PROPOSED PESTICIDE INTERMEDIATES, SPECIALTY CHEMICALS ...environmentclearance.nic.in/writereaddata/Online/TOR/0_0_07_Aug_… · 1 form-i for proposed pesticide intermediates, specialty

1

FORM-I

For

PROPOSED PESTICIDE INTERMEDIATES, SPECIALTY

CHEMICALS, PHARMACEUTICAL INTERMEDIATES AND

PERFUMERY CHEMICAL UNIT

of

M/s. V INDIA CHEMICAL INDUSTRIES PVT. LTD.

Plot No. CH-11/A, Dahej-I, Dahej Industrial Estate,

Tal: Vagra, Dist: Bharuch, Gujarat

2

APPENDIX I

FORM 1 (I) Basic Information

Sr.

No.

Item Details

1. Name of the Project/s V India Chemical Industries Pvt. Ltd.

2. S.No. in the Schedule 5 (f)

3. Proposed capacity/area/length/tonnage

to be handled/command area/lease

area/number of wells to be drilled

Proposed Chemicals: 725 MT/Month (Please refer

annexure-2)

No bore well to be drilled within the premises.

4. New/Expansion/Modernization New

5. Existing capacity/area etc. N.A.

6. Category of project i.e. ‘A’ or ‘B’ ‘A’

7. Does it attract the general condition? If

yes, please specify.

N.A.

8. Does it attract the specific condition? If

yes, please specify.

N.A.

9. Location Dahej Industrial Area, Dahej, Tal: Vagra, Dist: Bharuch,

Gujarat

Plot/Survey/Khasra No. Plot. No. CH-11/A

Village GIDC, Dahej - I

Tehsil Vagra

District Bharuch

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Nearest Railway Station: Bharuch: 40 km

Nearest Airport: Baroda: 92 km

11. Nearest Town, city, District Headquarters

along with distance in kms.

Nearest town: Bharuch: 40 km, Nearest District Head

quarter: Bharuch: 40 km

12. Village Panchayats, zilla parishad,

Municipal corporation, Local body

(Complete postal addresses with

telephone nos. to be given)

Village: Dahej, Tal: Vagra, Dist: Bharuch, Gujarat.

13. Name of the applicant V India Chemical Industries Pvt. Ltd.

14. Registered address Plot No. CH-11/A, Dahej–I, Dahej Industrial Estate, Tal:

Vagra, Dist: Bharuch, Gujarat.

15. Address for correspondence: V India Chemical Industries Pvt. Ltd.

D/G-12, Sardar Patel Complex,

Station-GIDC Road, Nr. State Bank of India,

GIDC, Ankleshwar-393002,

Dist: Bharuch (Guj.)

Name Mr. Ankit Shah

3

Designation (Owner/Partner/CEO) Director

Address Plot No. CH-11/A, Dahej–I, Dahej Industrial Estate, Tal:

Vagra, Dist: Bharuch, Gujarat.

Pin Code 392130

E-Mail [email protected]

Telephone No. +919879104761

Fax No. --

16. Details of Alternative Sites examined, if

any location of these sites should be

shown on a topo sheet.

No

17. Interlinked Projects No

18. Whether separate application of

interlinked project has been submitted?

Not applicable

19. If Yes, date of submission Not applicable

20. If no., reason Not applicable

21. Whether the proposal involves

approval/clearance under: If yes, details

of the same and their status to be given.

(a) The Forest (Conservation) Act,

1980?

(b) The Wildlife (Protection) Act,

1972?

(c) The C.R.Z Notification, 1991?

Not applicable, as the project is located in industrial

estate.

22. Whether there is any Government

order/policy relevant/relating to the site?

No

23. Forest land involved (hectares) No

24. Whether there is any litigation pending

against the project and/or land in which

the project is propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if

any and its relevance with the proposed

project.

No

4

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which will

cause physical changes in the locality (topography, land use, changes in water bodies,

etc.)

Sr.

No.

Information/Checklist confirmation Yes

/No?

Details thereof (with approximate

quantities / rates, wherever possible)

with source of information data

1.1 Permanent or temporary change in land

use, land cover or topography including

increase in intensity of land use (with

respect to local land use plan)

No Proposed Project is within GIDC Estate,

Dahej

1.2 Clearance of existing land, vegetation

and buildings?

Yes Minor site clearance activities shall be

carried out to clear shrubs and weed.

1.3 Creation of new land uses? No --

1.4 Pre-construction investigations e.g. bore

houses, soil testing?

No --

1.5 Construction works? Yes Approved plan for construction is

attached as Annexure: 1.

1.6 Demolition works? No --

1.7

Temporary sites used for construction

workers or housing of construction

workers?

No --

1.8 Above ground buildings, structures or

Earthworks including linear structures,

cut and fill or excavations

Yes Approved plan for construction is

attached as Annexure: 1.

1.9

Underground works including mining or

tunneling?

No --

1.10 Reclamation works? No --

1.11 Dredging? No --

1.12 Offshore structures? No --

1.13 Production and manufacturing Yes Manufacturing process, chemical

reaction and mass balance is attached

as Annexure: 3.

1.14 Facilities for storage of goods or

materials?

Yes Dedicated storage area for storage of

Raw Materials and finished products,

solvents, etc. shall be provided.

1.15

Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes Effluent Treatment Plant, MEE and SBT

will be installed to treat effluent so as to

achieve the GPCB norms.

5

Option-1: Treated effluent will be

disposed into CETP as soon as soon as

CETP starts working.

Option-2: Treated effluent after will be

recycled back in plant premises for

various purpose.

Details of water consumption & effluent

generation with segregation of effluent

streams are attached as Annexure: 4.

Details of proposed Effluent Treatment

scheme are attached as Annexure: 5.

Details of Solid Hazardous waste

generation and disposal is attached as

Annexure: 6.

1.16

Facilities for long term housing of

operational workers?

Yes Local operational staff of about 40

people shall be employed.

1.17 New road, rail or sea traffic during

construction or operation?

No --

1.18 New road, rail, air waterborne or other

airports etc?

No --

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No --

1.20 New or diverted transmission lines or

pipelines?

No --

1.21

Impoundment, damming, converting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No --

1.22 Stream crossings? No --

1.23

Abstraction or transfers or the water

form ground or surface waters?

Yes No ground water shall be used. The

requirement of raw water shall be met

through GIDC Water Supply.

1.24

Changes in water bodies or the land

surface affecting drainage or run-off?

No --

1.25

Transport of personnel or materials for

construction, operation or

decommissioning?

No --

1.26 Long-term dismantling or

decommissioning or restoration works?

No There is no dismantling of any sort. Not

applicable.

1.27 Ongoing activity during No No Impact on the Environment

6

decommissioning which could have an

impact on the environment?

1.28

Influx of people to an area in either

temporarily or permanently?

No This is a well developed Industrial Area

and due to project, @ 40 people shall be

employed for operation.

1.29 Introduction of alien species? No

1.30 Loss of native species of genetic

diversity?

No

1.31 Any other actions? No

2. Use of Natural resources for construction or operation of the Project (such as land, water,

materials or energy, especially any resources which are non-renewable or in short supply):

Sr.

No

Information/checklist confirmation Yes/

No?

Details there of (with approximate

quantities/rates, wherever possible) with

source of information data

2.1 Land especially undeveloped or

agriculture land (ha)

No

2.2 Water (expected source & competing

users) unit: KLD

Yes Water requirement will meet through the

GIDC Water Supply. For detailed water

balance refer Annexure – 4.

2.3 Minerals (MT) No Not applicable

2.4

Construction material -stone,

aggregates, sand / soil (expected

source MT)

Yes Company shall use Sand, stone, Cement

and Structural Steel for Construction as

required.

2.5 Forests and timber (source - MT) No No wood shall be used as construction

material or as a fuel.

2.6

Energy including electricity and fuels

source, competing users Unit: fuel

(MT), energy (MW)

Yes Power required from GEB is 250 KVA .

D.G. Set = 100 KVA x 2 (For Emergency

only)

Fuel

Fuel for proposed boilers:

Natural Gas = 1,40,000 SCM/Month or

Agro Waste = 10 MT/Day

HSD = 50 Liter/Hr.

2.7 Any other natural resources (use

appropriates standard units)

No --

7

3. Use, storage, transport, handling or production of substances or materials, which could be

harmful to human health or the environment or raise concerns about actual or perceived risks

to human health.

Sr.

No.

Information / Checklist confirmation Yes/

No?


quantities / rates wherever possible)


3.1 Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes

Please refer Annexure : 8.

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No Not applicable as site is located in Dahej

Industrial Area, Dahej.

3.3 Affect the welfare of people e.g. by

changing living conditions?



3.4

Vulnerable groups of people who could

be affected by the project e.g. hospital

patients, children, the elderly etc.,



3.5 Any other causes No

4. Production of solid wastes during construction or operation or decommissioning MT/month)

Sr.

No.

Information/Checklist confirmation Yes/

No?




4.1 Spoil, overburden or mine wastes No --

4.2

Municipal waste (domestic and or

commercial wastes) No --

4.3

Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Please refer Annexure: 6

4.4 Other industrial process wastes Yes Please refer Annexure: 6

4.5 Surplus product Yes Please refer Annexure: 3

4.6

Sewage sludge or other sludge from

effluent treatment

Yes Please refer Annexure: 6

4.7 Construction or demolition wastes No Construction waste shall be utilized for

leveling, land filling in the premises.

4.8 Redundant machinery or equipment No --

4.9 Contaminated soils or other materials No --

4.10 Agricultural wastes No --

4.11 Other solid wastes No Please refer Annexure: 6

8

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr.

No.


No?


quantities/rates, wherever possible)


5.1 Emissions from combustion of fossil

fuels From stationary or mobile sources

Yes Details of flue & process gas emission

are attached as Annexure: 7

5.2 Emissions from production processes No Reactors shall be connected to

common scrubber system.

Details of emission levels from process

are attached as Annexure: 7.

Details of Air Pollution Control

measures are attached as Annexure:

7.

5.3 Emissions from materials handling

including storage or transport

Yes All liquid raw materials shall be

procured in bulk tankers and shall be

transferred through a closed circuit

pipe lines by pumps.

Solid raw material shall be handled in

closed charging rooms with proper

ventilation and charged through close

pipeline into reactors.

5.4 Emissions from construction activities

including plant and equipment

No Utmost care will be taken during

construction activity and water

sprinklers shall be utilized whenever

necessary.

5.5

Dust or odours from handling of

materials including construction

materials, sewage and waste

No All the waste shall be stored in

designated places and shall be

transported to TSDF or Cement

Industries/Incineration Site in their

own approved closed vehicles.

5.6 Emissions from incineration of waste No Not applicable as the Incinerable waste

shall be sent to Cement

Industries/common incineration

system.

5.7 Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No No open burning of waste will be

carried out.

5.8 Emissions from any other sources No

9

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.


No?

Details there of (with approximate

Quantities /rates, wherever possible)

With source of source of information data

6.1

From operation of equipment e.g.

engines, ventilation plant, crushers

Yes There are few activities due to which noise

would be generated. The equipments

resulting in noise generation are machinery

of plant and Diesel generator. Adequate

noise control measures will be provided

whenever required.

Proper and timely oiling, lubrication and

preventive maintenance will be carried out

for the machineries & equipments to

reduce noise generation.

Use of PPE like ear plugs and ear muffs will

be made compulsory near the high noise

generating machines.

Noise monitoring shall be done regularly in

plant area.

The D.G. Set will be installed in a closed

room and provided with acoustic

enclosure.

The unit will increase the plantation

species in the proposed greenbelt within

the premises which will prevent the noise

pollution in surrounding area.

6.2 From industrial or similar processes Yes All machinery / equipment shall be well

maintained, shall have proper foundation

with anti vibrating pads wherever

applicable and noise levels within

permissible limits.

Acoustic enclosures shall be provided for

DG set.

6.3 From construction or demolition No

6.4 From blasting or piling No

6.5 From construction or operational

traffic No

6.6 From lighting or cooling systems No

6.7 From any other sources No Acoustic enclosures shall be provided for

DG set.

10

7. Risks of contamination of land or water from releases of pollutants into the ground or

into sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No


No?




7.1

From handling, storage, use or spillage

of hazardous materials

Yes All the raw material shall be stored

separately in designated storage area

and safely. Bund walls shall be provided

around raw materials storage tanks for

containing any liquid spillage.

Other materials shall be stored in bags /

drums on pallets with concrete flooring

and no spillage is likely to occur. Please

refer Annexure : 8.

7.2

From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No Sewage effluent shall be treated in

Septic Tank/Soak Pit.

The treated effluent shall be sent to

CETP for further treatment or reused in

plant premises.

7.3

By deposition of pollutants emitted to

air into the land or into water

No The factory is located in Dahej

Industrial Area, Dahej. The treated

effluent shall be sent to CETP or reused

in plant premises.

7.4 From any other sources No Not applicable

7.5 Is there a risk of long term build up of

pollution in the environment from

these sources?

No

Full- fledged Environmental

Management System (EMS) will be

installed. i.e. ETP, Air Pollution Control

systems, Solid Hazardous Waste

Handling and Management as per

norms, etc. which will eliminate the

possibility of building up of pollution.

11

8. Risks of accident during construction or operation of the Project, which could affect

human health or the environment:

Sr.

No

Information/Checklist confirmation

Yes/

No?




8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes The risk assessment will be carried out

and all mitigative measures shall be

taken to avoid accidents.

8.2 From any other causes No Not applicable

8.3 Could the project be affected by natural

disasters causing environmental

damage (e.g. floods, earthquakes,

landslides, cloudburst etc)?

No --

9. Factors which should be considered (such as consequential development) which could lead

to environmental effects or the potential for cumulative impacts with other existing or

planned activities in the locality

Sr.

No.


No?




9.1 Lead to development of supporting.

laities, ancillary development or

development stimulated by the project

which could have impact on the

environment e.g.:

* Supporting infrastructure (roads,

power supply, waste or waste water

treatment, etc.)

• housing development

• extractive industries

• supply industries

• other

Yes Site is located in Dahej Industrial Area,

Dahej, having all required infrastructure.

This industrial zone is having existing road

infrastructure, power supply are to be

utilized.

Local people will be employed and no

housing is required.

Please refer Annexure – 9.

9.2

Lead to after-use of the site, which

could have an impact on the

environment

No

--

9.3 Set a precedent for later developments No Not applicable

9.4 Have cumulative effects due to

proximity to Other existing or planned

projects with similar effects

No

12

(III) Environmental Sensitivity

Sr.

No

Information/Checklist confirmation Name /

Identity

Aerial distance (within 25 km).

Proposed Project Location Boundary.

1 Areas protected under international

conventions national or local legislation for

their ecological, landscape, cultural or other

related value


Dahej, Tal. Vagra, Dist. Bharuch, Gujarat.

2 Areas which are important or sensitive for

Ecological reasons - Wetlands, watercourses or

other water bodies, coastal zone, biospheres,

mountains, forests


Dahej, Dist. Bharuch, Gujarat.

.

3 Areas used by protected, important or

sensitive species of flora or fauna for breeding,

nesting, foraging, resting, over wintering,

migration


Dahej, Tal: Vagra, Dist. Bharuch, Gujarat.

4 Inland, coastal, marine or underground waters Yes Arabian Sea- 27 Km

River Narmada- 6 Km

5 State, National boundaries Yes --

6 Routes or facilities used by the public for to

recreation or other tourist, pilgrim areas.

No Not applicable

7 Defense installations No NIL

8 Densely populated or built-up area Yes Bharuch city: 5 lakh population

9 Areas occupied by sensitive man-made land

community facilities)

No

10 Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture,

fisheries, tourism, tourism, minerals)

Yes

The project being in notified industrial

area does not affect agricultural land.

11 Areas already subjected to pollution or

environmental damage. (those where existing

legal environmental standards are exceeded)


Dahej, Tal: Vagra, Dist. Bharuch, Gujarat.

12 Are as susceptible to natural hazard which

could cause the project to present

environmental problems (earthquake s,

subsidence ,landslides, flooding erosion, or

extreme or adverse climatic conditions)

- N.A.

IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – 10.

13

14

ANNEXURES

1 PLANT LAYOUT

2 LIST OF PRODUCTS WITH PRODUCTION CAPACITY AND RAW MATERIALS

3 BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE

WITH FLOW DIAGRAM

4 WATER CONSUMPTION AND EFFLUENT GENERATION WITH SEGREGATION OF

EFFLUENT STREAMS

5 DETAILS OF PROPOSED EFFLUENT TREATMENT PLANT

6 DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL

7 DETAILS OF AIR POLLUTION CONTROL MEASURES

8 DETAILS HAZARDOUS CHEMICAL STORAGE FACILITY

9 SOCIO - ECONOMIC IMPACTS

10 PROPOSED TERMS OF REFERENCES

15

ANNEXURE: 1

PLANT LAYOUT

134 m

94.85 m

N

Plant –III (Specialty

Chemical) – 25 m x

30 m

Plant –I (Pharma

Intermediates) – 25 m

x 30 m

Plant –II

(Pesticide

Intermediates) –

25 m x 20 m

RM &

Product

Godown -

10 m x 20

m

Plant –IV

(Perfumery

Chemical) – 25

m x 20 m

Utility Area –

20 m x 15 m

Storage

Tank Farm

Area

10 m x 25

m

ETP + RO + MEE + SBT

59.52 m

Assembly Point

Assembly

Point

Total Area: 5101.23 m2

Green belt Area: 1340m2

1. 5 m x 60 m = 300 m2

2. 8 m x 70 m = 560 m2

3. 10m x 22m = 220 m2

4. 5m x22 m = 110 m2

5. Other = 150 m2

Admn.

Buildin

g

15m x

20 m

RM &

Product

Godown -

10 m x 25

m

S.C

.

Parking

16

ANNEXURE: 2

LIST OF PRODUCTS WITH PRODUCTION CAPACITY

Sr.

No. NAME OF PRODCUTS

Proposed

Quantity

(MT/M)

1.0 PHARMACEUTICAL INTERMEDIATES

1.1 2, Diazo 1- Napthol, 5- Sulphonic Acid Sodium Salt ( NAS)

150

1.2 2,7 Di Chloro 4- ( 2- Dibutyl Amine) Ethane Fluorine

1.3 1,2 Di Methoxy Benzene

1.4 Ortho Phenoxy Aniline

1.5 3- Quinoline Carboxyllic Acid 7- Chloro -1- Cyclopropyl -1,4 – dihydro 8-

Methyl 4-Oxo – Ethyl Ester

1.6 L-2- Chloropropionic Acid Isobutyl ester

1.7 2- Phenyl Benzimidazol -5- Sulphonic Acid

1.8 Neodecanoyl Chloride

1.9 2- Ethyl Hexanoyl Chloride

1.10 2,3 Dichloro Benzoyl Chloride

1.11 3-(4-Amino-3, 5-Di Methyl Phenyl) Prop-2-ene Nitrile

1.12 4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-

yl)Amino]Benzonitrile

1.13 1-(6-Amino-9H-Purin-9-Yl)Propan-2-Ol

1.14 4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile

1.15 4-[(5- Hydroxy Pyrimidin-2-yl )Amino] Benzonitrile

1.16 4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile

1.17 4-({6-Amino-5-Bromo-2-[(4-Cyanophenyl) Amino ]Pyrimidin-4-

yl}Oxy)-3,5-Dimethyl Benzonitrile

2.0 AGROCHEMICAL INTERMEDIATES

2.1 CCMP / 2- Chloro 5- Chloromethyl Pyridine

150

2.2 CCMT / 2- Chloro 5- Chloromethyl Thiazole

2.3 Na- TCP / 3,5,6 Tri Chloro Pyridinol Sodium Salt

2.4 TCAC / Tri Chloro Acetyl Chloride

2.5 3-Methyl 4- Nitro Imino Per hydro1,3,5 Oxidiazine

2.6 1,2,4 Triazole

2.7 TFP Acid Chloride / Lambda Acid Chloride

17

2.8 Meta Phenoxy Benzyl Alcohol

2.9 4,4’ Thio Diphenol

2.10 Transfluthrin Acid Chloride

2.11 D- Allethrollone

2.12 4- HPA / ( R HPPA - ( R (+) -2- [ 4- (5- Chloro -3- Fluoro pyridine -2- yloxy

Phenoxy ) ] Propionic Acid

2.13 N- NII – N- Nitro Imino Imidazolidine

3.0 SPECIALTY CHEMICALS

3.1 EBASA – Ethyl Benzyl Aniline Sulphonic Acid

125

3.2 5- Cyano Phthalide

3.3 5- Bromo Phthalide

3.4 2- Chloro 6- Nitro Benzotrifluoride

3.5 2,4 Di Chloro 3,5 Dinitro Benzotrifluoride

3.6 Diphenyl Sulfide

4.0 PERFUMARY CHEMICALS

Group -1

4.1 Allyl Caproate

50

4.2 Allyl Haptanoate

4.3 Isobutyl Caproate

4.4 Amyl Caproate / Iso Amyl Caproate

4.5 Hexyl Caproate

4.6 Allyl Phenoxy Acetate

4.7 Octyl Acetate

4.8 Decycle Acetate

4.9 Hexyl Iso Butyrate

4.10 Phenoxy Ethyl Iso butyrate

4.11 Citronellyl Acetate

4.12 Geranyl Tiglate

4.13 Phenyl Ethyl Tiglate

4.14 Cinnamyl Cinnamate

4.15 Ethyl Butyrate

Group -2

4.16 Sandalite

4.17 Purasandal

4.18 Megasandal

18

4.19 DIPAL 50

4.20 PRINILE

4.21 Isogasmine P

Group -3

4.22 Citralite

4.23 Praistone

4.24 Applitone

4.25 Herboxane

Group -4

4.26 SAFRANAL

50 4.27 CDEA

Grand Total MT / Month 725 MT/

Month

By-Products:

S. No. Name of By-Products Proposed Quantity

MT/Month

1. Sodium Sulphate Salt 95

2. HCl (32%) (Recycle in plant Premises) 810

3. Sodium Sulphite (20%) 1237

4. AlCl2 (25%) 776

5. Potassium Chloride 620

6. Caustic Lye 40% (Recycle in plant Premises) 74

7. Formic Acid(Recycle in plant Premises) 150

8. Phosphoric Acid 278

19

LIST OF RAW MATERIALS

Product Raw-material Quantity (MT/MT)

1) Pharmaceutical Intermediates

2- Diazo 1- Napthol, 5-

Sulphonic Acid

Sodium Salt

Sulfo Tobias Acid 1.089

Sodium Nitrate 0.190

30 % HCl Solution 0.600

Sodium Carbonate Solution 1.415

10 % Sodium Hypo Chlorite Solution 1.879

Caustic Soda Lye 0.137

Sodium Chloride Salt 0.287

2,7 Di Chloro 4- ( 2-

Dibutyl Amino) Ethane

Fluorene

DMF 0.200

Chlorine Gas 1.393

Methanol 0.090

EDC 0.250

Aluminum Chloride 1.293

Chloro Acetyl Chloride 0.945

Sodium Borohydrate 0.100

Di Butyl Amine 0.500

1,2 Dimethoxy

Benzene

1,2 Di Hydroxy Benzene 0.810

Caustic Lye 48 % 0.650

Di Methyl Sulphate 2.050

Ortho Phenoxy Aniline Phenol 0.592

2-Nitro Chlorobenzene 0.992

Sodium Hydroxide 0.257

Solvent : 1,2-Dichlorobenzene/DCT 0.030

Iron (Fe) Powder 0.962

Acetic Acid 0.020

Soda Ash 0.015

3- Quinoline

Carboxyllic Acid 7-

Chloro 1-

Cyaclopropyl-1.4

Dihydro 8- Methyl 4-

Oxo Ethyl Ester

3- Quinoline Carboxyllic Acid 7- Chloro

1- Cyaclopropyl-1.4 Dihydro 8- Methyl

4- Oxo 0.752

Cyclopropyl Chloride 0.252

Catalyst – PTSA 0.012

Ethyl Chloride 0.213

20

Solvent – Toluene 0.050

2 % Soda Ash Soln 0.198

L -2- Chloro Propionic

Acid Isobutyl Ester

DL - Propionic Acid 0.451

Chlorine Gas 0.431

Solvent – EDC 0.050

Iso Butyl Acid 0.441

2 % Soda Ash Solution 0.196

2- Phenyl

Benzimidazol -5-

Sulphonic Acid

2- Phenyl Benzimidazol 0.712

Solvent – Xylene 0.049

Chloro Sulphonic Acid 0.428


Neodecanoyl Chloride Neodecanoyl Acid 0.921

Solvent – n- Hexane 0.040

DMF – Catalyst 0.010

Thionyl Chloride 0.728

Dilute Caustic Solution 1.568


2- Ethyl Hexanoyl

Chloride

2- Ethyl Hexanoyl Acid 0.895





2,3 Dichloro Benzoyl

Chloride

2,3 Dichoro Benzoic Acid 0.920





3-(4-Amino-3, 5-Di

Methyl Phenyl) Prop-

2-Ene Nitrile

4- Chloro 2,6 Dimethyl Aniline 0.911

2- Propene nitrile 0.304

Solvent – DMF 0.040

Potassium Carbonate 0.872

5 %Soda Ash Solution 0.490

21

4-[(4-{[4-(2-Cyano

Ethenyl)-2,6-1) Di

Methyl Phenyl ]

Amino} Pyrimidin-2-


3-(4- Chloro - 3,5 - Dimethylphenyl)

Prop - 2- enenitrile

0.475

4- [ (4- Chloro Pyrimidine yl) amino ]

Benzonitrile 0.627




1-(6-AMINO-9H-

PURIN-9-YL)PROPAN-

2-OL

6- Amino 9-H Purin 0.712

4- Methyl 1,3 Dioxolan 2- one 0.524

Solvent – Toluene 0.040

Catalyst 0.015


4-[(4-Hydroxy

Pyrimidin-2-yl) Amino]

Benzonitrile

2- Chloro Pyrimidine 4- ol 0.630

4- Amino Benzonitrile 0.552


Catalyst 0.012



4-[(5- Hydroxy

Pyrimidin-2-yl )Amino]

Benzonitrile

4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-

yl)amino] Benzonitrile 1.020

Phosphorus Oxychloride 0.514

Solvent – Xylene 0.060

Catalyst 0.010



4-[(5-Oxo-4,5-Dihydro

Pyrimidin-2-yl) Amino]

Benzonitrile

1-(4-Cyano phenyl) Guanidine 0.764

Methyl (2Z) -3- Methoxy 2- Propionate 0.544

Solvent – Methanol 0.050

Catalyst 0.010

Caustic flakes 0.220


4-({6-Amino-5-Bromo-

2-[(4-Cyanophenyl)

6- Amino 2- Chloro Pyrimidine 4- ol 0.362

4- Amino Benzonitrile 0.279

22

Amino ]Pyrimidin-4-

yl}Oxy)-3,5-Dimethyl

Benzonitrile


Catalyst -1 0.012


4- Chloro 3,5 - Dimethyl Benzonitrile 0.495

Bromine Liquid 0.183

Catalyst -2 0.014

50 % Hydrogen Peroxide Solution 0.080


Pesticide Intermediates

1,2,4 –Triazole Formic Acid 1.937

Ammonia 0.872

Hydrazine Hydrate 0.968

3- Methyl 1,2,4 –

Triazole

Hydrazine Carboxaldehyde 0.733

1-Imino Ethanamine HCl 1.150

Sodium Methoxide 0.660

Ethanol 0.040

3- Methyl 4- Nitro

Imino Per hydro1,3,5

Oxidiazine

Formic Acid 2.880

N- Methyl Nitro Guanidine 0.778

Metane Sulphonic Acid 0.044


Catalyst 0.012

Solvent -DMF 0.090

( R (+) -2 – [ 4 ( 4- ( 5-

Chloro -3- Fluoro

Pyridine -2- Yloxy

Phenoxy ) ] Propionic

Acid / 4- HPPA / R –

HPPA

Hydro Quinone 0.930

2-Chloro Propionic Acid 0.864

Caustic Lye 48% 0.243

30% HCl 0.374

MIBK 0.060

4 – 4’ Thio Diphenol Phenol 1.900

Sulphur Dichloride 0.945

Toluene 0.030

Soda Ash 0.320

D+ dl Allethrollone &

DL – Isomeres

2- Methyl Furan 1.109

EDC 0.080

DMF 0.060

23

POCl3 1.524

Allyl Chloride 0.661

Toluene 0.050

THF 0.060

Mg Metal 0.205

Sodium Acetate 0.170

Acetic Acid 0.534

2-Chloro 5-

Chloromethyl Pyridine

(CCMP)

Benzyl Amine 0.912

Propanaldehyde 0.494

Toluene 0.075

Acetic Anhydride 0.802

DMF 0.050

Tri ethyl amine 0.048

EDC 0.130

Acetonitrile 0.100

Phosphorus Oxy Chloride 2.125

Chlorine 0.330


2 – Chloro 5-

Chloromethyl Thiazol

Allyl Chloride 1.123


Chlorine 0.875

Caustic Lye 0.569

Potassium Thio Cyanate 1.190

Sulfuryl Chloride 1.028

Solvent MDC 0.080

Chloro Butoxy Ethyl

Acetate

Butyl Cellosole 0.015

Mono Chloro Acetic Acid 0.630

Soda Ash 0.020

Lambda Acid Chloride Tri Chloro Tri Fluoro Ethane 1.350

Methyl Pentanoate 1.110

Catalyst -1 0.011

Catalyst -2 0.015


Tertiary Butyl Alcohol - TBA 1.248

Na- Metal 0.210

24

Solvent n- Hexane 0.100

Di Methyl Formamide 0.221

Sulfuric Acid 98 % 0.044

Caustic Lye 46 – 48 % 3.233

Solvent Methanol 0.100


Meta Phenoxy Benzyl

Alcohol

MPBAD 1.100

Hydrogen 0.300

Catalyst 0.015

Iso Propyl Alcohol 0.060


N-Nitro Imino

Iminozoladine

Sulfuric Acid 1.930

Guanidine Nitrate 1.175

EDA 0.710

Caustic Lye 3.090

Sodium Tri Chloro

pyridinol [Na TCP]

TCAC 0.850

Acrylonitrile 0.350

EDC 0.040


Tri Chloro Acetyl

Chloride

Acetic Acid 0.345

Chlorine 1.840

Sulfur Mono Chloride 0.200

Caustic Soda Lye 48% 0.492

Transfluthrin Acid

Chloride

Trans Cypermethrin Acid 3.000

EDC 0.050


HCl 30% 3.663

n-Hexane 0.040

DMF 0.006


Specialty Chemical

Ethyl Benzyl Aniline

Sulphonic Acid

Ethyl Benzyl Aniline 0.686

Sulphuric Acid 0.678

Oleum 65 % 0.669

5- Cyano Phthalide Terephthallic Acid 1.138

25

23 % Oleum 0.371

DMF 0.009


Solvent - Toluene 0.050

Ammonia Gas 0.122

2-Chloro 6- Nitro

Benzonitrile

2:3 DCNB 1.099

DMF 0.222

NaCN 0.222

CuCN 0.148

5 % Ammonia 1.000

Sodium Hypochlorite soln 1.100

MCB 0.050

2,4 Di Chloro 3,5 Di

Nitro Benzotrifluoride 2,4 Di Chloro Benzotrifluoride 1.000

Nitric Acid 0.780

Sulphuric Acid / Spent Sulphuric Acid 3.400

Oleum 28 % 3.000


33% Hydrochloric Acid 0.110


Di Methyl Formamide 1.500

Di Phenyl Sulphide Benzene 2.941

Ferric Chloride 0.015

Catalyst -1 0.010

Sulfuryl Chloride 0.750


Perfumery Chemical

Group A

Allyl Caproate Allyl Alcohol 0.375

Caproic Acid 0.752

P-toluene sulphonic acid 0.015

Soda Ash 0.005

AllYL HEPTANOATE Allyl Alcohol 0.346

Heptanoic acid 0.769


Soda Ash 0.005

26

Isobutyl caproate Isobutyl alcohol 0.430

Caproic acid 0.682


Soda Ash 0.004

Amyl caproate or

Isoamyl caproate

Amyl alcohol 0.470

Caproic acid 0.632


Soda Ash 0.004

Hexyl caproate Hexyl alcohol 0.505

Caproic acid 0.588


Soda Ash 0.004

AllYL Phenoxyacetate Allyl Alcohol 0.306

Phenoxy acetic acid 0.796


Soda Ash 0.005

Octyl Acetate Octanol 0.760

Acetic Acid 0.570


Soda Ash 0.005

Decyl Acetate Decyl alcohol 0.800

Acetic Acid 0.360


Soda Ash 0.005

Hexyl isobutyrate Hexyl alcohol 0.598

Isobutyric acid 0.517


Soda Ash 0.004

Phenoxyethylisobutyr

ate

Phenoxyethanol 0.667

Isobutyric acid 0.425


Soda Ash 0.004

Citronellyl Acetate Citronellol 0.800

Acetic Anhydride 0.528

Geranyl tiglate Geranyl alcohol 0.655

27

Tiglic acid 0.430


Soda ash 0.005

Phenyl ethyl tiglate Phenylethyl alcohol 0.602

Tiglic acid 0.496


Soda ash 0.004

Cinnamyl cinnamate Cinnamyl chloride 0.578

Sodium cinnamate 0.646

Triethylamine 0.144

Ethyl butyrate Ethyl alcohol 0.400

butyric acid 0.765


Soda Ash 0.003

Group -B

SANDALITE Campholenic Aldehyde 0.740

Butyraldehyde 0.355

Methanol 0.030

Sulphuric Acid (30%) 0.103


Caustic Lye (50%) 0.015

Methanol 0.103

Sodium Borohydride 0.066

Acetic Acid 0.100

PURASANDAL Campholenic Aldehyde 0.793

Propionaldehyde 0.309

Methanol 0.032



Caustic Lye (50%) 0.016

Sodium Borohydride 0.063

Acetic Acid 0.099

Megasandol Campholenic Aldehyde 0.750

MEK 0.022

Methanol 0.022

28

Caustic Potash 0.044

Acetic acid 0.187


DIPAL Propionaldehyde 1.250


Acetic acid 0.043

PRINILE

ISOJASMONE P

Benzyl Cyanide 0.608

Cyclohexanone 0.507

Cyclohexane 0.260

Methanol 0.015


Acetic Acid 0.070

Cyclopentanone 0.581

Valeraldehyde 0.598

Methanol 0.023



HCl 0.290


Group - C

Citralite D,Limonene / orange terpenes 1.333

Methanol 0.020


Diethanolamine 0.033

PRAISTONE Ethyl acetoacetate 0.700

Propylene glycol 0.410

Toluene 0.028

APPLITONE Ethyl acetoacetate 0.752

Ethylene glycol 0.358

Toluene 0.030

HERBOXANE Valeraldehyde 0.465

Hexylene glycol 0.639


Toluene 0.037

Soda ash 0.011

29

Group-D

SAFRANAL Citral 1.052

Aniline 0.684

Cyclohexane 0.105


Sodium bicarbonate 0.021

Dimethyl formamide 0.063

Cyclohexane 0.063

Bromine 1.105

Lithium Carbonate 0.610

CDEA Citral 0.680

Ethyl alcohol 0.411

PTSA 0.006

Triethylorthoformate 0.003

Soda ash 0.006

30

SO3H

SO3H

NH2

+

Sulfo Tobias Acid

NaNO2

Sodium Nitrate

+ HCl

Hydrochloric Acid

N=N.Cl

SO3H

SO3H

Diazonium Salt of Sulfo Tobias Acid

+ NaOCl

Sodium Hypochlorite

NaOH

SO3Na

ONa

N2

2- Diazo 1- Napthol, 5- Sulphonic Acid Sodium Salt

ANNEXURE: 3

BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH FLOW

DIAGRAM

Brief Manufacturing Process :

1) 2- Diazo 1- Napthol, 5- Sulphonic Acid Sodium Salt

Stage – 1

Sulfo Tobias Acid undergoes diazotization reaction by Sodium Nitrate in presence of strong Acid

gives Diazonium Salt of Sulfo Tobias Acid.

Stage -2

Diazonium Salt of Sulfo Tobias Acid undergoes oxidation reaction by means of Sodium

Hypochlorite in presence of Caustic Solution to give the final product as 2- Diazo 1- Napthol, 5-

Sulphonic Acid Sodium Salt.

Chemical Reactions:

31

Mass Balance for 1.0 MT

Sr.

No. In Put Quantities Out Put Quantities

Items/ Raw Materials Quantity in Kgs Products / Bi Products Quantity

in Kgs

1 Sulfo Tobias Acid 1100 2- Diazo 1- Napthol, 5-

Sulphonic Acid Sodium Salt 1010

2 Sodium Nitrate 192 Sodium Chloride Solution 3540

3 30 % HCl Solution 605 Aqueous Layer to ETP 1830

4 Water for reaction &

washings 5622 Sodium Chloride Solution 4895

5 Sodium Carbonate

Solution 1430

6 10 % Sodium Hypo

Chlorite Solution 1898

7 Caustic Soda Lye 138

8 Sodium Chloride Salt 290

Total 11275.0 11275.0

32

2. 2,7 Di Chloro 4- ( 2-Dibutyl Amino) Ethane Fluorene

Stage -1 :

Fluorene is reacted with chlorine in presence of Catalyst & Solvent DMF to give Dichloro

Fluorene.

Stage -2 :

2,7 Di Chloro Fluorene undergoes Friedel Craft reaction with Chloro Acetyl Chloride in presence

of anhydrous Aluminum Chloride to give the Acetyl derivative of Dichloro Fluorence.

Stage – 3 :

The above product is further reacted with Sodium Borohydrate to give the intermediate product

as 2,7 Di Chloro 4- Oxy Carbonyl Fluorene

Stage-4 :

2,7 Di Chloro 4- Oxy Carbonyl Fluorene finally reacted with N- Di Butyl Amine to give the final

Product as 2,7 Di Chloro 4- ( 2-Dibutyl Amino) Ethane Fluorene

Chemical Reactions:

Stage-1

Stage-2

2,7 Di Chloro Fluorene M.W. 235.0

Cl

Cl

2HCl

+ DMF

Cl2

+

Fluorene M.W. 166.0

COCH2Cl

Cl

Cl


Cl

Cl

2,7 Di Chloro 4- Chloro Methyl Carbonyl Fluorene

M.W. 235.0

+ ClCH2COCl

EDC

Chloro Acetyl Chloride M.W. 113.0.0

+

HCl

33

Stage-3 O

Stage- 4

CH

CH 2

Cl

Cl


Cl

Cl

2,7 Di Chloro 4- Oxy Carbonyl Fluorene M.W.

277.0

+ NaBH4

Methanol

Sod. Boro Hydride M.W. 37.80

+

COCH2Cl

Cl

Cl

+

CH CH2

CH2CH2CH2CH3 HN CH2CH2CH2CH3

CH2CH2CH2CH3 N CH2CH2CH2CH3

Cl

CH

OH

Cl


2,7 Di Chloro 4- ( 2-Dibutyl

Amino) Ethane Fluorene

O

34

Material Balance / Mass Balance

Sr.


Items/ Raw Materials Quantity in Kgs Products / Bi

Products

Quantity in

Kgs

1 SR-1 1400 Product 1005

2 DMF 7000 Recovered DMF 6800

3 Catalyst -1 140 DMF Loss 200

4 Chlorine Gas 1400 30 % Hydrochloride

Acid 2050

5 Methanol 4000 Recovered Methanol 3910

6 EDC 11350 Methanol Loss 90

7 Aluminum Chloride 1300 Recovered EDC 11100

8 Chloro Acetyl Chloride 950 EDC Loss 250

9 Sodium Borohydrate 100 25 % Aluminum

Chloride Solution 5200

10 Di Butyl Amine 500 Solid Waste 15.0

11 Water 3730 Aq. Layer 1250

Total 31780.0 31870.0

35

3) 1,2 Dimethoxy Benzene: ( Veratrole)

Pyrocatechol ( 2- Hydroxy Phenol) on reaction with caustic converts to Di sodium salt which then

undergoes methylation by Dimethyl Sulphate in presence of catalyst to give the final product as

1,2 Di Methoxy Phenol known as Veratrol.

Chemical Reactions :

3)


Sr.


Items/ Raw Materials Quantity

in Kgs

Products /

Bi Products

Quantity

in Kgs

1 1,2 Di Hydroxy Benzene

810.0

Veratrole

1000.0

2 Caustic Lye 48 % 650.0 Aq. Layer to ETP 3520.0

3 Di Methyl Sulphate 2050.0

4 Water 1000.0

Total 4520.0 4520.0

OCH3 2 NaOH

+

+

OH OH

2 (CH3)2 SO4

2 H2O

+

2 Na(CH3)SO4

+

OCH3

1,2 – Di Methoxy Benzene

( Veratrole )

1,2 Di Hydroxy Benzene

( Catechol)

36

4) Ortho Phenoxy Aniline:

Brief Manufacturing Process:

Step: 1

Phenol is reacted with 2-Nitro Chlorobenzene in Presence of Sodium Hydroxide to get

intermediate as 2-Nitro- Diphenyl Ether

After the reaction solvent 1, 2 Dichlorobenzene is charged for the extraction for the product and

Sodium Chloride salt which is formed during the reaction it is isolated by filtration

Organic mass along with intermediate is forwarded to next step.

Step: 2

2-Nitro- Diphenyl Ether is undergoes reduction reaction by Iron Powder as well as Acetic Acid to

produce the root product as 2-Amino- Diphenyl Ether

Iron Hydroxide which is formed during the reduction reaction is isolated from the mass by

filtration.

And organic mass is taken for further step

Step: 3

Organic mass is subjected to distillation to strip of the solvent to get the crude product 2-Amino-

Diphenyl Ether which is finally distilled out to get the pure product as 2-Amino- Diphenyl Ether

Chemical Reaction:

STEP-1 OH

Cl

NO2

NO2

+O

+ +

Phenol2- NitroChlorobenzene

2-NitroDiphenyl Ether

NaCl H2O

Sodium Chloride Water

NaOH

M.Wt. = 94.0 M.Wt. = 215 M.Wt. = 58.5 M.Wt. = 157.5 M.Wt. = 18 STEP-2

NO2

NH2

+ + +Fe CH3COOH Fe(OH)3

Iron Powder

Acetic Acid

Iron Hydroxide

Na2CO3

+ H2O

Water

2O

2-NitroDiphenyl Ether

O

2-AminoDiphenyl Ether

M.Wt. = 18 M.Wt. = 107 M.Wt. = 185 M.Wt. = 60 M.Wt. = 56 M.Wt. = 215

37

Mass Balance/Material Balance (All quantities are in Kg)

2- Amino Diphenyl Ether

Input Output

Sr.No Raw Materials / Items Kg/Batch Sr.No Product/By Products Qty/Batch

1 Phenol 592 1 2- Amino Diphenyl

Ether 1000

2 2-Nitro Chlorobenzene 992 2 Recovered Solvent 1170

3 Sodium Hydroxide 257 3 Solvent Loss 30

4 Solvent : 1,2-

Dichlorobenzene/DCT 1200 4 Water Distillalte 288

5 Iron (Fe) Powder 962 5 Sodium Chloride 376

6 Acetic Acid 20 6 Iron Sludge 1960

7 Soda Ash 15 7 Distillate Residue 14

8 Water 800 - -

Total 4838 Total 4838

38

5) 3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4- Oxo Ethyl

Ester.


Step: 1

3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyclopropyl 1,4 Dihydro 8- Methyl 4- Oxo is reacted

with Cyclopropyl Chloride in Presence of Catalyst and Solvent to get intermediate as –

3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4- Oxo .

Step: 2

3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4 - Oxo .

Finally reacted with Ethyl Chloride in presence of Catalyst and Solvent to give the final product as

3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4- Oxo Ethyl Ester.

Chemical Reactions:

ClCH3

NH

O

C

O

OH

3-Quinoline Carboxylic Acid 7- Chloro

1- Cyaclopropyl -1.4 Dihydro

8- Methyl

+ Cl

Cyclo propyl Chloride

HCl

OH

O

C

O

N

CH3Cl

8- Methyl 4-Oxo

1- Cyaclopropyl -1.4 Dihydro

3-Quinoline Carboxylic Acid 7- Chloro

+ CH3CH2Cl

Ethyl Chloride Product

ClCH3

N

O

C

O

OC2O5

39


In- put Out – Put

Sr.

No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch

1

3- Quinoline Carboxyllic Acid 7-

Chloro 1- Cyaclopropyl-1.4

Dihydro 8- Methyl 4- Oxo

760

3- Quinoline Carboxyllic Acid 7-

Chloro 1- Cyaclopropyl-1.4

Dihydro 8- Methyl 4- Oxo Ethyl

Ester

1010

2 Cyclopropyl Chloride 255 Recovered Solvent 1950

3 Water for 30 % HCl Soln 292 Solvent Loss 50

4 Catalyst – PTSA 12 30 % HCl Solution 418

5 Ethyl Chloride 215 Aqueous Layer to ETP 306

6 Solvent – Toluene 2000

7 2 % Soda Ash Soln 200


40

6) L -2- Chloro Propionic Acid Isobutyl Ester.


Stage – 1:

DL – Propionic Acid undergoes chlorination reaction by Chlorine Gas in Presence of catalyst as

well as Solvent to give an Intermediate as DL -2- Chloro Propionic Acid

Stage – 2:

DL – 2- Chloro Propionic Acid further undergoes epimerization reaction in Presence of catalyst as

well as Solvent to give an Intermediate as L -2- Chloro Propionic Acid as well as DL -2- Chloro

Propionic Acid .

L- 2- Chloro Propionic Acid is isolated as pure form for further reaction.

Stage -3 :

L- 2- Chloro Propionic Acid finally undergoes Esterification reaction by Iso Butyl Acid in presence

of Catalyst as well as Solvent to give the final Product as L -2- Chloro Propionic Acid Isobutyl

Ester.

Chemical Reaction:

Cl

CH3CH2-COOH + CL2 �� CH3-CH-COOH + HCL

DL-Propionic Acid Chlorine L-2 – Chloro Propionic Acid

Cl OH

CH3-CH-COOH + C6H12O6 �� CH2- CH-CH2.CH3

Iso Butyl Acid L -2- Chloro Propionic Acid Isobutyl Ester

41


In- put Out – Put

Sr.No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch

1 DL - Propionic Acid 460 L -2- Chloro Propionic Acid 1020

2 Chlorine Gas 440 Recovered Solvent 1950

3 Solvent – EDC 2000 Solvent Loss 50

4 Iso Butyl Acid 450 30 % HCl Solution 760

5 Catalyst -1 8.0 Aqueous Layer to ETP 294

6 2 % Soda Ash Solution 200 Distillation Residue 12

7 Water for 30 % HCl

Formation 528


42

N

N

H H

N

N

S

O O

O

H

Cl.SO3H

2- Phenyl Benzimidazole 2-Phenyl Benzimidazole 5- Sulphonic Acid

7) 2- Phenyl Benzimidazol -5- Sulphonic Acid.


2- Phenyl Benzimidazol when undergoes Sulphonation reaction by Chlorosulphonic Acid in

presence of Solvent Xylene followed by Soda Ash wash gives the final Product as

2- Phenyl Benzimidazol -5- Sulphonic Acid.



In- put Out – Put

Sr.


1 2- Phenyl Benzimidazol 720 2- Phenyl Benzimidazol -5-

Sulphonic Acid 1010

2 Solvent – Xylene 2400 Recovered Solvent 2350

3 Chloro Sulphonic Acid 432 Solvent Loss 50


Solution 320 30 % HCl Solution 455

5 2 % Soda Ash Soln 200 Aqueous Layer to ETP 207


43

CH3 C

CH3

CH3

CH2.CH2.CH2.CH2.CH2 C OH

O

Neodecanoyl Acid

+ SOCL2

Thinoyl Chloride

CH3 C

CH3

CH3

CH2.CH2.CH2.CH2.CH2 C CL

O

+ SO2 + HCl

Neodecanoyl Chloride

8) Neodecanoyl Chloride


Neodecanoyl Acid undergoes chlorination reaction by Thionyl Chloride in Presence of Catalyst as

well as Solvent to give an Product as Neodecanoyl Acid Chloride.

During the reaction Hydrochloric Acid as well as Sulphur Dioxide Gases are evolved which are

scrubbed to Water as well as Dilute Caustic Solution to get the byproduct as 30 % HCl Solution

and 20 % Sodium Sulphite Solution.

Chemical Reactions:


In- put Out – Put

Sr.


1 Neodecanoyl Acid 930 Neodecanoyl Chloride 1010

2 Solvent – n- Hexane 2000 Recovered Solvent 1960

3 DMF – Catalyst 10 Solvent Loss 40

4 Thionyl Chloride 736 30 % HCl Solution 660

5 Water for 30 % HCl 460 20 % Sodium Sulphite Solution 1980

6 Dilute Caustic Solution 1584 Aqueous Layer to ETP 555

7 2 % Soda Ash Soln 500 Distillation Residue 15


44

CH3-CH-CH2.CH2.CH2-C-Cl

C2H5 O

+ SOCl2

OC2H5

CH3-CH-CH2.CH2.CH2-C-OH + HCL + SO2

2-Ethyl Hexanoyl Acid Thionyl Chloride 2- Ethyl Hexanoyl Chloride

9) 2- Ethyl Hexanoyl Chloride


2- Ethyl Hexanoyl Acid undergoes chlorination reaction by Thionyl Chloride in Presence of

Catalyst as well as Solvent to give an Product as 2- Ethyl Hexanoyl Acid Chloride.




Chemical Reactions:


In- put Out – Put

Sr.


1 2- Ethyl Hexanoyl Acid 904 2- Ethyl Hexanoyl Chloride 1010




5 Water for 30 % HCl Solution 587 20 % Sodium Sulphite Solution 4460


7 2 % Soda Ash Soln 200 Distillation Residue 15


45

COOH

Cl

Cl

+ SOCl2

Cl

Cl

C

O

Cl

+ HCl + SO2

2,3 Dichloro Benzoic Acid Thionyl Chloride 2,3 Dichloro Benzoyl Chloride

10 ) 2,3 Dichloro Benzoyl Chloride


2,3 Dichloro Benzoyl Acid undergoes chlorination reaction by Thionyl Chloride in Presence of

Catalyst as well as Solvent to give an Product as 2,3 Dichloro Benzoyl Acid Chloride.




Chemical Reactions:


In- put Out – Put

Sr.


1 2,3 Dichoro Benzoic Acid 930 2,3 Dichloro Benzoic Chloride 1010




5 Water for 30 % HCl 423 20 % Sodium Sulphite Solution 3190


7 2 % Soda Ash Solution 200 Distillation Residue 12


46

11) 3-(4-Amino-3, 5-Di Methyl Phenyl) Prop-2-Ene Nitrile


4- Chloro 2,6 Dimethyl Aniline when reacted with 2- Propene nitrile in presence of catalyst &

solvent it gives the final product as 3- ( 4- Chloro – 3,5 – Dimethylphenyl ) Propene nitrile .

Potassium Carbonate is used as acid scavenger which eats up the Hydrochloric acid which is

formed during the reaction and gives our Potassium Chloride as byproduct along with water

molecule. Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.

Reaction Chemistry:

CH3

NH2

CH3Cl

Formula Weight: 155.6247

Molecular Formula: C8H10ClN

4-chloro-2,6-dimethylaniline

+ CH2 CN


Molecular Formula: C3H3N

prop-2-enenitrile

K2CO3

TBAB

CH3

NH2

CH3NC


Molecular Formula: C11H12N2

3-(4-amino-3,5-dimethylphenyl)prop-2-enenitrile

47

Mass Balance / Material Balance

Material Balance / Mass Balance (All Quantities are in Kg)

3-(4- Chloro - 3,5 - Dimethylphenyl) Propene Nitrile

INPUT OUTPUT

Sr

No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch

1 4- Chloro 2,6 Dimethyl Aniline 930

3-(4- Chloro - 3,5 – Dimethyl

Phenyl) Propene Nitrile 1020

2 2- Propene nitrile 310

Recovered Solvent – DMF 1960

3 Solvent – DMF 2000

Solvent Loss – DMF 40

4 Catalyst 15

Potassium Chloride mix Salt 1110

5 Potassium Carbonate 890 Aqueous Layer to ETP 1015

6 5 %Soda Ash Solution 500

7 Water for Reaction & Washing 500


48

12) 4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-



3- ( 4- Chloro - 3,5 - Dimethylphenyl ) Prop -2- enenitrile is reacted with 4- [ (4- Chloropyrimidine

2-yl) amino ] Benzonitrile in presence of catalyst & solvent it gives the final product as 4-[(4-{[4-

(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-yl)Amino]Benzonitrile


formed during the reaction and gives our Potassium Chloride & Potassium Bi Carbonate as

byproducts along with water molecule.

Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.

Reaction Chemistry:

CH3

NH2

CH3NC



3-(4-amino-3,5-dimethylphenyl)prop-2-enenitrile

+N

NCl NH

CN


Molecular Formula: C11H7ClN4

4-[(4-chloropyrimidin-2-yl)amino]benzonitrile

K2CO3, TBAB

CH3

NH

CH3NC

N

N NH

CN



4-[(4-{[4-(2-cyanoethenyl)-2,6-dimethylphenyl]amino}pyrimidin-2-yl)amino]benzonitrile

49



4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-


INPUT OUTPUT

Sr

No Raw Materials / Items Kg/Batch Product / Bi Product

Qty/Ba

tch

1

3-(4- Chloro - 3,5 -

Dimethylphenyl) Prop -

2- enenitrile 485

4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1)

Di Methyl Phenyl ] Amino}

Pyrimidin-2-yl)Amino]Benzonitrile 1020

2 4- [ (4- Chloro Pyrimidine yl)

amino ] Benzonitrile 640




4 Catalyst 15

Potassium Chloride + Potassium

Bi Carbonate mix Salt 550





50

13) 1-(6-AMINO-9H-PURIN-9-YL)PROPAN-2-OL


6- Amino 9-H Purin when reacted with 4- Methyl 1,3 Dioxolan 2- one in presence of catalyst &

solvent- Toluene it gives the final product as 1-(6-Amino-9H-Purin-9-yi )Propane -2-Ol

Carbon Dioxide gas is formed during the reaction which is stripped off the reaction mass. Solvent

Toluene is used which is recovered after the reaction & recycled to fresh batches.

Reaction Chemistry:

N

N

NH2

N

NH



9H-purin-6-amine

O O

O

CH3


Molecular Formula: C4H6O3

4-methyl-1,3-dioxolan-2-one

+

Toluene

-CO2

N

N

NH2

N

NOH

CH3


Molecular Formula: C8H11N5O

1-(6-amino-9H-purin-9-yl)propan-2-ol

51



1-(6-AMINO-9H-PURIN-9-YL)PROPAN-2-OL

INPUT OUTPUT

Sr


1 6- Amino 9-H Purin 720

1-(6-Amino-9H-Purin-9-yi )

Propane -2-ol 1010

2 4- Methyl 1,3 Dioxolan 2- one 530

Recovered Solvent – Toluene 1960

3 Solvent – Toluene 2000

Solvent Loss – Toluene 40

4 Catalyst 15

Aqueous Layer to ETP 755




52

14) 4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile


2- Chloro Pyrimidine 4- ol is when reacted with 4- Amino Benzonitrile in presence of catalyst &

solvent it gives the final product as 4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile.




Reaction Chemistry:

N

N ClOH


Molecular Formula: C4H3ClN2O

2-chloropyrimidin-4-ol

+

NH2

CN



4-aminobenzonitrile

K2CO3, TBAB

N

NOH NH

CN



4-[(4-hydroxypyrimidin-2-yl)amino]benzonitrile

53



4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile

INPUT OUTPUT

Sr


1 2- Chloro Pyrimidine 4- ol 640

4-[(4-Hydroxy Pyrimidin-2-yl)

Amino] Benzonitrile 1015

2 4- Amino Benzonitrile 560




4 Catalyst 12

Potassium Chloride + Potassium

Bi Carbonate mix Salt 960





54

15) 4-[(5- Hydroxy Pyrimidin-2-yl )Amino] Benzonitrile


4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile when undergoes de oxy Chlorination

process with in presence of Phosphorus Oxychloride catalyst & Solvent – Xylene to give the final

product as 4-[(5-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile.




Reaction Chemistry:

Step -1

N

N NH

CN

OH

N

N NH

CN

O

N

N NH

CN

ClChlorination, POCl 3



4-[(5-oxo-4,5-dihydropyrimidin-2-yl)amino]benzonitrile


Molecular Formula: C11H7ClN4

4-[(5-chloropyrimidin-2-yl)amino]benzonitrile



4-[(5-hydroxypyrimidin-2-yl)amino]benzonitrile

OR

55



4-[(5-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile

INPUT OUTPUT

Sr


1 4-[(5-Oxo-4,5-Dihydro Pyrimidin-

2-yl)amino] Benzonitrile 1040

4-[(5-Hydroxy Pyrimidin-

2-yl) Amino] Benzonitrile 1020

2 Phosphorus Oxychloride 525

Recovered Solvent –

DMF 2940

3 Solvent – Xylene 3000


4 Catalyst 10

Sodium Chloride mix

Salt 310

5 Caustic Lye 48 % 400 Phosphoric Acid 460





56

16) 4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile


1-(4- Cyano phenyl ) Guanidine is when reacted with Methyl (2Z) -3- Methoxy 2- Propionate in

presence of catalyst & Solvent it gives the final product as 4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl)

Amino] Benzonitrile.

Methanol is used as Solvent and caustic soda flakes used as catalyst for cyclization reaction.

Solvent is used which is recovered after the reaction & recycled to fresh batches.

Reaction Chemistry:

NH

CN

NH2

NH

N

N NH

CN

O



1-(4-cyanophenyl)guanidine

+

COOCH3

OCH3

CH3OH

CH3ONa


Molecular Formula: C5H8O3

methyl (2Z)-3-methoxyprop-2-enoate



4-[(5-oxo-4,5-dihydropyrimidin-2-yl)amino]benzonitrile

57



4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile

INPUT OUTPUT

Sr


1 1-(4-Cyano phenyl) Guanidine 780

4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-

yl) Amino] Benzonitrile 1020

2 Methyl (2Z) -3- Methoxy 2-

Propionate 555

Recovered Solvent – Methanol 2950

3 Solvent – Methanol 3000

Solvent Loss – Methanol 50

4 Catalyst 10

Sodium Methoxide mix Salt 270

5 Caustic flakes 225 Aqueous Layer to ETP 780




58

17) 4-({6-Amino-5-Bromo-2-[(4-Cyanophenyl) Amino ]Pyrimidin-4-yl}Oxy)-3,5-Dimethyl

Benzonitrile


Step -1:

6- Amino 2- Chloro Pyrimidine 4- ol is reacted with 4- Amino Benzonitrile in presence of Solvent-

DMF & Catalyst to give the Intermediate Product as 4 – [ 4- Amino -6- Hydroxypyrimidine 2- yl)

amino ] Benzonitrile (I ).


formed during the reaction and gives our Potassium Chloride & Potassium Bi Carbonate as

byproducts along with water molecule. Solvent DMF is used which is recovered after the reaction

& recycled to fresh batches.

Step -2

4 – [ 4- Amino -6- Hydroxypyrimidine 2- yl) amino ] Benzonitrile (I ) is further reacted with

4- Chloro 3,5 - Dimethyl Benzonitrile in presence of catalyst & Solvent it gives the Intermediate

(II) as 4- ({ 6- Amino -2- [( 4- Cyanophenyl) amino ] Pyrimidine -4 –yl} oxy ) -3,5- Dimethyl

Benzonitrile (II).

Hydrochloric acid which is formed during the reaction which is scrubbed to water for formation

of 30 % Hydrochloride Solution.

Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.

Step -3:

4- ({ 6- Amino -2- [( 4- Cyanophenyl) Pyrimidine -4 –yl} oxy ) -3,5- Dimethyl Benzonitrile (II).

is finally undergoes bromination reaction by liquid Bromine in presence of catalyst & Solvent-

EDC to give the final product as 4- ({ 6- Amino -5- Bromo -2- [( 4- Cyanophenyl)amino]

Pyrimidine -4 –yl} oxy ) -3,5- Dimethyl Benzonitrile

Hydrogen Peroxide 50 % Solution is used for hydrobromination whereby resulting Hydrobromic

acid is further reacted with Hydrogen Peroxide & gives away second radical of Bromine.

Solvent EDC is used which is recovered after the reaction & recycled to fresh batches.

59

Reaction Chemistry:

N

N NH

CN

NH2

OH

+K2CO3

N

N ClOH

NH2

CN

NH2

N

N NH

CN

NH2

O

CN

CH3CH3

CN

Cl

CH3CH3

+

N

N NH

CN

NH2

O

CN

Br

CH3CH3Bromination


Molecular Formula: C4H4ClN3O

6-amino-2-chloropyrimidin-4-ol



4-aminobenzonitrile

DMF



4-[(4-amino-6-hydroxypyrimidin-2-yl)amino]benzonitrile


Molecular Formula: C9H8ClN

4-chloro-3,5-dimethylbenzonitrile



4-({6-amino-2-[(4-cyanophenyl)amino]pyrimidin-4-yl}oxy)-3,5-dimethylbenzonitrile


Molecular Formula: C20H15BrN6O

4-({6-amino-5-bromo-2-[(4-cyanophenyl)amino]pyrimidin-4-yl}oxy)-3,5-dimethylbenzonitrile

60



4-({6-Amino-5-Bromo-2-[(4-Cyanophenyl) Amino ]Pyrimidin-4-yl}Oxy)-3,5-Dimethyl

Benzonitrile

INPUT OUTPUT

Sr


1 6- Amino 2- Chloro

Pyrimidine 4- ol

370

4-({6-Amino-5-Bromo-2-[(4-

Cyanophenyl) Amino ]Pyrimidin-

4-yl}Oxy)-3,5-Dimethyl

Benzonitrile 1020

2 4- Amino Benzonitrile 285




4 Catalyst -1 12

Potassium Chloride mix Salt 440

5 Potassium Carbonate 340 30 % HCl Solution 300

6 4- Chloro 3,5 - Dimethyl

Benzonitrile 505

10 % HBr Solution 110

7 Water for HCl Solution

Formation 210


8 Bromine Liquid 187

9 Catalyst -2 15

10 50 % Hydrogen Peroxide

Solution 80

11 Water for HBr Solution

Formation 100


13 Water for Reaction &

Washing 250


61

Pesticide Intermediates:

1) 1,2,4 –Triazole

A) Brief Manufacturing Process

Formic Acid is reacted with dry ammonia to form Formamide which on reaction with hydrazine

hydrate gives out the final Product 1:2:4 Triazole. During the reaction ammonia & water

molecules are formed in stechiometric quantities.

B) Chemical Reactions

2HCOOH + 2NH3

Formic Acid Ammonia - 4 x H2O

(MW 46) (MW 17)

O

2H – C – NH2 + H2N - NH2 . H2O

Formamide Hydrazine Hydrate

(MW 45) (MW 50)

N

N + 3H2O + NH3

N

H

1,2,4 Triazole Water Ammonia

(MW 69) (MW18) (MW 17)

62

Mass Balance:

1:2:4 Triazole Material / Mass Balance for 1.0 MT

In Put /Ton Out Put /Ton

No. Name of Item Qty. No. Name of Items Qty.

1 Formic Acid 2000.0 1 1,2,4 Triazole 1032.0

2 Ammonia 900.0 2 22% NH3 Sol. 2968.0

3 Hydrazine Hydrate 1000.0 3 Aq. Layer to ETP 1740.0

4 Water 2315.0 4 Recovered Formic Acid 400.0

5 Recovered Hydrazine Hydrate 75.0

Total 6215.0 Total 6215.0

63

C 3

N

2) 3- Methyl 1,2,4 –Triazole

Process Description: Hydrazine Carboxaldehyde is reacted with 1- Imino Ethanamine Hydrochloride in presence of Sodium Methoxide as well as Solvent – Ethanol form 3- Methyl 1,2,4 Triazole.

Chemical Reaction

STEP-1

H2N H

N C +

H O

HN

NH2

HCl + NaOCH

Ethyl Alcohol

CH3

N

+ N

H

CH3OH

+ NaOH +

NH4Cl

CH3

Hydrazine Carboxaldehyde

1- Imino ethenamine

hydrochloride

Sodium Metoxide

3-Methyl-1,2,4-Triazole

Methanol Sodium Hydroxide Amonium

Chloride

M.W t = 60.00

M.Wt = 94.5

M.W t = 54.00

M.Wt = 83.00

M.Wt = 32.00

M.Wt = 40.00 M.Wt = 53.50

Mass Balance:

64

65

3) 3- Methyl 4- Nitro Imino Per hydro1,3,5 Oxidiazine :

BRIEF MANUFACTURING PROCESS: -

Step:-I

N-Methyl N-Nitro Guanidine (NMG) undergoes cyclization by the reaction of Para

Formaldehyde (PFA) in presence of solvent (Formic Acid) and catalyst to form Oxidiazine

derivatives as an intermediate.

Further organic mass containing Formic Acid is taken for distillation to recover Formic Acid.

After it is diluted with water, neutralized with Caustic Soda Lye, cool it to form crystal & filtered

it to get Oxidiazine Compound

CHEMICAL REACTIONS :

N-Methyl Nitro Guanidine Para formaldehyde Oxidiazine

NH NH

NH

CH3

N+

O-

O

+ O

H

H

2 N

O

NH

N

CH3

N+

O-

O + OH2

66

Mass Balance 1,3,5 Oxidiazine I MT

Sr

No In Put /Ton

Out Put

/Ton

Name of Item Qty. No. Name of Items Qty.

1 Formic Acid 2880 1 1,3,5 Oxidiazine 1000

2 N- Methyl Nitro Guanidine 778 2 Recovered Formic Acid 2795

3 Metane Sulphonic Acid 44 3 Formic Acid Loss 155

4 Caustic Lye 48 % 390 4 Recovered Solvent DMF 2910

5 Catalyst 12 5 Solvent Loss 90

6 Solvent -DMF 3000 6 Mother Liqour 654

7 Water for Crysrallazation 1000 7 Aqeous Layer 500


67

OH

OH

+ CH3-CH-COOH

ClO

OH

CH COOH

CH3

Hydro Quinone 2-Chloro Propionic Acid 2-(4 Hydroxy Phenyl) Propionic Acid

COOHCH

OH

O

CH3

2-(4 Hydroxy Phenyl) Propionic Acid

+ CH3OH

CH3

O CH COOCH3

OH

+ H2O

+ NaOH + HCl

OH

COOCH3CHO

CH3 CH3

O CH COOH

OH

Product

4). ( R (+) -2 – [ 4 ( 4- ( 5- Chloro -3- Fluoro Pyridine -2- Yloxy Phenoxy ) ] Propionic Acid / 4-

HPPA / R – HPPA


Step:- I

Hydroquinone when reacted with 2- Chloro Propionic Acid in presence of Solvent and catalyst to form

2- ( 4- Hydroxy phenyl) Propionic Acid derivatives as an intermediate.

Step:- 2

2- ( 4- Hydroxy phenyl) Propionic Acid Hydroquinone when reacted with Methanol in presence of

Solvent and catalyst to form 2- ( 4- Hydroxy phenyl) Propionic Acid Methyl Ester.

Step:- 3

2- ( 4- Hydroxy phenyl) Propionic Acid Methyl Ester when undergoes hydrolysis reaction by caustic Soda

Lye gives the final Product as ( R (+) -2 – [ 4 ( 4- ( 5- Chloro -3- Fluoro Pyridine -2- Yloxy Phenoxy ) ]

Propionic Acid.


68

Mass Balance:

69

5). 4 – 4’ Thio Diphenol 50 MT / Month

A. Brief Manufacturing Process :-

Phenol and Sulphur Dichloride is reacted in presence of toluene which is needed as solvent, to

form crude 4 – 4’ Thio Di phenol (TDP).

Thio crude Thio di phenol is then purified by treatment of Soda – Ash solution in water to give

pure product.

B. Chemical Reaction :-

Toluene

HO + SCl2 + OH

Solvent

Phenol Sulphur Dichloride Phenol

(94) (103) (94)

HO O S OH + 2HCl

4 – 4’ Thio Di Phenol Hydrochloric Acid

218.0 (2 x 36.5)

Mass Balance:

70

O CH3

+ POCL3

CHO O

+ H3PO4

2 Methyl Furan Phosphorus Oxychloride Aldehyde of 2 Methyl Furan

O CHO

+ CH2=CH-Cl O C

O

CH5CH2

CH5CH2

O

C O

+ CH3COOH

O

CH3

OH

+ CH3COONa

Carbonyl of 2 Methyl Furan

Product

6) D+ dl Allethrollone & DL – Isomeres


Step:- I

2- Methyl Furan is reacted with Phosphorus Oxychloride in presence of catalyst and Solvent to

form Aldehyde of 2- Methyl Furan.

Step:- 2

Aldehyde derivative of 2- Methyl Furan 2- when undergoes Grignard reaction with Allyl Chloride

in presence of Solvent such as Toluene and THF as well as catalyst as Mg- Metal to form

Carbonyl compound of 2- Methyl Furan.

Step:- 3

Carbonyl derivative of 2- Methyl Furan finally undergoes epimerization reaction by Sodium

Acetate in presence of Acetic Acid to gives the final Product d + dl Allethrollone.

Racemic compound of Allethrollone is recovered in statiomatric qty and recycle to fresh batch.


71

Mass Balance:

72

7. 2-Chloro 5-Chloromethyl Pyridine (CCMP)

Chemical Reaction:

73

Mass Balance:

74

8. 2 – Chloro 5- Chloromethyl Thiazol

Step:- 1

Alloyl Chloride reacts with Chlorine to give tri Chloro Propane which on further reaction with

Caustic soda lye gives Dichloro Propane.( DCP)

Step -2

Dichloro Propane reacts with Potassium thiocyanate to give Chloro Iso thiocyanate

intermediate. This on reaction with Sulfuryl Chloride gives the intermediate 2-Chloro 5-

Chloromethyl Thiazol


Step – I CH2=CH–CH2Cl + Cl2 CH2Cl–CHCl–CH2Cl Allyl chloride Tri Chloro Propane M.W. = 76.5 M.W. = 147.5 CH2Cl–CHCl–CH2Cl + NaOH CH2Cl–CCl=CH2 + NaCl + H2O Di Chloro Propane M.W. = 111 CH2Cl–CCl=CH2 + KSCN CH2Cl–CSCN=CH2 + KCl CITC CH2Cl–CSCN=CH2 + SO2Cl2 S + HCl Cl N Cl

Chlorinatio

n

75

2 - Chloro 5 - Chloromethyl Thiazol

CCMT

INPUT OUTPUT

Sr


1 Allyi Chloride 1180

CCMT 1050

2 30 % HCl Solution 1440

Recovered Solvent – MDC 3920

3 Catalyst -1 14

Solvent Loss - MDC 80

4 Catalyst -2 14

30 % HCl Solution 2050

5 Chlorine 875 KCL Solution 3200

6 Caustic Soda Flakes 598

20 % Sodium Sulphite

Solution 5350

7 Potassium Thio Cyanate 1250


8 Sulfuryl Chloride 1080

Distillation Residue 15

9 Solvent MDC 4000

11 Water for Reaction &

Washings 1250


Solution 1738

13 Dilute Caustic for 20 %

Solution 4330


76

9) Chloro Butoxy Ethyl Acetate

A) Brief Manufacturing Process :-

The process of manufacturing Chloro Butoxy Ethyl Acetate is described as below.

Butyl cellosolve is reacted with Mono Chloro Acetic Acid (MCA) in presence of Catalyst

(H2SO4). This reaction gives out water molecule in stechiomatric Quality.

B) Chemical Reactions :-

Cl-CH2-COOH + HO-CH2- CH2 - OC4 H9

Mono Chloro Acetic Acid Butyl Cellosolve

(MW 94.5) (MW 118)

O

Catalyst

Cl- CH2 - C – O – CH2-CH2- O C4H9 + H2O

H2SO4

Chloro Butoxy Ethyl Acetate Water

(MW 194.5) (MW 18)

Mass Balance:

77

10) Lambda Acid Chloride

Brief Manufacturing Process

Lambda Cyhalothric Acid Chloride (LCHACl) Manufacturing Process Details

Methyl Pentanoate (MP) reacted with tri chloro tri fluoro ethane (TCTFE) in presence of tertiary butyl

alcohol solvent (TBA) to from Methyl Ester of Di Methyl Trichloro Tri Fluoro Heptonate (Haptanoate)

Haptanoate is further reacted with Sodium / Potassium Salt of Tertiary Butyl alcohol to give me ester of

Dichloro Trifluoro Propynyl Dimethyl Cyclopropane Carboxylate (Sat Methyl Ester) This on reaction with

Caustic Soda gives Methyl Ester & then Na Salt of Chloro Difluoro Propenyl Dimethyl Cylopropyne

Carboxyllic Acid (TFP Acid) which on Hydrochloric Acid treatment gives Chloro Difluoro Propynyl

Dimethyl Cyclo Propane Carboxyllic Acid.

This acid on chlorination by Thionyl Chloride gives Chloro Trifluoro Propynyl, Dimethyl Cyclopropane

Carboxylic Acid Chloride as the final product.

Lambda Cyhalothrin Acid Chloride

Chemical Reaction

78

79

Mass Balance:


Lambda Acid Chloride

INPUT OUTPUT

Sr


1 Tri Chloro Tri Fluoro Ethane 1350

Lambda Acid Chloride 1000

2 Methyl Pentanoate 1110

Recovered Solvent – TBA 11738

3 Catalyst -1 11

Solvent Loss - TBA 150

4 Catalyst -2 15

Recovered n- Hexane 4900

5 30 % HCl Solution 1500

n- Hexane loss 100

6 Tertiary Butyl Alcohol - TBA 12478 Recovered Methanol 1300

7 Na- Metal 210

Methanol- Loss 100

8 Solvent n- Hexane 5000

30 % HCl Solution 990

9 Di Methyl Formamide 221

20 % Sodium Sulphite Soln 3984

10 Sulfuric Acid 98 % 44

Recovered Methyl Pentanoate 20

11 Caustic Lye 46 – 48 % 3233


12 Solvent Methanol 1400 Distillation Residue 16

13 Thionyl Chloride 570



80

11) Meta Phenoxy Benzyl Alcohol

A Brief Manufacturing Process

Meta Phenoxy Benzaldelyde is reacted with Hydrogen Gas under pressure in presence of

hydrogenation Catalyst to give Meta Phenoxy Benzyl Alcohol (MPBAL) in stechiometric

proportion.

B) Chemical Reaction

O H

C

CH2 OH

H2

O

Catalyst

O

Meta Phanoxy Benzaldehyde

MPBAD MPBAL

M.W. = 198.0 M.W. = 200.0

Mass Balance:

Meta Phenoxy Benzyl Alcohol

In Put /Ton Out Put /Ton

No. Name of Item Qty. No. Name of Items Qty.

1 MPBAD 1100.0 1 MPBAL 1000.0

2 Hydrogen 300.0 2 Recovered IPA 2940.0

3 Catalyst 15.0 3 IPA Loss 60.0

4 Iso Propyl Alcohol 3000.0 4 MPBAD 100.0

5 5 % Soda Ash Solution 250.0 5 Hydrogen Loss 290.0

6 6 Aq Layer to ETP 275.0

Total 4665.0 Total 4665.0

81

12) N-Nitro Imino Iminozoladine


Preparation of Nitro Imino Imidazolidine

Step -1 :

Guanidine Nitrite is added slowly to concentrated Sulfuric Acid in presence of Catalyst and

Water to yield Nitro Guanidine.

Step - 2 :

Nitro Guanidine is further hydrolyzed with Caustic in presence of Ethylene Diamine & finally

undergoes cyclization reaction to give the final Product as Nitro Imino Imidazolidine

Reaction Chemical:

82

Mass Balance:

83

13) Sodium Tri Chloro pyridinol [Na TCP]

Brief Manufacturing Process

In a glass lined reactor, Trichloro acetyl chloride , Acrylonitrile react in presence of catalyst and

solvent to get crude Trichloro pyridinol. Which is dumped in to another reactor containing

sodium hydroxide in water, here sodium Trichloro pyridinol is formed. The slurry formed is

filtered out in filter press and wash cake with water. The cake is then dry in FBD and sell out.

Chemical Reaction:

Cl Cl

solvent

Cl3COCl + CH2=CHCN

Catalyst Cl N OH

water NaOH Lye

Cl Cl

ONa

Cl N

84

Mass Balance:

85

14) Tri Chloro Acetyl Chloride


In a glass lined reactor, charge Acetic acid and catalyst, purge chlorine gas to get r Trichloro

acetic Acid [ TCA ]. During TCA preparation Hydrochloric Acid gas generates is absorb in water

by scrubbing system. This Hydrochloric Acid can be sold out to local industry. Excess chlorine

gas is absorbed in another glass-lined reactor which contain Acetic acid and catalyst, So, no

excess chlorine is escape out to atmosphere. This Trichloroacetic acid is transfer to another

reactor for Trichloro acetyl chloride [ TCAC ] production with chlorine gas and Sulphur mono

chloride. During this reaction also Hydrochloric acid gas generate is absorb in water and Sulfur

dioxide is absorb in caustic soda lye solution. Both the solution will be use in house or sell in to

local market.


1) Tri chloro acetic acid (TCA)

CH3COOH + 3Cl2 Cl3CCOOH + 3HCl

Acetic acid Chlorine gas Trichloro acetic acid Hydrochloric acid

M.W.: 60 M.W.: 71x3=213 M.W.: 163.5 M.W.: 36.5x3=109.5

2) Tri chloro acetyl chloride (TCAC)

2Cl3CCOOH + ½ SCl + ¾ Cl2 Cl3CCOCl + 2HCl + ½ SO2

TCA Sulfur Mono Chlorine Gas TCAC Hydro Sulfur

M.W.: 163.5 chloride gas chloric acid dioxide

M.W.: 67.5 M.W.: 71.0 M.W.: 182.0 M.W.: 36.5 M.W.:64

86

Mass Balance:

87

15) Transfluthrin Acid Chloride


Step:- I

Hgh trans CMA when undergoes epimerization reaction in presence of Catalyst as well as

Solvent and to form R – Trans CMA isomer as an intermediate, which is isolated by acidification.

RS Trans CMA which is mixture of R & S Isomers is recovered in statiomatric quantity.

Catalyst is also recovered up to 98% and recycled to fresh Batch.

Step:- 2

R – Trans CMA isomer when undergoes chlorination reacted by Thionyl Chloride in presence of

Solvent- Hexane and Catalyst to form R – Trans CMAC.

Chemical Reaction:

Epimerization Epimerization

CH3 CH3

Cl2C=CH –CH – CH – COOH

CH3 CH3

Cl2C=CH –CH – CH – COOH + NaCl

R – Trans Cypermethric Acid

M.W. 209.0

CH3 CH3

Cl2C=CH –CH – CH – COOH + SOCl2

Cypermethric Acid

M.W. 209.0

CH3 CH3

Cl2C=CH –CH – CH – COCl + SO2 +

HCL

Cypermethric Acid Chloride

M.W. 227.5

88

Mass Balance:

89

Specialty Chemical

1. EBASA -- Ethyl Benzyl Aniline Sulphonic Acid :

Ethyl Benzyl Aniline ( EBA ) undergoes sulphonation reaction by Oleum 65 % in presence of

sulfuric acid to give EBASA. The resulting mass is Drowned to Ice – water Mixture for quenching.

The resulting mixture is centrifuged and the solid product is packed in Bags/ drums.

20 % Sulphuric Acid is generated as bi product which is being sold out to the actual user.


1)


Sr.

No. In Put Quantities Out Put Quantities Remarks

Items/ Raw

Materials

Quantity in

Kgs

Products / Bi

Products

Quantity

in Kgs

1 Ethyl Benzyl Aniline 800 Ethyl Benzyl Aniline

Sulphonic Acid 86 % 1165.0

Product is in the

form of Wet cake.

2 Sulphuric Acid 790 Spent Sulphuric Acid 4555.0 Sold as Bi Product

3 Oleum 65 % 780

4 Water 3350

Total 5720 5720

N – CH2C6H5

+

H2S2O7

+

Ethyl Benzyl Aniline

EBA )

Ethyl Benzyl Aniline Sulphonic Acid

( EBA )

H2SO4

+

H2SO4

C2H5

N – CH2C6H5

C2H5

SO3H

90

COOH

COOH

+ HO(CH2O)n H

C

O

O

OH

Terephthalic Acid Paraformaldehyde 5-Carboxy Phthalide

+ H2O

Step-1

Step-2

O

O

OH

O

O

C

+ SOCl2 DMF/Toluene

C

O

O

Cl

O

+ SO2 + HCl

5-Chloro Carboxy Phthalide

O

Cl

O

O

C

+ NH3

5-Chloro Carboxy Phthalide

+ HCl

O

CNH2

O

5- Carbonyl Phthalide

2) 5- Cyano Phthalide


Step I

Terephthallic Acid undergoes cyclization reaction in Presence of 23 % Oleum to give an

intermediate as 5-Carboxy Phthalide.

Step II

5-Carboxy Phthalide on further chlorination reaction by Thionyl Chloride in presence of Solvent

& Catalyst gives the Intermediate as 5- Chlorocarbonyl Phthalide.

Step III

5- Chloro carbonyl Phthalide on further reaction of ammonolysis by Ammonia Gas in presence

of Solvent & Catalyst gives the Intermediate as 5- Carbonyl Phthalide.

Step IV

5-Carbonyl Phthalide finally on de- hydration reaction by Thionyl Chloride in presence of

Solvent & Catalyst gives the final Product as 5- Cyano l Phthalide.

Chemical Reactions: -

91

Material Balance

Sr.

No. Input – Raw materials

Quantity

in Kg

Output- Product / Bi

Product

Quantity

in Kg

1 Terephthallic Acid 1150.0 5- Cyano

Phthalide 1010.0

2 23 % Oleum 375.0 Spent Acid to Sale 555.0

3 DMF 9.0 30 % Hydrochloric Acid

Solution 2520.0

4 Thionyl Chloride 1750.0 20 % Sodium Sulphate

Solution 9221.0

5 Solvent - Toluene 2400.0 Recovered Toluene 2350.0

6 Ammonia Gas 122.0. Toluene Loss 50.0

7 Water for 30 % HCl solution

Formation 1764.0 Aqueous Layer to ETP 1272.0

8 Dilute Caustic for 20 % Sodium

Sulphite Solution Preparation 8920.0 Distillation Residue 12.0

9 2 % Soda Ash Solution 500.0

TOTAL 16990.0 16990.0

92

3). 2-Chloro 6- Nitro Benzonitrile


2:3 Dichloro Nitro Benzene (2:3 DCNB) on Cyanation by Sodium cyanide and cuprous cyanide

gives the nitrile product as 2 - Chloro 6- Nitro Benzonitrile

The excess Sodium cyanide and cuprous cyanide is treated by 10 % Sodium Hydrochloride to 0.2

ppm level and then drained to ETP.

Chemical Reactions:

Material Balance

Sr.

No.

Input – Raw

materials

Quantity

in Kg

Output- Product /

Bi Product

Quantity

in Kg

Remarks

1. 2:3 DCNB 1110.0 2 - CNBN 1010.0 Final Product

2. DMF 225.0 Recovered DMF 215.0 Recycle

3. NaCN 225.0.0 DMF Loss 10.0

4. CuCN 150.0 MNCB 70.0 Bi- Product

5. Water 2000.0 DCNB 40.0 Bi- Product

6. 5 % Ammonia 1000.0 MCB recovered 2950 Recycle

7. Sodium Hypochlorite

soln 1100.0 MCB Loss 50.0

8. MCB 3000.0 Detoxified Aq. layer 4465.0 Sent to ETP

TOTAL 8810.0 TOTAL 8810.0

+

NaCl

NO2

2:3 Di Chloro Nitro

Benzene (2:3 DCNB)

MW.- 192.0

Cl

NaCN

+

2- Chloro 6-Nitro

Benzonitrile (CNBN)

MW. - 182.5

+

CuCN

Cl

NO2

Cl

CN

+

CuCl

Sodium

Chloride

MW-58.5

Cuprous

Chloride M.

W. - 99.0

93

4) 2,4 Di Chloro 3,5 Di Nitro Benzotrifluoride


Step I

2,4 Di Chloro Benzo Tri Fluoride undergoes Nitration reaction by Nitric Acid in Presence of Sulphuric Acid

to give 2,4 Di Chloro 3- Nitro Benzo Tri Fluoride

Step II

2,4 Di Chloro 30 Nitro Benzo Tri Fluoride on further Nitration by Nitric Acid in Presence of Oleum 28 %

gives the Intermediate as 2,4 Di Chloro 3,5 Di Nitro Benzo Tri Fluoride


Material Balance

Sr.


Quantity

in Kg


Product

Quantity

in Kg

1 2,4 Di Chloro Benzotrifluoride 1000.0 2,4 Di Chloro 3,5 Di Nitro

Benzotrifluoride 1000.0

2 Nitric Acid 780.0 Spent Acid to Sale 3340.0

3 Sulphuric Acid / Spent Sulphuric

Acid 3400.0 Spent Acid to Recycle 3400.0

4 Oleum 28 % 3000.0 Recovered DMF 1460.0

5 10 % Soda Ash Solution 200.0 DMF Loss 40.0

6 Water 200.0. Aqueous Layer to ETP 1055.0

7 33% Hydrochloric Acid 110.0

8 Caustic Lye 48 % 105.0

9 Di Methyl Formamide 1500.0

TOTAL 10295.0 TOTAL 10295.0

CF3

+

HNO3

H2SO4

H2SO4 +

+

HNO3

H2SO4

H2S2SO7

+

Cl

CF3 Cl

NO2 Cl

Cl 2,4 Di Chloro Benzo

Tri Fluoride MW-

215.0

Nitric Acid

MW- 63.0.0 2,4 Di Chloro 3- Nitro

Benzo Tri Fluoride

MW- 260.0

CF3 Cl

NO2 Cl

O2N

CF3 Cl

NO2 Cl

2,4 Di Chloro 3,5 Di Nitro Benzo

Tri Fluoride—MW- 305.0

+

HNO3

Sulphuric Acid

MW- 98.0

2,4 Di Chloro 3- Nitro Benzo

Tri Fluoride MW- 260.0

NO2

94

+ SOCl2 + S + 2 HCl

Benzene Thionyl Chloride Di Phenyl Sulphide

5) Di Phenyl Sulphide


When Benzene Acid undergoes reaction by Sulfuryl Chloride in presence of Catalyst Ferric

Chloride gives the Product Di Phenyl Sulphide.


Material Balance for 1.0 MT

Sr.


Quantity

in Kg


Product

Quantity in

Kg

1 Benzene 3000.0 Di Phenyl Sulphide 1020.0

2 Ferric Chloride 15.0 Recovered Benzene 2120.0

3 Catalyst -1 10.0 Benzene Loss 80/0

4 Sulfuryl Chloride 765.0 30 % Hydrochloric Acid

Solution 700.0

5 Water for 30 % HCl solution

Formation 490.0 Aqueous Layer to ETP 848.0

6 2 % Soda Ash Solution 500.0 Distillation Residue 12

TOTAL 4780.0 4780.0

95

Perfumery Chemical:

MANUFACTURING PROCESS DETAILS – Group A

01. Product Name – Allyl Caproate

Brief process:

Allyl Caproate can be prepared by refluxing mixture of Allyl Alcohol and Caproic acid in

presence of acid catalyst. After the completion of reaction,the reaction mass will be washed

with soda ash wash solution, and aqueous layer will be sent to ETP.

Chemical Reaction:

CH3OOHCH3 + CH2

CH2OH

CH3O

O

CH2 + H2O

Caproic Acid Allyl Alcohol Allyl Caproate Water

M.Wt – 119 M.Wt- 58 M.Wt- 159 M.Wt - 18

Material Balance:

Step: 1

Input Quantity

in Kgs

Out Put Quantity in Kgs

Allyl Alcohol 500 Allyl Caproate 1330

Caproic Acid 1000 Water generated during

reaction

151

96

247

P-toluene sulphonic

acid

20 Aqueous layer to ETP

Soda Ash 7

Water 50


96

02. Product Name – AllYL HEPTANOATE

Brief process:

Allyl heptanoate can be prepared by refluxing mixture of Allyl Alcohol and Heptanoic acid in

presence of acid catalyst. After the completion of reaction, the reaction mass will be washed

with soda ash solution, and aqueous layer will be sent to ETP.

Chemical Reaction:

CH3OOHCH3 + CH2

CH2OH

O

O

CH3

CH2

+H2O

Heptanoic acid Allyl Alcohol Allyl Heptanoate Water

M.Wt-133 M.Wt – 58 M.Wt – 173 M.Wt-18

Material Balance:

Step: 1

Input Quantity in

Kgs


Allyl Alcohol 450 Allyl Heptanoate 1300

Heptanoic acid 1000 Water generated during

reaction

135

92

227

P-toluene sulphonic

acid


Soda Ash 7

Water 50


97

03. Product Name – Isobutyl caproate

Brief process:

Isobutyl caproate can be prepared by refluxing mixture of Isobutyl Alcohol and Caproic acid in



Chemical Reaction:

CH3OOHCH3 +

O

O

CH3CH3

CH3

+H2OOH

Caproic acid Isobutyl Alcohol Isobutyl caproate Water

M.Wt-119 M.Wt – 74 M.Wt – 175 M.Wt-18

Material Balance:

Step: 1

Input Quantity in

Kgs


Isobutyl alcohol 630 Isobutyl caproate 1465

Caproic acid 1000 Water generated during

reaction

151 242

P-toluene sulphonic

acid

20 Aqueous layer to ETP 91

Soda Ash 7

Water 50


98

04.Product Name – Amyl caproate or Isoamyl caproate

Brief process:

Amyl caproate can be prepared by refluxing mixture of Amyl Alcohol and Caproic acid in



Chemical

Reaction:

CH3OOHCH3 +

O

O

CH3

CH3

+ H2OOH

Caproic acid Amyl Alcohol Amyl caproate Water

M.Wt-119 M.Wt – 88 M.Wt – 189 M.Wt-18

Material Balance:

Step: 1

Input Quantity in

Kgs


Amyl alcohol 743 Amyl Caproate 1580


reaction

151

89

240

P-toluene sulphonic

acid


Soda Ash 7

Water 50


99

05 Product Name – Hexyl caproate

Brief process:

Hexyl caproate can be prepared by refluxing mixture of Hexyl Alcohol and Caproic acid in



Chemical Reaction:

CH3OOHCH3 +

O

O

CH3

CH3

+ H2OOH

CH3

Caproic acid Hexyl Alcohol Hexyl caproate Water

M.Wt-119 M.Wt – 102 M.Wt –203 M.Wt-18

Material Balance:

Step: 1

Input Quantity in

Kgs


Hexyl alcohol 860 Hexyl Caproate 1700


reaction

151

86

237

P-toluene sulphonic

acid


Soda Ash 7

Water 50


100

06 Product Name – AllYL Phenoxyacetate

Brief process:

Allyl Phenoxyacetate can be prepared by refluxing mixture of Allyl Alcohol and Phenoxyacetic

acid in presence of acid catalyst. After the completion of reaction, the reaction mass will be

washed with soda ash solution, and aqueous layer will be sent to ETP.

Chemical Reaction:

+ CH2

CH2OH + H2O

O

O OO

OH

O

Phenoxyacetic acid Allyl Alcohol Allyl Phenoxyacetate Water

M.Wt-152 M.Wt – 58 M.Wt –192 M.Wt-18

Material Balance:

Step: 1

Input Quantity in

Kgs


Allyl Alcohol 385 Allyl Phenoxyacetate 1255

Phenoxy acetic acid 1000 Water generated during

reaction

118

89

207

P-toluene sulphonic

acid


Soda Ash 7

Water 50


101

07 Product Name – Octyl Acetate

Brief process:

Octyl Acetate can be prepared by refluxing mixture of Octanol and Acetic acid in presence of

acid catalyst. After the completion of reaction, the excess of Acetic acid is recovered & this is

salable.

Then reaction mass will be washed with soda ash wash solution, and aqueous layer will be sent

to ETP.

Chemical Reaction:

CH3 CH2OH + CH3COOH CH3O CH3

O

+ H2O

Octyl alcohol Acetic acid Octyl acetate Water

M.Wt – 130 M.Wt – 60 M.Wt -172 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Octanol 1000 Recovered Acetic Acid with

water (spent acid for sale)

426 (288+138)

Acetic Acid 750 Octyl Acetate 1315

P-toluene sulphonic

acid


Soda Ash 7

Water 50


102

08 Product Name – Decyl Acetate

Brief process:

Decyl Acetate can be prepared by refluxing mixture of Decyl alcohol and Acetic acid in presence

of acid catalyst. After the completion of reaction, the excess of Acetic acid is recovered & this is

salable.

Then reaction mass will be washed with soda ash wash solution, and aqueous layer will be sent

to ETP.

Chemical Reaction:

+ CH3COOH + H2OOHOCH3

O

Decyl alcohol Acetic acid Decyl acetate Water

M.Wt – 158 M.Wt – 60 M.Wt -200 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Decyl alcohol 1000 Recovered Acetic Acid with

water (spent acid for sale)

184 (70+114)

Acetic Acid 450 Decyl Acetate 1250

P-toluene sulphonic

acid


Soda Ash 7

Water 50


103

09 Product Name – Hexyl isobutyrate

Brief process:

Hexyl Isobutyrate can be prepared by refluxing mixture of Hexyl alcohol and Isobutyric acid in

presence of acid catalyst. After the completion of reaction, then reaction mass will be washed


Chemical Reaction:

+ + H2OOH

O

OHO

O

CH3

CH3 Hexyl alcohol Isobutyric acid Hexylisobutyrate Water

M.Wt – 102 M.Wt – 88 M.Wt -172 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Hexyl alcohol 1000 Hexyl isobutyrate 1670

Isobutyric acid 864 Water generated during

reaction

176

95

271

P-toluene sulphonic

acid


Soda Ash 7

Water 50


104

10 Product Name – Phenoxyethylisobutyrate

Brief process:

Phenoxyethyl Isobutyrate can be prepared by refluxing mixture of Hexyl alcohol and Isobutyric

acid in presence of acid catalyst. After the completion of reaction, then reaction mass will be

washed with soda ash wash solution, and aqueous layer will be sent to ETP.

Chemical Reaction:

+ + H2O

O

OH

OOH

O

O

O

Phenoxyethanol Isobutyric acid Phenoxyethylisobutyrate Water

M.Wt – 138 M.Wt – 88 M.Wt -208 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Phenoxyethanol 1000 Phenoxyethylisobutyrate 1500

Isobutyric acid 638 Water generated during

reaction

130

85

215

P-toluene sulphonic acid 20 Aqueous layer to ETP

Soda Ash 7

Water 50


105

11 Product Name – Citronellyl Acetate

Brief process:

Citronellyl Acetate can be prepared by esterification of Citronellol with Acetic anhydride in

presence of catalyst. After the completion of reaction, then reaction mass will be washed with

water . after settling spent acetic acid will be separated and stored in drums as salable by

products & organic layer neutralize d with soda ash wash solution, and aqueous layer will be

sent to ETP.

Chemical

Reaction:

+ + H2OOH OO

O

O

O

Citronellol Acetic Anhydride Citronellyl acetate Acetic Acid

M.Wt – 158 M.Wt – 102 M.Wt -200 M.Wt - 60

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Citronellol 1000 Spent Acetic Acid by product 610

Acetic Anhydride 660 Citronellyl Acetate 1250

Water 200


CH3COOH

106

12 Product Name – Geranyl tiglate

Brief process:

Geranyl tiglate can be prepared by esterification of geranyl alcohol with tiglic acid in presence

of resin catalyst. After the completion of reaction, Resin catalyst filtered and then washed with

soda ash wash solution, and aqueous layer will be sent to ETP.

Chemical Reaction:

OH

+

O

OH

O

O

CH3

CH3

+H2O

Geranylalcohol Tiglic acid Geranyl tiglate Water

M.Wt – 154 M.Wt – 100 M.Wt -236 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Geranyl alcohol 1000 Geranyl tiglate 1525

Tiglic acid 656 Water generated during

reaction

117

91

208

P-toluene sulphonic

acid


Soda ash 7

Water 50


107

13 Product Name – Phenyl ethyl tiglate

Brief process:

Phenyl ethyl tiglate can be prepared by esterification of Phenyl ethyl alcohol with tiglic acid in

presence of acid catalyst. After the completion of reaction, Resin catalyst filtered and then

washed with soda ash wash solution, and aqueous layer will be sent to ETP.

Chemical Reaction:

+

O

OH+ H2O

OH O

O CH3

Phenylethyl alcohol Tiglic acid Phenylethyl tiglate Water

M.Wt – 122 M.Wt – 100 M.Wt -204 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Phenylethyl alcohol 1000 Phenylethyl tiglate 1660

Tiglic acid 825 Water generated during

reaction

147

95

242

P-toluene sulphonic

acid


Soda ash 7

Water 50


108

14 Product Name – Cinnamyl cinnamate

Brief process:

Cinnamyl cinnamate can be prepared by esterification of cinnamyl chloride with sodium

cinnamate in presence of amine. After the completion of reaction, the mass washed with water

(sodium chloride solution) & organic mass neutralized with acetic acid.

Chemical Reaction:

Cl+

Na+

O

O-

O

O + NaCl

Cinnamyl chloride Sodium cinnamate Cinnamyl cinnamate Sodium chloride

M.Wt – 152 M.Wt – 170 M.Wt -264 M.Wt - 58

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Cinnamyl chloride 1000 Sodium chloride solution as

byproduct

665

Sodium cinnamate 1119 Cinnamyl cinnamate 1730

Triethylamine 25

Acetic acid 1

Water 250


109

15 Product Name –Ethyl butyrate

Brief process:

Ethyl butyrate can be prepared by refluxing mixture of Ethyl alcohol and butyric acid in

presence of acid catalyst. After the completion of reaction, then reaction mass will be washed


Chemical Reaction:

CH3

OH

+ CH3

OOH

CH3

OO

CH3

+ H2O

Ethyl alcohol butyric acid Ethyl butyrate Water

M.Wt – 46 M.Wt – 88 M.Wt -116 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Ethyl alcohol 1000 Ethyl butyrate 2500

butyric acid 1913 Water generated during

reaction

391

99

490

P-toluene sulphonic

acid


Soda Ash 7

Water 50


110

Group B

1 Product Name – SANDALITE

Brief process:

Step -1

SANDALITE can be prepared by adding mixture of Campholenic aldehyde and Butyraldehyde

under reflux of alkaline methanol. After the completion of reaction, the reaction mass is

neutralized with Sulphuric acid, then recover the excess of methanol; wash the mass with water

and taken for reduction.

Chemical Reaction:

CH3CH3

CH3 O+

O

CH3

CH3CH3

CH3

O

CH3

+H2O

Campholenic Aldehyde Butyraldehyde Cabal

water

M.Wt – 152 M.Wt – 72 M.Wt -206 M.Wt - 18

Material Balance:

Step: 1

Input Quantity in

Kgs


Campholenic

Aldehyde

1000 Cabal 1350

Butyraldehyde 480 Recovered Methanol &

Recycled

1960

Methanol 2000 Aqueous layer to ETP 790

Sulphuric Acid (30%) 140 Vapour loss 40

Sodium Methoxide 20

Water 500


111

Step -2

Above mentioned purified Cabal material is treated with alkaline sodium borohydride solution

in methanol media, after completion of process neutralized with acetic acid and recover the

excess of methanol; wash the mass with water and unload the crude.

Chemical Reaction:

CH3CH3

CH3

O

CH3

CH3CH3

CH3

OH

CH3

+ NaBH4+

Cabal Sodiumborohydride Sandalite

M.Wt – 206 M.Wt – 38 M.Wt -208

Material Balance:

Step-2:

Input Quantity in Kgs Out Put Quantity in Kgs

Purified Cabal 1350 Sandalite 1360

Caustic Lye (50%) 20 Recovered Methanol 1960


Sodium Borohydride 90 Vapour loss 40

Acetic Acid 135

Water 500


112

02. Product Name – PURASANDAL

Brief process:

Step -1

PURASANDAL can be prepared by adding mixture of Campholenic aldehyde and

propionaldehyde under reflux of alkaline methanol. After the completion of reaction, the

reaction mass is neutralized with Sulphuric acid, then recover the excess of methanol; wash the

mass with water and crude taken for reduction.

Chemical Reaction:

CH3CH3

CH3 O+ CH3

O CH3CH3

CH3

CH3

O

+ H2O

Campholenic Aldehyde Proionaldehyde Palca

water

M.Wt – 152 M.Wt – 58 M.Wt - 192 M.Wt - 18

Material Balance:

Step: 1


Campholenic

Aldehyde

1000 Palca 1255

Propionaldehyde 390 Recovered Methanol &

recycled

1960



Sodium Methoxide 20

Water 500


113

Step -2

Above mentioned purified Palca material is treated with alkaline sodium borohydride solution

in methanol media, after completion of process neutralized with acetic acid and recover the

excess of methanol; wash the mass with water and unload the crude.

Chemical Reaction:

CH3CH3

CH3

CH3

O

CH3CH3

CH3

CH3

OH

+ NaBH4

Palca Sodiumborohydride Purasandal

M.Wt – 192 M.Wt – 38 M.Wt -194

Material Balance:

Step: 1

Input Quantity in

Kgs


Palca 1255 Purasandal 1260

Caustic Lye (50%) 20 Recovered Methanol &

Recycled

1860


Sodium Borohydride 80 Vapour loss 40

Acetic Acid 125

Water 500


114

03 Product Name – Megasandol

Brief process:

Step -1

CAMAC can be prepared by adding mixture of Campholenic aldehyde and Methyl ethyl ketone

into mixture of methanol, Caustic potash and water under cold condition. After the completion

of reaction, the reaction mass is neutralized with Acetic acid, then recover the excess of

methanol and MEK (recycled for 3 times), Separate aqueous layer (recycled in next reaction)

and unload organic layer.

Chemical Reaction:

CHO+

O

O

+ H2O

Campholenic Aldehyde MEK CAMAC water

M.Wt – 152 M.Wt – 72 M.Wt – 206 M.Wt – 18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put Quantity in

Kgs

Campholenic

Aldehyde

300 CAMAC 400

MEK 750 Recovered Methanol & MEK

Recycled

1340


WATER 80 Vapour loss 18

Caustic Potash 16

Acetic acid 15


115

Brief process:

Step -2 : SUPER CAMEK

Super Camek can be prepared by adding purified camek into the mixture of methanol and

sodium hydroxide under cold condition. After the completion of reaction, the whole mass is

neutralized with acetic acid, wash the organic layer with water, all aqueous layer is sent to ETP,

recover the excess of methanol and collect the crude.

Chemical Reaction:

OO

+ NaOH

CAMAC Sodium Hydroxide Super CAMEK

M.Wt – 206 M.Wt – 38 M.Wt -206

Material Balance:

Step: 1


CAMAC 400 Super CAMEK 400

Methanol 400 Recovered Methanol 390

Sodium Hydroxide 40 Aqueous layer to ETP 300

Water 200 Vapour loss 10

Acetic Acid 60


116

Step -2 : METHYL CAMEK

Methyl Camek can be prepared by adding purified super camek into the mixture of dimethyl

formamide, toluene and sodium tertiary butoxide under cold condition. After the completion of

reaction, then add methyl bromide into the reaction mass under cold condition. After the

completion of reaction, the whole mass is quenched in chilled water after that mass is

neutralized with acetic acid, wash the organic layer with water, all aqueous layer is sent to ETP,

recover the excess of toluene and collect the crude.

Chemical Reaction:

CH3 CH3

CH3

CH3

O

CH3 +CH3Br

CH3 CH3

CH3

CH3

O

CH3

CH3

+ NaBr

Super CAMEK Methyl bromide Methyl CAMEK Sodium bromide

M.Wt –206 M.Wt –95 M.Wt -220 M.Wt -103

Material Balance:

Step: 1


Dimethyl formamide 800 Methyl CAMEK 422

Toluene 800 Recovered Toluene 784

Sodium Tert.

Butoxide


Methyl Bromide 190 Vapour loss 32

Super CAMEK 400 Dimethyl formamide 784

Water+Ice 600

Acetic Acid 20


117

Step -3: Megasantol

Above mentioned purified Methyl Camek material is treated with alkaline sodium borohydride

solution in methanol media, after completion of process neutralized with acetic acid and

recover the excess of methanol; wash the mass with water and unload the crude.

Chemical Reaction:

CH3 CH3

CH3

CH3

O

CH3

CH3

+ NaBH4

CH3 CH3

CH3

CH3

OH

CH3

CH3

+

Super camac Sodium borohydride Megasandol

M.Wt –220 M.Wt –95 M.Wt -222

Material Balance:

Step-2:


Methyl Camek 422 Megasandol 420

Caustic Lye (50%) 6 Recovered Methanol 590


Sodium Borohydride 40 Vapou loss 10

Acetic Acid 40

Water 200


Flow Chart:

Purified Methyl Camek

Caustic Lye

Methanol

Acetic Acid

Sodium Borohydride

Water

Stainless Steel

reactor Recovered Methanol &

recycled

Megasandol Aqueous layer to ETP

for Treatment

118

04 Product Name – DIPAL

Brief process:

DIPAL can be prepared by adding propionaldehyde into alkaline water. After the completion of

reaction, the reaction mass is neutralized with Acetic acid, then separate aqueous layer &

organic mass.

Chemical Reaction:

CH3 CHO2 + NaOH CH3

CH3

CHO

+ H2O

Propionaldehyde Sodium hydroxide Dipal Water

M.Wt –58x2 =116 M.Wt –40 M.Wt -98 M.Wt -18

Material Balance:

Step: 1


Propionaldehyde 200 Dipal 160

Water 100


Acetic acid 7

Total 312 312

Note: Water after neutralization the aqueous layer recycled for one more time, and then send

it for ETP for treatment.

119

05 Product Name – PRINILE

Brief process:

Step -1 : Prenile

Prinile can be prepared by adding mixture of benzyl cyanide and cyclohexanone under refluxing

alkaline methanol. After the completion of reaction, the reaction mass is neutralized with acetic

acid & recover the excess of methanol, then extract the mass with cyclohexane and wash the

material with water, aqueous layer sent to ETP, recover the excess of cyclohexane and collect

the crude.

Chemical Reaction:

N

+

O

N

+ H2O

Benzyl cyanide Cyclohexanone Prenile Water

M.Wt –117 M.Wt –98 M.Wt -197 M.Wt -18

Material Balance:

Step: 1


Benzyl Cyanide 210 Prinile 345

Cyclohexanone 175 Recovered

Cyclohexane

88

Cyclohexane 90 Recovered Methanol 225


Sodium Methoxide 21 Vapour Loss 40

Water 50

Acetic Acid 24

Total 800 Total 800

120

06. Product Name – ISOJASMONE P

Brief process:

Step -1

ISOJASMONE P can be prepared by adding mixture of cyclopentanone and valeraldehyde under

reflux of alkaline methanol. After the completion of reaction, the reaction mass is neutralized

with Sulphuric acid, then recover the excess of methanol; wash the mass with water and crude

taken for reduction.

Chemical Reaction:

O

+ CH3

CHO

O

CH3

+H2O

Cyclopentanone Valeraldehyde PCP water

M.Wt – 84 M.Wt – 86 Wt – 152 M.Wt – 18

Material Balance:

Step: 1


Cyclopentanone 100 PCP 175

valeraldehyde 103 Recovered Methanol &

recycled

196



Sodium Methoxide 2

Water 50

Total 463 Total 463

121

Step -2

Above mentioned purified PCP material is treated with HCl solution media, after completion of

process neutralized with Sodium hydroxide and wash the mass with water and unload the

crude.

Chemical Reaction:

OCH3

+ HCl

OCH3

PCP Hydrochloric acid Isojasmone P

M.Wt – 152 M.Wt – 36.5 M.Wt -152

Material Balance:

Step: 1

Input Quantity in

Kgs


PCP 175 Isojasmone P 172

HCl 50


Water 70

Total 335 Total 335

122

GROUP C

01 Product Name – Citralite

Brief process:

Citralite can be prepared by refluxing mixture of methanol and d-limonene/ orange terpenes in

presence of acid catalyst. After the completion of reaction, the organic mass neutralized and

excess of methanol is recovered & is to be recycled.

The reaction mass will be washed by water and aqueous layer will be sent to ETP.

Chemical Reaction:

+ CH 3OH Terpinyl methyl ether isomers

Citralite

Limonene Methanol M.Wt- 168

M.Wt –136 M.Wt –32

Material Balance:

Step: 1

Input Quantity in

Kgs


D,Limonene / orange

terpenes

1000 Recovered Methanol

recycled

750

Methanol 1000 Citralite 1230

P-toluene sulphonic acid 30 Aqueous layer to ETP 110

Diethanolamine 25 Vapour Loss 15

Water 50


123

02. Product Name – PRAISTONE

Brief process:

Praistone can be prepared by refluxing mixture of Propylene glycol and ethyl acetoacetate and

Toluene in presence of acid catalyst remove water continuously through ageotropic . After the

completion of reaction, recover Toluene. After solvent recovery unload the crude mass.

Chemical Reaction:

OO

O+ OH

OH O

OO

O + H2O

Ethylacetoacetate Propyleneglycol Praistone Water

M.Wt –130 M.Wt –76 M.Wt- 188 M.Wt –18

Material Balance:

Step: 1

Input Quantity in

Kgs


Ethyl acetoacetate 1000 Aq. Layer of effluent 157

Propylene glycol 586 Recovered Toluene

recycled

1960

P-toluene sulphonic

acid

1 Praistone 1430

Toluene 2000 Vapour loss 40


124

03.Product Name – APPLITONE

Brief process:

Applitone can be prepared by refluxing mixture of ethylene glycol and ethyl acetoacetate and

Toluene in presence of acid catalyst remove water continuously through ageotropic . After

completion of reaction, recover Toluene. After solvent recovery unload the crude mass.

Chemical Reaction:

OO

O

+OH

OHO

OO

O + H2O

Ethylacetoacetate Ethyleneglycol Applitone Water

M.Wt –130 M.Wt –62 M.Wt- 174 M.Wt –18

Material Balance:

Step: 1

Input Quantity in

Kgs

Out Put

Quantity in Kgs

Ethyl acetoacetate 1000 Aq. Layer of effluent 148

Ethylene glycol 477 Recovered Toluene recycled 1960

P-toluene sulphonic

acid

1 Applitone 1330

Toluene 2000 Vapour loss 40


125

04 Product Name – HERBOXANE

Brief process:

Herboxane can be prepared by refluxing mixture of valeraldehyde and Hexylene glycol and

Toluene in presence of acid catalyst remove water continuously through ageotropic . After the

completion of reaction, neutralize with soda ash water & recover Toluene. After solvent

recovery unload the crude mass.

Chemical Reaction:

CHO +

OH

OH

O

O + H2O

Valeraldehyde Hexylene glycol Herboxane Water

M.Wt –86 M.Wt –118 M.Wt- 186 M.Wt –18

Material Balance:

Step: 1

Input Quantity in

Kgs


Valeraldehyde 500 Water collected during

reaction

104

Hexylene glycol 687 Recovered Toluene

recycled

980

P-toluene sulphonic

acid

25 Herboxane 1075

Toluene 1000 Aqueous layer to ETP 145

Soda ash 12 Vapour loss 20

Water 100


126

Group –D

01 Product Name – SAFRANAL

Brief process:

Step -1 : TMCC

TMCC can be prepared by adding Anitral (Mixture of Citral, Aniline & Cyclohexane) into mixture

of Cyclohexane and 92% of Sulphuric Acid under cold condition. After the completion of

reaction, the reaction mass is quenched into chilled water, then separate spent acid , remain

organic layer is neutralized with sodium bicarbonate solution, then recover the excess of

cyclohexane and collect the crude.

Chemical Reaction:

CH3 CH3

CH3

CHO

+

NH2 CH3 CH3

CH3

CHO

Citral Aniline TMCC

M.Wt –152 M.Wt –93 M.Wt- 152

Material Balance:

Step: 1


Citral 100 TMCC 99

Aniline 65 Recovered

Cyclohexane

490

Cyclohexane 500 Spent Acid (by

product)

588

Sulphuric Acid (92%) 380 Vapour Loss 10

Sodium bicarbonate 2.0 Aniline recover 60

Water 200


127

Step -2 : Safranal

Safranal can be prepared by adding liquid Bromine into mixture of Dimethyl formamide &

purified TMCC under cold condition. After bromine addition, add lithium Carbonate into the

reaction mass and heat for some time, after completion of reaction, extract the mass with

cyclohexane, wash the organic mass with water(Lithium bromide solution as byproduct), and

also neutralized organic layer with sodium bicarbonate solution, then recover the excess of

cyclohexane and collect the crude.

Chemical Reaction:

CH3 CH3

CH3

CHO

+ Br2 + LiCO3

CH3 CH3

CH3

CHO

+LiBr

TMCC Bromine Lithium carbonates Safranal Lithium bromide

M.Wt –152 M.Wt –159.8 M.Wt- 66.9 M.Wt- 150 M.Wt- 86.8

Material Balance:

Step: 2


TMCC 99 Safranal 95

Dimethyl formamide 470 Recovered

Cyclohexane

314

Cyclohexane 320 Lithium bromide

solution as byproduct

1037

Bromine 105 Vapour Loss 6

Lithium Carbonate 58

Water 400


128

02 Product Name – CDEA

Brief process:

Step -1 :

CDEA can be prepared by refluxing mixture of ethyl alcol and Citral and Triethylorthoformate in

presence of acid catalyst . After completion of reaction, neutralize with soda ash solution and

unload the crude mass.

Chemical Reaction:

CH3 CH3

CH3

CHO

+ CH3

OH

CH3 CH3

CH3

O

O

CH3

CH3

+ H2O

Citral Ethyl alcohol CDEA Water

M.Wt –152 M.Wt –46x2=92 M.Wt- 226 M.Wt - 18

Material Balance:

Step: 1


Citral 1000 CDEA 1470

Ethyl alcohol 605

PTSA 10 Effluent to ETP 210

Triethylorthoformate 5

Soda ash 10

Water 50


129

ANNEXURE: 4

WATER CONSUMPTION AND EFFLUENT GENERATION

Proposed

Sr.

No.

Category Proposed Scenario (m3/day)

Water Consumption Waste Water

Generation

1. Industrial

Process 57 50

Boiler 20 1

Cooling 20 1

Washing 4 4

Scrubber 4 4

2. Gardening 5 -

3. Domestic 10 8

Total (Industrial) 105 60

Total 120 68

130

WATER BALANCE DIAGRAM

Raw Water – 120 KL/Day from GIDC

Domestic –

10 KL/Day

Process -

57 KL/Day

Boiler – 20

KL/Day

Cooling

Tower – 20

KL/Day

Gardening

– 5 KL/Day

Soak Pit/ Septic

Tank – 8 KL/Day

50 KL/Day 1 KL/Day 1 KL/Day

Effluent 60 KL/Day

Washing

– 4 KL/Day Scrubber

– 4 KL/Day

4 KL/Day 4 KL/Day

MEE –20 KL/Day

MEE Salt (1

MT/Day) �

TSDF

MEE Condensate (19 KL/Day)

Option-1: 60 KL/Day effluent

(Primary ETP) Option-2 : 60 KL/Day effluent

(Primary ETP)

Option-1: 59 KL/Day treated

effluent � CETP for further

treatment

Effluent (40 KL/Day) + 19

KL/Day MEE Condensate to

ETP = 59 KL/Day

Solvent Stripper –60 KL/Day

High COD Stream –

2 KL/Day � Common

Incinerator MEE –58 KL/Day

MEE Salt (4

MT/Day) �

TSDF

MEE Condensate (54 KL/Day)

SBT

RO RO Permeate -40 KL/Day

RO Reject – 14 KL/Day

131

ANNEXURE: 5

ETP DETAILS

Option-1

Process Description of Effluent Treatment Plant

M/s. V-India Chemical Industries pvt. Ltd. shall have an Effluent treatment plant consisting of

primary, secondary and advance treatment units. The effluent confirming to inlet standards of

CETP shall be sent to CETP (under execution). The details of proposed ETP are as follows.

For low COD and TDS Stream: I (40 KLD)

First all non-toxic and biodegradable streams of wastewater shall pass through Screen Chamber

(SC) where floating material shall be removed with help of Screen (S-01). Then effluent shall be

collected in Equalization cum Neutralization Tank-1 (ENT-1). Here, caustic is added from Caustic

Dosing Tank by gravity to maintain neutral pH of wastewater. Mixer is provided in ENT-1 to

keep all suspended solids in suspension and to provide proper mixing.

Then after, neutralized wastewater shall go to Flash Mixer-1 (FM-1) by gravity. Alum and

Polyelectrolyte shall be dosed from Alum Dosing Tank (ADT) and Polyelectrolyte Dosing Tank

(PEDT) respectively by gravity into FM to carry out coagulation by using a Flash Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler (PTS). Clear

supernatant from PTS shall be passed in Aeration Tank (AT). Here, condensate from MEE shall

be mixed with effluent. In AT biodegradation of organic matter of the wastewater shall be

carried out by bacteria (suspended growth) in the AT and for that oxygen shall be supplied by 2

nos. of air blowers (B-01) through diffusers. Air blowers also keep MLSS in suspension.

Nutrients will be added from NDTs to Aeration Tank for growth of Bacteria.

Then after, waste water shall go to Secondary Settling Tank (SST) from AT. Here, the suspended

solids shall be settled. Sludge shall be removed from bottom of SST and pumped to AT to

maintain MLSS and excess activated sludge shall be sent to Sludge Sump (SS). Clear supernatant

from SST shall be collected in Treated Effluent Sump before sending to CETP.

Sludge settled in PTS and excess sludge from SST shall be collected in Sludge Sump then sludge

shall be pumped to Filter Press where, dewatering shall be carried out before storage in HWSA

and ultimate disposal to TSDF. Leachate from FP shall be sent back to ENT-1 for further

treatment.

132

For High COD and high TDS Stream: II (20 KLD)

All High COD & TDS streams of wastewater shall be collected in Equalisation cum Neutralisation

Tank-2 (ENT-2) where caustic shall be added from Caustic Dosing tank to maintain neutral pH of

waste water. Then after, Neutralised wastewater shall be pumped to Flash Mixer-2 (FM-2)

where Alum and poly shall be added from Alum Dosing Tank and Poly Dosing Tank respectively.

Then after, coagulated wastewater shall be settled in Primary Settling Tank (PST). Sludge settles

in PST shall be sent to Sludge sump (SS) and then pumped to Filter Press (FP) for dewatering.

Clear effluent from PST shall be collected in Holding Tank (HT) before pumped to strippers.

Effluent from stripper shall be then collected in MEE Feed Tank before pumped to Multiple

Effect Evaporator. Condensate from MEE shall be sent back to Aeration Tank (AT) for further

treatment and solids from Dryer (ATFT) shall be collected and stored in HWSA for disposal in

TSDF.

133

SIZE OF TANKS

S.N. Name of unit Size (m x m x m) No. MOC/ Remark

Steam I -Low COD and TDS Stream (40 KLD )

1 Screen Chamber (SC) 2.0 x 0.5 (0.05 LD+0.5 FB) 1 RCC M25+A/A

Bk. Lining

2 Equalization cum Neutra-

lization Tank-1 (ENT-1)

3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A

Bk. Lining

4 Flash Mixer-1 (FM-1) 1.0 x 1.0 x (2.0 LD +0.5 FB) 1 RCC M25

5 Primary Tube Settler (PTS) 2.0 x 2.0 x (2.0 LD + 0.75 HB+

0.5 FB)

1 RCC M25

6 Aeration Tank (AT) 9.0 x 6.0x (4.5 LD +0.5FB) 1 RCC M25

7 Secondary Settling Tank(SST) 3.0 x 2.0 x(2.5 LD + 0.75 HB+0.5

FB)

1 RCC M25

10 Sludge Sump (SS) 2.5 x 2.5 x (2.5 LD + 0.5) 1 RCC M25

11 Filter Press (FP) 20 M3 / day 1 PP

12 Treated Effluent Sump(TES) 4.8 x2.5 x (2.5 LD+0.5 FB) 1 RCC M25

Stream II High COD and TDS Stream (20 KLD)

1 Equalisation cum Neutr-

alization Tank-2(ENT2)

3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A

Bk. Lining

2 Flash Mixer-2(FM-2) 1.0 x 1.0 x (1.5LD+0.5 FB) 1 RCC M25

3 Primary Settling Tank (PST) 2.0 x 1.2 x (2.0LD+0.5 FB) 1 RCC M25

4 Holding Tank (HT) 3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25

5 Strippers 20 m3/day 1 SS

6 MEE Feed Tank (MFT) 3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25

7 Four Stages Multiple Effect

Evaporators with ATFT (MEE

,ATFT)

20 m3/day 1 SS

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PCC = PLAIN CEMENT CONCREAT

SS = STAINLESS STEEL

PP = POPYPROPELINE

134

Flow Diagram:

135

Option-2:

Process Description of Effluent Treatment Plant

M/s. V-India Chemical Industries Pvt. Ltd. shall have an Effluent treatment plant consisting of

primary, SBT and advance treatment units. The details of ETP are as follows.

Low COD and TDS Stream: I (40 KLD)

First all non-toxic and biodegradable low Cod and TDS streams of wastewater shall pass

through Screen Chamber (SC) where floating material shall be removed with help of Screen (S-

01). Then effluent shall be collected in Equalization cum neutralization tank-1 (ENT-1). Mixer

will be provided in ENT-1 to keep all suspended solids in suspension. There continuous addition

and stirring of Caustic solution will be done to maintain neutral pH of wastewater from Caustic

Dosing Tanks (CDT) as per requirement by gravity.

Then after, neutralized wastewater shall go to Flash Mixer-1 (FM-1) by pumping. Alum and

Polyelectrolyte shall be dosed from Flocculants Dosing Tank (FLDT) and Polyelectrolyte Dosing

Tank (PEDT) respectively by gravity into FM to carry out coagulation by using a Flash Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler (PTS). Clear

supernatant from PTS shall be collected in Holding Tank-1 (HT-1). Here, MEE condensate water

shall be mixed with the effluent. From HT-1, effluent shall be pumped to Catalytic Advance

Treatment System (CAOS) as pre treatment, and then effluent will be collected in Holding Tank-

2 (HT-2).

Then after effluent will be pumped to Bio-Reactor-1 (BR-1). The process will be batch process

in which wastewater will be pumped and applied onto the top surface of the Bioreactor. The

design has suitable provision for manual removal of suspended solids from the bio-filter

surface. Distribution of wastewater over the media will be achieved via pumping, piping and

distribution arrangements. Separate distribution lines s h a l l b e provided for raw

wastewater as well as recycle water. There will be two modes of suspended solids handing. In

one types, suspended solids can be applied on the surface directly and can be scrapped out

manually may be once in a month. The top 2 inch layer can be replaced with the additive

material which is easily available in the local open market. The suspended solids will be

filtered out which includes additives that combine with organic of waste to produce manure.

In the second mode, solids can be retained in the settling tank and then can be removed

mechanically. Water first percolates through the bioreactor media which in houses cultured

media in 40-60 min and gets collected into the collection tank-1. It can then be pumped on to

the media again (recycling) in order to achieve maximum solid liquid contact.

Then after, it will be pumped to Bio-Reactor-2 and collected in Collection Tank-2 as Dissolved

organic and inorganic are oxidized and the water is purified further. Then effluent will be

pumped to Bio Reactor-3 and filtered effluent will be collected in RO Feed Tank. The

recirculation mode wi l l be provided in ROFT for further polishing of the effluent, if

136

required. Treated Effluent will then sent to RO Unit for further treatment. RO permeate shall be

reused in process and RO reject water shall be sent to MEE feed Tank for further treatment.

High COD and TDS Stream: II (20 KLD)

All High COD & TDS streams of wastewater shall be collected in Equalisation cum Neutralisation

Tank-2 (ENT-2), where caustic shall be added from Caustic Dosing tank to maintain neutral pH

of waste water. Then after, Neutralised wastewater shall be pumped to Flash Mixer-2 (FM-2)

where Alum and poly shall be added from Alum Dosing Tank and Poly Dosing Tank respectively.

Then after, coagulated wastewater shall be settled in Primary Settling Tank (PST). Sludge settles

in PST shall be sent to Sludge sump (SS) and then pumped to Filter Press (FP) for dewatering.

Clear effluent from PST shall be collected in Holding Tank-3 (HT-3) before pumped to strippers.

Effluent from stripper shall be then collected in MEE Feed Tank before pumped to Multiple

Effect Evaporator. Condensate from MEE shall be sent back to Holding Tank-1 (HT-1) for further

treatment and solids from Dryer (ATFT) shall be collected and stored in HWSA for disposal in

TSDF.

137

SIZE OF TANKS

Low COD and low TDS Stream: I (40 KLD)

S.N Name of unit Size (m x m x m) No. MOC/ Remark

1 Screen Chamber (SC) 2.0 x 0.5 (0.05 LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

2 Equalization cum

Neutralization Tank-1

(ENT-1)

3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

3 Flash Mixer-1 (FM-1) 1.0 x 1.0 x (2.0 LD +0.5 FB) 1 RCC M25

4 Primary Tube

Settler(PTS)

2.0 x 2.0 x (2.0 LD + 0.75 HB+

0.5 FB)

1 RCC M25

5 Holding Tank-1 (HT-1) 7.0 x 3.5 x (3.0 LD +0.5 FB) 1 RCC M25

6 Catalytic Advance

Oxidation System

(CAOS)

As per requirement 1 SS

7 Holding Tank-2 (HT-2) 6.0 x 3.0 x (3.0 LD +0.5 FB) 1 RCC M25

8 Bio Reactor-1 (BR-1) 25.0 x 7.0 x 3.3 1 RCC M25

9 Collection Tank-1 (CT-

1)

3.0 x 3.0 x (2.5 LD +0.5 FB) 1 RCC M25


11 Collection Tank-2 (CT-

2)

3.0 x 3.0 x (2.5 LD +0.5FB) 1 RCC M25


13 RO Feed Tank (ROFT) 4.5 x3.0 x (3.0 LD+0.5 FB) 1 RCC M25

14 RO Unit (RO) 80 m3/d 1 SS

15 Sludge Sump (SS) 3.0 m x 3.0 m x (2.5 m + 0.5) 1 RCC M25

16 Filter Press (FP)

20 M3 / d

1 PP

138

High COD and high TDS Stream: II (20 KLD)

S.N Name of unit Size (m x m x m) No. MOC/ Remark

1 Equalisation cum

Neutr- alization Tank-

2(ENT2)

3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

2 Flash Mixer-2(FM-2) 1.0 x 1.0 x (1.5LD+0.5 FB) 1 RCC M25

3 Primary Settling Tank

(PST)

2.0 x 1.2 x (2.0LD+0.5 FB) 1 RCC M25

4 Holding Tank-3 (HT-3) 3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25

5 Strippers 20 m3/day 1 SS

6 MEE Feed Tank (MFT) 4.0 x 4.0 x (2.5LD+0.5 FB) 1 RCC M25

7 Four Stages Multiple

Effect Evaporators with

ATFT (MEE ,ATFT)

40 m3/day 1 SS

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PP = POLYPROPELENE

MSEP = MILD STEEL EPOXY PAINTED

SS = STAINLESS STEEL

139

Flow Diagram:

140

ANNEXURE: 6

DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL

Type of

Waste

Schedule

Category

Source Quantity Disposal Method

ETP waste

34.3

ETP 15 MT/ Month Collection, Storage,

Transportation & Disposal to

TSDF site

Used Oil

5.1 Plant &

Machinery

0.2 KL/ Month Collection, Storage,

Transportation & recycle to

GPCB authorized recycler

Discarded

Containers/

Bags/

Carboys

33.3 Process Bags – 2000

NoS./ Month,

Drums – 500

Nos./ Month

Decontamination, Storage &

sent to GPCB registered vendor

Distillation

Residue

20.3 Process 15 MT/ Month Collection, Storage,


Incinerator site or sent to

cement industries for co-

processing

MEE Salt -- MEE 120 MT/Month Collection, Storage,


TSDF site Process

Waste (Iron

Sludge &

other sludge)

26.1 Process 70 MT/Month

Inorganic

Waste

-- Process 300 MT/Month

141

ANNEXURE: 7

DETAILS OF FLUE & PROCESS GAS EMISSION

Flue Gas Emission

1. Details of Flue Gas Stack; Stack Attached To Thermopack Boiler

SOURCES OF GASESOUS EMISSIONS STACK

Capacity 100 U

Fuel Used Natural Gas = 60,000 SM3/month or


Type of Emissions SO2 NOx SPM

Permissible Limits 262 mg/Nm3 94 mg/Nm

3 150 mg/Nm

3

Stack Height 25 m

Stack Diameter at the Top 600 mm

2. Details of Flue Gas Stack; Stack Attached To Steam Boiler


Capacity 2 TPH

Fuel Used Natural Gas = 80,000 SM3/month




3 150 mg/Nm

3

Stack Height 25 meters

Stack Diameter at the Top 600

3. Details of Flue Gas Stack; Stack Attached To D.G.Set


Capacity 100 KVA x 2

Fuel Used HSD = 50 Liter/Hr



3 150 mg/Nm

3

Stack Height 11 meters

142

4. Details of Process Vent ; Vent Attached To Process

Sr. No. Stack attached to Stack Height Air Pollution

Control System

Parameter Permissible Limit

Proposed

1 Process Vent-1 11 m Two Stage

Scrubber

NH3

175 mg/Nm3

2 Process Vent-2 11 m HCl

20 mg/Nm3

3 Process Vent-3 11 m HCl

SO2

20 mg/Nm3

40 mg/Nm3

143

ANNEXURE: 8

DETAILS HAZARDOUS CHEMICAL STORAGE FACILITY

Sr.

No.

Name of the

Hazardous

Substance

Maximum

Storage

Mode of

Storage

Actual

Storage

State &

Operating

pressure &

temperature

Possible type of

Hazards

1 Methanol 10 MT Tank 10 MT x 1 NTP Flammable/

Toxic

2 HCl 20 MT Tank 10 MT x 2 NTP Corrosive

3 EDC 10 MT Tank 10 MT x 1 NTP Flammable/

Toxic

4 DMF 10 MT Tank 10 MT x 1 NTP Flammable/

Toxic

5 Chlorine 4 MT Cylinder 900 Kg 7 Kg/cm2

pressure and

room temp.

Toxic

6 Toluene 15 MT Tank 15 MT x 1 NTP Flammable

7 Ammonia 5 MT Tank 5 MT x 1 NTP Toxic

8 Sulphuric Acid 10 MT Tank 10 MT x 1 NTP Corrosive

9 Thionyl Chloride 10 MT Tank 10 MT x 1 NTP Corrosive

10 Xylene 5 MT Tank 5 MT x 1 NTP Flammable

144

ANNEXURE 9

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement for the proposed project is expected to generate some permanent

jobs and secondary jobs for the operation and maintenance of plant. This will increase direct /

indirect employment opportunities and ancillary business development to some extent for the

local population. This phase is expected to create a beneficial impact on the local socio-economic

environment.

2) INDUSTRIES

Required raw materials and skilled and unskilled laborers will be utilized maximum from the local

area. The increasing industrial activity will boost the commercial and economical status of the

locality, to some extent.

3) PUBLIC HEALTH

The company regularly examines, inspects and tests its emission from sources to make sure that

the emission is below the permissible limit. Hence, there will not be any significant change in the

status of sanitation and the community health of the area, as sufficient measures have been

taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the existing factory is having proper linkage for the transport and communication, the

development of this project will not cause any additional impact.

In brief, as a result of the proposed project there will be no adverse impact on sanitation,

communication and community health, as sufficient measures have been proposed to be taken

under the EMP. The proposed project is not expected to make any significant change in the

existing status of the socio - economic environment of this region.

145

ANNEXURE – 10

PROPOSED DRAFT TERMS OF REFERENCE

1. Project Description

• Justification of project.

• Promoters and their back ground

• Project site location along with site map of 5 km area and site details providing various industries,

surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Water source and utilization including proposed water balance.

• Product spectrum (proposed products along with production capacity) and process

• List of hazardous chemicals.

• Mass balance of each product

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5 km

area.

• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project site.

For SPM, RSPM, SO2, NOx.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

• Existing socio-economic status, land use pattern and infrastructure facilities available in the study

area were surveyed.

4. Impacts Identification And Mitigatory Measures

• Identification of impacting activities from the proposed project during construction and

operational phase.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Solid waste quantification and disposal.

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

146

6. Risk Assessment

• Objectives and methodology of risk assessment

• Details on storage facilities

• Process safety, transportation, fire fighting systems, safety features and emergency capabilities to

be adopted.

• Identification of hazards

• Consequence analysis through occurrence & evaluation of incidents

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.

9. Information on Rain Water Harvesting

10. Green Belt Development plan

Documents

PROPOSED PESTICIDE INTERMEDIATES, SPECIALTY CHEMICALS ...environmentclearance.nic.in/writereaddata/Online/TOR/0_0_07_Aug_… · 1 form-i for proposed pesticide intermediates, specialty