 50.7

For NBI

i Benzimidazolone (BI) 615-16-7 0.67 10.05


For NMBI

i 5-methylbenzimidazolone (MBI) 5400-75-9 0.69 10.35


For Ac-DCPNA

i 2,5-Dichloroacetanilide (AcDCA) 2621-62-7 0.65 9.75

ii Nitric acid 7697-37-2 0.21 3.15

iii Sulfuric acid 7664-93-9 1.20 18

iv Ice 124-38-9 1.87 28.05

v Lime 8006-28-8 1.02 15.3

For NABT

i 3-Trifluoromethyl acetanilide (AABT) 351-36-0 0.62 9.3

ii Nitric acid 7697-37-2 0.20 3

iii Oleum 8014-95-7 1.19 17.85

iv Ice 124-38-9 3.22 48.3

v Lime 8006-28-8 1.08 16.2

For NIPA

i Isophthalic acid (IPA) 121-91-5 0.63 9.45

ii Nitric acid 7697-37-2 0.26 3.9

iii Sulfuric acid 7664-93-9 1.16 17.4

iv Lime 8006-28-8 0.97 14.55

6. Unit Process: Formylation with Vilsmeier Haack Reagent Such as;

For DEAB

i Phosphorus oxy chloride (POCl3) 10025-87-3 0.94 18.8

ii N, N-dimethylformamide (DMF) 68-12-2 0.49 9.8

iii N,N-diethyl aniline (N,N-DEA) 91-66-7 0.83 16.6

For DMAB


ii N, N-dimethylformamide (DMF) 68-12-2 0.55 11

iii N,N-dimethyl aniline (N,N-DMA) 121-69-7 0.81 16.2

For DMBA





iii 1,3 dimethoxybenzene (DMB) 151-10-0 0.87 17.4

For DHB



iii Resorcinol 108-46-3 0.84 16.8

7. Unit Process: Amidation Such as;,

For NMT-amide

i 3-Nitro-4-carbomethoxy Benzoylchloride (NMTCl)

64152-10-9 1.09 21.8

ii Recovered Liq.NH3 -- 0.49 9.8

iii Fresh Liq. NH3 7664-41-7 0.33 6.6

iv Hydrochloric acid (HCI) 7647-01-0 0.30 6.0

v Sodium hydroxide (NaOH) 1310-73-2 0.27 5.4

I For p-Nitro Benzamide

i Para-Nitro-benzoylchloride (PNBC) 122-04-3 1.12 22.4

ii Liq. NH3 (Recovered) -- 0.62 12.4

iii Liq. NH3 (Fresh) 7664-41-7 0.50 10.0

iv Hydrochloric acid (HCl) 7647-01-0 0.40 8.0

v Sodium hydroxide (NaOH) 1310-73-2 0.36 7.2

For DSA

i 4-amino-6-chloro-1,3-benzenedisulfonyl chloride (DSC)

671-89-6 1.17 23.4


iii Liq. NH3 (Fresh) 7664-41-7 0.12 2.4

iv Recover Methyl isobutyl ketone (MIBK) 108-10-1 1.89 37.8

v Fresh Methyl isobutyl ketone (MIBK) 0.06 1.2

vi Sodium hydroxide (NaOH) 1310-73-2 0.28 5.6

For ONCBPSA

i 4-Chloro-3-nitrobenzenesulfonyl chloride (ONCBPSC)

97-08-5 1.13 22.6


iii Liq. NH3 (Fresh) 7664-41-7 0.31 6.2

iv Hydrochloric acid (HCI) 7647-01-0 0.29 5.8

8. Unit Process: Acylation using Aluminium Trichloride Such as;

For DCPC

i Meta dichlorobenzene (MDCB) 441-73-1 0.69 6.9

ii Chloroacetyl chloride (CAC) 79-04-9 0.55 5.5

iii Aluminium trichloride (AlCl3) 7446-70-0 0.77 7.7

iv EDC (Recovered) -- 1.34 13.4

v 1,2-dichloroethane (EDC) (fresh) 107-06-2 0.03 0.3

For 2HMB

i 2,3-Dimethoxybenzaldehyde (DMBA) 86-51-1 1.13 11.3

ii Hydrochloric acid (HCI) 7647-01-0 0.82 8.2

iii Aluminium trichloride (AlCl3) 7446-70-0 0.89 8.9

iv Recovered 1,2-dichloroethane (EDC)

107-06-2 3.36 33.6

v Fresh EDC 0.09 0.9

9. Unit Process: Reduction

(A) Reduction with sodium hydrogen sulfide (NaSH) Such as;

For MCA

i m-nitro chloro benzene 121-73-3 1.26 126.0

ii (sodium hydrogen sulphide) 30% NaSH 207683-19-0 2.29 229.0



For 4-NAPSA

i 2-Chloro-3,5-dinitrobenzenesulfonic acid (CDNBSA)

4515-26-8 0.82 82

ii sodium hydrogen sulphide (30% NaSH ) 207683-19-0 0.89 89

For MSMAA

i N-Methyl-N-[4-(methylsulfonyl)-2-

nitrophenyl]amine (MSMNA)

30388-44-4 1.16 116

ii (sodium hydrogen sulphide) 30% NaSH 207683-19-0 1.45 145

(B) Reduction with Iron and acid in water Such as;

For MA

i Acetic acid 64-19-7 0.02 0.2

ii Iron Powder 7439-89-6 1.22 12.2

iii M-Nitro Anisole 555-03-3 1.27 12.7

iv Caustic lye 1310-73-2 0.04 0.4

For VJD

i Acetic Acid 64-19-7 0.02 0.2

ii Iron Powder 7439-89-6 0.52 5.2

iii N-{2-[2-hydroxyethyl)sulfonyl]ethyl}-3-nitrobenzamide (OJD)

Not available 1.11 11.1

iv Caustic lye 1310-73-2 0.03 0.3

For AOX

i Acetic Acid 64-19-7 0.02 0.2

ii Iron Powder 7439-89-6 0.57 5.7

iii 5-Nitro-N-(2-hydroxyethyl)-2,3-dimethylbenzenesulfonamide (NOXSA)

25959-70-0 1.13 11.3

iv Caustic lye 1310-73-2 0.03 0.3

For OPSAMIDE

i Acetic Acid 64-19-7 0.02 0.2

ii Iron Powder 7439-89-6 0.68 6.8

iii 4-hydroxy-3-nitrobenzenesulfonamide (ONCBPSAH)

24855-58-1 1.16 11.6

iv Caustic lye 1310-73-2 0.03 0.3

(C) Reduction by hydrogenation Such as;

For AMBI

i 5-Nitro-6-methylbenzimidazolone (NMBI) 83573-62-0 1.22 122

ii Hydrogen 1333-74-0 0.03 3.0

iii Catalyst 12635-27-7 0.03 3.0

iv Recovered N, N-dimethylformamide (DMF) 68-12-2 4.90 490

v Fresh DMF 0.04 4.0

For AM3

i 5-Acetomino-2-Nitro-Benzotrifluoride (NABT)

393-12-4 1.17 117

ii Hydrogen 1333-74-0 0.02 2.0

iii Catalyst 12635-27-7 0.03 3.0

iv Methanol (Recycled) -- 5.68 568

v Methanol (Fresh) 67-56-1 0.19 19

FOR MOPDA

i 3-nitro-4-aminotoluene (MNPT) 89-62-3 1.27 127

ii Hydrogen 1333-74-0 0.05 5.0

iii Catalyst 12635-27-7 0.03 3.0


v Fresh N, N-dimethylformamide (DMF) 0.19 19

For ABI

i 5-Nitrobenzimidazolone (NBI) 93-84-5 1.23 123

https://www.chemsrc.com/en/cas/30388-44-4_344200.html

https://www.chemsrc.com/en/cas/30388-44-4_344200.html



ii Hydrogen 1333-74-0 0.04 4.0

iii Catalyst 12635-27-7 0.03 3.0


v N, N-dimethylformamide (DMF ) (Fresh) 0.14 14.0

For AMBA

i (4-nitrobenzyl)methylamine (NMBA) 6315-57-7 1.27 127

ii Hydrogen 1333-74-0 0.04 4.0

iii Catalyst 12635-27-7 0.03 3.0

iv Methanol (Recycled) - 4.75 475


For MPBA

i Meta-phenoxy-benzaldehyde (MPB) 39515-51-0 1.01 101

ii Hydrogen 1333-74-0 0.01 1.0

iii Catalyst 12635-27-7 0.03 3.0

For AIPA

i 5-Nitro-Isophthalic acid (5-NIPA) 618-88-2 1.20 120

ii Hydrogen 1333-74-0 0.03 3.0

iii Catalyst 12635-27-7 0.03 3.0

iv Methanol (Recycled) - 5.74 574


For DABA

i 3,5-dinitrobenzoic acid (DNBA) 99-34-3 1.43 143

ii Hydrogen 1333-74-0 0.08 8.0

iii Catalyst 12635-27-7 0.03 3.0


v Methanol (Fresh) 67-56-1 0.09 9.0

For Ortho Phenoxy aniline

i 2-phenoxy-nitrobenzene (PNB) 2216-12-8 1.23 123

ii Hydrogen 1333-74-0 0.07 7.0

iii Catalyst 12635-27-7 0.03 3.0


v Methanol (Fresh) 67-56-1 0.09 9.0

10. (A) Unit Process: Chloroxidation/oxidation Such as ;

For SA

i Chlorine 7782-50-5 0.56 22.4

ii GBL Cond. Not available 0.81 32.4

For Ether amine

i Hydrochloric acid (HCI) 7647-01-0 0.75 30

ii Chlorine 7782-50-5 0.88 35

iii AHD Not available 1.00 40

For ONBSC/PNBSC

i Hydrochloric acid (HCI) 7647-01-0 0.50 20

ii Chlorine 7782-50-5 0.82 32.8

iii 2,2'-Dinitro diphenyl disulfide (DDD) 1155-00-6 0.69 27.6

(B) Such as sodium hypochlorite

i Caustic Lye 1310-73-2 0.06 2.208

ii 7% NaOCl soln from S acid -- 0.97 35.69

iii Chlorine 7782-50-5 0.02 0.73

11 Unit process for dehydration

(A) Dehydration using phosphorus oxychloride (POCl3) Such as;

For Nitrile

i Xylene (Recovered) -- 3.74 18.7

ii Xylene (fresh) 1330-20-7 0.12 0.60

iii 3-Nitro-4-carbomethoxy Benzoylchloride (NMT-Cl)

64152-10-9 1.16 5.8



iv Phosphorus oxy chloride (POCl3) 10025-87-3 0.86 4.3

(B) Dehydration by evaporation Such as

For sodium thiosulfate

i Thio ML 1.41 198.81

ii ML recovered -- 0.35 49.35

12 Unit process for chloro Sulfonation Such as;

For NOXSC

i Chlorosulfonic acid (CSA) 7790-94-5 1.34 33.5

ii 3-Nitro-ortho-xylene (NOX)

83-41-0 0.52 13.0

iii Lime

8006-28-8 1.03 25.75

For DSC

i Chlorosulfonic acid (CSA) 7790-94-5 1.48 37

ii m-Chloroaniline (MCA) 108-42-9 0.41 10.25

iii Lime 8006-28-8 0.82 20.5

For ONCBPSC

i Chlorosulfonic acid (CSA) 7790-94-5 1.11 27.75

ii Ortho-Nitro chlorobenzene (ONCB) 88-73-3 0.61 15.25

iii Lime 8006-28-8 0.73 18.25

13 Unit process for hydrolysis Such as;

For ONCBPSAH

i Hydrochloric acid (HCl 30%) -- 0.56 8.4

ii 3-Nitro-4-chlorobenzenesulfonamide (ONCBPSA)

17691-19-9 1.13 16.95

iii Caustic Lye 1310-73-2 0.75 11.25

For DCPNA

i N-(2,5-dichloro-4-nitrophenyl)acetamide (Ac-DCPNA)

38411-17-5 1.25 18.75

ii Caustic lye 1310-73-2 0.44 6.6

14 Unit process for Sulfonation Such as;

For DCASA

i Recovered Ortho-Dichlorobenzene (ODCB) 95-50-1 2.19 43.8

ii Fresh Ortho-Dichlorobenzene (ODCB) 0.06 1.2

iii 3,4-Dichloroaniline (3,4-DCA) 95-76-1 1.27 25.4

iv Sulfuric acid 0.32 6.4

For FJD

i Recovered Ortho-Dichlorobenzene (ODCB) 95-50-1 2.61 52.2

ii Fresh Ortho-Dichlorobenzene (ODCB) 0.08 1.6

iii VJD Not available 0.78 15.6

iv Sulfuric acid 7664-93-9 0.28 5.6

15 Unit process for neutralization Such as ;

For sodium sulfite

i Sodium sulphite Soln (73%) 7757-83-7 1.0 217.15

ii ML recycle 0.14 30.4

16 Unit process for purification Such as ;

For HCl (30%)

i Hydrochloric acid (HCl) 7647-01-0 1.0 400.0

17 Unit process for Methoxylation Such as ;

For CMA

i Methanol (R) -- 0.55 11.0

ii Methanol (F) 67-56-1 0.23 4.6

iii Sodium (Metal) 7440-23-5 0.14 2.8



iv Recovered Dimethyl sulfoxide (DMSO) 67-68-5 3.86 77.2

v Fresh Dimethyl sulfoxide (DMSO) 0.09 1.8

vi Recovered 2,6-dichlorotoluene (DCT) 118-69-4 0.23 4.6

vii Fresh 2,6-dichlorotoluene (DCT) 1.04 20.8

viii Cyclo Hexane (R) 110-82-7 4.75 95.0

ix Cyclo Hexane (F) 110-82-7 0.19 3.8



Water and Waste Water Management At present, the fresh water consumption is 87.99 m3 /day sourced from GIDC Vapi. After

proposed expansion, the fresh Water requirement is 206.86 kL/day supply will be met from

GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.

At present, total industrial effluent generation is 42.11 kL/day. Out of which 15.91 kL/day of high

TDS effluent is evaporated in MEE and balance 26.2 kL/day of normal effluent is treated in

primary, secondary and tertiary effluent treatment plant and finally discharge into underground

effluent drainage line to CETP for further treatment and disposal into tidal zone of River

Damanganga to Arabian Sea. Condensate is recycling in process.

After proposed expansion, the industrial Waste Water Generation is 83.37 kL/day. Out of which

24.3 kL/day of high TDS effluent is evaporated in MEE and balance 59.07 kL/day of normal

effluent is treated in primary, secondary and tertiary effluent treatment plant and finally

discharge into underground effluent drainage line to CETP for further treatment and disposal

into tidal zone of River Damanganga to Arabian Sea. Condensate will recycled in process.

Domestic waste water (8 kL/day) will be disposed off through Septic Tank.

Air Emission and its Control Measures

Flue gas emission:

At present, the unit is having one number of coal fired 7 TPH capacity of steam boiler and one

number of HSD fired D G Set of 250 KVA capacity x 2 Nos. Adequate height of chimney and

MDC followed by bag filter provided to the boiler and adequate height of chimney is provided to

D G set.

After proposed expansion, there will be no addition of boiler, as existing boiler having spare

capacity to take care of additional steam requirement.

Process gas emission:

At present, there is a generation of process gas like SO2, NOx, HCl, Cl2 and NH3 from

sulphonation, Nitration, Chlorination, Amination and Oleum storage tank. To scrub all the said

gases we have provided total five numbers of two stage scrubbing system and 11 meters

height of vent.

After proposed expansion, there will be a generation of process gas emission like SO2, NOx,

HCl, Cl2 and NH3 from sulphonation, Nitration, Chlorination, Amination and Oleum storage

tank. To scrub all the said gases we will utilize existing five numbers of two stage scrubbing

system and 11 meters height of vent. Thus after proposed expansion, there will be no addition

of new scrubbing system. (Detail of Air pollution control measures is attached as Annexure-

10)



Hazardous Wastes and its Management

S. No.

Description Quantity, MT/Year Method of disposal

Remarks

Existing After Proposed expansion

1. ETP Waste (35.3)

48.0 80.0 Collection, storage, transportation, disposal at TSDF

VWEMCL

-

2. Used oil (5.1) 0.12 0.15 Collection, storage, transportation, disposal by

selling to registered re-processors

-

3. Discarded containers, bags/liners

(33.1)

9.0 15.0 Collection, storage, decontamination, reuse for

packing of hazardous waste or sold to authorized recycler.

-

4. Organic distillation

residue from the process ( 26.1)

44.76 67.52 Sent for co-processing or incineration

-

5. Salt from MEE (35.3)

235.2 2293 Collection, storage, transportation, disposal at TSDF

VWEMCL

-

6. Waste from process (Iron Oxide) (26.1)

288 209.64 Collection, storage, transportation, disposal at TSDF

VWEMCL

-

7. Salt from Process (26.1)


VWEMCL

-

8. Sludge from wet scrubber (37.1)


VWEMCL

-

9. 30% HCL (Sch: II B15)

2925.18 0 Sell to actual users as a by-product by tanker

Will be Converted into product

10. NaCl Salt Direct recovery from

ANF ( 26.1)

415.68 0 Sell to actual users or Collection, storage, transportation, disposal

at TSDF VWEMCL

No generation after proposed

expansion

11. Spent Acid (78%) (Sch: II

B15)



expansion

12. Sodium Bromide Solution (28%)

( Sch: II B6)



expansion

13. NaNO2 Solution (25%) ( Sch: II B

24)



expansion

14. AlCl3 Solution (30%) (Sch: II

B10)

1665 306.06 Sell to actual users as a by-product by tanker

-

Solid Waste

15. Fly Ash 242.5 485 Sell to Brick/Cement Manufacturer

-



2. Introduction of the Project and the Proponent.

Name of the project Proponent: M/s Sarna Chemicals Pvt. Limited (Unit: II)

M/s Sarna Chemicals Pvt. Limited (Unit: II) is a medium scale unit is located in notified

industrial Area, GIDC, Vapi Di: Valsad, Gujarat having total plot area of 8219 m2 & total

investment after proposed expansion will be Rs. 20.32 crore. The proponent wishes to enhance

the Production capacity of Existing Products as well introduce new similar group of products.

The intermediates products are especially used dyes & pigment industries as per requirement.

The unit is operated by technocrats having more than 35 years of experience in manufacturing

and marketing of various dyes intermediates worldwide.

The company has established well equipped production plant which is being managed by

dedicated, qualified & skilled persons.

The proposed expansion project is to enhance the capacity of all the dyes intermediates to

1673.35 MT per month and process capabilities to manufacture all types of dyes intermediates.

The proposed expansion project site lies on 20022’19.38” N Latitude & 72056’47.69” E

Longitude. M/s Sarna Chemicals Pvt. Limited (Unit: II) is located at Plot. No. 1708, A-2/1715,

phase III area, GIDC Vapi, Di: Valsad in Gujarat state. GIDC Vapi is centrally located in the both

sides of National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by

Union territories of Daman on the western side and Dadra & Nagar Haveli on the eastern side.

Vapi is the biggest railway station in the study area. Beside the rail connectivity, the site is also

well connected by road transport. There is a good network of roads in the area and contributes

for the development and economic growth of the area. The National Highway No. 8 (Surat –

Mumbai) is a six lane and double tracked. This highway has given a further boost to the

economic growth of this area. The other major road is state highway No. 185 (Daman – Vapi –

Silvasa Road) which is crosses the NH – 8 in Vapi town. Almost every village in the district is

now well connected to each other by a Pucca road.

About Vapi town: Vapi Township has emerged as an Industrial hub on the Gujarat – Maharashtra

border. Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi

has gained a special status on the industrial map of the country mainly for chemical

manufacturing industrial units. Over the years, it has emerged as a major cosmopolitan industrial

township equipped with hospitals, school & colleges, community centres, temples, churches,

mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post

offices, banks, telephone exchange, hotels, guesthouses etc. The town has got a major face-lift

after the completion of national highway. Other links roads are also of good standard. Mumbai,

the economic capital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar”

is 370 kms away. The district Head Quarter – Valsad is 30 km from Vapi town.

VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-1968. The

entire estate, which was developed in phases, is now spread over 1140 hectares and houses

more than 1400 industries, most of which are small-scale industrial units although some of them

have grown into bigger units at later stage. The industrial township is basically a declared

“Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical related,

such as Dyes and Dyes intermediates, pigments, pesticides, fine chemicals, pharmaceuticals,



etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints,

food processing, printing, etc. One of the country’s largest common effluent treatment plants has

been setup in Vapi industrial estate. Being a major industrial & commercial centre, it caters to

other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and

Nagar Haveli, etc.

M/s Sarna Chemicals Pvt. Limited (Unit: II) was started in the year of 1988.

Most of the products have been developed through strong in-house R&D.

The Group’s turnover is about Rs. 73 Crores for the year 2016-17

The management is concerned about Environment and Safety issues and gives utmost

importance to these aspects by continuous training & improvement followed by various external

Audits. Company is ISO 9001:2015, 14001-2015, 18001-2007 certified. We have a strong in-

house R&D team. We have a small Pilot plant at this site to support the R & D activities.

(i) Identification of the project proponent :

M/s Sarna Chemicals Pvt. Limited (Unit: II) is a medium scale unit is located at notified industrial

Area, GIDC Vapi, Di: Valsad, a well enthusiastic & professionally managed manufacturer.

List of Directors:

S. No. Name of Directors

1. Mr. S S Sarna (Chairman & MD)

2. Dr. Mohit Rajani (Director)

The Chairman and managing director of the company Mr S S Sarna is a chemical technologist

from UDCT, Gold medallist from Bombay university and other directors are well qualified in

Engineering, Management, Accounts, operations and Marketing field.

Apart from these there are Expert from Field- Industries, safety, health, environment , Financial

Institutes and others as a Part time / Independent Directors on Board for Better Management ,

They are :

Mr. Pramod Upadhyay (General Manager)

Mr. Dr. Mahesh Chhatbar ( Manger- R & D, QC, QA)

Mr. Pravat Sahoo (Manager- Engineering)

Mr. Shyam Simon (Safety manager)

They help us to achieve & perform better & better.

ii) Brief description of nature of the Project : M/s Sarna Chemicals Pvt. Limited (Unit: II) proposes to enhance the production capacity at

Plot No. 1708, A-2/1715, Phase: III, GIDC, Vapi-396195, Dist.- Valsad (Gujarat).

The proposed expansion project involves the capacity enhancement of existing Products as well

as new products. As per the amended EIA notification- 2006, the proposed products are covered

under category 5(f)- B and hence require Prior Environmental Clearance.

iii) Need for the project and its importance to the country and region:

The proposed project provides a potential growth opportunity for the ongoing business of the

company. The company is engaged in the business of manufacturing of Various Dyes

intermediates. The project would also help the company to support the Indian economy in the



following way:

Growth in Export Revenue and thereby increasing the inflow of foreign currency which is

much needed by our country.

Our products are well accepted by international users and can substitute the international

speciality Grades.Thus the Domestic Industry can replace the imported dyes

intermediates used by them with ours and there by curtail the outflow of foreign currency

spent on dyes intermediates imported by them.

Potential increase in Job opportunities for the Local surroundings.

Boost to the Local service providers and the overall improvement in the economic

activities like Local raw materials Suppliers, Transporters, contractors, clearing and

forwarding agents and other allied suppliers.

The Company Objective is to achieve:

Consolidation of dyes intermediates business. The Proposed expansion will help the

company to move towards more specialized products and there by focus on value addition

which will improve the shareholder’s worth.

The Proposed increase in capacity will also assist the company to reduce the costs due to

increase in the sale of manufacturing and intern make the company’s products more

competitive in the market.

Considering the nature of chemicals business, the proposed increase in capacity will also

help the company to standardize and produce the chemicals with more consistency

because higher volumes will help to achieve better control over Physico-chemical

conditions while manufacturing.

To generate Local Employment

iv) Demand –Supply Gap :

Our dyes intermediates chemicals are mainly used by various dyes and pigments industries as

per requirement. Since our products are approved by quality conscious users which are

multinational companies. We can cater to the ever increasing demand in India as well as in the

Export Market like CZECH Republic, Canada, China, Mexico, Switzerland, Indonesia, Germany,

Thailand, South Korea, Belgium, Finland, Netherland, Japan, USA and Russia etc.

v) Imports vs. Indigenous production:

Existing products manufactured in the country will be very much economical compared to

Imports of the same and also the export of the same will earn extra revenue generation for our

county.

vi) Export Possibility:

Existing products have high export potential. Also these products have very good potential in the

local market.

Additional capacities of product range required over & above the unit’s existing capacities, as

the company expects strong growth of exports to the extent of 40-50%. Local market also shows

strong growth potential.

vii) Domestic / export Markets:

The company’s products are used by various dyes and pigments industries as per requirement.

These are having very good demand in domestic as well as international markets.

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

There will be very good opportunity of employment generation directly and indirectly due to



proposed expansion project. Due to proposed project there will be requirement of manager,

supervisor, operator and semi-skilled workers. For this, the company will employ about

additional 35 people to fulfil it’s need to handle the plant.

Presently there are 75 numbers of employees. There will be additional 35 numbers of

employees, thus total 110 numbers of employees after proposed expansion.

3 Project Description:

(i) Type of Project including interlinked and interdependent projects, If any:

The proposed project is an interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary &

project site layout) with coordinates:

The map showing general location, specific location and project boundary and project site lay out is

enclosed as Annexure-1. Plant layout is attached as Annexure-2.

(iii) Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted:

The proposed activity will be accommodated in the notified industrial area having proper industrial

infrastructure so; there is no alternate site consideration. Proposed expansion will be carried out in

exiting premises only. (Land allotment letter is attached as Annexure-8)

(iv) Size or magnitude of operation:

As per the proposed project cost, the project is covered under medium Scale category of

manufacturing industries.

(v) Project description with process details (a schematic diagram/ flow chart showing the

project layout components of the project etc. Should be given):

Detailed project description with process details is enclosed as Annexure-3

(vi) Raw material required along with estimated quantity, likely source, marketing area of

final products/s, mode of transport of raw Material and finished product:

Detailed raw material requirement along with estimated quantity, likely source, marketing of final

products, mode of transport of raw materials and finished products & characteristics of

hazardous chemicals are as below:



Table 1: Details on Product Transportation

S. No.

Product Physical

State Dispatch

Mode of transport

1. m-Nitrochlorobenzene (MNCB) Solid-melt

Domestic Packed in

drum Truck/container

2. o-Nitrochlorobenzene (ONCB) Solid-melt

Captive use Packed in

drum

3. p-Nitrochlorobenzene (PNCB) Solid Domestic Packed in bags Truck/container

4. [2-(2-aminoethoxy) ethyl chloride]

hydrochloride (2-AEC HCl) Solid Captive use Packed in bags

5. m-Nitrobenzoyl chloride (MNBC) Solid Captive use Packed in bags

6. Scwander Acid Chloride or 4-(2-chloro

ethyl sulfonyl)- butyryl chloride (SACL)

Liquid Export Packed in

drums Truck/container

7. 3-Nitro-4-carbomethoxy

Benzoylchloride (NMT-Cl) Solid-melt


drum

8. isopropyl 4-chlorobutanoate

(Chloroester) Liquid Captive use

Packed in drum

9. 5-chloro-2-amino-benzotrifluoride (5-

ClABTF) Solid Export

Packed in bags Truck/container

10. Isophthaloyl chloride (ITC) Solid-melt


drum

11. 4-Carbomethoxy-3-nitro-2,5-

dichlorobenzanilide (N-OPLA) Solid Captive use Packed in bags

12. 2-{[2-(aminoethoxy)ethyl]thio}ethane

al (AHD) Liquid Captive use

Packed in drum

13. N-{2-[(2-hydroxyethyl)thio]ethyl}-3-

nitrobenzamide (CJD) Solid Domestic/Export


14. 4-[(2-hydroxyethyl)thio]butanoic acid

(GBL-Condensed) Liquid Export

Packed in drum

Truck/container

15. 2,2'-Dinitro diphenyl disulfide (DDD) Solid Captive use --

16. 2-Amino-2-hydroxy-diethyl sulphide

(SAMBA-3) Liquid Export

Packed in drum

Truck/container

17. 1,2,4-TRIAZOL-3-ONE (Triazolone) Solid Export Packed in bags Truck/container

18. Carbohydrazide or 1,3-Diaminourea

(1,3 DAU) Solid Domestic


19. 5-Nitro-N-(2-hydroxyethyl)-2,3-dimethylbenzenesulfonamide

(NOXSA) Solid Captive use Packed in bags

20. Diphenyl isophthalate (DPI) Solid Export Packed in bags Truck/container

21. Benzimidazolone (BI) Solid Captive use Packed in bags

22. 5-methylbenzimidazolone (MBI) Solid Captive use Packed in bags

23. Semicarbazide Hydrochloride (SCH) Solid Domestic Packed in bags Truck/container



24. 1,2/1,3/1,4-Dimethoxybenzene

(1,2/1,3/1,4-DMB) Liquid Captive use

Packed in drum

Truck/container

25. N-ethyl-1,8-naphtho lactum (NEL) Solid Export Packed in bags Truck/container

26. 2-Hydroxy-4-methoxy benzaldehyde

(2-HMB) Solid-melt

Export Packed in


27. 5-Nitrobenzimidazolone (NBI) Solid Captive use Packed in bags

28. 5-Nitro-6-methylbenzimidazolone

(NMBI) Solid Captive use


29. 2,4/3,4/2,5-Dimethoxy Nitrobenzene

(NDMB [2,4/3,4/2,5]) Solid Captive use Packed in bags

30. 2,5-Dichloro-4-nitroaniline (DCPNA) Solid Export Packed in bags Truck/container

31. 5-Acetomino-2-Nitro-Benzotrifluoride

(NABT) Solid Captive use Packed in bags

32. 5-Nitro-Isophthalic acid (5-NIPA) Solid Domestic Packed in bags Truck/container

33. 2,3-Dihydroxybenzaldehyde (DHB) Solid Captive use Packed in bags

34. 2,3-Dimethoxybenzaldehyde (DMBA) Solid Captive use Packed in bags

35. 4-Dimethyl amino benzaldehyde

(DMAB) Solid Captive use Packed in bags

36. 4-Diethyl amino benzaldehyde

(DEAB) Solid Export


37. p-Nitrobenzamide (PNBA) Solid Captive use Packed in bags

38. 3-Nitro-4-carbomethoxy Benzamide

(NMT-AMIDE) Solid Captive use Packed in bags

39. 5-Chloro-2,4-disulfamylaniline (DSA) Solid Domestic Packed in bags Truck/container

40. 3-Nitro-4-chlorobenzenesulfonamide

(ONCBPSA) Solid Captive use Packed in bags

41. 2,4-Dichloro phenacylchloride (DCPC) Liquid Export Packed in


42. 2-Hydroxy-4-methoxy benzaldehyde

(2-HMB) Solid Export


43. m-Chloroaniline (MCA) Liquid Domestic/Export Packed in


44. 3-amino-2-hydroxy-5-

nitrobenzenesulfonic acid Sodium salt (4NAPSA)

Solid Domestic/Export Packed in bags Truck/container

45. 3-Amino-4-methylamino-phenyl

methyl sulfone (MSMAA) Solid Domestic/Export


46. m-Anisidine (MA) Liquid Domestic/Export Packed in


47. 3-amino-N-{2-[(2-

hydroxyethyl)sulfonyl]ethyl}benzamide (VJD)

Solid Captive use Packed in bags Truck/container



48. 5-amino-N-(2-hydroxyethyl)-2,3-

dimethylbenzenesulfonamide (AOX) Solid Domestic


49. 3-Amino-4-hydroxy-

benzenesulfonamide (OPSAMIDE) Solid Domestic


50. 5-amino benzimidazolone (ABI) Solid Domestic/Export Packed in bags Truck/container

51. 5-amino-6-methyl benzimidazolone

(AMBI) Solid Domestic/Export


52. 4-methyl-2-amino-aniline (MOPDA) Solid Captive use Packed in bags

53. 5-acetamino-2-amino benzotrifluoride

(AM3) Solid Domestic/Export


54. 5,6-Diaminobenzimidazolone Solid Export Packed in bags Truck/container

55. (4-aminobenzyl)methylamine (AMBA) Liquid Export Packed in


56. m-phenoxy-benzylalcohol (MPBA) Liquid Captive use Packed in

drum

57. 5-Amino-Isophthalic acid (AIPA) Solid Export Packed in bags Truck/container

58. 3,5-Diamino-benzoic acid (DABA) Solid Captive use Packed in

Bags

59. Scwander Acid or 4-(2-chloro ethyl

sulfonyl)-butyric acid (S-acid) Solid Export/Domestic

Packed in Bags

Truck/container

60. 2(2-amino ethoxy)-2'-chloro-

diethylsulfone hydrochloride solution (Etheramine)

Liquid Export/Domestic Packed in


61. o-Nitrobenzene sulfonyl Chloride

(ONBSC) Solid Captive use

Packed in Bags

62. p-Nitrobenzene sulfonyl Chloride

(PNBSC) Solid Captive use

Packed in Bags

63. Sodium hypochlorite Liquid Domestic Packed in


64. 3-Nitro-4-carbomethoxy-benzonitrile

(Nitrile) Solid Export

Packed in Bags

Truck/container

65. Sodium thiosulfate Solid Domestic Packed in

Bags Truck/container

66. 2,2-dimethyl-5-nitro-benzenesulfonyl

chloride (NOXSC) Solid Captive use

Packed in Bags

67. 4-amino-6-chloro-1,3-

benzenedisulfonyl chloride (DSC) Solid Captive use

Packed in Bags

68. 4-Chloro-3-nitrobenzenesulfonyl

chloride (ONCBPSC) Solid Captive use

Packed in Bags

69. 4-hydroxy-3-nitrobenzenesulfonamide

(ONCBPSAH) Solid Captive use

Packed in Bags

70. 2,5-Dichloro-4-nitroaniline (DCPNA) Solid Captive use Packed in

Bags



71. 3,4-Dichloro-aniline 6-sulfonic acid

(DCSA) Solid Export

Packed in Bags

Truck/container

72. (2-({2-[(3- Aminobenzoyl) amino] ethyl} sulfonyl) ethyl hydrogen

sulphate) FJD solid Export

Packed in Bags

Truck/container

73. Sodium sulfite Solid Domestic Packed in


74. Hydrochloric acid Liquid Domestic Packed in


75. 3-chloro-2-methyl-anisole Liquid Export Packed in


76. 2-phenoxyaniline Solid Domestic Packed in


Table 2: Details of Raw Material Transportation

S. No.

Substance Physical State

Source of Supply

Means of Transportation

Distance of supplier from project site

(km)

1. Nitrobenzene Liquid Domestic/Import Tanker/drum 50-5000

2. Chlorine Gas Domestic Cylinder 50-500

3. Ferric Chloride Solid Domestic bags 50-500

4. Lime Solid Domestic bags 50-500

5. Isophthalic acid Solid Import bags 50-5000

6. Thionyl Chloride Liquid Domestic Drums/tanker 50-500

7. Caustic Lye Liquid Domestic Drums/tanker 50-500

8. MNBA Solid Domestic bags 50-500

9. NMMT Solid Domestic bags 50-500

10. BTL Liquid Import/Domestic Drums/tanker 50-500

11. IPA Liquid Import/Domestic Drums/tanker 50-5000

12. ABTF Liquid Import Drums/tanker 5000

13. Sulfuryl chloride Liquid Domestic Drums/tanker 50-500

14. MCB Liquid Domestic Drums/tanker 50-500

15. AEE liquid Import Drums/tanker 5000

16. DCA Solid Domestic bags 50-500

17. Phosphorus trichloride

Liquid Domestic Drums/tanker 50-500

18. Soda Ash Solid Domestic bags 50-500

19. NaOH Solid Domestic bags 50-500

20. HCl Liquid In House Drums/tank -

21. Methanol Liquid Import Drums/tanker 5000

22. Samba-III Liquid Domestic Drums/tanker 50-500

23. ME Liquid Import Drums/tanker 5000

24. ONCB Solid-melt In House Drums -

25. NaSH Liquid Domestic Drums/tanker 50-500

26. sulfur Solid Domestic bags 50-500

27. CEA Liquid Import Drums/tanker 5000



28. Formic acid Liquid Domestic Drums/tanker 50-500

29. DMC Liquid In House Drums/tank -

30. HH (80%) Liquid Import Drums/tanker 5000

31. NOXSC Solid In House Bags -

32. MEA Liquid Import Drums/tanker 5000

33. phenol Liquid Domestic Drums/tanker 50-500

34. EDC Liquid Import Drums/tanker 5000

35. OPDA Solid In House bags -

36. Urea Solid Import bags 50-5000

37. MOPDA Solid In House bags -

38. Resorcinol Solid Import/Domestic bags 50-5000

39. DMS Liquid Domestic Drums/tanker 50-500

40. DHB Solid In House Bags

41. Pot. carbonate Solid Domestic bags 50-500

42. Acetone Liquid Import Drums/tanker 5000

43. Lactum Solid Import Bags 50-5000

44. DES Liquid Domestic Drums/tanker 50-500

45. ODCB Liquid Domestic Drums/tanker 50-500

46. Nitric acid Liquid Domestic Drums/tanker 50-500

47. AcDCA Solid In House Bags -

48. Sulfuric acid Liquid Domestic Drums/tanker 50-500

49. AABT Solid In House Drums/tank -

50. Oleum Liquid Domestic Drums/tanker 50-500

51. Isophthalic acid Solid Import bags 50-5000

52. MDC Liquid Domestic Drums/tanker 50-500

53. Phosphorus oxy chloride

Liquid Domestic Drums/tanker 50-500

54. DMF Liquid Import Drums/tanker 50-5000

55. 1,2/1,3-DMB Liquid In House Drums/tank -

56. N,N-DMA Liquid Import Drums/tanker 50-5000

57. N,N-DEA Liquid Import Drums/tanker 50-5000

58. ONCB/PNCB/MNCB Solid-melt In house Drums -

59. Liq. NH3 Liquid In House Drum/tanker -

60. DSC Solid In House Bags -

61. NH3 gas Gas Domestic Cylinder 50-500

62. MIBK Liquid Import Drums/tanker 5000

63. MDCB Liquid Domestic Drums 50-500

64. CAC Liquid Import Drums/tanker 5000

65. AlCl3 Solid Domestic Bags 50-500

66. CDNBSA Solid In House Bags -

67. MSMNA Solid In House Bags -

68. m-nitro anisole Liquid In House Bags -

69. Iron powder Solid Domestic Bags 50-500

70. Acetic acid Liquid Domestic/Imported Drums/tanker 50-5000

71. OJD Solid In House Bags -

72. Hydrogen Gas Domestic Cylinder 50-500

73. Raney-Ni Solid Domestic Bags 50-500

74. MNPT Solid Domestic Bags 50-500

75. MPB Solid In House Bags -

76. DNBA Solid In House Bags -

77. Xylene Liquid Import/Domestic Drum/tanker 50-5000

78. CSA Liquid Domestic Bags 50-500

79. Ac-DCPNA Solid Domestic Bags 50-500



80. 3,4-DCA Solid Domestic Bags 50-500

81. VJD Solid In House Bags -

82. DCT Liquid Import Drum/tanker 50-5000

83. Sodium Solid Domestic Bags 50-500

84. DMSO Liquid Domestic Drum/tanker 50-500

85. Cyclo hexane Liquid Domestic/Import Drum/tanker 50-5000

86. 2-phenoxy-nitrobenzene

Liquid Domestic/Import Drum/tanker 50-5000



vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should

briefly outline:

Resource optimization/recycling and reuse envisaged in the project (solvent recovery system)

in detail are as mentioned below.

The raw materials will be stored in closed containers and will be handled through closed

system to avoid the handling losses.

Condensate from MEE is recycled in the process to minimize the fresh water consumption.

The solvents are distilled in-house and reused in the manufacturing process. Details of

solvent use & recovery are as under.

Table 3: Product wise Solvent Used/Recovered Per Ton, Per Month of Product

After Proposed Expansion

S. No.

Raw Materials Consumption in MT

Per Ton Per month

1. For N-OPLA

I. MCB (Recovered) 3.22 32.2

II. MCB (fresh) 0.09 0.9

2. For BI

I. MCB (Recovered) 3.34 66.8

II. MCB (fresh) 0.08 1.6

3. For DCPC

I. EDC (Recovered) 1.34 13.4

II. EDC (Fresh) 0.03 0.3

4. For ABI

I. DMF (Recycled) 4.80 480

II. DMF (Fresh) 0.14 14

5. For Nitrile

I. Xylene (Recovered) 3.74 18.7

II. Xylene (fresh) 0.12 0.60

6. For DCASA

I. ODCB (Recovered) 2.19 43.8

II. ODCB (fresh) 0.06 1.2

7. For CMA

I. Methanol ® 0.55 11.0

II. Methanol (F) 0.23 4.6

III. DMSO ® 3.86 77.2

IV. DMSO (F) 0.09 1.8

V. Cyclo Hexane ® 4.75 95.0

VI. Cyclo Hexane (F) 0.19 3.8



Table 4: Summary of Overall Solvent Use & Losses after Proposed Expansion

S. No.

Name of the solvent

Total Consumption, TPM

Recovery, TPM

Loss/with residue, TPM

% Recovery

1. MCB 101.5 99.0 2.5 97.5

2. EDC 13.7 13.4 0.3 97.8

3. DMF 494 480 14 97.16

4. Xylene 19.30 18.7 0.60 96.90

5. ODCB 45.0 43.8 1.2 97.3

6. Methanol as

reactant 15.6 11.0 4.6 70.5

7. DMSO 79.0 77.2 1.8 97.7

8. Cyclo hexane 98.8 95.0 3.8 96.1

viii) Availability of water its source, Energy/power requirement and source should be given

Availability of water its source, Energy/power required and its source is below.

Water will be sourced from Notified industrial estate, GIDC Vapi. Water withdrawal Permission is

attached as Annexure: 4

Table 5: Overall Water Consumption at Existing & after Expansion, m3/day

Water consumption, m3/day

S. No. Particulars Existing Total after expansion

1. Domestic 5.0 8.0

2. Processing , Product washing & scrubber

26.35 52.91

3. Boiler 45.0 80.0

4. Cooling 20.0 70.0

5. Floor, equipment & container Washing

5.0 20.0

6. Gardening 2.0 3.0

7. Total 103.35 233.91

8. Total Industrial 96.35 222.91

9. Condensate from MEE 9.18 27.05

10. Net fresh consumption 94.17 206.86



Effluent generation, m3/day

S. No. Particulars Existing Total after expansion

Normal Concentrated

(high TDS) Normal

Concentrated (high TDS)

1. Domestic 5.0 0 8.0 0

2. Processing , Product washing & scrubber

14.2 15.91 23.07 24.3

3. Boiler 4.0 0 6.0 0

4. Cooling 3.0 0 10.0 0

5. Floor, equipment & container Washing

5.0 0 20.0 0

6. Total 31.2 15.91 67.07 24.3

7. Total Industrial 26.2 15.91 59.07 24.3

8. High TDS to MEE 0 15.91 0 24.3

9. High TDS to MEE from

Unit:I 0 9.7 0 9.7

10. Total high TDS to MEE 0 25.61 0 34.0

11. Net Discharge to ETP 26.2 0 59.07 0



Note:

After proposed expansion, total fresh water consumption will be 206.86 m3/day.

After proposed expansion, Total industrial effluent generation will be 83.37 m3/day.

Out of which 83.37 m3/day of industrial effluent; 24.3 m3/day of high TDS effluent will

be segregated and will be treated in MEE and high TDS effluent from Unit: I is 9.7 will

be treated in MEE of Unit: II. Average 27.05 m3/day of MEE condensate will be

recycled and 6.37 MT/day of salt will be disposed off into TSDF.

Average 59.07 m3/day of normal effluent will be treated in primary, secondary and

tertiary effluent treatment plant and discharge into CETP Vapi for further treatment

and disposal into tidal zone of River Damanganga to Arabian Sea.

Water Balance Diagram at Existing Scenario

Total water consumption, 103.35 M3/day (Fresh: 87.99 + Recycled: 15.36 )

Domestic: 5.0Processing, product washing

& Scrubber: 26.35

Boiler: 45 Cooling: 20 Washing: 5 Gardening: 2

30.11

High TDS: 15.91 Normal: 14.2

Salt:3.63 Condensate::15.36

Blow Down: 4

MEE

Blow Down: 3.0 5.0

Total Normal effluent: 26.2

Primary, secondary, Tertiary ETP

CETP, Vapi

Septic tank

For product: (Na2S2O3 ): 6.04

Recycle in processTSDF

ETP: 4.0 ETP: 5.0ETP: 3.0

ETP:14.2

Tidal zone of River Damanganga to Arabian Sea

High TDS from Unit: I: 9.7

Figure 1: Water Balance Diagram at Existing Scenario



Water Balance Diagram After proposed Expansion



& Scrubber: 52.91


47.37


Salt: 6.37 Condensate: 27.05

Blow Down: 6

MEE

Blow Down: 10.0 20.0



CETP, Vapi

Septic tank


ETP: 6.0 ETP: 20.0ETP: 10.0


High TDS

from Unit: I: 9.7

Figure 2: Water Balance Diagram after Expansion

Table 6: Energy Requirements and Its Source

S. No

Particulars Existing

Kg/h

After Proposed expansion

kg/h

Source

1. Steam

requirement 4000 7000

Will be obtained by existing 7 TPH boiler

Table 7: Power Requirements and Its Source

S. No.

Particulars Existing After

Proposed expansion

Source

1. Power – Electricity

requirement 350 KVA 900 KVA

Sourced from Dakshin Gujarat

Vij Co. Ltd.

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

Management/disposal:

Quantity of waste to be generated (liquid and solid) and scheme for their Management/

disposal is enclosed as Annexure-5.

(x) Schematic representations of the feasibility drawing which give information of EIA

purpose:

A schematic representation of the feasibility drawing is enclosed as Annexure -9.



4 Site Analysis

(i) Connectivity:

The project is located in notified Industrial Estate of Vapi which is very well connected to National

Highway no.8 and Western Railways. The nearest airport is Mumbai which is 150 KM away from

the project site by road.

(ii) Land Form, Land use and Land ownership:

The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation.

(iii) Topography (along with map) :

Topography map showing the elevation of the study area below. The topographical map is

enclosed as Annexure-7.

(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from

the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification

should be given:

The existing land is located in the notified industrial area and a copy of which is enclosed as

Annexure-8

(v) Existing Infrastructure:

Notified industrial area of GIDC Vapi has available infrastructure like water, electricity, roads, rail,

transportation, availability of raw material and drainage system.

(vi) Soil classification:

General soil classification of the area is as under:

Soil Characteristics & Land use classification: The study area is located at outer part of

Dadra. Northern part of the site is fully developed for settlement with cropping pattern.

Eastern part of the site location has Loamy, clay, Red soil.

The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This

type of soil is not suitable for cultivation purpose.

The land is suitable for industrial development.

Damanganga River is located at approx. 5.6 km distance from the site location; both side of the

river has mixed soil type (Sand, clay & Basaltic soil).

(vii) Climate data from secondary sources:

Rainfall Data :

The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having

coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the study

area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and

western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot and

Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400



mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and

Daman & Diu) are characterized as sub humid climate. The remaining part of the state receives

rainfall between 500-1000 mm and generally falls under semi-arid climate. Considering the

abnormality of weather particularly rainfall during the monsoon period, the observed and predicted

rainfall was then analyzed for its validity.

Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)

S.

No. Region

Rainfall Projection

(in mm) June - Oct

Normal Rainfall (in mm)

Rainfall Projection

(% Departure from normal)

1. Middle Gujarat 905.3 796 13.7

2. South Gujarat 696.3 575 21.0

3. Project site 2071.7 1433.7 44.5

4. Saurashtra 767.1 580.4 32.2

5. Gujarat State 1110.1 846.5 31.1

Source: AAU, Anand, Gujarat

Temperature Data:

The site is located in the southern part of Gujarat. The secondary data was collected from free data

of Worldclim.org for the year 2010. The project site temperature regime for medium to high level

temperature (30-32 °C) during the seasonal months (June to Sep).

(viii) Social Infrastructure available:

Social Infrastructure in Valsad district is as under :

Education: There are 990 primary, 161 secondary and higher secondary schools.

There are 6 ITIs offering several industrial training Institutes programs which includes, fitting,

armature & motor rewinding, electrician, information technology and electronic system

maintenance etc., 166 Higher Secondary School, One Government polytechnic College is present

in the district offering courses in civil, chemical, electrical, mechanical and plastic engineering, 6

nos. of ITI’s with an intake capacity of 360, 1 no. of Polytechnic College With 120 seats, there is

one Engineering College, Pharmacy College, Arts, Commerce, Science, B. Ed and Law College.

Valsad district also has institutes which offer management studies with fulltime MBA.

Source: Department of Education, 2007

Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10

Government and 1 Municipal hospital present in the district. Valsad has several private specialized

hospitals to provide a comprehensive range of tertiary and secondary care services backed by

state-of-the-art technology and trained medicos. A multi-specialty Hospital, (branch of Nadkarni

Group of Hospitals) is present in Vapi, providing services in general and laparoscopic surgery,

trauma, orthopaedic and urology etc. The hospital is one of the few centres in India offering Uterine

Thermochoice Thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients.

Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital and

Adarsh Hospital are also present in Valsad.

Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is also known

Fire Temple for the Parsi community in India, makes the city a famous pilgrimage center

throughout the world. Dharampur is surrounded on three sides by the Sahyadri Mountains which

grace the town with pleasant climate throughout the year. The collection at the Lady Wilson

Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides

this, District Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, which



has increased the graph of tourist flow in the district.

5. Planning Brief:

Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country

Planning /Development authority Classification :

There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in

the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper mills,

paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat

Industrial Development Corporation (GIDC) notified area of Vapi.

Land use Planning (breakup along with green belt etc) :

The existing as well as proposed expansion project is located within the Notified Industrial Area by

Government of Gujarat and due to the proposed project there will not be any change in the land

use pattern of the region. Proposed Green belt planning in the project area is as below.

The company has already developed 1800 m2 green belt and proposes additional 900 m2 (~33%)

of green belt of the total land, i.e. 8219 sq. meter. The company shall develop green belt along the

periphery of the proposed site and in common premises available outside the company premises.

While selecting the plants species to be grown in the green belt zone, following points will be taken into account:

1. Climatic condition and soil characteristics of the region.

2. The air pollution emitted by the industry – gaseous and particulate matter. Plant interaction with

both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes

them from the atmosphere.

3. Characteristics of plants including shapes of crowns considered necessary for effective

absorption of pollutant gases and removal of dust particles.

4. Height of the plants should not be too high to be lethal.

5. For absorbance of gases, the duration of the foliage should be longer.

6. Vegetation controls soil erosion rates significantly. The decrease of water erosion rates with

increasing vegetation cover is exponential. This review reveals that the decrease in water

erosion rates with increasing root mass is also exponential. Plant species having good root

system are selected, so that soil erosion can be checked.



Table 8: Site Plan with Area Table at Existing & After proposed expansion

S. No Particulars Area in m2

Existing Proposed Total after expansion

1.0 Total plot Area 8219 0 8219

1.1 Production Plant 1600 300 1900

1.2 Office & lab area 600 0 600

1.3 OHC Area 15 0 15

1.4 Green Belt 1800 900 2700

1.5 Raw materials & other Storage 570 50 620

1.6 Solvent storage area 200 0 200

1.7 Utility 400 100 500

1.8 ETP & solid waste storage area 700 300 1000

1.9 Toilet block 15 0 15

1.10 Internal road 100 0 100

1.11 Open space 2219 -1650 569



Figure 3: Site map with Green Belt Development Planning



(iv) Assessment of Infrastructure demand (Physical & Social) :

There is no need for any infrastructure demand in terms of physical or social needs for the

proposed expansion.

(v) Amenities/ Facilities :

Notified industrial area GIDC of Vapi has the available infrastructure like water, electricity,

roads, rail, transportation, availability of raw material and drainage system.

6 Proposed Infrastructure:

(i) Industrial Area (Processing Area).

The proposed infrastructure to manufacture products will be built with standard

engineering design considering all the relevant parameters related to environment, health

and safety.

(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project

(iii) Green Belt:

Green belt will be provided and maintained at the tune of 33% of the total land area.

(iv) Social Infrastructure :

Not applicable

(v) Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc):

The project site is very well connected by road through National Highway no. 8, western railways.

(vi) Drinking Water management (Source & Supply of water ) :

Source of water is from GIDC water supply services.

(vii)Sewerage System:

GIDC has provided sewerage system to dispose the sewage effluent.

(viii) Industrial Waste Management:

Normal Industrial liquid effluent generated after proposed expansion will be treated in the

primary, secondary & tertiary ETP and will be discharged through GIDC underground

drainage to CETP and concentrated effluent will evaporated in multi effect evaporator. (CETP

Membership certificate is attached as Annexure-6)

Generated domestic liquid waste is being disposed off through soak pit system to

drainage.



(ix) Solid/Hazardous Waste Management after Expansion:

S. No.

Description Quantity, MT/Year Method of disposal

Remarks

Existing After Proposed expansion

1. ETP Waste (35.3)


VWEMCL

-

2. Used oil (5.1) 0.12 0.15 Collection, storage, transportation, disposal by

selling to registered re-processors

-

3. Discarded containers, bags/liners

(33.1)

9.0 15.0 Collection, storage, decontamination, reuse for

packing of hazardous waste or sold to authorized recycler.

-

4. Organic distillation

residue from the process ( 26.1)

44.76 67.52 Sent for co-processing or incineration

-

5. Salt from MEE (35.3)

235.2 2293 Collection, storage, transportation, disposal at TSDF

VWEMCL

-

6. Waste from process (Iron Oxide) (26.1)


VWEMCL

-

7. Salt from Process (26.1)


VWEMCL

-

8. Sludge from wet scrubber (37.1)


VWEMCL

-

9. 30% HCL (Sch: II B15)


Will be Converted into product

10. NaCl Salt Direct recovery from

ANF ( 26.1)

415.68 0 Sell to actual users or Collection, storage, transportation, disposal

at TSDF VWEMCL


expansion

11. Spent Acid (78%) (Sch: II

B15)



expansion

12. Sodium Bromide Solution (28%)

( Sch: II B6)



expansion

13. NaNO2 Solution (25%) ( Sch: II B

24)



expansion

14. AlCl3 Solution (30%) (Sch: II

B10)

1665 306.06 Sell to actual users as a by-product by tanker

-

Solid Waste

15. Fly Ash 242.5 485 Sell to Brick/Cement Manufacturer

-

(Membership certificate is attached as Annexure-6)



(x) Power Requirement & Supply / Source:

Power requirement for proposed project will be taken from DGVCL.

7. Rehabilitation and Resettlement (R&R) Plan:

(i) Policy to be adopted (Central/ State) in respect of the project affected persons

including home oustees, land oustees and landless labourers (a brief outline to be

given):

There will be no rehabilitation and resettlement undertaken as labours and workers from

local & nearby areas for the proposed construction activity which will be minor as the

proposed expansion activity is to be undertaken at the existing site.

8. Project Schedule & Cost Estimates:

(i) Likely date of start of construction and likely date of completion (Time schedule

for the project to be given):

After obtaining Environmental clearance and Consent to Establish from GPCB, the company

shall start the proposed minor construction and commissioning of the project.

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

project:

Estimated project cost along with the analysis in terms of economic viability of the project is



given as below. Table 9: Capital Cost Projection

Cost in INR (Lakhs)

S. No.

Particulars Existing Proposed Total

1.0 Land 8219 m2 87.51 0 87.51

2.0 Building 103.0 623.24 726.24

3.0 Equipment & machineries 359.0 509.23 868.23

4.0 Pipes & fittings 10.0 8.96 18.96

5.0 Utilities 5.0 32.14 37.14

6.0 Environmental Management

System 55.0 240.1 295.1

Total Project Cost 619.51 1413.67 2033.18

7.0 Utilities

7.1 Boiler, TPH 7.0 0 7.0

7.2 Cooling Tower, TR 250 250 500

7.3 Chilling plant, TR 40 110 150

7.4 D.G. Set (Standby), KVA 250 x 2 500 1000

8.0 Power from DGVCL, KVA 350 550 900

9.0 Fuel

9.1 Coal, kg/h for steam boiler

(7Tons/H) 1050 0 1050

9.2 Fuel (HSD), kg/h for D.G.Set (Capacity: 250 & 250 KVA)

80 0 80

10.0 Water from GIDC Vapi kL/day 87.99 118.87 206.86

11.0 Waste Water (Industrial)

kL/day 26.2 33.5 59.7

Table 10: Project Viability

S. No.

PARTICULARS AMOUNT (INR Crore)

1. Proposed Sale 60.0

2. Raw Material Cost 36.0

3. Power & Fuel 1.0

4. Labour Cost 1.28

5. Environmental Management System 1.98

6. Maintenance Cost 1.28

7. Selling, packing & Office Expenses 2.56

8. Financial charges 1.0

9. Proposed Profit 14.9

The company will provide budgetary provision for the recurring/operating expenses for

environmental issues while planning the allocation of funds during the annual budgetary

planning.

Table 11: Recurring/Operating Cost Per Annum

S. No. Component Proposed

(Rs. in Lakhs/annum)

1. Environment & Safety Management System 175.0

2. Greenbelt Maintenance 10.0



3. Solid waste Disposal 50.0

Total 235.0

9. Analysis of Proposal ( Final Recommendations):

(i) Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area:

Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare.

Local people will get direct financial benefit by way of employment.

Local people will get some contracts of supply and services to get indirect income.

Company will contribute in social upliftment by the way of improving education and health

facilities in nearby area.



ANNEXURES



ANNEXURE: 1

Location map showing the Project site and inter-state boundary within 10 kms radius


Expansion project- Dyes Intermediates Page 44

ANNEXURE: 2

Plant Layout



ANNEXURE: 3

Detailed project description with process details - MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance & mole balance for the product.

MANUFACTURING PROCESS , CHEMICAL REACTION & MASS BALANCE

1 (A) Chlorination with Chlorine such as Meta Nitro Chloro Benzene (MNCB)

HCl

�

Nitrobenzene (NB)(123)

Chlorine(71)

o-Nitrochlorobenzene(ONCB)(157.5)

Hydrochloricacid(36.5)

P-Nitrochlorobenzene(PNCB)(157.5)

m-Nitrochlorobenzene(MNCB)(157.5)

Nitrobenzene(NB)(123)

HCl

Process: Charge raw material, dehydrate it and add catalyst Ferric chloride and purge chlorine. Test the completion ofreaction. Then wash the reaction mass with water. Wash water is drained to ETP. Then reaction mass is transfer to thecontinuous fractional distillation column for separating isomers. Excess chlorine is scrubbed in reactant mass trap (use innext batch).

Where R =Nitro group

Generalized Reaction Scheme

Reaction Scheme of particular example with high effluent load



(1( A) Mass Balance for MNCB/PNCB/ONCB

Reactor

NitrobenzeneChlorineFerric Chloride

Washing1st water wash2nd & 3rd water wash

Excess Chlorinescrubbed in Nitro Benzenetrap (next batch

chlorination)

Fractional Distillation Handling Loss

MNCB & PNCB/ONCB

1st Wash water Neutralization

Lime

Filteration

Filtrate to MEE

Solid waste TDSF2nd & 3rd wash water to ETP

HCl (g) Scrubber

Water

HCl (30 %)For product

(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: MNBC

Process: Charge raw material,(MNBA ) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.

Reaction Scheme of particular example

SOCl2 SO2 HCl

m-Nitro-benzoic acidMNBA(167)

Thionyl ChlorideTC(119)

m-Nitrobenzoyl ChlorideMNBC(185.5)

Sulfur dioxide(64)

Hydrochloric acid(36.5)

COOH

NO2

COCl

NO2



(1 (B) Mass Balance for MNBC

ReactorMNBATC (R)TC (F)

HCl (g)SO2 (g)

Distillation

MNBC

Recovered TC TC (: HCl (g) + (SO2 (g)

Water

Caustic lyeML recycle

Water

Sodium Sulphite solnFor product

ML recycle

Water Scrubber

Alkali Scrubber

HCl (30%) For product

(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: NMTCl

Process: Charge raw material,(NMMT) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.


SOCl2 SO2 HCl


NMTCl(243.5)

Sulfur dioxide(64)


NMMT(225)

COOMe

COOH

NO2

COOMe

COCl

NO2



(1 (B) Mass Balance for NMTCl

ReactorNMMTTC (R)TC (F)

HCl (g)SO2 (g)

Distillation

NMTCl

Recovered TC TC ( HCl (g) + (SO2 (g)

Water


Water


ML recycle

Water Scrubber

Alkali Scrubber


(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: Chloroester

Process: Charge raw material,(BTL and IPA) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.


SOCl2 SO2 HCl


Chloro-ester(164.5)

Sulfur dioxide(64)


BTL(86)

O

O

OH

O

O

Cl

IPA(60)



(1 (B) Mass Balance for Chloro-ester

ReactorBTLTC (R)TC (F)IPA

HCl (g)SO2 (g)

Distillation

Chloro ester


Water


Water


ML recycle

Water Scrubber

Alkali Scrubber


IPA loss 23 Kg

(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: SACl

Process: Charge raw material,(S-Acid) add thionyl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next batch.


SOCl2 SO2 HCl


SACl(233)

Sulfur dioxide(64)


HO

S

O

Cl

O

O

S-acid(214.5)

Cl

S

O

Cl

O

O



(1 (B) Mass Balance for SACl

ReactorS-AcidTC (R)TC (F)

HCl (g)SO2 (g)

Distillation

SACl


Water


Water


ML recycle

Water Scrubber

Alkali Scrubber


(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: AEC.HCl

Process: Charge raw material,(AEE.HCL) add thionyl chloride. During addition hydrochloric acid generated isscrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye toform sodium sulfite which is sold. After reaction is completed excess thionyl chloride is recoverd and recycle in next

batch.


H2N

O

OHHCl

SOCl2 H2N

O

ClHCl

SO2 HCl

2Aminoethoxyethanol2AEE.HCl(141.5)


2AEC.HCl(160)

Sulfur dioxide(64)




(1 (B) Mass Balance for AEC.HCl

Reactor :

AEE HClTC (R) TC (F)

HCl (g) SO2 (g)

Distillation

AEC.HCl

Recovered TCTC :20 kgs (12 kgs: HCl(g) + 11 kgs (SO2 (g)

Water

Caustic lyeML recycleWater

Sodium Sulphite soln (73%) For product

ML recycle

Water Scrubber

Alkali Scrubber

HCl (30%)For product

(1 (B) Chlorination with Thionyl Chloride/Sulfuryl Chloride: 5ClABTF

Process: Charge raw material,(ABTF) add sulfuryl chloride. During addition hydrochloric acid generated is scrubbed in water and converted to 30% HCl solution. Sulfur dioxide generated is also scrubbed in caustic lye to form sodium sulfite which is sold.


SO2Cl2 SO2 HCl

Sulfuryl chloride(135) 5ClABTF

(237.5)

Sulfur dioxide(64)


ABTF(203)

NH2

CF3

NH2

CF3

Cl



(1 (B) Mass Balance for 5ClABTF

Reactor

ABTFSul. ChlorideMCB (R) MCB (F)

HCl (g)SO2 (g)

Distillation

5ClABTF

Recovered MCB MCB loss

Water


Water

Sodium Sulphite soln For product

ML recycle

Water Scrubber

Alkali Scrubber






(1 (B) Mass Balance for ITC

ReactorITATC (R)TC (F)

HCl SO2

Distillation

ITC

Recovered TC TC (HCl (g) + (SO2 (g)

Water


Water

Sodium Sulphite soln For product

ML recycle

Water Scrubber

Alkali Scrubber

HCl (30%)For product

(1 © Chlorination with Phosphrous Tri Chloride (PCl3) and Condensation such as N-OPLA

Process: The solution/suspension of raw material in proper solvent is heated to reacting temperature and chlorinating agent is added slowly. Aftercompletion of reaction tested by analytical technique, amine was added and maintained at reacting temperature. After completion of theamidation it is filtered to obtain the wet cake. and the ML is recycled in next batch and loss of solvent is compensated by adding requisitequantity of fresh solvent. After 4-5 batch the filtrate is taken for distillation and solvent is distilled out and residue is send to incineration waste.The wet cake is washed with waterand washing is end to MEE.


3HCl33

3 H3PO3

Where R= 4-carbomethoxy-3-nitro-benzoylR’=2,5-dichlorophenyl


3

3HCl

Phosphorus acid(82)


2,5-Dichloroaniline2,5-DCA(162)

PCl3H3PO3

33

3-Nitro-4-carbomethoxyBenzoic acidNMMT(225)

4-Carbomethoxy-3-nitro-2,5-dichlorobenzanilideN-OPLA(369)

Phosphorus trichloride(137.3)



(1 © Mass Balance for N-OPLA

Reactor

NMMTPhosphorus trichlorideMCB MLMCB (fresh)2,5 DCASoda ash

carbon dioxide loss

Salt solution to MEE

MCB Loss Product: N-OPLA

After 4-5 recycle and then distillation; Residue

MCB ML

Filter Wet cake: 1496 kgs

Water

Washing



(2) Mass Balance for Condensation such as CJD

Reactor

MNBCCaustic lyeSup-3

WaterHCl

Aq. Layer to MEEEvaporation loss

Layer Separation

CJD



(2) Mass Balance for Condensation such as CJD

Reactor

MNBCCaustic lyeSup-3

WaterHCl

Aq. Layer to MEEEvaporation loss

Layer Separation

CJD



(2) Mass Balance for Condensation such as GBL

Reactor

Chloro esterCaustic lyeSup-1

HClWater

Filtrate to MEEEvaporation lossLayer separation

GBL

(2) Condensation such as DDD

Process: Charge Water/solvent, add raw material containing base like nucleophilic group. Simultaneously add main raw material containingleaving group and also add NaOH with maintaining pH. Maintain till completion of reaction. During reaction the salt generated is dissolved inaqueous layer which is separated from organic layer of reaction mass. Aqueous layer treated in MEE and recoverwater is recycled.


Base like NaOH

NaZ H2O

Where R = HO-CH2-CH2-S-CH2-CH2-; HO-CH2-CH2-; NH2-CO-NH-; NH2-R‘ = 3-nitrobenzoyl; ClNH3-CH2-CH2-O-CH2-CH2-; iPr-OOC-(CH2)2-CH2-; 2-Nitrophenyl-; -CO-X = NH; SH; Z = Chloride, OH; MeO-

Reaction Scheme with Perticular Example with High Effluent Load

NO2

Cl

NaOH NaSH S

SS

NO2

O2N

2NaCl H2O

ONCBM.Wt. 157.5

CausticM. Wt. 40

SodiumhydrogensulfideM. Wt. 56

SulfurM. Wt. 32 DDD

M. Wt. 308

Sodium ChlorideM. Wt. 58.5

WaterM. Wt. 18



(2) Mass Balance for Condensation such as DDD

Reactor

ONCBNaSHCaustic lyeSulfureWater

Filtration

Water Wash5% HCl Wash

Filtrate to MEE

Wet cake 1160 kgWater to ETPWater to ETPEvaporation loss

DDD



(2) Mass Balance for Condensation such as SAMBA-III

Reactor

Sup-1Sup-2Caustic lyeMethanol

Filtration Salt

Distillation Methanol recoverMethanol loss

SAMBA-III

(2) Condensation such as Triazolone

Process: Charge solvent (formic acid), add raw material containing base like nucleophilic group (semicarbazide). Simultaneously add main rawmaterial containing leaving group (formic acid) and maintain till completion of reaction. After completion of reaction formic acid is distilled andrecycled. Traces of formic acid is then removed by co-distilltion with water. Product is filtered and ML partly used in next batch and part of itsend to ETP

Reaction Scheme

H2N NH

NH2

o

H

O

OH

HN

N

NH

O

2H2O

Semicarbazide(75)

Formic acid(46)

Triazolone(85)

Water(18) x2



(2) Mass Balance for Condensation such as Triazolone

ReactorSemicarbazideFormic acid freshFormic acid recover

Water recovered Distillation

Formic acid recoverFormic acid lossWater loss.Water ML 1828used in next batchsend to ETP.

Triazolone

(2) Condensation such as 1,3-DAU

Process: Charge raw material containing base like nucleophilic group (Hydrazine hydrate). Simultaneously add main raw material containingleaving group (dimethyl carbonate) and Maintain till completion of reaction. After completion of reaction, excess hydrazien is distilled andmethanoladded and product formed is filtered. ML is recycled.

Reaction Scheme

MeO OMe

o

2H2O

Dimethyl Carbonate(90)

Hydrazine hydrate(50)

1,3-DAU(90)

Water(18) x2

2N2H2.H2O

NH

O

NH

H2N NH2 2MeOH

Methanol(32) x 2



(2) Mass Balance for Condensation such as 1,3-DAU

ReactorDMCHH freshHH Recoverd

Distillation

Methanol

HH recycle

FiltrationMethanol recoveredMethanol lossHH loss

Water loss

1,3-DAU

(2) Condensation such as DPI

Process: Charge Water and EDC, add raw material containing base like nucleophilic group (Phenol). Simultaneously add main raw materialcontaining leaving group (ITC) and also add NaOH with maintaining pH. Maintain till completion of reaction. During reaction the salt generatedis dissolved in aqueous layer which is separated from organic layer of reaction mass. Aqueous layer treated in MEE and recover water isrecycled.

Reaction Scheme

ITC(203)

Phenol (94) x 2

2NaOH

Sodium hydroxide(40) x 2

2NaCl

Salt(58.5)x 2

2H2O

Water(18) x 2

COCl

COCl

OH

2

COOPh

COOPh

DPI(318)



(2) Mass Balance for Condensation such as DPI

Reactor

ITCCaustic Phenol

EDC (recoverd)EDC freshWater recycle

Layer separation

Water Wash

Filtrate to MEE

Distillation

Washing water recycledEDC recoverEDC loss

Water loss

DPI

(2) Condensation such as NOXSA

Process: Charge Water, add raw material containing base like nucleophilic group (Monoethaanol amine MEA). Simultaneously add main rawmaterial containing leaving group (NOXSC) and also add NaOH with maintaining pH. Maintain till completion of reaction. During reaction thesalt generated is dissolved in aqueous layer which is separated from organic cake of reaction mass. Aqueous layer treated in MEE

Reaction Scheme

ClO2S

NO2

NOXSC(249.5)

H2N

OH2

MEA(61)

O2S

NO2

NH

HO

NOXSA(274)

NaOH

Sodium hydroxide(40)

NaCl

Salt(58.5)

H2O

Water(18)



(2) Mass Balance for Condensation such as NOXSA

Reactor

NOXSCMEANaOH

Water

Filtrate to MEEWater loss

Filtration

NOXSA

(3) Deamination process such as SCH

Process: Charge amino compound (HH) and urea. Heat the reaction mass at reacting temperature till completion of reaction. During the reactionammonia liberated is srubbed in the water to make 30% aq. Ammonia. This aq. Ammonia is used as raw material in other products or will be soldin the market. After completion of reaction, HH is distilled and methanol is added. it is cooled and HCl is added . The product formed is filtered toseparate. The Filtrate MLis recycle in next batch.

Reaction Scheme

Hydrazine (32)

H2N NH2

O

Urea (60) SCH(111.5)

NH3

Ammonia(17)

NH2NH2 HCl


O

NH

NH2

H2N

HCl



(3) Mass Balance for Deamination such as SCH

ReactorUreaHH freshHH (rec)

Ammonia gas

Salt formation and Filtration Product: SCH

Filtrate ML MCB Methanol lossResidueRecycle Qty-4X/5 after 4-5

recycle it is for distillation

Scrubber

Water

30% solution of liquor ammonia used in Amidation process

DistillationHH recoveredHH loss

Methanol(R)Methanol (F)

HCl (g)

(3) Deamination process such as MBI

Process: Charge Solvent (MCB) and add amino compound (MOPDA) and urea. Heat the reaction mass at reacting temperature till completion ofreaction. During the reaction ammonia liberated is srubbed in the water to make 30% aq. Ammonia. This aq. Ammonia is used as raw material inother products or will be sold in the market. After completion of reaction, it is cooled and filtered to separate the product. The Filtrate ML isrecycle in next batch.

Reaction Scheme

NH2

NH2

MOPDA (122)

H2N NH2

O

Urea (60)

NH

HN

O

MBI(148)

2NH3

Ammonia(17) x 2



(3) Mass Balance for Deamination such as MBI

Reactor

UreaMOPDAMCB (Recycle)

MCB (fresh)

Ammonia gas

Filtration Product: MBI

Filtrate ML MCBMCB lossResidue

Recycle Qty-4X/5 after 4-5 recycle it is for distillation

Scrubber

Water


(3) Deamination process such as BI

Process: Charge Solvent/water and add amino compound and urea. Heat the reaction mass at reacting temperature till completion ofreaction. During the reaction ammonia liberated is srubbed in the water to make 30% aq. Ammonia. This aq. Ammonia is used as raw materialin other products or will be sold in the market. After completion of reaction, it is cooled and filtered to separate the product. The Filtrate ML isrecycle in next batch.


or NH3

Where R = NH2-; -NH-Ph-NH-; -NH-Ph(Me)-NH-


Urea(60)

Ammonia(17)

O-PhenelenediamineOPDA(108)

BenzimidazoloneBI(134)

2NH3



(3) Mass Balance for Deamination such as BI

Reactor

UreaOPDAMCB (Recycle) MCB (fresh)

Ammonia gas

FiltrationProduct:

Benzimidazolone

Filtrate ML MCB MCB loss Residue

Recycle Qty-4X/5 after 4-5 recycle it is for distillation

Scrubber

Water




Reactor

ResorcinolDMSCaustic Lye

Water

Layer Separation

Crude product for distillation

1,3-DMB

Residue

(4) Mass Balance for Alkylation such as 1,3 DMB

Filtrate ML to MEE

(4) Unit Process Alkylation such as NEL

Process: Add main raw material (lactum) in solvent (ODCB) and then DES is added simultaneously with caustic lye maintaining pH 8-9. Aftercompletion of reaction, layers are separated. Organic layer is send to distillation where pure product is obtained. Aqueous layer is send to MEE.

Reaction Scheme

HN

O

Lactum(169) x 2

O

S

O

O

O

2NaOH

N

O

NEL(197) x 2

2 2

Diethyl sulfateDES(154)

Sodium hydroxide(40) x 2

Sodium sulfate (142)

2H2O

Water(18) x 2

Na2SO4



Reactor

LactumDESCaustic lyeODCB (fresh)ODCB (recovered)Water

Layer Separation


NEL

ODCB recoveredODCB loss

Residue

Mass Balance for Alkylation such as NEL

Filtrate ML to MEE

(4) Unit Process Alkylation such as 2HMB

Process: Add main raw material in solvent (acetone) and then DMS is added simultaneously with potassium carbonate maintaining pH 8-9. Aftercompletion of reaction, solid salt is filtered . Organic layer is send to distillation where pure product is obtained.

Reaction Scheme

CHO

OH

OH

S

OO

O

O

CHO

OH

O

K2CO3 K2SO42 2 CO2 H2O

DHB(138) x 2

DMS(126)

Potassium carbonate138

2HMB(152) x 2

Potassium sulfate(174)

Carbon dioxide(44)

Water(18)



Reactor

DHBDMSK2CO3Acetone (recover)Acetone (fresh)

Filtration


2HMB

ResidueAcetone (recycle)

Acetone loss

Mass Balance for Alkylation: 2HMB

Filtrate ML to MEE

CO2

(5) Unit Process Nitration with dilute nitric acid such as NDMB

Process: Charge 25% dilute nitric acid. Add raw material (DMB) at reacting temperature. Maintain till completion of reaction. Cool the reactionmass and filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water andwashing is send to ETP.

Reaction Scheme

HNO3

DMB(138)

Nitric acid(63)

NDMB(183)

H2O

Water(18)

OMe

OMe

OMe

OMe

O2N



Mass Balance for Nitration NDMB

ReactorDMBDNA (25%)

Wet cake Washing

Filter Product (NDMB)

Water

ML recycleAfter adding required quantity of 98% nitric

acid

Washing ML send to ETP

(5) Unit Process Nitration with dilute nitric acid such as NBI

Process: Charge 25% dilute nitric acid. Add raw material (BI) at reacting temperature. Maintain till completion of reaction. Cool the reactionmass and filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water andwashing is send to ETP.

Reaction Scheme

NH

HN

O HNO3

NH

HN

O

O2N

BI(134)

Nitric acid(63)

NBI(179)

H2O

Water(18)



Mass Balance for Nitration NBI

ReactorBIDNA (25%)

Wet cake Washing

Filter Product (NBI)

Water


acid


(5) Unit Process Nitration with dilute nitric acid such as NMBI

Process: Charge 25% dilute nitric acid. Add raw material (MBI) at reacting temperature. Maintain till completion of reaction. Cool the reactionmass and filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water andwashing is send to ETP.

Reaction Scheme

NH

HN

O HNO3

NH

HN

O

O2N

MBI(148)

Nitric acid(63)

NMBI(193)

H2O

Water(18)



Mass Balance for Nitration NMBI

ReactorMBIDNA (25%)

Wet cake Washing

Filter Product (NMBI)

Water


acid


(5) Unit Process Nitration with dilute nitric acid such as Ac-DCPNA

Process: Charge Sulfuric acid and Add raw material and add nitric acid at reacting temperature. Maintain till completion of reaction. Drawn thereaction mass in ice water and filter it. Filtrate obtained is neutralize in ETP to get salt (TSDF) and ETP waste water. Wet cake is washed withwater and washing is send to ETP.

Reaction Scheme

HNO3

Ac-DCA(204)

Nitric acid(63)

Ac-DCPNA(249)

H2O

Water(18)

NHAc

Cl

NHAc

Cl

ClCl

NO2

H2SO4

Sulfuric acid(98)

H2SO4

sulfuric acid(98)



Mass Balance for Nitration Ac-DCPNA

Reactor Ac-DCANitric acidSulfuric acid

Wet cake Washing

Drawning

Product (Ac-DCPNA)

Water

Washing to ETPSpent acid

Filter

IceWater

NeutralizationLime

ML to ETPsalt water loss

Water loss

(5) Unit Process Nitration with dilute nitric acid such as NIPA

Process: Charge Sulfuric acid and Add raw material (IPA) and add nitric acid at reacting temperature. Maintain till completion of reaction. Drawnthe reaction mass in ice water and filter it. Filtrate obtained is neutralize in ETP to get salt (TSDF) and ETP waste water. Wet cake is washed withwater and washing is send to ETP.

Reaction Scheme

HNO3

IPA1(166)

Nitric acid(63)

NIPA(211)

H2O

Water(18)

H2SO4

Sulfuric acid(98)

H2SO4

sulfuric acid(98)

COOH

COOH

COOH

COOHO2N



Mass Balance for Nitration NIPA

Reactor IPANitric acidSulfuric acid

Wet cake Washing

Drawning

Product (NIPA)

Water


Filter

Water

NeutralizationLime


Water loss

(5) Unit Process Nitration with dilute nitric acid such as NABT

Process: Charge 25% dilute nitric acid. Add raw material at reacting temperature. Maintain till completion of reaction. Cool the reaction massand filter it. Filtrate obtained is recycled in next batch after correcting concentration of nitric acid. Wet cake is washed with water and washing issend to ETP.


H2OHNO3

Where R = methoxy; -NH-CO-NH; Methyl


NH2Ac

CF3

HNO3

NH2Ac

CF3

H2O

AABTM.Wt. 204

Nitric acidM. Wt. 63

NABTM. Wt. 249

WaterM. Wt. 18

NO2



(5) Mass Balance for Nitration such as NABT

Reactor AABTNitric acidOleum

Wet cake Washing

Drawning

Product (NABT)

Water


Filter

Ice

NeutralizationLime


(6) Unit Process Formylation such as DEAB

Process:Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material (NN-DEA). Maintain it till completion of reaction. Add water andneutralize Layers are separated. Aqueous layer is send to MEE for salt and water recovery. Organic layer is washed with water and washing send to MEE..

Reaction Scheme

NEt2

POCl3 N

O

H 3H2O

NEt2

CHO

H3PO4 2HCl HN(CH3)2. HCl

NN-DEA(149)

Phosphorus oxychloride(153.5)

DMF(73)

Water(18) x 3

DEBA(177)

Phosphoric acid(98)

Hydrochloric acid(36.5) x 2

Dimethyl ammonium chloride(81.5)



(6) Mass Balance for Unit Process Formylation such as DEAB

Reactor

POCl3DMFNN-DEA

Water

Wet cakeFilter

Water

Washing ML send to MEE Filtrate ML to MEE

Washing of Wet cakeProduct

Water loss

(6) Unit Process Formylation such as DMAB

Process:Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material (NN-DMA). Maintain it till completion of reaction. Add water andneutralize Layers are separated. Aqueous layer is send to MEE for salt and water recovery. Organic layer is washed with water and washing send to MEE..

Reaction Scheme

NMe2

POCl3 N

O

H 3H2O

NMe2

CHO


NN-DMA(121)


DMF(73)

Water(18) x 3

DMBA(149)

Phosphoric acid(98)





(6) Mass Balance for Unit Process Formylation such as DMAB

Reactor

POCl3DMFNN-DMA

Water

Wet cakeFilter

Water



Water loss

(6) Unit Process Formylation such as DMBA

Process:Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material (DMB). Maintain it till completion of reaction. Add water, cooled andfiltered. Filtrate ML is neutralize and send to MEE. Wet cake is washed with water and washing is send to ETP.

Reaction Scheme

OMe

OMe

POCl3 N

O

H 3H2O

OMe

OMe

CHO


DMB(138)


DMF(73)

Water(18) x 3

DMBA(166)

Phosphoric acid(98)





Reactor

POCl3DMFDMBWater

Wet cakeFilter

Water



Water loss

(6) Mass Balance for Unit Process Formylation such as DMBA

(6) Unit Process Formylation such as DHB

Process:When product is liquid (DMAB; DEAB):Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material. Maintain it till completion of reaction. Add water and neutralize withcaustic lye. Layers are separated. Aqueous layer is send to TEE for salt and water recovery. Organic layer is washed with water and washing send to ETP.When product is solid (DHB, DMB):Charge DMF and add phosphorus oxy chloride. Heat it and add main raw material. Maintain it till completion of reaction. Add water, cooled and filtered.Filtrate ML is neutralize and send to MEE. Wet cake is washed with water and washing is send to ETP.


�

POCl3 5NaOH 3H2O

Na2HPO4 Me2NH 5H2O 3NaCl

Where R = NEt2; NMe2; Methoxy; hydroxy


POCl3 5NaOH 3H2O

Na2HPO4 Me2NH 5H2O 3NaCl

Resorcinol(110)

Phosphorusoxychloride(153.5)

DMF(73)

Caustic(40)

water(18)

DihydroxybenzaldehydeDHB(138)

Disodiumhydrogenphosphate(142)

DimethylammoniumChloride(45)

water(18)

Salt(58.5)



Reactor

POCl3DMFResorcinol

Water

Wet cake

Filter

Water

Washing ML send to MEE

Filtrate ML to MEE

Washing of Wet cake

Product

Water loss

(6) Mass Balance for Unit Process Formylation such as DHB

(7) Unit Process Amidation such as NMT-amide

Process: Charge Water Add liquor ammonia (23%), cool to 0-5�C. Add acyl chloride. Check for completion of reaction. After completion ofreaction filter it in ANF, wash with water ( and this wash is directly use in the next batch as ammonia gas scubbing then another ammonia+water will make up) Cake dry and filtrate take in another vessel, heat to 75�C and add caustic flakes at 75�C to recover excess ammonia which ispurge washing of last batch. After recoverof ammonia remaining to MEE to recover the salt.

Reaction Scheme

COCl

NO2

COOMe

2NH3

CONH2

NO2

COOMe

NH4Cl

NMTCl(243.5)

Ammonia(17) x 2

NMT-Amide(224)

NH4Cl NaOH NH3 NaCl H2O

AmmoniumChloride(53.5)

Sodiumhydroxide(40)

Ammonia(17)

Sodium Chloride(58.5)

Water(18)




NMTClwaterLiq. NH3 (Recovered)

Liq. NH3 (Fresh)HCl

Reactor

Washing of wet cakeFilter

Product

Water

NH3 (g)Filtrate ML NaOH

NaCl soln to MEE

Wet cake

Wash Water

Scrubber

Liquor Ammonia recycle

(7) Mass Balance for Unit Process Amidation such NMT-amide

Water loss

(7) Unit Process Amidation such as p- Nitro Benzamide (PNBA)



2 NH4Clor or

Where R = 4-carbomethoxy-3-nitro-phenyl; 4-nitrophenyl; 2-amino-3-sulfonyl-4chloro phenyl


p-NitrobenzoylChloridePNBC (185.5)

Ammonia(17)

p-Nitrobenzamide(PNBA)(167)

Ammonium Chloride(53.5)

NaOH NH3 NaCl H2O

Sodium Hydroxide(40)

Ammonia(17)

Sodium chloride(58.5)

Water(18)

2

NH4Cl

Ammonium Chloride(53.5)

NH4Cl



PNBCwaterLiq. NH3 (Recovered)

Liq. NH3 (Fresh)HCl

Reactor


Product

Water

NH3 (g)Filtrate ML NaOH

NaCl soln to MEE

Wet cake

Wash Water

Scrubber


(7) Mass Balance for Unit Process Amidation such as p- Nitro Benzamide (PNBA)

(7) Unit Process Amidation such as DSA

Process: Charge MIBK ;cool to 0-5�C. Add sulfonyl chloride (DSC). Add ammonia gas. Check for completion of reaction. After completion ofreaction. Distill out the MIBK. Filter it in ANF, wash with water ( and this wash is heat to 75�C and add caustic flakes at 75�C to recover excessammonia which is purge in next batch). After recoverof ammonia remaining to MEE to recover the salt.

Reaction Scheme

4NH3 2NH4Cl

DSC(324.5)

Ammonia(17) x 4

DSA(285.5)



Sodiumhydroxide(40)

Ammonia(17)


Water(18)

AmmoniumChloride(53.5) x 2

NH2

Cl

SO2Cl

ClO2S

NH2

Cl

SO2NH2

H2NO2S



DSCLiq. NH3 (Recovered)Liq. NH3 (Fresh)MIBK (recover)MIBK (fresh)

Reactor

Filter

NH3 (g) recycle Filtrate ML NaOH

NaCl soln to MEE

Wet cake

(7) Mass Balance for Unit Process Amidation such DSA

Steam distillationWaterMIBK recoveredMIBK loss

Water lossProduct

(7) Unit Process Amidation such as ONCBPSA


Reaction Scheme

Cl

2NH3 NH4Cl

ONCBPSC(272)

Ammonia(17) x 2

ONCBPSA(252.5)



Sodiumhydroxide(40)

Ammonia(17)


Water(18)


NO2

SO2Cl

Cl

NO2

SO2NH2



ONCBPSC waterLiq. NH3 (Recovered)Liq. NH3 (Fresh)HCl

Reactor


Product

Water

NH3 (g)Filtrate MLNaOH

NaCl soln to MEE

Wet cake

Wash Water

Scrubber


(7) Mass Balance for Unit Process Amidation such ONCBPSA

Water loss

(8) Unit Process Acylation such as 2HMB

Process: In EDC, Add main raw materials, charge aluminium chloride heat and maintain till completion of reaction. Drawn the reaction mass to thewater, separate layer and aqueous layer (containing AlCl3) is sell to actual user. Organic layer is washed with water and washing is send to ETP.During reaction HCl gas evolved is scrubbed in water. Organic layer is for distillation to get finished product. Recoverd EDC is recycle in next batch.

Reaction Scheme

CHO

OMe

OMe

AlCl3

CHO

OH

OMe

Al(OH)3 CH3Cl 2HCl

DMBA(166)

Aluminium trichloride(133.5)

2HMB(152)

Aluminium hydroxide(78)

Methyl chloride(50.5)


3H2O

water(18) x 3

Al(OH)3 3HCl AlCl3 3H2O

Aluminium hydroxide(78)


Aluminium trichloride(133.5)

Water(18) x 3



DMBAHClAlCl3EDC (Recovered)EDC (Fresh)

Reactor

Water

(8) Mass Balance for Acylation such as 2HMB

Methyl chloride Gas loss

DrowningWater

Layer Separation Organic Layer

AlCl3 solution (30%) to be sold Wash Water to ETP

Distillation

EDC recovered Residue ProductEDC LossWater Loss

(8) Unit Process Acylation such as (2,4 Di Chloro Phenacylchloride DCPC)

Process: In EDC, Add main raw materials, charge aluminium chloride heat and maintain till completion of reaction. Drawn the reaction mass to thewater, separate layer and aqueous layer (containing AlCl3) is sell to actual user. Organic layer is washed with water and washing is send to ETP.During reaction HCl gas evolved is scrubbed in water. Organic layer is for distillation to get finished product. Recoverd EDC is recycle in next batch.


AlCl3�HCl

Where R = chloro, methoxyR’ = chloroacyl


AlCl3

HCl

m-DichlorobenzeneMDCB(147)

Chloro-acetyl-chlorideCAC(113)

AluminiumChloride(133.5)

2,4-DichlorophenacylchlorideDCPC(223.5)




MDCBCACAlCl3EDC (Recovered)EDC (Fresh)

Reactor

Water

(8) Mass Balance for Acylation such as (2,4 Di Chloro Phenacylchloride DCPC)

HCl Gas Scrubber

Water

HCl for productDrowningWater

Layer Separation Organic Layer

AlCl3 solution (30%) to be sold Wash Water to ETP

Distillation

EDC recovered Residue ProductEDC Loss Water Loss

(9 (A) Unit Process Reduction with Sodium hydrogen sulfide (NaSH) such as m- Chloro Aniline (MCA)

Process: In a vessel charge water and raw material. Heat and add reducing agent (NaSH). Test completion of reaction. After completion ofreaction, layer is separated and layer containing co-product sodium thiosulfate. Organic layer is washed with water. Organic layer transferred tovacuum distillation where pure product is obtained.

Generalized reaction scheme:

6 NaSH 4H2O3Na2S2O3�4

Where R= Cl-phenyl; 3-nitro-5-sulfonyl-6-hydroxy-phenyl; 3-methylsulfone-6- methylamine-phenyl

3-NitrochlorobenzeneMNCB(157.5)

SodiumHydrogenSulfide(56)

Water(18)

m-ChloroanilineMCA(127.5)

Sodium Thiosulfate(158)

6 NaSH 4H2O 3Na2S2O34



m-nitro chlorobenzene30% NaSHWater

Reduction Vessel

Distillation

Water (R)Water (F)

Distillation

Product MCA

Water Recycle

(9) (A) Mass Balance Reduction with Sodium hydrogen sulfide (NaSH) such as m- Chloro Aniline (MCA)

Layer Separation Sodium Thio Sulphate for product

Organic Layer Wash Water to ETP

Residuewater loss

(9 (A) Unit Process Reduction with Sodium hydrogen sulfide (NaSH) such as 4NAPSA

Process: In a vessel charge water and raw material (CDNBSA). Heat and add reducing agent (NaSH). Test completion of reaction. After completionof reaction, filter it and layer containing co-product sodium thiosulfate and sellable wet cake.

Reaction Scheme

OH

NO2HO3S

NO2

CDNBSA(264)x 4

6 NaSH H2O4

OH

NH2HO3S

NO2

4 3Na2S2O3

Sodium hydrogen sulfide(56) x 6

Water(18) 4-NAPSA

(234)x 4

Sodium thiosulfate(158) x 3



CDNBSAWaterNaSH

Reduction Vessel

Filter

Product 4NAPSA

(9) (A) Mass Balance Reduction with Sodium hydrogen sulfide (NaSH) such as 4NAPSA

Sodium Thio Sulphate for productwater loss

(9 (A) Unit Process Reduction with Sodium hydrogen sulfide (NaSH) such as MSMAA

Process: In a vessel charge water and raw material (MSMNA). Heat and add reducing agent (NaSH). Test completion of reaction. After completionof reaction, filter it and layer containing co-product sodium thiosulfate. Wet cake is washed with water to get pure product

Reaction Scheme

MSMNA(230) x 4

6 NaSH H2O44 3Na2S2O3

Sodium hydrogen sulfide(56) x 6

Water(18) MSMAA

(200) x 4

Sodium thiosulfate(158) x 3

NHMe

SO2CH3

NO2

NHMe

SO2CH3

NH2



MSMNAWaterNaSH

Reduction Vessel

Filter

Product MSMAA

(9) (A) Mass Balance Reduction with Sodium hydrogen sulfide (NaSH) such as MSMAA

Sodium Thio Sulphate for productwater loss

Wet cake washingWater for washing Washing water to ETP

(9 B) Unit Process Reduction with Iron and acid in water such as m- Anisidine (MA)

Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material and maintain till reaction iscompleted. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtained byvacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.

acid49Fe 4H2O

3Fe3O44


Where R= methoxy-phenyl; N-{2-[(2-hydroxyethyl)sulfonyl]ethyl}benzamide

Acetic acid

m-nitroanisoleMNA(153)

Iron powder(56)

Iron Oxide(232)

Water(18)

m-anisidineMA(123)

49Fe 4H2O 3Fe3O44



(9 B) Mass balance for Reduction with Iron and acid in water such as m- Anisidine (MA)

Acetic acidWater (F)Water ®Iron PowderM-Nitro AnisoleCaustic lye

Reduction Vessel

Vaccum Distillation

Water lossWater recycleIron oxide waste to TSDF

Product : m-Anisidine

(9 B) Unit Process Reduction with Iron and acid in water such as VJD

Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material (OJD) and maintain till reaction iscompleted. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtained byvacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.

Reaction Scheme

NO2

CONHCH2CH2SCH2CH2OH

O

O

9Fe 4H2O

NH2

CONHCH2CH2SCH2CH2OH

O

O

Acetic acid

3Fe3O4

OJD(302)

Iron powder(56)x 9

Water(18) x 4

VJD(272)

Iron oxide(232)x 3

4 4

(9 B) Mass balance for Reduction with Iron and acid in water such as VJD

Acetic acidWater (F)Water (R)Iron PowderOJDCaustic lye

Reduction Vessel

Vaccum Distillation


Product : VJD



(9 B) Unit Process Reduction with Iron and acid in water such as AOX

Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material (NOXSA) and maintain till reaction iscompleted. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtained byvacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.

Reaction Scheme

9Fe 4H2OAcetic acid

3Fe3O4

NOXSA(274) x 4

Iron powder(56) x 9

Water(18) x 4

AOX(244) x 4

Iron oxide(232) x 4

NO2

S

NH

O

O

HO

NH2

S

NH

O

O

HO

(9 B) Mass balance for Reduction with Iron and acid in water such as AOX

Acetic acidWater (F)Water (R)Iron PowderNOXSACaustic lye

Reduction Vessel

Vaccum Distillation


Product : AOX



(9 B) Unit Process Reduction with Iron and acid in water such as OPSAMIDE

Process: In a vessel charge water, iron powder and acetic acid as catalyst, heat and then add raw material (ONCBPSAH) and maintain till reactionis completed. Test completion of reaction. Shift pH to 7-7.5 using caustic lye Separate the organic layer and iron sludge. Pure product is obtainedby vacuum distillation of organic layer. Iron sludge and residue from distillation is sent to incineration waste.

Reaction Scheme

9Fe 4H2OAcetic acid

3Fe3O4

ONCBPSAH(234.2)

Iron powder(56) x 9

Water(18) x 4

OPSAMIDE(204.2) x 4

Iron oxide(232) x 4

OH

NO2

SO2NH2

OH

NH2

SO2NH2

4 4

(9 B) Mass balance for Reduction with Iron and acid in water such as OPSAMIDE

Acetic acidWater (F)Water (R)Iron PowderONCBPSAHCaustic lye

Reduction Vessel

Vaccum Distillation


Product : OPSAMIDE



(9C) Unit Process Reduction Hydrogenation such as AMBI

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NMBI), solvent (DMF:Water) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

NH

HN

O2N

O 3H2

NH

HN

H2N

O 2H2O

NMBI(193)

Hydrogen(2) x 3

AMBI(163)

Water(18) x 2

NMBI Hydrogen CatalystDMF (Recycled)DMF (Fresh)

Reactor

Catalyst RecycleFilter

DMF lossWater LossProduct AMBI

Residue

Filtrate ML

(9C) Unit Process Reduction by Hydrogenation such as AMBI

Filtrate

Crystallizer

Filter

After 5-6 recycle taken for distillation



(9C) Unit Process Reduction Hydrogenation such as AM3

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NABT), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

3H2

NH2

CF3

2H2O

AcHN

NABT(248)

Hydrogen(2) x 3

AM3(218)

Water(18) x 2

AcHN CF3

NO2

NABTHydrogen CatalystMethanol (Recycled)Methanol (Fresh)

Methanol loss Water LossProduct AM3

(9C) Unit Process Reduction by Hydrogenation such as AM3

Reactor


Residue

Filtrate ML

Filtrate

Crystallizer

Filter




(9C) Unit Process Reduction Hydrogenation such as MOPDA

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (MNPT, solvent (MCB) and catalyst is charge in hydrogenatorreactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogen pressure wasreleased in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pure product. FiltrateML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches the filtrate is takenfor distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

NH2

NO2

3H2

NH2

NH2

2H2O

MNPT(152)

Hydrogen(2) x 3

MOPDA(122)

Water(18) x 2

MNPTHydrogen Catalyst MCB (Recycled) MCB (Fresh)

MCB lossWater LossWater recoverProduct

(9C) Unit Process Reduction by Hydrogenation such as MOPDA

Reactor


Residue

Filtrate ML

Filtrate

Crystallizer

Filter




(9C) Unit Process Reduction Hydrogenation such as ABI

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material, solvent and catalyst is charge in hydrogenator reactor.Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogen pressure was released inwater. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pure product. Filtrate ML isrecycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches the filtrate is taken fordistillation and solvent is distilled out and residue is sent to incineration waste.


3H2 2H2OCatalyst

Water(18)

3H2Catalyst

5-Nitro-BenzimidazoloneNBI (179)

Hydrogen(2)

5-AminoBenzimidazoloneABI (149)

2H2O

Where R = CF3; NHCOCH3; CH3; -NHCONH-; -NH2Catalyst = Pd or Ni

Reaction Scheme of Particular Example having maximum effluent load



NBIHydrogenCatalystDMF (Recycled)DMF (Fresh)

Reactor


DMF lossWater LossProduct ABI

Residue

Filtrate ML

(9C) Unit Process Reduction by Hydrogenation such as ABI

Filtrate

Crystallizer

Filter


(9C) Unit Process Reduction Hydrogenation such as AMBA

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NMBA), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

3H2

NH2

2H2O

NMBA(166)

Hydrogen(2) x 3

AMBA(136)

Water(18) x 2

NO2

HN HN



(9C) Unit Process Reduction by Hydrogenation such as AMBA

NMBA Hydrogen CatalystMethanol (Recycled)Methanol (Fresh)

Methanol loss Water LossProduct AMBA

Reactor


Residue

Filtrate ML

Filtrate

Crystallizer

Filter


(9C) Unit Process Reduction Hydrogenation such as MPBA

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (MPB), and catalyst is charge in hydrogenator reactor.Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogen pressure was released inwater. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pure product. Filtrate ML isrecycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches the filtrate is taken fordistillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

2H2

MPB(198) Hydrogen

(2) x 2MPBA(200)

PhO CHO PhO CH2OH



MPBHydrogen Catalyst

Reactor


Product

(9C) Unit Process Reduction by Hydrogenation such as MPBA

Filtrate

Distillation

Residue

(9C) Unit Process Reduction Hydrogenation such as AIPA

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (NIPA), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

3H2

NH2

2H2O

NIPA(211)

Hydrogen(2) x 3

AIPA(181)

Water(18) x 2

NO2

COOH

HOOC

COOH

HOOC



(9C) Unit Process Reduction by Hydrogenation such as AIPA

NIPA Hydrogen CatalystMethanol (Recycled)Methanol (Fresh)

Methanol loss Water LossProduct

Reactor


Residue

Filtrate ML

Filtrate

Crystallizer

Filter


(9C) Unit Process Reduction Hydrogenation such as DABA

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (DNBA), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

6H2

NH2

4H2O

DNBA(212)

Hydrogen(2) x 6

DABA(152)

Water(18) x 4

NO2

COOH

O2N

COOH

H2N



(9C) Unit Process Reduction by Hydrogenation such as DABA

DNBA Hydrogen CatalystMethanol (Recycled)Methanol (Fresh)


Reactor


Residue

Filtrate ML

Filtrate

Crystallizer

Filter


(9C) Unit Process Reduction Hydrogenation such as o-phenoxy aniline

Process: Hydrogenator reactor was flushed with inert nitrogen and then Raw material (2PNB), solvent (Methanol) and catalyst is charge inhydrogenator reactor. Temperature and hydrogen pressure is maintained till completion of reaction .After completion of reaction, hydrogenpressure was released in water. Catalyst is isolated by Filteration and recycled. Filtrate is cooled to 0-5�C and filtered again to isolate the pureproduct. Filtrate ML is recycled in next batch and loss of solvent is compensated by adding requisite quantity of fresh solvent. After 6-7 batches thefiltrate is taken for distillation and solvent is distilled out and residue is sent to incineration waste.

Reaction Scheme

3H2 2H2O

2PNB(215)

Hydrogen(2) x 6

O-phenoxy aniline(185)

Water(18) x 4

OPh OPh

NO2 NH2



(9C) Unit Process Reduction by Hydrogenation such as Ortho Phenoxy Aniline

PNB Hydrogen CatalystMethanol (Recycled)Methanol (Fresh)


Reactor


Residue

Filtrate ML

Filtrate

Crystallizer

Filter




(10 A) Unit Process Chloroxidation/Oxidation such as S Acid

Process: Charge water or washing of last batch containing HCl. Then Charge main raw material. Shift pH to 0.5 by adding extra HCl. Cool and passchlorine gas till completion of reaction . Settle down the product and remove mother liquor, give water wash to the product. Washing is recycle innext batch reaction. Mother liquor is distilled to recover 30% HCl. Or Charge water; HCl and main raw material. Cool and pass chlorine gas tillcompletion of reaction. Excess of HCl and water is distilled to get desired quantity of HCL left in product. Distilled acidic water is recycled in nextbatch.


Cl2� H2O HCl

Iso-propyl alcohol(60)

2Cl2 2H2O

3HCl

GBL-condensed(164)

Chlorine(71)

Water(18)

Schwander Acid(S. Acid; 214.5)



Where R = HOOC-CH2-CH2-CH2-; NH2-CH2-CH2-O-CH2-CH2-; O-Nitrophenyl- etcR‘ = HO-CH2-CH2-; O-Nitrophenyl etcR'‘ = Cl-CH2-CH2-; Cl-



Recycled Water Chlorine GBL Cond.

Reactor Excess Chlorine

Filter

Filtrate MLWater

(10 A) Mass balance for Unit Process Chloroxidation/Oxidation such as S Acid

Scrubber

NaOH and water

NaOCl Soln. (7%) for product

Wet cake

Washing of Wet cake

Wash Water recycled in next

batch

DistillationLoss

Product: S Acid

IPA recovered & reused in Chloroester

product

HCl (30%) Recovered for product

Product

Loss

(10 A) Unit Process Chloroxidation/Oxidation such as Ether amine

Process: Charge water or washing of last batch containing HCl. Then Charge main raw material (AHD). Shift pH to 0.5 by adding extra HCl. Cooland pass chlorine gas till completion of reaction . Excess of HCl and water is distilled to get desired quantity of HCL left in product. Distilled acidicwater is recycled in next batch.

Reaction Scheme

H2N

O

S

OH

AHD(165)

2Cl2

Chlorine(71) x 2

H2O

Water(18)

H2N

O

S

Cl2HCl

O

O

HCl

Ether amine(252)




WaterHClChlorineAHD


(10 A) Mass balance for Unit Process Chloroxidation/Oxidation such as Ether amine

Scrubber

NaOH and water

NaOCl Soln. for product

Distillation

Water loss HCl Recovered for product

Product

(10 A) Unit Process Chloroxidation/Oxidation such as ONBSC/PNBSC

Process: Charge water or washing of last batch containing HCl. Then Charge main raw material (DDD). Shift pH to 0.5 by adding extra HCl. Cooland pass chlorine gas till completion of reaction . Settle down the product and remove mother liquor, give water wash to the product. Washing isrecycle in next batch reaction. Mother liquor is distilled to recover 30% HCl. Or Charge water; HCl and main raw material. Cool and pass chlorinegas till completion of reaction. Excess of HCl and water is distilled to get desired quantity of HCL left in product. Distilled acidic water is recycled innext batch..

Reaction Scheme

DDD(308)

5Cl2

Chlorine(71) x 5

4H2O

Water(18) x 4

8HCl

ONBSC(221.5)


S S

NO2O2N

NO2

SO2Cl

2



(10 A) Mass balance for Unit Process Chloroxidation/Oxidation such as ONBSC/PNBSC

Recycled Water HClChlorineDDD


Filter

Filtrate ML

Water

Scrubber

NaOH and water

NaOCl Soln. for product Wet cake

Washing of Wet cake

Wash Water

recycled in next batch

Distillation Loss

Product: ONBSC

Water loss HCl Recovered for product

Product

(10 B) Unit Process Chloroxidation/Oxidation such as Sodium Hypo Chlorite

Process: Charge sodium hypo chlorite (7%) solution from S acid and caustic lye and purged the chlorine gas in it. The resultantproduct is 10% Sodium Hypo Chlorite Solution.

2NaOHCl2 NaOCl NaCl

ChlorineM. Wt. 71

Sodium hydroxideM. Wt. 40

Sodium hypochloriteM. Wt. 74.5

H2O

SaltM. Wt. 58.5

WaterM. Wt. 18

Reaction Scheme

Caustic LyeNaOCl soln from S acidChlorine

Reactor

Sodium hypochlorite soln

(10 B) Mass Balance Unit Process Chloroxidation/Oxidation such as Sodium Hypo Chlorite

Water loss



(11 A) Unit Process Dehydration using POCl3 such as Nitrile

Process: Charge Xylene and main raw material. Add phosphorus oxy chloride and heat the reaction. HCl gas evolved is scrubbed in waterto make 30% HCl solution. The reaction mass is then drowned in the water and layers are separated. Aqueous layer is send to MEE afterneutralization. Organic layer is for azeotropically distillation with water to recover the xylene. After complete recovery of xylene reactionmass is cooled and filtered to obtained the product and filtrate is then send to ETP.

POCl3� HPO2Cl2


2H2OHCl H3PO4


2HCl

NMT-amide(224)

PhosphorusOxychloride(153.3)

Nitrile(206)

Phosphoric acid (98)


POCl3 HPO2Cl2

Where R = Nitro, Methyl carboxylate group etc




Xylene (Recovered)Xylene (fresh)NMT-Cl POCl3

Reactor HCl (g)

Drawning

Layer Separation Water wash to MEE

Scrubber

Water

HCl for product

Recycled Water

Organic Layer for DistillationWater

Xylene LossXylene Recovered

Water loss

Filter Recovered Water

Product: Nitrile

(11 A) Mass Balance for Unit Process Dehydration using POCl3 such as Nitrile



Thio MLML recovered

CarbonReactor

Carbon wasteFilter

Filtrate to MEE

Crystalizer

FilterProduct: Sodium Thio sulphate

crystal

Filtrate MLRecycle in next batch distillation

(11 B) Mass balance for Unit Process Dehydration by Evaporation such as Sodium Thio Sulfate

Condensate used in processWater loss

(12) Unit Process for Chloro sulphonation such as NOXSC

Process: Charge CSA and main raw material and heat the reaction to reacting temperature. Drawn the reaction mass to ice wate r and filter the cake obtained. Filtrate is sell as spent acid.


�

ClSO3H H2O

ClSO3H

NOXM. Wt. 151

CSAM. Wt. 116.5

NOXSCM. Wt. 249.5

WaterM. Wt. 18

H2O

Where R = NH2; Cl; CH3

Reaction Scheme with Particular Example with High Effluent Load



CSANOX Reactor

Drawning in water

Water

Filtration

ML (H2SO4 + HCl)

Wet cake

Water wash

Washing ML Recycled

Product

(12) Mass Balance for Unit Process Chloro sulphonation such as NOXSC

Lime

SaltSend to TSDF

Calcium chloride solution (19-23%)used as a brine in

chilling plant

Water loss

(12) Unit Process for Chloro sulphonation such as DSC

Process: Charge CSA and main raw material (MCA) and heat the reaction to reacting temperature. Drawn the reaction mass to ice water and filter the cake obtained. Filtrate is neutralize with lime to get salt and brine

Reaction Scheme

Cl

2ClSO3H

Cl

SO2Cl

2H2O

MCA(127.5)

CSA(116.5) x 2

DSC(324.5)

Water(18) x 2

NH2NH2

ClO2S



(12) Mass Balance for Unit Process Chloro sulphonation such as DSC

CSAMCA

Reactor

Drawning in water

Water

Filtration

ML (H2SO4 + HCl)

Wet cake

Water wash

Washing ML Recycled

Product

Lime

Salt Send to TSDF Calcium chloride solution (20-25%)used as a brine in

chilling plant

Water loss

(12) Unit Process for Chloro sulphonation such as ONCBPSC

Process: Charge CSA and main raw material (ONCB) and heat the reaction to reacting temperature. Drawn the reaction mass to ice water and filter the cake obtained. Filtrate is neutralize with lime to get salt and brine

Reaction Scheme

Cl

NO2

ClSO3H

Cl

NO2

SO2Cl

H2O

ONCB(157.5)

CSA(116.5)

ONCBPSC(256)

Water(18)



CSAONCB

Reactor

Drawning in water

Water

Filtration

ML (H2SO4 + HCl)

Wet cake

Water wash

Washing ML Recycled

Product

(12) Mass Balance for Unit Process Chloro sulphonation such as ONCBPSC

Lime

Salt Send to TSDF Calcium chloride solution (19-23%)used as a brine in

chilling plant

Water loss



(13) Unit Process For Hydrolysis such as ONCBPSAH


Process: Charge main raw material and water. Add sodium hydroxide and heat to reaction temperature. After completion of reaction shift the pH to 1-2 by 30% HCl and then cool and filter. Filtrate is treated in MEE to get salt.

NaOH NaCl

HCl

ONCBPSAM. Wt. 252.63�

Sodium HydroxideM. Wt. 40

Hydrochloric acidM. Wt. 36.5

ONCBPSAHM. Wt. 234.19

Sodium ChlorideM. Wt. 58.5

2NaOH 2NaCl

Where R = Nitro, SONH2


HCl (30%)ONCBPSAWater

Caustic Lye

Reactor

Filter

Water

Filtrate ML to MEE Water wash to MEE

Wet cake for washing Wet cake for drying

Product

(13) Mass Balance for Unit Process Hydrolysis ONCBPSAH

Water loss



(13) Unit Process For Hydrolysis such as DCPNA

Process: Charge main raw material (Ac-DCPNA) and water. Add sodium hydroxide and heat to reaction temperature. After completion of reaction and then cool and filter. Filtrate is treated in MEE to get salt.

Reaction Scheme

NHAc

Cl

Cl

NO2

NaOH

NH2

Cl

Cl

NO2

CH3COONa

AC-DCPNA(249)

Sodium hydroxide(40)

DCPNA(207)

Sodium acetatesalt(82)

Ac-DCPNAWaterCaustic Lye

Reactor

Filter

Water

Filtrate ML to MEE Water wash to MEE

Wet cake for washing Product

(13) Mass Balance for Unit Process Hydrolysis DCPNA



(14) Unit Process For Sulphonation such as DCASA


Process: Charge solvent, main raw material and sulfuric acid and heat the reaction to reacting temperature. Recover the solvent by steam distillation and filter the product. ML is send to ETP.

H2O

3,4-DCAM. Wt. 162

Sulfuric acidM. Wt. 98

DCASAM. Wt.242

WaterM. Wt. 18

H2O

Where R = NH2; Cl


ODCB (Recovered)ODCB (fresh)3,4-DCA

Sulfuric acid

SS reactor

Steam DistillationWater

Filtration

ML to ETP

Wet cake

Recover ODCBLoss ODCBWater loss

Product

(14) Mass Balance for Unit Process Hydrolysis such as DCASA



(14) Unit Process For Sulphonation such as FJD

Process: Charge solvent (ODCB), main raw material (VJD) and sulfuric acid and heat the reaction to reacting temperature. Recover the solvent by steam distillation and filter the product. ML is send to ETP.

Reaction Scheme

NH2

CONHCH2CH2SCH2CH2OH

O

O

H2SO4

NH2

CONHCH2CH2SCH2CH2OSO3H

O

O

H2O

VJD(272)

Sulfuric acid(98)

FJD(352)

Water(18)

ODCB (Recovered)ODCB (fresh)VJDSulfuric acid

SS reactor

Steam DistillationWater

Filtration

ML to ETP

Recover ODCB Loss ODCBWater loss

Product

(14) Mass Balance for Unit Process Hydrolysis such as FJD



(15) Unit Process for Neutralization such as Sodium Sulphite

Chemical reaction :

Process: Sulfur dioxide treated with caustic lye and water is distilled. The material is then cystalize and filtered. The solid sodium sulfite isobtained. The filtrate MLis then recycled in next batch distillation. The condensate from the reaction is used in process or in utility.

2NaOH Na2SO3 H2O

Sulfur dioxideM. Wt. 64

Sodium hydroxideM. Wt. 40

Sodium sulfiteM. Wt. 126

WaterM. Wt. 18

Sodium sulphite Soln (73%)ML recycle

Crystalizer

Filter

Filtrate MLRecycle in next batch

Sodium sulphite crystal

(15) Mass Balance for Unit Process Crystallization such as Sodium Sulphite

(16) Unit Process for Purification such as Hydro Chloric acid (30%)

Process: 30% HCl from scrubbing system is passed through resin (Agrion A 600 MP) and the colorless 30% HCl obtained.

Resin treatment tank filled with Resin

30% HCl

Washing of resin after4-5 treatment with water

White HCl

Resin recycled

Water Water washing

(16) Mass Balance for Unit Process for Purification such as Hydro Chloric acid (30%)



(17) Unit Process For Methoxylation such as CMA


Process: Charge methanol to the reactor and add sodium metal to it portion wise. Maintain till completion of sodium methoxide formation. Addsolvent and Remove methanol by simple distillation. Add main raw material slowly and maintain till completion of reaction. After completion ofreaction filter to remove the salt and extract the material in cyclo hexane. Distill the cyclo hexane layer to get product; main raw material andcyclo hexane.

�

CH3ONa NaCl

2,6-DichlorotolueneDCTM. Wt. 161

Sodium methoxideM. Wt. 54

3-Chloro-2-methylanisoleCMAM. Wt. 156.5

Salt58.5

CH3ONa NaCl

Where R = CH3; Cl




Reactor

Methanol (R) Methanol (F)Sodium (Metal) DMSO (R)DMSO (F)DCT (R)DCT (F)

Filter

(17) Mass Balance for Unit Process For Methoxylation such as CMA

Methanol recoveredMethanol loss

Salt to TSDF

Filtrate

Product Extraction & Layer Separation

Cyclo Hexane (R)Cyclo Hexane (F) DMSO layer recycle

DistillationCyclo Hexane recoveredCyclo hexane LossResidue

Product: CMA DCT

DMSO loss



ANNEXURE: 4 Water requirement letter from Notified industrial estate



ANNEXURE: 5

Quantity of Waste Water (liquid waste) generation and its management :

Sr. No. Particulars Existing Total after expansion

Normal Concentrated (high TDS)

Normal Concentrated (high TDS)

1 Domestic 5.0 0 8.0 0

2 Processing , Product washing & scrubber

14.2 15.91 23.07 24.3

3 Boiler 4.0 0 6.0 0

4 Cooling 3.0 0 10.0 0

5 Floor, equipment & container Washing

5.0 0 20.0 0

6 Total 31.2 15.91 67.07 24.3

7 Total Industrial 26.2 15.91 59.07 24.3

8 High TDS to MEE 0 15.91 0 24.3

9 High TDS to MEE from Unit:I

0 9.7 0 9.7

10 Total high TDS to MEE 0 25.61 0 34.0

11 Net Discharge to ETP 26.2 0 59.07 0

Note:

After proposed expansion, total fresh water consumption will be 206.86 m3/day.

After proposed expansion, Total industrial effluent generation will be 83.37 m3/day.

Out of which 83.37 m3/day of industrial effluent; 24.3 m3/day of high TDS effluent will be segregated and will be treated in MEE and high TDS effluent from Unit:I is 9.7 will be treated in MEE of Unit:II. Average 27.05 m3/day of MEE condensate will be recycled and 6.37 MT/day of salt will be disposed off into TSDF.

Average 59.07 m3/day of normal effluent will be treated in primary, secondary and tertiary effluent treatment plant and discharge into CETP Vapi for further treatment and disposal into tidal zone of River Damanganga to Arabian Sea.



Water Balance Diagram at Existing Scenario



& Scrubber: 26.35


30.11


Salt:3.63 Condensate::15.36

Blow Down: 4

MEE

Blow Down: 3.0 5.0



CETP, Vapi

Septic tank

For product: (Na2S2O3 ): 6.04


ETP: 4.0 ETP: 5.0ETP: 3.0

ETP:14.2


High TDS from Unit: I: 9.7

Water Balance Diagram After proposed Expansion



& Scrubber: 52.91


47.37


Salt: 6.37 Condensate: 27.05

Blow Down: 6

MEE

Blow Down: 10.0 20.0



CETP, Vapi

Septic tank


ETP: 6.0 ETP: 20.0ETP: 10.0


High TDS

from Unit: I: 9.7



Details of proposed Effluent Treatment Plant

Design Criteria : Product : Dyes Intermediates Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : 83.37 KL/day Max. Design Parameters : As under Effluent Characteristics:

No Effluent parameters

Process +

washing

Boiler +

cooling

Equip + floor + container

washing/scrubber

Combined normal effluent

Concentrated effluent

1 pH 5.50 8.1 6.5 4.50 5.2

2 Temperature 0 C. 32 30 30 31 32

3 Colour (Pt-Co) 600 60 180 400 500

4 SS, mg/l 417 121 456 356 400

5 TDS, mg/l 6322 3400 2850 5300 200000

6 COD value, mg/l 3650 10 1448.8 3108 32700

7 BOD value, mg/l 1020 124 350 988 8600

8 Chlorides, mg/l 820 120 280 636 120000

9 Sulphates, mg/l 1050 210 850 684 68000

10 O & G, mg/l 5.12 13.6 8.9 4.6 1.56

11 NH3-N, mg/l 35 ND 22.2 19 65

12 Phosphates, mg/l 1.2 ND 1.2 1.4 1.28

13 Phenolic , mg/l 2.4 ND ND 1.3 ND



Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install: Details of effluent treatment plant for normal industrial effluent stream:

Sr. No.

Name of Equipment Capacity in (KL) MOC

Existing Proposed

01 Oil & Grease Chamber 5.0 5.0 RCC

02 Collection Tank 23.0 23.0 RCC/TL

03 Equalization tank 50.0 50.0 RCC/TL

04 Neutralization Tank 2 Nos. 6.0 12.0 MSRL

05 Lime Dozing Tank 1.0 1.0 MS

06 FeSO4 Dozing Tank 0.2 0.2 HDPE

07 P. E. Dozing Tank 0.05 0.05 HDPE

08 Floculator 2.5 5.0 MS/FRP

09 Primary Lamella separator 7.0 14.0 MS/FRP

10 First stage Aeration tank with diffuser

100.0 100.0 RCC

11 Floculator 2.0 2.0 MS/FRP

12 Secondary Lamella separator 2.0 4.0 MS/FRP

13 second stage Aeration tank with diffuser

100.0 100.0 RCC

14 Secondary Clarifier 45.0 45.0 RCC

15 Holding Tank 40.0 40.0 RCC

16 Carbon Sand Filter Bed 1.6 3.2 MS

17 Sand Filter Bed 1.6 3.2 MS

18 Final discharge tank 2.0 2.0 HDPE

19 Air Blower with Condenser for Diffuser

400 m3/h 400 m3/h -

20 Transfer Pump 6 Nos. 6 Nos. CI

21 Filter Press 48 48 PP

22 Final Discharge Tank 5.0 5.0 HDPE

23 Energy Meter 1 No. 1 No. -

24 Discharge Flow Meter 1 No. 1 No. -

25 Online pH meter 1 No. 1 No. -

Details of effluent treatment plant for concentrated effluent stream:

S. No. Name of the unit Capacity MOC

1 Collection tank 10 kl RCC/TL

2 Neutralization tank 1 Kl MSRL

3 Filter nutsch 0.5 KL HDPE

4 Holding tank for treated effluent to MEE

10 kl HDPE





DETAILS OF MULTI EFFECT EVAPORATOR FOR HIGH TDS EFFLUENT

Concentrated Effluent (High TDS) generated per day to be evaporated in MEE:

Average quantity per day : 34 m3/day

S. No.

Name of Equipment

ID

MOC

Capacity

Retention time

Req. Prov.

1. Storage Tank V - 1 HDPE 30 KL 2 day 7 hrs

2. Condensate collection Vessel V - 2 M.S 500 L 1 h 2 hrs.

3. Salt Collection vessel V - 3 M.S. 500 L 3 hrs 10 hrs

4. Crystallizer V - 4 SS 6 KL 2 hrs 10 hrs

5. CALENDRIA-1 CL - 1 Titanium 28 M2 1 h 2 hrs



8. PRE-HEATER PHE-1 Titanium 2.2 M2 - -



11. Pump - 1 P - 1 CI 3 HP - -

12. Pump - 2 P - 2 CI 5 HP - -

13. Pump - 3 [ VCP ] P - 3 CI 10 HP - -

14. Pump - 4 P - 4 CI 5 HP - -

15. Nutsch Filter N - 1 MSRL 2.25 M2 - -

16. Centrifuge CF-1 SS 48 - -



ANNEXURE: 6

MEMBERSHIP CERTIFICATE OF CETP, VAPI



ACCEPTANCE LETTER OF CETP AUTHORITY FOR ACCEPTANCE OF ADDITIONAL EFFLUENT



MEMBERSHIP CERTIFICATE FOR TSDF & CHIWF





ANNEXURE: 7



ANNEXURE: 8 Copy of plot allotment letter issued by GIDC





COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA



ANNEXURE: 9 A schematic representation of the feasibility drawing



ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED

EXPANSION

The details of air pollution & its control measures at existing & after proposed expansion are as under;

Flue gas emission: At present, the unit is having one number of coal fired 7 TPH capacity of steam boiler and two

numbers of HSD fired D G Set of 250 KVA capacity each. Adequate height of chimney and MDC followed by bag filter provided to the boiler and adequate height of chimney is provided to D G set.

After proposed expansion, there will be no addition of boiler, as existing boiler having spare capacity to take care of additional steam requirement.

Process gas emission:

At present, there is a generation of process gas like SO2, NOx, HCl, Cl2 and NH3 from sulphonation, Nitration, Chlorination, Amination and Oleum storage tank. To scrub all the said gases we have provided total five numbers of two stage scrubbing system and 11 meters height of vent.

After proposed expansion, there will be a generation of process gas emission like SO2, NOx, HCl, Cl2 and NH3 from sulphonation, Nitration, Chlorination, Amination and Oleum storage tank. To scrub all the said gases we will utilize existing five numbers of two stage scrubbing system and 11 meters height of vent. Thus after proposed expansion, there will be no addition of new scrubbing system.(Detail of Air pollution control measures is attached as Annexure-10)

S. No. Particulars Details Remarks

Existing Proposed Total after expansion

FLUE GAS EMISSION

1.0 Steam Boiler, TPH

7 0 7 Existing

1.1 Fuel used Imported coal 0 Imported coal

1.2 Fuel Consumption, kg/h

1050 0 1050

1.3 APC MDC & bag filter

0 MDC & bag filter

1.4 Height & Dia of chimney

30 m 0 30 m

2.0 D G Set: I 250 KVA 0 250 KVA Standby

2.1 Fuel used HSD 0 HSD

2.2 Fuel Consumption 40 kg/h 0 40 kg/h

2.3 APC Exhaust 0 Exhaust

2.4 Height of exhaust 11 meters 0 11 meters

3.0 D G Set: II 250 KVA 0 250 KVA Standby

3.1 Fuel used HSD 0 HSD

3.2 Fuel Consumption 40 kg/h 0 40 kg/h

3.3 APC Exhaust 0 Exhaust

4.0 D G Set: III 0 500 KVA 500 KVA Standby

4.1 Fuel used 0 HSD HSD



4.2 Fuel Consumption 0 80 kg/h 80 kg/h

4.3 APC 0 Exhaust Exhaust

PROCESS GAS EMISSION

5.0 Stack attached to Chlorinator Chlorinator

Chlorinator Existing

5.1 Pollutant HCl,Cl2 HCl,Cl2 HCl,Cl2

5.2 APC provided Two stage water followed

by alkali scrubber

Two stage water

followed by alkali scrubber

Two stage water

followed by alkali

scrubber

5.3 Height of vent 11 m 11 m 11 m

5.4 Expected emission

HCl: <20 mg/m3

Cl2: < 5 mg/m3

HCl: <20 mg/m3 Cl2: < 5 mg/m3

HCl: <20 mg/m3 Cl2: < 5 mg/m3

6.0 Stack attached to Sulphonator Sulphonator

Sulphonator Existing

6.1 Pollutant SO2 SO2 SO2

6.2 APC provided Two stage alkali scrubber

Two stage alkali

scrubber

Two stage alkali

scrubber



SO2: <40 mg/m3

SO2: <40 mg/m3

SO2: <40 mg/m3

7.0 Stack attached to Nitrator Nitrator Nitrator Existing

7.1 Pollutant NOx NOx NOx

7.2 APC provided Two stage alkali scrubber

Two stage alkali

scrubber

Two stage alkali

scrubber



NOx: <25 mg/m3

NOx: <25 mg/m3

NOx: <25 mg/m3

8.0 Stack attached to Amidator Amidator Amidator Existing

8.1 Pollutant NH3 NH3 NH3

8.2 APC provided Two stage Water scrubber

Two stage Water

scrubber

Two stage Water

scrubber



NH3: <175 mg/m3

NH3: <175

mg/m3

NH3: <175 mg/m3

9.0 Stack attached to Oleum Storage tank

Oleum Storage

tank

Oleum Storage tank

Existing

9.1 Pollutant SO2 SO2 SO2

9.2 APC provided Acid followed by alkali scrubber

Acid followed by alkali scrubber

Acid followed by alkali scrubber





SO2: <40 mg/m3

SO2: <40 mg/m3

SO2: <40 mg/m3

1. Specifications of Falling Film Graphite HCl Scrubber: Type : Parallel flow falling film type Tube side : HCl gas, Cl2 gas, water, HCl solution Shell side : cooling water HCl/Cl2 gas /hour : 100 kg/h Scrubbing media : water Heat of solution kcal/h : 10000 kcal/h Cooling water required at 40 approach : 2.5 m3/h No of tubes required : 65 tubes, 20 dia x 2.5 m length HTA required : 10 m2 Diameter of scrubber : 350 mm Overall length : 3000 mm MOC tubes : Glass MOC shell : HDPE/Graphite Specifications of tails tower Inlet HCl : 50 kg/h Inlet Cl2 gas : 2 kg/h Scrubbing media : Water, 58 kg /h, to be fed to main scrubber Tower dia : 350 mm Packed length : 1500 mm Overall length : 2000 mm MOC : FRP Packing dia : 40 mm PP Outlet HCl : 0.0025 KG/h Chlorine gas : 6 kg/h Specifications of Alkali Ventury Inlet HCl : 0.0025 kg/h Inlet Cl2 gas : 2 kg/h Scrubbing media : 10 % dilute alkali Size of Ventury : 150 dia x 1250 mm ht. MOC : FRP Alkali circulation tank : 2000 liter HDPE Circulation pump : 2.5 m3/h S/S Vent diameter : 150 mm Height of vent : 11 meters



2. Specification of SO2 Gas scrubbing system

Sr. No.

Name of the Equipment Capacity

1 Scrubber size 420 mm dia x 5000 mm

2 MOC of scrubber HDPE

3 Type of packing PP Racing ring

4 Height of packing 3500 mm

5 Alkali Circulation tank 5 m3, HDPE

6 Alkali circulation pump 3 HP

7 ventury scrubber 300 dia x 3000

8 Alkali circulation tank 1 m3

9 Alkali circulation pump 10 m3/h

10 Height of vent 11 meter

11 Dia of vent 150 mm

Specification of Ammonia gas scrubbing system

Sr. No.

Name of the Equipment Capacity

1 Ammonia gas Cooler 5 m2, with cooling water

2 Height of scrubber 420 mm dia x 2500 mm height

3 MOC of scrubber PP/FRP

4 Type of packing PP Racing ring

5 Height of packing 2500 mm

6 Water Circulation tank 5m3, MS jacketed with chilled water cooling

7 Water circulation pump 3 HP

8 Liquor ammonia cooler 10 m2

9 Capacity of Blower 3 HP

10 Height of vent 11 meter

11 Dia of vent 150 mm

4. Specification of NOx scrubbing system: Scrubber dia : 400 mm Packed length : 3000 mm Overall scrubber height : 4500 mm MOC of scrubber : PP/FRP Scrubbing media : 10 % NaOH Dilute alkali circulation tank : 2000 liter HDPE Alkali circulation pump : 3 m3/h, SS, 10 m head Vent size : 200 mm, 11 m height.



5. Specification of Scrubber attached to Oleum Storage tank:

No Details of Two stage Scrubber Size

1 Acid pot 500 liters, HDPE

2. Packed height in meters 2 mt.

3. Dia in meters 0.3

4. Circulating liquid Dilute caustic

5. Size of tank 100 liters, HDPE

6. Capacity of the pump ,m3/h 3 HP

7. Capacity of the blower, Nm3/h 1500

8. Vent diameter in mm 200

9. Height of the vent from ground 11 mt

10 Sampling arrangement provided

Details of Multicyclone separator followed by bag filter attached to Boiler

Particular Details

Capacity of Boiler 7 tones/h

Type of fuel used Steam coal + lignite

Quantity used 1050 kg/h

Gas volume 10000 Am3/h

Size of MDC 915 x 915 x 1350 mm

MOC MS

Number of clones 16

Size of clones 125 x 80 NB

Gas temperature 150 0C

Dust load 15 gms/m3

Particle size Above 5 microns

Filtration area 160 m2

Actual filter rate 1.04 m3/m2/min

Pressure drop 150 mm Wg

Nos. of Bag filter 121(Ryton)

Size of bags 116 mm dia x 3660 mm length

Rotary valve 200 mm, CI

Rotor rpm 20

Height of Chimney 35 meters ( common)

Dia of chimney 900 mm



Primary

Circulation

Tank

Primary

HClSCRUBBER

Secondary

Circulation

Tank

Gas From

Plant

Tail

SCRUBBERFor HCl

Un Condensed HCl

gas

Caustic Lye

Circulation

Tank

Header

To

Atmosphere

EXISTING HCl/CL2 SCRUBBER SYSTEM

V

E

N

T

U

R

Y



Primary

Circulation

Tank

Primary

HCl

SCRUBBER

Secondary

Circulation

Tank

Gas From

Plant

Tail

SCRUBBER

For HCl

Un

Condense

d HCl

gas

Caustic Lye

Circulation

Tank

Header

To

Atmosphere

PROPOSED HCl & SO2 SCRUBBER SYSTEM

V

E

N

T

U

R

Y

NaHSO3

Manufacturing

Reactor



PG

DILUTE

Ammonia

VENT

REACTOR

NH3

SCRUBBER

PACKED

TOWER

VENTURY

SCRUBBER

CHW

22 %

AMMONIA

Ammonia Gas

Liquor ammonia

Storage tank

Recycled to process

TWO STAGE AMMONIA SCRUBBING SYSTEM



NRV

PG

DILUTE NaOH

10 %

NaOH

PACKED

COLUMN

NOx

SCRUBBER

NaOH LYE

VENTURY SCRUBBER

BLOWER

STACK

NITRATION

REACTOR

NOx FUMES

NITRATION REACTORS

TWO STAGE NOx SCRUBBING SYSTEM

FOR NITRATION REACTORS

MIXED ACID



Sulphonator

Oleum StorageTank

Sulfuric AcidTrap Tank

500 Lit, HDPE CausticSolution,

100 Lit, HDPE

Alkali circulation pump

Blower

ACID & ALKALI SCRUBBER ATTACHED TO OLEUM STORAGE

Alkali Scrubber



ANNEXURE 11 COPY OF ENVIRONMENTAL CLEARANCE FOR EXISTING PLANT

Baart sarkar Payaa-varNa evaM vana maM~alaya

Government of India Ministry of Environment & Forests

(IA Division) Paryavaran Bhawan

CGO Complex, Lodhi Road New Delhi – 110 003

E-mail: [email protected] Telefax: 011: 2436 3973

F. No. J-11011/345/2008- IA II (I) Dated: September 19, 2008

To, The Director M/s Sarna Chemicals Pvt. Ltd (Unit:II). Plot no. 805/2 & 3 , III phase, GIDC Vapi, Dist. Valsad, Gujarat-396195

e-mail : [email protected]

Sub: Expansion of Dyes intermediates manufacturing unit at plot no 1708 & A2-1715, 3rd

phase, GIDC Vapi, dist. Valsad, Gujarat by M/s Sarna chemicals Pvt. Ltd. - Environmental Clearance regd.

Sir,

This has reference to your letter no. nil dated 22.04.2008 along with form 1 and prefeasibility report on the above mentioned subject seeking environmental clearance under the Environment Impact Assessment Notification, 2006. 2. The Ministry of Environment and Forests has examined your proposal. It is noted that M/s Sarna chemicals Pvt. Ltd. have proposed for expansion of Dyes intermediates manufacturing unit. The unit is located at GIDC Vapi which is identified as on of the critically polluted areas by the CPCB. River Damanganga flows at a distance of 3 Kms. Company is in position of 5500 m2 of land area and additional land of 2702 m2 will be utilized for the proposed expansion. Total plant area after the proposed expansion will be 8250 m2. Green belt will be developed in the 180 m2 of land area. No eco-sensitive areas are located within 10 km radius of the plant. The details of the products to be manufactured are annexed. Cost of the project is Rs. 619.00 lakhs of which Rs. 55.00 lakhs is utilized for environmental protection measures. 3. Total water requirement after the proposed expansion will be 94.6 m3/day which will be sourced from GIDC, Vapi. Waste water generation will be 42.45 m3/day, out of which 2.05 m3/day high TDS effluent will be evaporated in proposed evaporation system & 40.4 m3/day of dilute effluent stream will be treated in primary, secondary & tertiary effluent treatment plant & treated effluent will be sent to CETP, Vapi. Three stage scrubbing system will be provided for control of HCl, Cl2 and SO2 emissions. Water scrubber followed by acid tank will be provided to control the NH3 emission. NOx emission will be controlled by 2-stage scrubbing system. Oleum storage tanks

mailto:[email protected]



will be provided by acid pot followed by packed alkali tower. To control the particulate emissions from the coal fired boiler, multi cyclone separator and bag filter will be

-2- provided. The gaseous emissions will be dispersed through a stack 30m height. IPA, Toluene, Methanol, MCB, EDC will be used as solvents. Solvents will be recovered & reused. All reactors will be connected to condensers with chilled water circulation. Power requirement of 350 KVA is sourced from DGVCL. No additional power is required for the proposed expansion. Stand by power supply will be met from two numbers of D G set having capacity 250 KVA each. Fuel for DG set will be HSD (40 lts/h) and boiler will be coal (750 kg/h.).

3. After proposed expansion, iron oxide waste generated from the process (24 MTPM ) will be disposed to TSDF Vapi. Organic Distillation residue (3.73 MTPM) will be sent to common incinerator of VWEMCL Vapi. ETP waste (4.0 MTPM) will be sent to VWEMCL Vapi. Salt from evaporator (19.6 TPM) will be sent to actual users/ VWEMCL Vapi. Salt from the process (256 TPM) and sludge from wet scrubber (0.010 TPM ) will be sent to common TSDF, Vapi for final disposal. Discarded containers (150 Nos/Month) will be reused for packing of finish products or sold to authorized recyclers. Waste oil/used oil ( 0.01 TPM ) will be sold to registered re-refiner.

4. The Dye intermediates manufacturing unit are listed at serial no. 5(f) of schedule of EIA Notification, 2006 and categorized under “A” or “B” category depending upon the location of the plant outside or inside the notified industrial area. In instant case the plant is located within the notified industrial area GIDC Vapi and covered under category “B”. But the Vapi is an identified critically polluted area hence as per general condition of EIA Notification, 2006 the proposal has been appraised at centre. The proposal was considered by the Expert Appraisal Committee in its 84rd meeting held on 19-21st August, 2008.The public consultation of the project is not required as per para 7 (i)-III (b) Stage (3) – public consultation of EIA Notification, 2006. 5. Based on the information submitted by the Project Authorities, the Ministry of Environment and Forests hereby accords the environmental clearance to the above project under the provisions of EIA Notification dated 14th September, 2006 subject to compliance of the following specific and general conditions: A SPECIFIC CONDITIONS: i) The Effluent generation shall not exceed 42.45 m3/d. The effluent shall be segregated into

high TDS (2.05 m3/d) and Low TDS streams (40.40 m3/d) and 1.60 m3/d condensate from the triple effect evaporator. The dilute effluent stream after primary, secondary and tertiary treatment shall meet the industry specific discharge standards notified under Environment (Protection) Act, 1986. The high TDS effluent stream shall be treated in triple Effect Evaporator followed by treatment in ETP.

ii) GPCB shall not permit any new discharges from new industries or expansion of existing industries in the area that lead to CETP Vapi till the said CETP’s and FETP meet the required standards and have adequate hydraulic capacities.

iii) The company shall obtain Authorization under the Hazardous Waste (Management and

Handling) Rules, 2003 for management of Hazardous wastes and prior permission from GPCB shall be obtained for disposal of solid / hazardous waste in the TSDF.

iv) The process emissions in the form of HCl, Cl2, SO2, NH3 and NOx , shall be controlled by scrubber. Graphite scrubber followed by water and alkali scrubber for control of HCl and Cl2, alkali scrubber for SO2 and NOx, Water scrubber for NH3 and acid followed by alkali scrubber for Oleum storage tank and SOx shall be install to scrub the emissions. Monitoring arrangements shall be provided in the vents/stacks and emissions shall conform to the



prescribe standards. Monitoring of sources and fugitive emissions in the work zone environment, product, raw materials storage area etc. shall be regularly carried out. The emissions shall conform to the limits imposed by GPCB. The monitoring reports shall be submitted to the SPCB/CPCB/ROMoEF.

v) For control of fugitive emission following steps shall be followed :

A. Closed handling system shall be provided for chemicals. B. Reflux condenser shall provided over reactor. C. System of leak detection and repair of pump/pipeline based on preventive maintenance. D. The acids shall be taken from storage tanks to reactors through closed pipeline. Storage

tanks shall be vented through trap receiver and condenser operated on chilled water. vi) Solvent management shall be as follows :

A. Reactor shall be connected to chilled brine condenser system B. Reactor and solvent handling pump shall have mechanical seals to prevent leakages. C. The condensers shall be provided with sufficient HTA and residence time so as to

achieve more than 95% recovery D. Solvents shall be stored in a separate space specified with all safety measures. E. Proper earthing shall be provided in all the electrical equipment wherever solvent

handling is done. F. Entire plant shall be flame proof. The solvent storage tanks shall be provided with

breather valve to prevent losses. vii) During transfer of materials spillages shall be avoided and garland drains be constructed to

avoid mixing of accidental spillages with domestic waste and storm drains. viii) The project authorities shall develop greenbelt in 33% of plant area as per the guidelines of

CPCB to mitigate the effect of fugitive emission. ix) Adequate financial provision shall be made in the budget of the project for implementation of

the above suggested environmental safeguards. Fund so earmarked shall not be diverted for any other purposes.

x) Occupational health surveillance of the workers shall be done on a regular basis and records

maintained as per the Factories Act. xi) The company shall make the arrangement for protection of possible fire hazards during

manufacturing process in material handling. xii) The project authorities shall undertake measures for rainwater harvesting and ground water

recharge.

GENERAL CONDITIONS i. The project authorities shall strictly adhere to the stipulations of the SPCB/state government

or any statutory body. ii. No further expansion or modifications in the plant shall be carried out without prior approval

of the Ministry of Environment and Forests. In case of deviations or alterations in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any.



iii. The project authorities shall strictly comply with the rules and regulations under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 as amended. Authorization from the SPCB shall be obtained for collection, treatment, storage, and disposal of hazardous wastes.

iv. Ambient air quality monitoring stations shall be set up in the downwind direction as well as

where maximum ground level concentration are anticipated in consultation with the State Pollution Control Board.

v. For control of process emissions, stacks of appropriate height as per the Central Pollution

Control Board guidelines shall be provided. The scrubbed water shall be sent to ETP for further treatment.

vi. The company shall undertake following Waste Minimization measures :-

Metering of quantities of active ingredients to minimize waste. Reuse of by-products from the process as raw materials or as raw material

substitutes in other processes. Maximizing recoveries Use of automated material transfer system to minimize spillage. Use of Closed Feed system into batch reactors.

vii) The project authorities must strictly comply with the rules and regulations with regard to

handling and disposal of hazardous wastes in accordance with the Hazardous Wastes (Management and Handling) Rules, 2003. Authorization from the SPCB shall be obtained for collections/treatment/ storage/disposal of hazardous wastes.

viii. The overall noise levels in and around the plant area shall be kept well within the standards

(85 dBA) by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. The ambient noise levels shall conform to the standards prescribed under Environment (Protection) Act, 1986 Rules, 1989 viz. 75 dBA (day time) and 70 dBA (night time).

ix. A separate Environmental Management Cell equipped with full fledged laboratory facilities

shall be set up to carry out the environmental management and monitoring functions.

x. The implementation of the project vis-à-vis environmental action plans shall be monitored by Ministrys Regional Office /SPCB / CPCB. A six monthly compliance status report shall be submitted to monitoring agencies.

-5- xi. The project proponent shall inform the public that the project has been accorded

environmental clearance by the Ministry and copies of the clearance letter are available with the SPCB and may also be seen at Website of the Ministry at http://envfor.nic.in. This shall be advertised within seven days from the date of issue of the clearance letter, at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the Ministry`s Regional Office.

xii. The project authorities shall inform the Regional Office as well as the Ministry, the date of

financial closure and final approval of the project by the concerned authorities and the date of start of the project.

6. The Ministry may revoke or suspend the clearance, if implementation of any of the above conditions is not satisfactory.

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7. The Ministry reserves the right to stipulate additional conditions, if found necessary. The company in a time bound manner shall implement these conditions.

8. Any appeal against this environmental clearance shall lie with the National Environment Appellate Authority, if preferred within a period of 30 days as prescribed under Section 11 of the National Environment Appellate Authority Act, 1997.

9. The above conditions will be enforced, inter-alia under the provisions of the Water (Prevention & Control of Pollution) Act, 1974, Air (Prevention & Control of Pollution) Act, 1981, the Environment (Protection) Act, 1986, Hazardous Wastes (Management and Handling) Rules, 2003 and the Public Liability Insurance Act, 1991 along with their amendments and rules.

(Dr. P L Ahujarai) Director

Copy to : - 1. The Secretary, Department of Environment and Forests, Govt. of Gujarat, Secretariat

Gandhinagar-382010 2. The Chairman, Central Pollution Control Board, Parivesh Bhavan, CBD-cum-Office Complex,

East Arjun Nagar, New Delhi ? 110032. 3. The Chairman, Gujarat State Pollution Control Board, Paryavaran Bhavan, Sector-10A,

Gandhinagar-382010. 4. The Chief Conservator of Forests (Central), Ministry of Environment & Forests, Regional Office

(WZ), Ravishankar Nagar, Link Road-3 , Bhopal- 462016, M.P. 5. Adviser IA(II), Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New

Delhi-110003 6. Monitoring Cell, Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New

Delhi-110003. 7. Guard file. 8. Record file

(Dr. P L Ahujarai) Director



ANNEXURE 12

COPY OF EXISTING CCA









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PRE-FEASIBILITY REPORT - …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/20_Jan... · Unit Process: Formylation with Vilsmeier Haack Reagent Such as ... CMA 3-chloro-2-methyl