m/s. anu products ltd. -...

FORM-1

for

PROPOSED PESTICIDE MANUFACTURING UNIT IN

SARIGAM IND. ESTATE

of

M/s. ANU PRODUCTS LTD.

C-1B/3206, 3208, 3210, 3212,

Chemical Zone, GIDC Sarigam-396 155,

Dist: Valsad, Gujarat

Prepared by:

APPENDIX I

(See paragraph - 6)

FORM 1

(I) Basic Information

Name of the Project : M/s. Anu Products Ltd.

Location f site alternatives under

consideration

: M/s. Anu Products Ltd.

C-1B/3206, 3208, 3210, 3212,

Chemicals Zone, GIDC Sarigam-396 155,

Dist.: Valsad (Gujarat)

Size of the Project : Please refer Annexure –I.

Expected cost of the project : Rs. 5 crores

Contact Information : Mr. M. R. Narayanan

(General Manager)

M/s. Anu Products Ltd.

C-1B/3206, 3208, 3210, 3212,

Chemicals Zone, GIDC Sarigam-396 155,

Dist.: Valsad (Gujarat)

Phone No.: (0260) 2781414

Mobile No.: 9924106799, 9321092191

e-mail: [email protected]

[email protected]

Screening Category : A-5(b)

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,

mining lease area and production capacity for mineral production, area for mineral exploration,

length for linear transport infrastructure, generation capacity for power generation etc.,)

(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 there of with approximate

quantities frates, wherever possible)

with source of information data

1.1 Permanent or temporary change in land use,

land cover or topography including increase

intensity of land use (with respect to local land

use plan)

No Proposed project activity is within the

Sarigam GIDC Industrial Estate.

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 The Project site is located on level

ground, which does not require any

major land filling for area grading

work.

1.4 Pre-construction investigations e.g. bore

Houses, soil testing?

No

1.5 Construction works?

Yes Please refer Annexure – II.

1.6 Demolition works? No

1.7 Temporary sites used for construction works

or housing of construction workers?

No

1.8 Above ground buildings, structures or

earthworks including linear structures, cut and fill or excavations

Yes Please refer Annexure – II.

1.9 Underground works mining or tunneling?

No

1.10 Reclamation works?

No

1.11 Dredging?

No

1.12 Off shore structures?

No

1.13 Production and manufacturing processes?

Yes Please refer Annexure –III.

1.14 Facilities for storage of goods or materials?

Yes Raw material storage area & Finished

products area will be developed for

proposed project activity.

1.15 Facilities for treatment or disposal of solid waste

or liquid effluents ?

Yes Effluent generated shall be given

primary, secondary & tertiary

treatment and send to CETP of M/s.

Perfect Enviro Control System Ltd.,

Sarigam for further treatment and final

disposal.

Hazardous waste will be send to TSDF

of M/s. Vapi Waste Effluent

Management Company Pvt. Ltd.

(VWEMCL), Vapi for final disposal

and organic waste will be send to M/s.

GEPIL, Surat for incineration.

For details please refer Annexure – IV

& V.

1.16 Facilities for long term housing of operational workers?

No

1.17 New road, rail or sea traffic during Construction

or operation?

Yes Addition of very few trucks per day.

1.18 New road, rail, air waterborne or other transport

infrastructure including new or altered routes and stations, ports, 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, culverting, realignment or other changes to the hydrology of

watercourses or aquifers?

No

1.22 Stream crossings? No

1.23 Abstraction or transfers of water form ground

or surface waters? Yes Water requirement will 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?

Yes Transportation of personnel or raw

material and products will be primarily

by road only.

1.26 Long-term dismantling or decommissioning or

restoration works? No

1.27 Ongoing activity during decommissioning

which could have an impact on the

environment?

No

1.28 Influx of people to an area either temporarily

or permanently? No

1.29 Introduction of alien species?

No

1.30 Loss of native species or 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 thereof (with approximate

quantities /rates, wherever possible)


2.1 Land especially undeveloped or agricultural land

(ha)

No Proposed project activity will be within

Chemicals Zone, Sarigam GIDC Industrial

Estate, Dist: Valsad.

2.2 Water (expected source & competing users)

unit: KLD

Yes Water Source: GIDC Water Supply

For details please refer Annexure – VI.

2.3 Minerals (MT) No

2.4 Construction material - stone, aggregates,

and / soil (expected source - MT)

Yes Construction materials, like steel, cement,

crushed stones, sand, rubble, etc. required

for the proposed project shall be procured

from the local market of the region.

2.5 Forests and timber (source - MT) No

2.6 Energy including electricity and fuels (source,

competing users) Unit: fuel (MT), energy (MW)

Yes Please refer Annexure – VII.

2.7 Any other natural resources (use appropriate

standard units)

No

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 Details there of (with approximate

quantities/rates, wherever possible) with

source of information data

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 –VIII.

3.2 Changes in occurrence of disease or affect

disease vectors (e.g. insect or water borne

diseases)

No

3.3 Affect the welfare of people e.g. by changing

living conditions?

No

3.4 Vulnerable groups of people who could be

affected by the project e.g. hospital patients,

children, the elderly etc.

No

3.5 Any other causes No

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

Sr.

No.


quantities/rates, wherever possible)


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 – V.

4.4 Other industrial process wastes Yes Please refer Annexure – V.

4.5 Surplus product No

4.6 Sewage sludge or other sludge from effluent

treatment Yes

Please refer Annexure – V.

4.7 Construction or demolition wastes No

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 Yes

Please refer Annexure – V.

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

Sr.

No.




5.1 Emissions from combustion of fossil fuels

from stationary or mobile sources

Yes Please refer Annexure – IX.

5.2 Emissions from production processes Yes Please refer Annexure – IX.

5.3 Emissions from materials handling storage or

transport

No

5.4 Emissions from construction activities

including plant and equipment

No

5.5 Dust or odours from handling of materials

including construction materials, sewage and

waste

No

5.6 Emissions from incineration of waste No

5.7 Emissions from burning of waste in open air e.g. slash materials, construction debris)

No

5.8 Emissions from any other sources No

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

Sr.

No.



with source of information data with


6.1 From operation of equipment e.g. engines,

ventilation plant, crushers

Yes The Noise level will be within the

prescribed limit. At noisy areas adequate

preventive & control measures will be

taken. No significant noise, vibration or

emission of light & heat from the unit.

6.2 From industrial or similar processes Yes - Do-

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

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.


quantities/rates, wherever possible) with


7.1 From handling, storage, use or spillage of

hazardous materials

Yes Please refer Annexure – VIII.

7.2 From discharge of sewage or other effluents to

water or the land (expected mode and place of

discharge)

Yes • The final treated effluent from the

industry shall go to CETP for further

treatment and final disposal.

• Effluent generation from the domestic

will be send to septic tank/soak pit.

7.3 By deposition of pollutants emitted to air into

the and or into water

No

7.4 From any other sources No

7.5 Is there a risk of long term build up of

pollutants in the environment from these

sources?

No

8. Risk of accidents during construction or operation of the Project, which could affect human

health or the environment

S.No. Information/Checklist confirmation Yes/No Details there of (with approximate



8.1 From explosions, spillages, fires etc from

storage, handling, use or production of

hazardous substances

Yes Please refer Annexure – X.

8.2 From any other causes No

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

(II) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance (within 15km.) Proposed

project location boundary

1 Areas protected under international

conventions, national or local legislation for their ecological, landscape, cultural or other

related value

- Proposed project site is within the Sarigam

GIDC Industrial Estate, Dist.: Valsad

2 Areas which important for are or sensitive Ecol

logical reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres,

mountains, forests

Daman

Ganga

River

Daman Ganga River - 13 km away from

Project Site.

3 Area used by protected, important or sensitive

Species of flora or fauna for breeding, nesting,

foraging, resting, over wintering, migration

Dadra

Nagar

Haveli

Reserve

Forest

Dadra Nagar Haveli Reserve Forest – 15

km away from Project Site.

4 Inland, coastal, marine or underground waters - No inland, costal or marine within 15 km

from the proposed project

5 State, National boundaries - N.A. 6 Routes or facilities used by the public for access

to recreation or other tourist, pilgrim areas

- Public transportation

Sr. No.

Information/Checklist confirmation

Yes/No

Details there of (with approximate



9.1 Lead to development of supporting. utilities, 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 industry

• supply industry

• other

Yes Please refer Annexure – XI.

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

9.4 Have cumulative effects due to proximity to

other existing or planned projects with similar

effects

No

7 Defense installations - N.A.

8 Densely populated or built-up area Vapi Vapi is around 18 km away from the

proposed project site.

9 Area occupied by sensitive man-made land uses Hospitals, schools, places of worship,

community facilities)

No

10 Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture, fisheries, tourism, minerals)

No

11 Areas already subjected to pollution

environmental damage. (those where existing

legal environmental standards are exceeded)or

- N.A.

12 Areas 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: N.A.

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products along with their Production Capacity

II Plant Layout

III Brief Manufacturing Process Description

IV Details of Effluent Treatment Plant

V Details of Hazardous Waste Generation and Disposal

VI Details of water consumption & waste water generation

VII Details of Fuel & Energy Requirements

VIII Details of Hazardous Chemicals Storage & Handling

IX Details of Stacks and Vents

X Risk Scenario

XI Socio-economic Impacts

ANNEXURE-I

_______________________________________________________________________

LIST OF PROPOSED PRODUCTS ALONG WITH THEIR PRODUCTION

CAPACITY WITH RAW MATERIALS

SR. NO. NAME PROPOSED QUNTITY

(MT/MONTH)

Pesticide Products

1 Glyphosate

100

2 PMIDA (Intermediate)

3 Acephate

4 Cypermethrin

5 Permethrin

6 Lambda Cyhalothrin

7 Alphamethrin

8 Imidaclorpid

9 Acetamipid (Acetamiprid)

10 Thioclorpid

11 Temephos

12 Dichlorovos

13 Thiomethoxan (Thiomethoxam)

14 Metsulfuron Methyl

15 Paraquat

16 Imazethapyr

17 2-4 D-Ethyl Ester

18 Copper Oxy Chloride

19 Ziram

20 Carbendazim

21 Butachlor

22 Chloropyriphos

23 Tricyclozole

24 Bifenthrin

25 Chodinofop

26 4-Amino 1,2,4 Triazole (Intermediate)

By Products

27 Ammonium Acetate Solution (44.92 %) 179.4

28 Sodium Sulfide (Sulfit)e 110.7

29 HCl (30 %) 92

ANNEXURE-II

_______________________________________________________________________

PLANT LAYOUT

HO

HOP

O

CH2 NCH2COOH

CH2COOH

++

O2CH2COOH

NCH2

O

PHO

HO

HCO2 HCHO+

ANNEXURE-III

_______________________________________________________________________

MANUFACTURING PROCESS

1. GLYPHOSATE

1.1 Process Description

PMIDA is oxidize under pressure at 50 oC in presence of carbon catalyst. The mass is

concentrated, crystallize, filter and dried to get Glyphosate technical.

1.2 Chemical Reaction

1.3 Material Balance

Stage - 1: Preparation of IDA.HCl

Cl - CH

2

- COOH + NH

4

OH + Ca(OH)

2

+ HCl + H

2

O

Monochloro

Acetic Acid

Ammonium

Hydroxide

Calcium

Hydroxide

Hydrochloric

Acid

Water

HCl

NH

CH

2

- COOH

CH

2

- COOH

+ CaCl

2

+ H

2

O

IDA.HCl

Calcium Chloride

Water

Stage - 2: Preparation of PMIDA

IDA.HCl

CH2 - COOH

CH2 - COOH

NH

HCl

+ H

3

PO

3

+ HCHO + H

2

O

Phosphorus Acid

Formaldehyde

Water

P - CH

2

- N

OHO

HO

CH

2

- COOH

CH

2

- COOH

+ H

2

O + HCl

PMIDA

Water Hydrochloric Acid

(Phosphono Methyl Imino Diacetic Acid)

2. PMIDA (Intermediate)


MCA (Monochloro acetic acid) is reacted with Ammonia in presence of Calcium hydroxide

forming hydrochloric salt of IDA (Imino di acetic acid). The reaction is carried out at 45°C

under atmospheric condition. After reaction the mass is chilled to below 10°C & filtered. Wet

cake of IDA.HCl is further reacted with phosphorus acid & Formaldehyde at 110 to 115°C to

give PMIDA.

PMIDA is reacted with Ammonia solution to make Ammonium salt of PMIDA, which further

with oxygen in presence of carbon catalyst to give Ammonium salt of Glyphosate. During

reaction CO2 & Formaldehyde gas is evolved which is scrubbed in water scrubber followed by

caustic scrubber. The mass is acidified with Sulphuric acid & crystallized it as 0 to 5°C to get

Glyphosate acid.


H2O 1300 Kg

MCA 1332.15 kg

20% Amm. Sol. 119.82 kg

Ca(OH)2 522.21 kg

HCl 30% 257.26 kg

22.48% CaCl2 solution 2337.03 kg

H3PO3 577.97 kg

37% HCHO 211.4 kg

H2O 380.6 kg

IDA.HCl 1194.71 kg

Evaporation loss 18.6

Kg

Waste water 2156.14 kg

PMIDA 1600 kg

HCl 1410 kg


Stage : 1

IDA. HCl

Reaction

Stage : 2

PMIDA

Reaction

3. ACEPHATE


Dimethyl Phosphoro Amido Thioate (DMPAT) is isomerizes to Methamediphos catalytic

reaction at 30oC and atmospheric pressure. After Isomerization, the mass is reacted with

acetic anhydride at 40oC in the presence of Dichloro methane as solvent. It is neutralized with

aqueous ammonia. The layers are separated and aqueous layer containing Ammonium acetate

is sold as by product. The organic layer is taken in another reactor for dichloromethane

recovery and Acephate separation.

Recovered dichloromethane is recycled in the next batch and Acephate solution. It is

centrifuged at 50oC. Ethyl acetate is recovered from the mother liquor of crude Acephate cake

and it is recycled. The residue is incinerated. The cake is dried in rotary vacuum dryer. The

dry acephate is filled in bags as final packing.


CH3O S CH3S O

P NH2 P NH2

CH3O CH3O

Dimethyl phosphoro amido thioate Methamidophos

CH3S O CH3 CO CH3S O

P NH2 + O P NHCOCH3 + CH3COOH

CH3O CH CO CH3O

Methamidophos Acetic anhydride Acephate Acetic acid

CH3COOH + NH4OH CH3COONH4 + H2O

Acetic acid Ammonium hydroxide Ammonium Acetate water

4. CYPERMETHRIN


The reaction mixture of Cypermethric acid chloride & metaphenoxybenzaldehyde is reacted

with sodium cyanide in presence of hexane. The reaction is carried under controlled

temperature conditions in presence of phase transfer catalyst.

The reaction mass is then washed with water. After completion of washing the organic mass is

taken up for recovery of the excess hexane, to get Cypermethrin technical.

The Aqueous waste with traces of sodium cyanide is de

Sodium Hypochlorite 8% concentrated solution. The solution is treated such that the treated

waste contains sodium cyanide up level of < 0.2 ppm.




ence of phase transfer catalyst.


taken up for recovery of the excess hexane, to get Cypermethrin technical.

The Aqueous waste with traces of sodium cyanide is detoxified by treating the aqueous with


waste contains sodium cyanide up level of < 0.2 ppm.




toxified by treating the aqueous with


5. PERMETHRIN


Meta Phenoxy Benzyl Alcohol is reacted with Cypermethric Acid Chloride (CMAC) to

give the Permethrin mass.

Hydrochloric acid gas is generated during the reaction which is scrubbed in water to get

30% solution of hydrochloric acid. The resu

carbonate solutions as well as water. And finally the remnesant water is dehydrated off &

to get the pure Permethrin Tech.




30% solution of hydrochloric acid. The resulting mass is then washed by potassium


to get the pure Permethrin Tech.



lting mass is then washed by potassium


6. LAMBDA CYHALOTHRIN


Crysanthanic Acid is chlorinated with thionyl chloride as the chlorinating agent using hexane

as the solvating media. Sulphur di Oxide and hydrochloric acid gas which is evolved is

scrubbed in a two stage scrubber.

The reaction mass Tri Fluoro Propenyl Acid Chloride (TFP Acid Chloride) is then condensed

with Meta Phenoxy Benzaldehyde, Sodium Cyanide to form the Product Cyhalothrin. In this

process n - Hexane is used as solvent along with phase transfer Catalyst.

The reaction mass of Cyhalothrin is washed with water. The aqueous is separated for

detoxification. Solvent- n-Hexane is stripped off to get pure Cyhalothrin oil. Finally Cyhalothrin

oil is epimerized in Isopropyl Alcohol to give Lambda Cyhalothrin of 85 % (Min.)

An aqueous layer which contains traces of Sodium Cyanide is detoxified by the treatment of

Sodium Hypochlorite Solution (8 - 10%) up to < 0.2 ppm Level. Then it is mixed up with main

ETP stream for further treatment & finally discharged to CETP System.

Cl2 HC

CH3 CH3

C

O

O CH CN

O

Epimerisation

Cypermethrin Alphamethrin

O

CNCH

CH3CH3

HCCl2 CO2

7. ALPHAMETHRIN


The cypermethrin is subjected to epimerization at 25 oC in the presence of triethyl amine in

solvent hexane to obtain alphamethrin. Then it is filtered and dried under vacuum. Hexane and

TEA are recovered and recycled. The purity of Alphamethrin obtained will be minimum 95 %.



INPUT QTY

(KG)

OUTPUT QTY

(KG)

Cypermethrin 1250 Alphamethrin 1000

Triethylamine 300 Triethylamine (Recovered) 285

Water 500 n-Hexane (Recovered) 552

n-Hexane Cypermethrin 250

n-Hexane (Recovered) 552 Waste water 563

n-Hexane (Fresh) 48

Total 2650 Total 2650

N N NH

N-NO

2

N

Cl.CH

2

+

Cl

2-Chloro5-Chloro Methyl Pyridine

NaOH

DMF

N

Cl

2

N NH

N-NO

2

CH

2

I Mida Cloprid

8. IMIDACLORPID


(A) dimethylformamide is charged into the reactor to which is added 2-nitroimidazolidine.(B)

2-chloro-5-chloromethylpyridine is charged into the reactor to form solution. (C) Solution in

reactor (B) is charged to reactor mass of (A) to which is added sodium hydroxide. It is stirred

for 6 hrs. After reaction is complete the reaction mass is filtered to remove Nacl formed in the

reaction. The filtrate is distilled to remove DMF. The concentration filtrate is reacted with

hydrochloric acid to precipitate imidacloprid which is filtered and dried.



BASIS: 1MT/day

Reactor

Reactor

Filter

Reactor

Filter

600 Kg 2-Chloro-5-Chloromethyl Pyridine

2000 Liter DMF

1500 Liter DMF

510 Kg 2-Nitroiminoimidazolidine

160 Kg Caustic Soda

DMF

Cake sodium chloride to solid

waste

40 Liter Hydrochloric acid

Imidacloprid for drying

Filtrate to Effluent

N

Cl

CH

2

Cl

+

HN - C - CH

3

CH

3

N

CN

CH

2

Cl

N

N

CH

3

CH

3

N

CN

DMF

K

2

CO

3

2-Chloro 5-Chloromethyl Pyridine

2-Cyanoimino

2-methylamino Ethane

Acetamiprid

9. ACETAMIPID


(A) 2-Chloro 5- chloro methyl pyridine is charged to a reactor containing dimethylformalmide.

It is stirred for 1hr to form solution. (B) Dimethylformamide is charged to the reactor to which

is added 2-cyanoimino 2-methylamino ethane and stirred for 1 hrs. (C) Solution in (A) is

charged to solution (B) followed by potassium carbonate. It is stirred for 4.5hrs. After reaction

is complete the reaction mass is filtered to remove potassium chloride formed during the

reaction. DMF which is recycled to the concentration reaction mass is added 30% hydrochloric

acid to precipitation out acetamiprid which is filtered and dried



BASIS: 1 MT/day

Reactor

(A)

Reactor

Filter

Reactor

(B)

Filter


2000 Liter DMF

1500 Liter DMF

460 Kg 2-Cynoimino 2-Methylamino Ethane

340 Kg Potassium Carbonate

DMF

Cake of Potassium chloride

60 Liter Hydrochloric acid (30%)

Acetamiprid for drying

Filtrate to rectification

HN S

N

CN

+

N

Cl

ClCH2

K

2

CO

3

DMF

N

Cl

CN

N

N S

2-Cyanoimino Thiazole

2-Chloro 5-Chloromethyl Pyridine

Thiacloprid

10. THIOCLORPID


(A) dimethylformamide is charged into the reactor to which is added 2-chloro 5-chloromethyl

pyridine and stirred to form solution. (B) Dimethylformamide is charged into the reactor to

which is added 2-cyanoimino thiazole. It is stirred to form solution. (C) Solution in reaction

(A) is charged to solution in (B) followed by potassium carbonate. It is stirred for 6hrs. After

reaction is complete, the reaction mass is filtered to remove potassium chloride formed during

the reaction. The filtrate is concentrated by distilled DMF which is recycled to the concentrated

mass is now added, hydrochloric acid to precipitate out THIACLOPRID which is filtered and

dried.



BASIS: 1 MT/day


Cake of Potassium chloride

50 Liter Hydrochloric acid

Reactor

Reactor

Filter

Reactor

Filter

1800 Liter DMF

1500 Liter DMF

530 Kg 2-Cynoimino Thiazole


DMF

Thiacloprid for drying


11. TEMEPHOS


TDS is condensed with DMTC in presence of a phase transfer catalyst. MDC is used as

solvent. Caustic Lye is added to the mass for pH maintaining. After complete reaction, the

mass is heated & water is added for the purpose of washing. Aqueous is separated and

discharged to ETP for further treatment. MDC is then recovered to 95% (min) to give

Temephos Tech. (90%) as final product.

End Use

Pesticide formulation & as an Insecticide.


12. DICHLOROVOS


Dichlorovos Technical is manufactured by condensing Chloral and trimethyl Phosphate. After

condensation Methyl Chloride is removed by deg

The Dichlorovos thus obtained is packed in HMHDPE drums and dispatched.



condensation Methyl Chloride is removed by degassing.

The Dichlorovos thus obtained is packed in HMHDPE drums and dispatched.


HN

O

N

N- NO

2

-CH

3

+

N

S

Cl

CH

2

Cl

DMF

K

2

CO

3

Cl

N

S

N

O

N-CH

3

N

NO

2

4-Nitroimino 3-methyl Isoxazole

2-Chloro 5-Chloro

mthyl Tiazole

Thiamethoxam

13. THIOMETHOXAN


(A)Dimethylformamide is charged into the reactor, to which is added of 2-chloro 5-

chloromethyl thiazole. (B) 4-Nitroimino 3-methyl isoxazole is charged into

Dimethylformamide take into the reactor. It is stirred for 1 hr to form solution. (C) Solution in

(B) is charged into reaction mass of solution (A) to which is added potassium carbonate. It is

stirred for 5 hr. After reaction is over the reaction mass is filtered to remove potassium chloride

formed in the reaction. The filtrate is distilled to remove DMF. The concentrated filtrate is

reacted with 30 % Hydrochloric acid to precipitate Thiamethoxam.



BASIS: 1 MT/day

Reactor

(B)

Reactor

Filter

Reactor

(A)

Filter

600 Kg 4-Nitroimino-3-methyl Isoxazole

2000 Liter DMF

2000 Liter DMF

638 Kg 2-Chloro-5-Chloromethyl Thiazole


DMF

Thiamethoxam for drying


50 Liter Hydrochloric Acid (30%)

Cake of Potassium Chloride to

Solid wast

C

S NH

2

O

O

O

O - C - H

+ O

C

O-CH

2

-CH

3

Cl

Na

2

CO

3

O-Sulfamoyl Methyl Benzoate

Ethyl Chloro Formate

CH

3

CH

2

O

C

NHS

CH

3O

C

O

+

N

N

N

NH

2

H3

CO

CH

3

2 Amino 4methoxy 6 methyl 1,3,5 triazine

O

C

O

CH

3

O

C

O

O

C

O

S NH

C N

N

N

CH

3

OCH

3

Metsulfurun-Methyl

14. METSULFURON METHYL


O-Sulfamol methyl benzoate is charged into the reactor to which xylene is charged this is

further reacted with Ethylcloroformate and soda ash is added slowly. After reaction is over the

reaction mass is filtered to remove sodium chloride. The filterate is taken into another reactor

to which is added 2, amino 4- methyl 1,3,5triazine. The mass is stirred for 4 hrs. After reaction

is over Xylene is distilled out which is recycled,, the mesulfuron methyl formed is filtered and

dried.



BASIS: 1MT/day

Reactor

Filter

Reactor

Filter

1500 Liter Xylene

160 kg Soda Ash

650 kg o-Sulfomoyl methyl benzoate

330 kg Ethylchloro formate

Wet cake to Solid

Waste Filtrate

425 kg 2-amino 4-methoxy 6-methyl

1,3,5 triazine

Filtrate

Xylene Distilled

Metsulfuron Methyl for Drying

N

N

+ 2 CH

3

Cl

H

3

CN

N

+ CH

3

. 2Cl

-

Bipyridyl Methyl Chloride

15. PARAQUAT


Bipyridyl is added to water to which is added methyl chloride gas. The mass is stirred,

concentrated and filtrate is recycled.



BASIS: 1 MT/Day

Reactor

Filter

1650 Liter Water

650 Kg Water Bipyridyl

420 Kg Methyl Chloride

Wet Cake for Paraquat Drying

Filtrate

N

C

2

H

5

C

C

O

O

O

+

H

3

C

CH

2

CH

CH

3

NH

2

CH

3

C

O

NH

2

O

O

C

C

N

C

2

H

5

N

C

CH

3

H

2

C-CH

3

C

CH

3

O

NH

2

+

NaOH

N

N

C

2

H

5

C

O

OH

O

CH

3

CH

2

CH

2

CH

2

2,3 Dicarboxylic acid anhydride,

5-methyl pyridine

2-amino 2,3 dimethyl butyramide

Imazethapyr

16. IMAZETHAPYR


Xylene is charged in to the reactor to which is added dicarboxylic acid anhydride, 5-methyl

pyridine followed by 2-amino 2, 3,dimethyl butyramide. The mixture is stirred for 6hrs. After

completion of reaction 25% sodium hydroxide is charged. After reaction is over aqueous layer

is separated, xylene is distilled out which is recycled and reaction mass is filtered to give

imazethapyr.



BASIS: 1 MT/day

Reactor

Reactor

Filter

1500 Liter Xylene

650 kg 2,3 dicarboxylicacidanhydride 5-ethyl pyridine

480 kg 2-amino 2,3 dimethyl butyramide

584 Kg

Caustic Soln. (25%)

Aqueous Layer

Aqueous Layer

Xylene Distilled

Effluent

Imazethapyr to Drying

O.CH 2COONa.H 2O

Cl

Cl

H2SO4 C2H5OH+ +

Cl

Cl

O-CH2-C-O-CH2-CH3

O

NaHSO 4 2H2O+ +

17. 2-4 D-ETHYL ESTER


Sodium Salt is charged into the reactor along with Ethyl Alcohol to from Homogenous

mixture.

Sulphuric acid is added slowly into the reactor. The mass is continuously stirred for 3 hrs.

Bottom layer separated from organic mass and sent for neutralization and recovery. Mother

liquor is washed, neutralized and heated to about 70 oC to make it moisture free and packed in

200 kg barrels.


100 kg S S

558 kg Sulphuric

Acid (98%)

327 kg Alcohol (90%)

Mother Liquor

Spent

954.8 kg

930.2 kg

To next stage

To Detoxificaation

Mother Liquor 954.8 Kg

800 Ltr Water

+

30 kg TEA

879 kg Ester

40 kg

821.85 kg Effluent

44 kg Water atm.

loss

Final product

Recycled

To Detoxificaation

821.85 kg

+ +

930.2 kg

+

65 kg NaOH

665.4 kg Na2SO4 By Product

1151.65kg Effluent

To ETP


Stage : 1

Condensatio

n

879.4 kg Ester

40 kg untreated

acid

20 kg water

8.4 kg H2So4

125.25 kg Alcohol (100

%)

159.44 kg Sulphuric (100

%)

468.40 kg Na So4

Stage : 2

Neutralizatio

n & Recovery

125.25 kg

Alcohol (100

%)

+

Stage : 3

Detoxification 125.25 kg

Alcohol (100

%)

+

2Cu + 2HCl CuCl2.Cu(OH) 2

O2

18. COPPER OXY CHLORIDE


Copper scrap is charged into a reactor and HCl added. Air is continuously purged into the

reactor till Copper Oxy Chloride technical is formed. Mother liquor is discharged and

neutralized to obtain 7 pH. Copper Oxy Chloride is centrifuged to obtain wet cake which is

further dried for final product.


Copper Scrap Fresh 622 kg

HCL (30%) 591 kg

Water 800 kg

Air

Recycled Copper Scrap 2387

kg Recycled HCl (3%) 1000 kg

Water (Air Scrubber) 800 kg

1000 kg. 3% HCl Soln.

from Air Scrubber

2387 kg. Copper Scrap

1056 kg.COC Tech.

2000 kg. Water

19.5 kg. HCl (100%)

Recycled

Recycled

2813

slurry COC

pH-6-6.5

to next stage

Slurry 6161

+

Water 500 kg.

+

NaOH 21.40 kg

1500 kg COC cake

+ 5176.15 kg. water

+ 31.25 kg. NaCl

+ 5 kg.

5212.40 kg

To

effluent

treatment

1500 kg by cake

1051 kg COC

449 kg Water

Final Product

Loss of atmosphere


Stage : 1

Air

Oxidation

Stage : 2

Neutralizatio

n

+

Filtration

Stage : 3

Drying

+

Filtration

(A)

NH

CH

3

CH

3

+ CS2 + NaOH

N - C -S Na

+ H

2

O

Dimethyl

Amine

Carbon

Disulphide

CH

3

Sodium Dimethyl Dithio Carbamate

(B)

N

CH

3

CH

3

- C - S Na + ZnSO

4

S

CH

3

S

CH

3

N - C -S Zn

CH

3

-S -C -N

CH

3

CH

3

S

Zinc Dimethyl Dithio Carbamate

2

19. ZIRAM


(A) Caustic soda solution is charged to the reactor to which added water and dimethylamine

solution (40%). Then carbondisulfide is added slowly to complete the reaction to give of

sodium dimethyl dithiocarbamate solution(40%). (B) Above solution is charged into the reactor

to which added water and zinc sulphate heptahydrate solution in water. The reaction mass is

stirred for two hours and filtered, washed to give ziram.(C) Water is charged into the reactor to

which added ziram wet cake. The reaction mass is stirred for 2-3 hrs and packed ziram 27% cs.



BASIS: 5000 Liter/day

Reactor

Reactor

Filter

Reactor

850 Liter Water

1200 Kg DMA

905 kg C. S. Lye

850 kg Carbon Disulfide

7000 Liter Water 1520 Kg Zinc Sulphate Heptahydrate Soln.

1500 Liter Water

To Packing

Filtrate

Wet

Cake

S = C

H

3

C - O

NH

2

NH

2

S

O

O

O

H

3

C

+

Thiourea

Dimethyl Sulphate

H

3

C - S

- C

NH

2

NH

2

+(SO

4

)

-

Y

2

+ O = C

Cl

O - CH

3

Methyl Chloroformate

+ NaOH

H

3

C - S - C

NH

2

N

C

O

O - CH

3

+

NH

2

NH

2

O-Phenylene Diamine

Methanol

NH

N

C

- N - C

O

OCH

3

Carbendazim

20. CARBENDAZIM


(A) Thiourea is mixed with water and to is dimethyl sulphate. It is refluxed and cooled to room

temperature (B) This is added to another reactor to which is added Methyl clorofomate, water

and 25% caustic soda solution. This is stirred for 2 hrs and filtered. (C) The wet cake is reacted

with O-Phynylene diamine and methanol.The reaction mass is stirred for 3 hrs and then

methanol is distilled out and carbendazim formed is filtered and dried.



660 kg o-Phenylene

diamine

Reactor

Reactor

Reactor

Filter

Filter

420 kg Thiourea

200 Liter Water

600 kg Dimethyl Sulphate

520 kg Methyl Chloroformate

3000 Liter Water

880 Kg NaOH soln. (25%)

1000 Liter Methanol

Filtrate to Effluent

Carbendazim

Methanol distilled and

recycled

N

C2H5

C2H5

CH2Cl

COCH 2ClC4H9OH+

COCH 2Cl

C2H5

C2H5

N

CH2OC4H9

NH3

CH2OC4H9N

C2H5

C2H5

COCH 2Cl

Butachlor

21. BUTACHLOR


MRM is reacted with Butanol to get Butachlor Technical under controlled temperature.

Ammonia gas is purged to neutralize the hydrochloric acid formed. Mother Liquor is washed to

remove ammonium chloride and taken for concentration to get Butachlor Technical.



Reactor + Neutralizer

SS Reactor

(Washing)

Distillation

Filtration

MRM (900 Kg)

Butanol (650 Kg Recycle +

350 Kg = 1000 kg)

Ammonia Gas (50-60 Kg)

Water (1000 Kg)

Butanol (650 Kg) Recycle to

Reactor + Neutralizer

Butachlor (1050 Kg) for packing

Water (1000 Kg)

NH4Cl (175 Kg)

To ETP

&

Recovery

CCl3COCl CH2 CH.CN+

OH

Cl

Cl

Cl

N

N

Cl

Cl

Cl

OH

+ NaOH

Cl

Cl

Cl

N

ONa

+ H2O

ONa

N

Cl

Cl

Cl

+ Cl P

OC2H5

OC2H5

SCl

Cl

Cl

N

S

OC2H5

OC2H5PO

NaCl+

22. CHLOROPYRIPHOS


NaHTCP is reacted with DETC in presence of phase transfer catalyst at room temp. EDC is

used as solvent. After reaction aqueous phase in separated and sent to ETP for treatment.

Organic mass is concentrated under vacuum to get CPP technical.


400 KGS

450 KGS

401Kgs

2000 KGS

12 KGS CATALYST

TCAC

DRUM

2900 KGS

310 KGS 3000 KGS

5272 KGS

400 KGS

1962 KGS HTCP MASS

5400 KGS WATER

3000 KGS CAUSTIC LYE

(47-48%)

UTILITY

BRINE WATER 1010-15 C

UTILITY

LPS -4 KGS

CH-WATER

10362 KGS Na-HTCP MASS

5217 KGS 4145 KGS

5834 KGS 4557 KGS

UTILITY

CHILD WATER

3500 KGS

1391 KGS

7781 KGS

Utility CW


V-9022 ACN DAY

TANK 5 S 316, 2.2 KL 15 MTR.

ACN TANK

V- 9001A SS 316, 12

KL 0 MTR

HTCP REACTOR

R-9003 C MSGL

6.3 KL 5 MTR

HTCP REACTOR

R-9003 B MSGL

8.3 KL 5 MTR

HCL SCRUBBER

FRB 10 Mtr

TCAC DAY

TANK MSLL, 2.5

KL 10 MTR

HTCP REACTOR

R-9004 B MSGL

8 KL 5 MTR

CPN TANK

R-9004B

MSLL,KL

0 MTR

HTCP DISTILATION

R-9005 A MSGL 6.3

KL 15 MTR

N3 - HTCP PREPARATION

R-9001 SS-316, 10 KL 10

MTR PRESSURE REACTOR

R-9008 SS-316, 7.5 KL

15 MTR

PRESSURE REACTOR

R-9008 SS-316, 6 KL 10

MTR

CPN ®TANK, ICU

V-

MSGL, 1 KL

0 MTR

CPN (RS) TANK, II CUT

V- 5101A

MSLL, 6 KL

0 MTR

SLURRY HOLD TANK

PP+FRP 10 KL

10 MTR

SLURRY COOLER MS

14 KL + 10 MTR

ML HOLD TANK

MS CARBON 10 KL

9 MTR

SLURRY FILTRATION

PP FILTER PRESS

5 MTR WAT CAKE

SLURRY PREPARATION V- 9013 A MS FRP, 5 KL 5 MTR

SLURRY PREPARATION V- 9013 A MS FRP, 5 KL 5 MTR

TOXIFICATION REACTOR R- 9002 A SS FRP, 6.5 KL 10 MTR

FILTRATION WOODEN FILTER PRESS NOs OF PLATE

1 st

SEPRATOR

SS 316 10 MTR

2 nd

SEPRATOR

SS 316 5 MTR

ML TANK V- 9010 MA CARBON 12 KL 0 MTR

EMUISON TANK V-43 S SS 31 B KL 0 MTR

ORGANIC HOLD TANK SS 316, 5 KL 0 MTR

EDC RECOVERY R-9007 A SS 316, 6 KL 15 MTR

CRYSTALISER CR-1, SS 316 10 MTR

CRYSTALISER CR-2, SS 316 10 MTR

METHANOL RECOVERY R- 9006 SS 316, 6 KL 5 MTR

7762.4 KGS MASS FOR FILTRATION 7752.4 KGS MASS FOR FILTRATION

3400 KGS SLURRY

500 KGS WATER (2 TIMES)

7552.4 KGS CLEAR FILTARATE (ORG +AQ) 200 KGS WAT CAKELUT

EMULSION

352.4 KGS

4400 KGS URG

3800 KGS Aqu

1000 KGS WASH

PRODUCT CPP TECH GRADE 3500 KGS

ML FOR 2 nd

CROP 1775.6 KGS FOR 2 nd

CROP

500 KGS AS 2 nd

CROP

1275.6 KGS

RESIDUE

795.6

4500 KGS ORGAN MASS FOR EDC RECOVERS

4860 KGS CRUDE (6 EDC LOTS)

1820 KGS

EDC LOSS

16200 KGS

EDC RECOVER

50 KGS METHANOLE RECOVER

50 KGS

METHANOLE RECOVER

3800 KGS EDC 35 KGS NaCl 59 KGS HCl 7 KGS TEBA 0.4 KGS 4-DMAP 636 KGS DETC 120 KGS Na2Co3 10KGS MOREWAT

1800 KGS WET CARE

1600 KGS WATER

1800 KGS WET CARE

1600 KGS WATER

PART –B PART –A

23. TRICYCLOZOLE


2 Hydrazino -4- Methyl Benzo Thiozole is reacted with Formic Ac

reaction at 110 degree Centigrade. The reaction mass is maintained for about 8

completion of the reaction the mass is drowned in Chilled water. Subsequently it is filtered in a

nutche. The massed is centrifuged and dried


Methyl Benzo Thiozole is reacted with Formic Acid; this is a cyclzation

reaction at 110 degree Centigrade. The reaction mass is maintained for about 8


nutche. The massed is centrifuged and dried to get in a tray drier for Tricyclozole (technical).

id; this is a cyclzation

reaction at 110 degree Centigrade. The reaction mass is maintained for about 8-10 hrs. On


to get in a tray drier for Tricyclozole (technical).

F

F

F

c c c cc

Cl

Cl

Cl

CH2CH2

CH3

CH3

OCH 3

O

H

+ CH3 CH3

CH3

OK

C

CH3

Cl

cc

F

F

F CH

CH3O

OCH 3

c+SOCl2

c

OCH3

CHc

Cl

CH3

F3C

Cl

+

HOH 2C CH3

F3C

CH3

Cl

c CH

CH3O

c

CH3

O

CH2

Bifenthrin

24. BIFENTHRIN


Hexane is charged into reactor to which is added cyhalothrin followed by potassium t-butoxide.

It is stirred for 4 hrs. after reaction is complete, the reaction mass is cooled. Water is added to

remove potassium chloride formed in the reaction. Aqueous layer is separated and hexane is

distilled out. After that thionyl chloride is charged. Hydrochloric acid gas and sulfur dioxide is

scrubbed in caustic solution. After reaction is over again hexane is added and excess of thionyl

chloride is recovered by distillation. This is followed by addition of 2-methyl 3-methylhydroxy

bipyridyl. It is stirred for 6 hrs. after reaction is over hexane is distilled out and after cooling

Bifenthrin is filtered and dried.



BASIS: 1 MT/Day

Reactor

Filter

815 Kg Cyhalothrin

3000 Liter Hexane

480 Kg 2-methyl

3-methylhydroxy bipyridyl

276 Kg Potassium t-butoxide 300 Liter SOCl2

SO2 + HCl to scrubber

Hexane distilled recycled

Solvent

Bifrnthrin

N

Cl

Cl

Cl

F2+

F

FCl

Nsolvent

OH

OH

+

N

OH O Cl

F

+H3C CH C

OC2H5

OHCl

O

N

F

Cl O CH

CH3

COOH

Clodinofop

25. CLODINOFOP


2,3,5 Trichloro pyridine is reacted with fluorine in a vessel to give 2,3 Difluoro 5-chloro

pyridine which is further reacted with hydroquinone solvent is distilled out and reaction mass is

cooled and filtered. The product is further reacted with ethyl ester of 2-chloro propionic acid in

presence of toluene. After reaction is over, the toluene is distilled out. The reaction mass is

cooled and filtered to give Clodinofop which is dried.



BASIS: 1 MT/Day

Reactor

Filter

375 Kg Hydroquinone

260 Kg 2,3,5 Trichloro pyridine 130 Kg F2

Solvent

Solvent

Solvent

Reactor

Filter

3000 Liter Toluene 470 Kg ethyl ester of 2-chloro propionic acid

Toluene

Toluene distilled

Filter Cake Clodinofop for drying

H.NH.NH 2.H2O HCHO H C

O

N

H

NH2+

Hydrazene Hydrate Formic Acid

2H2O+

NH2

H

N

O

CH

Reflux

140 oC

H

H

NH2

+ 2H2ONC

N

N

C

4-Amino 1,2,4 Thiazole

26. 4-AMINO 1,2,4 TRIAZOLE


Hydrazene Hydrate is charged in reactor followed by formic acid at 45 oC. The mass is

refluxed at 140 oC for 24 hrs. Mass is cooled to 50

oC and dried atmospherically. Finally

powder is dried in a drier and packed.



Reactor

Hydrazene Hydrate (80 %) 1800 kg

Formic Acid (85 %) 1548 kg

Methanol 105 kg

Effluent 2453 kg

4-amino 1,2,4 Triazole 1000 kg

ANNEXURE - IV

DESCRIPTION OF EFFLUENT TREATMENT PLANT WITH FLOW DIAGRAM

M/s. Anu Products Ltd. is proposing a new ETP of consisting of primary, secondary and

tertiary treatment units. A detail of the proposed ETP plant with unit dimensions is given

below.

PROCESS DESCRIPTION OF PROPOSED ETP

Raw effluent from all the plants will be transferred by means of effluent transfer pumps to Oil

& Grease Trap. The oily scum will be removed here and then effluent will be allowed to enter

into Collection cum Equalization Tank. The fixed type diffusers will be provided at the bottom

& air will be supplied by Air Blowers. This tank will take care of shock loading. The equalized

effluent will be pumped to Neutralization Tank where acid/alkali solution will be dosed by

dosing pumps.

The neutralized effluent will be transferred to Flash Mixer by effluent transfer pumps, where

polyelectrolyte will be added as a coagulation aid. The effluent from Flash Mixer will be

overflowed to Flocculation Tank, where flocs will be formed and will taken to Primary

Lamella type Settling tank for separation of solids as primary sludge. The clarified effluent

from Primary settling tank will overflowed to two stage aeration tank, where Urea & DAP will

be dosed.

The effluent in the Aeration Tank will be treated in extended type activated sludge process.

Retrievable type fine bubble membrane diffusers will be provided at the bottom of tank for

supply of air into the system. The overflow of Aeration Tank will be taken Holding Tank. The

settled biomass from bottom will be recirculated by recirculation pumps to Aeration Tank to

maintain required biomass level.

The effluent from Holding Tank will be pumped to Pressure Sand Filter to remove TSS and

will be passed to Activated Carbon Filter, to remove the color and polish the effluent to meet

the GPCB norms. The outlet of Activated Carbon Filter will be enter to underground GIDC

drainage by means of HDPE pipe laid from Activated Carbon Filter to GIDC Chamber.

The sludge will be drained into Sludge Thickner. The sludge consistency will be increased in

Sludge Thickner. The sludge from the bottom of Sludge Thickner will be fed to Decanter to get

sludge cake having more consistency of solids. The overflow from Sludge Thickner will go

into Overflow chamber, from where it will be pumped to Collection Sump for further

treatment. High COD stream will be segregated and send to Common Incinerator facility for

incineration.

Proposed Effluent treatment plant flow diagram is given in Figure and list of units of ETP with

their size are given in Table.

LIST OF ETP UNITS AND SIZE:

Sr.

No.

Unit Dimensions

1 Oil & Grease Trap 1 x 1.5 x 1.2

2 Collection Tank 3.2 x 3.2 x 2.5 (2 nos.)

3 Effluent transfer pump 1 HP

4 Neutralization tank 2.9 x 2.9 x 2 (2 nos.)

5 Flash mixer/ Flocculater 1.2 x 1.2 x 1.5

6 Primary Lamella type settling tank with tube

deck packing

3.2 x 3.2 x 2.5

7 Filter press 28 x 28

8 Two Stage Aeration tank with in built Clarifier 9.6 x 6.4 x (4.5 + 0.5)

9 Activated sludge recirculation pump 1 HP

10 Treated Effluent collection tank 3.16 x 3.16 x 2.5

11 Filter pump -

12 Pressure san filter 1.6 x 2.5

13 Activated carbon filter 1.6 x 2.5

EFFLUENT TREATMENT PLANT

ANNEXURE - V

HAZARDOUS WASTE GENERATION AND DISPOSAL

SR.

NO.

TYPE OF WASTE TOTAL PROPOSED

QUANTITY

CATEGORY NO. DISPOSAL

1 ETP Sludge 5 MT/Month 34.3

To TSDF, Vapi for land filling

2 Used Oil 0.01 KL/Month 5.1 Reuse/recycle for lubrication

3 Discarded Containers/bags 920 nos./Month 33.3 Decontamination, detoxification and sold to GPCB

approved vendors

4 Distillation residue 0.85 MT/Month 29.1 To common Incinerator of M/s. PECS, Sarigam for

incineration

5 Filter Aids 0.09 MT/Month 35.1 To common Incinerator of M/s. PECS, Sarigam for

incineration

6 Contaminated cotton waste 0.042 MT/Month - To TSDF, Vapi for land filling

7 Waste insulation material 0.09 MT/Month - To TSDF, Vapi for land filling

8 Fly Ash 0.5 MT/Month - To Proposed Ash dump facility with premises or Sold to

Cement Brick Manufacturer or send to TSDF, Vapi for

land filling

C:\Users\Admin\Desktop\FORM-1 (EC Extension).docx of 100

ANNEXURE – VI

DETAILS OF WATER CONSUMPTION AND WASTEWATER GENERATION

SR.

NO.

CATEGORY WATER

CONSUMPTION

LITERS /DAY

EFFLUENT

GENERATION

LITERS /DAY

1 Process 32,000 22,000

2 Boiler 16,000 11,000

3 Cooling 15,000 2,500

4 Washing/Floor/Equip.

/drum washing

3,500 3,200

5 Others/

Gardening

1,500 1,500

6 Domestic 2,000 1,800

Total 70,000 42,000


ANNEXURE-VII

_______________________________________________________________________

FUEL & ENERGY REQUIREMENT

TOTAL POWER REQUIREMENT (KVA)

Sr.

No. Scenario

Project

(KVA) Total (KVA)

1 Proposed 500 500

SOURCE OF POWER (KW)

Sr. No. Scenario Source

1 Proposed DGVCL

DG set (750 KVA)

(as emergency used only)

FUEL REQUIREMENT

Sr.

No.

Fuel Total Proposed

Consumption

1 FO 45 KL/Month

2 Diesel 200 Liter /Month


ANNEXURE-VIII

___________________________________________________________________________________________________________________

STORAGE DETAILS OF HAZARDOUS CHEMICALS

Sr.

No

Name of

Hazardous

Quantity

stored

(Including in

process

& handling)

(MT/Month)

Places of

its

Storage

State &

Operating

Pressure &

Temp.

Type of Hazards

Possible (Fire, explosive,

toxic release, spillage etc.

Control measures

provided

1 Sulphuric Acid 15 Tank Ambient Corrosive, Spillage

• Dyke around the tank will be provided.

• Fire Extinguishers & Hydrant points

will be provided.

2

MDC 10 Tank Ambient Fire, Spillage



will be provided.

3

DMS

10 Drum Ambient Fire, Spillage

• Drum will be stored on pallet with the

suitable trap.


will be provided.

4

Ethyl Acetate 15 Tank Ambient Fire, Spillage



will be provided.

5 Acetic

anhydride 10 Tank Ambient Corrosive, Toxic



will be provided.

6

Iso Propyl

Alcohol

15 Tank Ambient

Fire, Spillage



will be provided.


7 Hexane 15 Tank Ambient Fire, Spillage



will be provided.

8 HCl (30%) 15 Tank Ambient Corrosive, Toxic



will be provided.

9 Toluene 15 Tank

Ambient Fire, Spillage



will be provided.

10 DMF 10 nos.

(250 kg) Drum Ambient Fire, Spillage

• Drum will be stored on pallet with the

suitable trap.


will be provided.

11 Xylene 10 nos.

(200 kg each) Drum

Ambient Fire, Spillage • Drum will be stored on pallet with the

suitable trap.


will be provided.

12 Thiourea 5 Bag Ambient

Corrosive, Toxic • Bags will be stored on pallet with the

suitable trap.


will be provided.

13 Ethanol 10 Tank

Ambient Corrosive, Toxic • Dyke around the tank will be provided.


will be provided.

14 Formaldehyde 10 nos.

(200 kg each)

Drum

Ambient Fire, Spillage • Drum will be stored on pallet with the

suitable trap.


will be provided.

15 Butanol 10 nos. Drum Ambient Fire, Spillage • Drum will be stored on pallet with the


(170 kg each) suitable trap.


will be provided.

16 Ammonia Soln.

(20%) 15 KL Tank Ambient Fire, Spillage



will be provided.


ANNEXURE-IX

_______________________________________________________________________

DETAILS OF STACKS & VENTS (PROPOSED)

Sr.

No.

Stack/Venatt

ached to

Type of

Emission

Stack

Height

(meter)

Stack

Diameter

(meter)

Pollution Control

Equipment

Fuel name and

Quantity/hour

1 Boiler SPM

Sox

NOx

30 1.23

-

Furnace Oil

45000 Liter/Month

2 Chlorination

of acid to

acid chloride

with Thionyl

Chloride-

Process Vent

HCl

SO2

11 0.076 Water scrubber

followed by alkali

scrubber & ventury

scrubber

-

4 D. G. Set SPM

SO2

NOx

11 0.1

-

Diesel

200 Liter/Month


ANNEXURE-X

_______________________________________________________________________

RISK SCENARIO

Scenario MCL Scenario Pressure Temp. Quantity

1. Pool fire due to release of Methylene

Dichloride

Ambient Ambient 10 MT

2. Pool fire due to release of Ethyl

Acetate


3. Release of Acetic Anhydride - toxic

effect


4. Pool fire due to release of Iso Propyl

Alcohol


5. Pool fire due to release of Hexane Ambient Ambient 15 MT

6. Pool fire due to release of Toluene Ambient Ambient 15 MT

7. Pool fire due to release of Ethanol Ambient Ambient 10 MT

8. Release of Ammonia Soln. (20 %) -

toxic effect

Ambient Ambient 15 m

3


Detailed Summary of Results:

Detailed Results of the consequence analysis of above-mentioned scenarios have been given

below:

Scenario # 1: Pool fire due to Release of Methylene Dichloride (MDC)

A release from the Methylene Dichloride storage Tank

Temperature & Pressure - Ambient

Capacity - 10 MT

Results indicate:

Effective diameter of the pool - 4.45 m

(100 % fatality within the pool area)

Fatality Zone radius - 16.76 m

Injury Zone radius (First degree burns) - 24.08 m

Preventative / Mitigation Measures:

Storage: Store in a tightly closed container. Keep from contact with oxidizing materials. Store in

a cool, dry, well-ventilated area away from incompatible substances. Store below 40C. Keep

away from active metals.

Handling: Wash thoroughly after handling. Remove contaminated clothing and wash before

reuse. Use with adequate ventilation. Loosen closure cautiously before opening. Avoid contact

with eyes, skin, and clothing. Do not get in eyes, on skin, or on clothing. Keep container tightly

closed. Avoid contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not ingest

or inhale.

Protection: Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described

by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard

EN166. Skin: Wear appropriate protective gloves to prevent skin exposure. Clothing: Wear

appropriate protective clothing to prevent skin exposure.

Small spills/leaks: Absorb spill with inert material, (e.g., dry sand or earth), then place into a

chemical waste container. Avoid runoff into storm sewers and ditches which lead to waterways.

Clean up spills immediately, using the appropriate protective equipment. Remove all sources of

ignition. Provide ventilation


Note: For this scenario, the software used doesn’t give the footprint as an output. Its gives

only the value (i.e. the radius of the fire pool etc.), From the source there will be a fireball of

given radius.


LA

YO

UT

FO

R S

CE

NA

RIO

# 1

= FATALITY ZONE

= INJURY ZONE


Scenario # 2: Pool fire due to Release of Ethyl Acetate

A release from the Ethyl Acetate storage Tank


Capacity - 15 MT

Results indicate:






Storage: Keep away from heat, sparks, and flame. Keep away from sources of ignition. Store in a

tightly closed container. Store in a cool, dry, well-ventilated area away from incompatible

substances.

Handling: Wash thoroughly after handling. Use with adequate ventilation. Ground and bond

containers when transferring material. Avoid contact with eyes, skin, and clothing. Empty

containers retain product residue, (liquid and/or vapor), and can be dangerous. Keep container

tightly closed. Avoid contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not

pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat, sparks or open

flames.

Protection: Wear appropriate protective gloves, clothing and goggles.

Small spills/leaks: Avoid runoff into storm sewers and ditches which lead to waterways. Remove

all sources of ignition. Absorb spill using an absorbent, non-combustible material such as earth,

sand, or vermiculite. Provide ventilation. A vapor suppressing foam may be used to reduce

vapors. Water spray may reduce vapor but may not prevent ignition in closed spaces.



given radius.


LA

YO

UT

FO

R S

CE

NA

RIO

# 2

= FATALITY ZONE

= INJURY ZONE


Scenario # 3: Release of Acetic Anhydride- toxic effect

Release of Acetic Anhydride from storage tank:

Storage Temperature: - Ambient

Storage Pressure: Ambient

Results indicate:

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 5.38 kilograms/min

(averaged over a minute or more)

Total Amount Released: 186 kilograms

Note: The chemical escaped as a liquid and formed an evaporating puddle.

Footprint Information:

Dispersion Module: Gaussian

Red LOC (200 ppm = TEEL-3) Max Threat Zone: 19 meters

Note: Footprint was not drawn because effects of near-field patchiness make dispersion

predictions unreliable for short distances.

Yellow LOC (5 ppm = TEEL-1) Max Threat Zone: 119 meters

Orange LOC (5 ppm = TEEL-2) Max Threat Zone: 119 meters


Storage: Keep away from heat, sparks, and flame. Keep away from sources of ignition. Do

not store in direct sunlight. Keep container closed when not in use. Keep from contact with

oxidizing materials. Store in a cool, dry, well-ventilated area away from incompatible

substances. Keep away from water. Flammables-area.

Handling: Remove contaminated clothing and wash before reuse. Do not allow water to get

into the container because of violent reaction. Ground and bond containers when transferring

material. Use spark-proof tools and explosion proof equipment. Do not breathe dust, vapor,

mist, or gas. Do not get in eyes, on skin, or on clothing. Empty containers retain product

residue, (liquid and/or vapor), and can be dangerous. Avoid contact with heat, sparks and

flame. Use with adequate ventilation. Discard contaminated shoes. Do not pressurize, cut,

weld, braze, solder, drill, grind, or expose empty containers to heat, sparks or open flames.

Keep from contact with moist air and steam.


Protection: Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as

described by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European

Standard EN166. Skin: Wear appropriate protective gloves to prevent skin exposure.

Clothing: Wear appropriate protective clothing to prevent skin exposure.


chemical waste container. Avoid runoff into storm sewers and ditches which lead to

waterways. Clean up spills immediately, using the appropriate protective equipment. Remove

all sources of ignition. Use a spark-proof tool. Provide ventilation. Do not expose spill to

water. Spill may be neutralized with lime. Cover with material such as dry soda ash or

calcium carbonate and place into a closed container for disposal. A vapor suppressing foam

may be used to reduce vapors.

Fire fighting: Wear a self-contained breathing apparatus in pressure-demand,

MSHA/NIOSH (approved or equivalent), and full protective gear. Vapors may form an

explosive mixture with air. Vapors can travel to a source of ignition and flash back. During a

fire, irritating and highly toxic gases may be generated by thermal decomposition or

combustion. Water Reactive. Material will react with water and may release a flammable

and/or toxic gas. Use water spray to keep fire-exposed containers cool. Wear appropriate

protective clothing to prevent contact with skin and eyes. Wear a self-contained breathing

apparatus (SCBA) to prevent contact with thermal decomposition products. Containers may

explode in the heat of a fire. Flammable Liquid. May ignite or explode on contact with steam

or moist air. Extinguishing media: Use dry sand or earth to smother fire. If water is the only

media available, use in flooding amounts. DO NOT USE WATER! Do NOT use straight

streams of water. Contact profession

Scenario # 3: Release of Acetic Anhydride- toxic effect

Source strength (Release rate)


Scenario # 4: Pool fire due to Release of Iso Propyl Alcohol

A release from the Iso Propyl Alcohol storage Tank


Capacity - 15 MT

Results indicate:






Storage: Keep away from sources of ignition. Store in a cool, dry place. Store in a tightly closed

container.

Handling: Wash thoroughly after handling. Wash hands before eating. Use only in a well

ventilated area. Use spark-proof tools and explosion proof equipment. Empty containers retain

product residue, (liquid and/or vapor), and can be dangerous. Do not get on skin or in eyes. Avoid

ingestion and inhalation. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty

containers to heat, sparks or open flames.



chemical waste container. Clean up spills immediately, using the appropriate protective

equipment. Scoop up with a nonsparking tool, then place into a suitable container for disposal.

Remove all sources of ignition.

Fire fighting: Use water in flooding quantities as fog. Use foam, dry chemical, or carbon dioxide.

Cool all affected containers with flooding quantities of water. Apply water from as far a distance

as possible. Use water spray to knock-down vapors. Keep run-off water out of sewers and water

sources.



given radius.


LA

YO

UT

FO

R S

CE

NA

RIO

# 4

= FATALITY ZONE

= INJURY ZONE


Scenario # 5: Pool fire due to Release of Hexane

A release from the Hexane storage Tank


Capacity - 15 MT

Results indicate:






Storage: Keep away from heat and flame. Keep away from sources of ignition. Store in a tightly

closed container. Keep from contact with oxidizing materials. Store in a cool, dry, well-ventilated

area away from incompatible substances.

Handling: Wash thoroughly after handling. Remove contaminated clothing and wash before

reuse. Use only in a well ventilated area. Ground and bond containers when transferring material.

Avoid contact with eyes, skin, and clothing. Do not breathe dust, vapor, mist, or gas. Empty

containers retain product residue, (liquid and/or vapor), and can be dangerous. Take precautionary

measures against static discharges. Avoid contact with heat, sparks and flame. Do not ingest or

inhale. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat,

sparks or open flames.

Protection: Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described

by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard

EN166. Skin: Wear appropriate protective gloves to prevent skin exposure. Clothing: Wear

appropriate protective clothing to prevent skin exposure.


chemical waste container. Avoid runoff into storm sewers and ditches which lead to waterways.

Clean up spills immediately, using the appropriate protective equipment. Scoop up with a

nonsparking tool, then place into a suitable container for disposal. Remove all sources of ignition.

Provide ventilation. A vapor suppressing foam may be used to reduce vapors.


Fire fighting: Wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH

(approved or equivalent), and full protective gear. Vapors may form an explosive mixture with

air. Vapors can travel to a source of ignition and flash back. During a fire, irritating and highly

toxic gases may be generated by thermal decomposition or combustion. Use water spray to keep

fire-exposed containers cool. Extremely flammable liquid. Water may be ineffective. Material is

lighter than water and a fire may be spread by the use of water. Vapors may be heavier than air.

They can spread along the ground and collect in low or confined areas. Will be easily ignited by

heat, sparks or flame. Containers may explode if exposed to fire. Extinguishing media: For small

fires, use dry chemical, carbon dioxide, water spray or alcohol-resistant foam. Water may be

ineffective. Water may spread fire. If water is the only media available, use in flooding amounts.

For large fires, use water spray.



given radius.


LA

YO

UT

FO

R S

CE

NA

RIO

# 5

= FATALITY ZONE

= INJURY ZONE


Scenario # 6: Pool fire due to Release of Toluene

A release from the Toluene storage Tank


Capacity - 15 MT

Results indicate:






Handling & Storage: Protect against physical damage. Store in a cool, dry well-ventilated

location, away from any area where the fire hazard may be acute. Outside or detached storage is

preferred. Separate from incompatibles. Containers should be bonded and grounded for transfers

to avoid static sparks. Storage and use areas should be No Smoking areas. Use non-sparking type

tools and equipment, including explosion proof ventilation. Containers of this material may be

hazardous when empty since they retain product residues (vapors, liquid); observe all warnings

and precautions listed for the product.

Protection: Eyes: Immediately flush eyes with plenty of water for at least 15 minutes, lifting

lower and upper eyelids occasionally. Get medical attention immediately. Skin: In case of contact,

immediately flush skin with plenty of soap and water for at least 15 minutes while removing

contaminated clothing and shoes. Wash clothing before reuse. Call a physician immediately.

Fire fighting: Dry chemical, foam or carbon dioxide. Water may be used to flush spills away

from exposures and to dilute spills to non-flammable mixtures. In the event of a fire, wear full

protective clothing and NIOSH-approved self-contained breathing apparatus with full facepiece

operated in the pressure demand or other positive pressure mode. Water spray may be used to

keep fire exposed containers cool.



given radius.


LA

YO

UT

FO

R S

CE

NA

RIO

# 6

= FATALITY ZONE

= INJURY ZONE


Scenario # 7: Pool fire due to Release of Ethanol

A release from the Ethanol storage Tank


Capacity - 10 MT

Results indicate:






Handling & Storage: Store in a segregated and approved area. Keep container in a cool, well-

Ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all possible

sources of ignition (spark or flame). Do not store above 23 oC.

Protection: Eyes: Check for and remove any contact lenses. Immediately flush eyes with running

water for at least 15 minutes, keeping eyelids open. Cold water may be used. Get medical

attention.

Small spills/leaks: Dilute with water and mop up, or absorb with an inert dry material and place

in an appropriate waste disposal container.



given radius.


LA

YO

UT

FO

R S

CE

NA

RIO

# 7

= FATALITY ZONE

= INJURY ZONE


Scenario # 8: Release of Ammonia Soln. (20%)- toxic effect

Release of Ammonia Soln. (20%) storage tank:

Storage Temperature: - Ambient

Storage Pressure: Ambient

Results indicate:

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 314 grams/min

(averaged over a minute or more)

Total Amount Hazardous Component Released: 18.5 kilograms

Footprint Information:

Dispersion Module: Gaussian

Red LOC (750 ppm = ERPG-3) Max Threat Zone: < 10 meters



Orange LOC (150 ppm = ERPG-2) Max Threat Zone: 14 meters



Yellow LOC (25 ppm = ERPG-1) Max Threat Zone: 34 meters




Storage: Keep in a cool, dry, dark location in a tightly sealed container or cylinder. Keep away

from incompatible materials, ignition sources and untrained individuals. Secure and label area.

Protect containers/cylinders from physical damage.

Handling: All chemicals should be considered hazardous. Avoid direct physical contact. Use

appropriate, approved safety equipment. Untrained individuals should not handle this chemical or

its container. Handling should occur in a chemical fume hood.



Small spills/leaks: Keep material out of water sources and sewers. Attempt to stop leak if without

undue personnel hazard. Use water spray to knock-down vapors. Vapor knockdown water is

corrosive or toxic and should be diked for containment. Land spill: Dig a pit, pond, lagoon,

holding area to contain liquid or solid material. Dike surface flow using soil, sand bags, foamed

polyurethane, or foamed concrete. Absorb bulk liquid with fly ash or cement powder. Neutralize

with vinegar or other dilute acid. Water spill: Neutralize with dilute acid. Use mechanical dredges

or lifts to remove immobilized masses of pollutants and precipitates.

Fire fighting: Wear positive pressure breathing apparatus and full protective clothing.Small fires:

dry chemical or carbon dioxide. Large fires: water spray, fog or foam. Apply water gently to the

surface. Do not get water inside container. Move container from fire area if you can do it without

risk. Stay away from ends of tanks. Cool containers that are exposed to flames with water from

the side until well after fire is out. Isolate area until gas has dispersed.



given radius.

Source strength (Release rate)


ANNEXURE-XI

_______________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

During construction phase, skilled and unskilled manpower will be needed. This will

temporarily increase the employment opportunity. Secondary jobs are also bound to be

generated to provide day-to-day needs and services to the work force. This will also

temporarily increase the demand for essential daily utilities in the local market.

The manpower requirement for the proposed expansion 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

During construction of the project, the 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

During construction period, workers will be provided with basic amenities like safe water

supply, low cost sanitation facilities, first aid, required personal protective equipment, etc.

Otherwise, there could be an increase in diseases related to personal hygiene.

Emission, if uncontrolled from process and utility stacks may cause discomfort, burning of

eyes to the recipients in the down wind direction. This may be caused due to the failure of

control equipment / process. 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 expansion 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 expansion is not expected to make any significant change in

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

m/s. anu products ltd. -...

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