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PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09,HALDIA
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PROJECT PRE-FEASIBILITY REPORT
For
THE PROPOSED EXPANSION PROJECT FOR THE MANUFACTURING OF PESTICIDE TECHNICALS
Category: 5(b)
Of
M/s UPL Limited, UNIT # 09
Located at:
Haldia Industrial Area; Durgachak, Haldia, East Midnapur, West Bengal, India
PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09,HALDIA
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CONTENTS
1 EXECUTIVE SUMMARY 1
1.1 PROJECT PROPONENT 1 1.2 ABOUT PROJECT 1 1.3 SYNOPSIS OF THE REPORT 3
2 INTRODUCTION 7
2.1 BACKGROUND 7 2.1.1 CSR Activity at Haldia 7 2.1.2 Key Personnel 7 2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT. 8 2.3 JUSTIFICATION FOR THE PROJECT: 11 2.3.1 Need for the Project and its Importance to the Country and or Region, 11 2.3.2 Demand-Supply Gap. 11 2.3.3 Imports vs. Indigenous Production. 11 2.3.4 Export Possibility. 11 2.3.5 Domestic / export Markets 12 2.3.6 Employment Generation (Direct and Indirect) due to the Project 12
3 PROJECT DESCRIPTION 13
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF
ANY 13 3.2 LOCATION & ACCESSIBILITY 13 3.3 ENVIRONMENTAL SENSITIVITY 17 3.4 SITE ALTERNATIVE STUDY 19 3.5 SIZE OR MAGNITUDE OF OPERATION. 19 3.6 PROJECT DESCRIPTION WITH PROCESS DETAILS 19 3.6.1 Acephate (Existing Route) 19 3.6.2 Acephate (Proposed New Route – After Expansions) 22 3.6.3 Di Ethyl P-Tosyloxym Ethylphosphonate ( DESMP - New) 25 3.6.4 Metamitron ( Existing – No Expansion) 27 3.6.5 Di Methoate (Existing – No Expansion) 31 3.6.6 ETHION (Existing – No Expansions) 33 3.6.7 Methyl Sulfenilyl Caramate (ASULAM - EXISTING – No Expansions) 35 3.6.8 PRETILACHLOR (EXISTING – No Expansions) 37 3.6.9 Methoxy Ethyl Mercuric Chloride (BAGALOL - EXISTING – No
Expansions) 41 3.7 RAW MATERIAL REQUIREMENT 44 3.8 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE 47 3.9 RESOURCE REQUIREMENT 47 3.9.1 Land 47 3.9.2 Water 49 3.9.3 Power 49 3.9.4 Fuel 49 3.10 POLLUTION SOURCES, TREATMENT AND DISPOSAL 50 3.10.1 Effluent & Sewage 50 3.10.2 Air Emission 50 3.10.3 Solid Waste / Hazardous Generation 52
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4 SITE ANALYSIS 53
4.1 CONNECTIVITY 53 4.1.1 Road Connectivity 53 4.1.2 Rail Connectivity 53 4.1.3 Air Connectivity 54 4.1.4 Water Connectivity 54 4.1.5 Land Form, Land use and Land Ownership : 54 4.2 TOPOGRAPHY (ALONG WITH MAP) 54 4.3 LAND USE 54 4.3.1 CRZ applicability 55 4.4 EXISTING INFRASTRUCTURE 55 4.4.1 Water 55 4.4.2 Power 55 4.4.3 Telecommunication 56 4.4.4 Drainage 56 4.5 SOIL CLASSIFICATION 56 4.6 CLIMATE 56 4.7 DEMOGRAPHY OF THE PROJECT INFLUENCE AREA 57 4.8 SOCIAL INFRASTRUCTURE AVAILABLE 57
5 PLANNING BRIEF 59
5.1 PLANNING CONCEPT 59 5.2 POPULATION PROJECTION 59 5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC 59 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ( PHYSICAL & SOCIAL) : 61 5.5 AMENITIES/ FACILITIES 61
6 PROPOSED INFRASTRUCTURE 62
6.1 INDUSTRIAL AREA (PROCESSING AREA). 62 6.2 RESIDENTIAL AREA (NON PROCESSING AREA) : 62 6.3 GREENBELT 62 6.4 SOCIAL INFRASTRUCTURE 62 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/ WATER
WAYS ETC) 62 6.6 DRINKING WATER MANAGEMENT ( SOURCE & SUPPLY OF WATER ) : 62 6.7 SEWERAGE SYSTEM 62 6.8 INDUSTRIAL WASTE MANAGEMENT 62 6.9 SOLID/HAZARDOUS WASTE MANAGEMENT 62 6.10 POWER REQUIREMENT & SUPPLY / SOURCE 63
7 REHABILITATION AND RESETTLEMENT (R&R) PLAN 64
7.1 POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OF THE PROJECT AFFECTED
PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A
BRIEF OUTLINE TO BE GIVEN): 64
8 PROJECT SCHDULE & COST ESTIMATION 65
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION 65 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC
VIABILITY OF THE PROJECT 65
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9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 66
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE
LOCAL PEOPLE INCLUDING TRIBAL POPULATION ANY IN THE AREA 66 9.2 CONCLUSION: 66
List of Tables
Table 1-1 Brief Summary of Project 3 Table 2-1 List of existing Products & Proposed Products with expansion quantities 8 Table 2-2 List of By-products 10 Table 2-3 Manpower Requirement 12 Table 3-1 Environmental Settings of the Site 17 Table 3-2 Mass Balance for Acephate (Existing Route) 20 Table 3-3 Mass Balance for Acephate (Proposed Route) 24 Table 3-4 Mass Balance for DESMP 26 Table 3-5 Mass Balance for Metamitron 29 Table 3-6 Mass Balance for Di-Methoate 32 Table 3-7 Mass Balance – ETHION 34 Table 3-8 Mass Balance for ASULAM 36 Table 3-9 Mass balance for Pretilachlor 39 Table 3-10 Mass Balance for BAGALOL 42 Table 3-11 Raw Material Requirement Details 44 Table 3-12 Solvent Recovery Details 47 Table 3-13 Water Balance Details 49 Table 3-14 Waste Water Balance 50 Table 3-15 Existing and Proposed Air Emissions Details (Flue Gas) 51 Table 3-16 Existing and Proposed Process Stack Emissions 51 Table 4-1 Existing and Proposed Land Use Details 55 Table 4-2 Climatic Condition in the Study Area 56 Table 4-3 Demography of Haldia at a Glance 57 Table 4-4 Working Population of Haldia 57 Table 5-1 Existing and Proposed Land Use Details 60 Table 6-1 Solid/Hazardous Waste Management 63 Table 6-2 Non Hazardous Waste Management 63 Table 8-1 Project Cost Breakup 65
PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09, HALDIA
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1 EXECUTIVE SUMMARY
1.1 PROJECT PROPONENT
UPL Limited (formerly known as United Phosphorous Limited) is an International Company having base operations in about 12 Countries for the manufacture of Agrochemical and intermediates chemicals. UPL of late has made a significant entry in Seed business as well. In Gujarat, UPL Limited, is engaged in manufacturing of wide range of pesticides (technical), intermediates of pesticides, and other inorganic chemicals. United Phosphorus Limited, popularly known as ‘UPL’, started its operation in the year 1969. Since then it has established well equipped 11 Manufacturing units in India i.e. Vapi, Ankleshwar, Jhagadia, Halol, Tarapur (Maharashtra), Jammu & Haldia (West Bengal)] & total global 33 locations of manufacturing. Thus, the company has grown rapidly over the years. The company is a leading Agrochemical and Intermediates Chemicals manufacturing company. The company has marketing network in 130 countries including America, Europe, Africa, besides in all states of India. The product range of the company includes agrochemicals, Industrial Chemicals & Specialty chemicals. UPL Management have taken up various CSR activities and major activities are in the field of education, health protection and improvement of infrastructure facilities. The important organizations under the umbrella of UPL are Sanskardeep Vidyalaya (Ankleshwar), Gyandham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology (Ankleshwar). 1.2 ABOUT PROJECT
M/s UPL Limited (Unit: 9) is located in Haldia Industrial area, falling under Medium Scale
category manufacturing products as mentioned under for which the company had obtained
Consent To Establish and Operate from West Bengal State Pollution Control Board.
The company proposes for expansion of capacity from 460 MT/month to 2100 MT/month
under the category “Pesticides technical & Intermediates”
It is categorized under project activity 5(b) and Screening Category “A” (sector- Pesticides
industry and pesticide specific intermediates (excluding formulations)) of the EIA
notification dated 14-09-2006 and therefore requires prior Environmental Clearance from the
Environment Impact Assessment Authority, Ministry of Environment & forests, New Delhi.
Proposed Project Cost: Rs. 165.31 crores.
The unit is manufacturing pesticides product as Pesticides technical like Acephate / Metamitron, Di-Methoate Or Ethion, Asulam and liquid Formulation Products like Ethion 50% EC, Dimethoate 30 %EC, Quinolphos 25% EC, Asulam (Methyl Sulfanilyl Carbamate 40% W/v Solution) , Asulam (Methyl Sulfanilyl Carbamate 50% W/v Solution) , and Solid Formulation Products like Acephate 75%, Metamitron 50% and Bagalol (MEMC 15%).
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The Company now plans to expand the capacity of existing products at pesticide technical grade and also plans to add new product Diethyl P - Toluene Methyl Sulphonyloxy Phosphonate (DESMP) as Pesticides technical product. The Unit is having various infrastructure facilities to take care of effluent generated and control of air pollution. The facility includes effluent treatment plant with primary and secondary and tertiary treatment. Treated effluent is discharged to green belt canal for further disposal to Hooghly River which ultimately meets to Bay of Bengal. The solid/hazardous waste generated is disposed off at TSDF site operated by West Bengal Waste Management Ltd (WBWML). The Company had obtained 01 (One) Environmental Clearance for pesticides & formulations, as follows.
1. Environmental Clearance No.: J.11011/914/2008-IA II(i) dated April 29th ,2009 in name of
United Phosphorous Limited, Durgachak, Haldia – 721602.
The copy of above environmental clearances is attached as Annexure – 01. 1.2.1.1 Applicability of EIA notification – 2006
UPL LIMITED (UNIT#09) is an existing manufacturing facility located at Haldia Industrial Area, West Bengal. The Unit is manufacturing Technical grade pesticides and formulations. Now, the Company proposes to expand the existing products at the existing site. It is categorized under project activity 5(b) and Screening Category “A” (sector- Pesticides industry and pesticide specific intermediates (excluding formulations)) of the EIA notification dated 14-09-2006 and therefore, requires prior Environmental Clearance from the Ministry of Environment Forests and Climate Change (MoEF&CC), New Delhi UPL- Haldia Units (Unit No. 9) had accorded the Environmental Clearance (EC) from Ministry of Environment and Forests (MoEF) for 625 MTPM metric tons per month (MTPM) vide F.No. J-11011/914/2008-IA II(I) dated 29.04.2009. UPL, Haldia has been submitted the six monthly compliance report to Regional Office of MoEF&CC. The Unit has implemented Environmental Management System Standard i.e. ISO 14001, Occupational Health & Safety Assessment Standards i.e. OHSAS 18001 and Quality management System Standards i.e. ISO 9001. UPL voluntarily adopted the Codes of Practice of Responsible Care (RC) initiatives. UPL is one among the few industries permitted to use Responsible Care logo by Indian Chemical Council (ICC). 1.2.1.2 Justification for the Project:
Presently, India is leading in the manufacture of pesticides and pesticide intermediates and is likely to become a world leader in future. Most of the pesticide products become immune to pests in short period and newer types of pesticides are to be replaced to meet the pest control requirements. UPL is having own R&D Division and is able to develop new processes for manufacture of alternative pesticide products. The company also has technology for manufacture of different pesticides and intermediates as they have acquired several units internationally.
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To fulfil the demand supply gap, it is decided to make optimal use of the facilities at UPL Unit#09 site by providing additional supporting infra-structure & hence this project for addition & expansion. 1.3 SYNOPSIS OF THE REPORT
The pre-feasibility report includes a brief introduction of the company, need and justification of the project, manufacturing process description, required and available resources, proposed Environment Management Systems, land-use and proposed infrastructure, project schedule and cost estimate and proposed Terms of reference for conducting the EIA studies. UPL has engaged M/s ERM India limited as an Environmental Consultant to conduct the EIA studies for obtaining Environmental Clearance (EC) for UPL Unit#09, located at Haldia, West bangal. Proposed project at a glance is mentioned in following Table.
Table 1-1 Brief Summary of Project
S. No.
Description Proposed Project Details
1 Name of project & Address Expansion of Manufacturing Capacity of existing products and manufacturing of new pesticides by M/s. UPL Limited Unit#09. Durgachak, Haldia. State – West Bengal.
2 Project Category The proposed project categorized under project activity 5(b) and Screening Category “A” (Pesticides industry and pesticide specific intermediates (excluding formulations)) of EIA notification dated 14-09-2006.
3 Project capital cost The Proposed project is for the expansion of the manufacturing capacity for existing unit. The capital cost of the Proposed project shall be approx. Rs. 16531 Lacs.
4 Products Sr. No
Product Category
Existing Production Capacity in MT/Month
Additional Capacity in MT/Month (Proposed in EC) in MT/Month
Total Production Capacity after Expansion (Including new products)in MT/Month
1 Pesticide Technical
460 1640 2100
2 Intermediate Products
NIL NIL NIL
3 Liquid Formulation*
950 NIL 950
4 Solid Formulation*
330 NIL 330
*The pesticide solid/liquid formulation products are excluded from Environmental Clearance as per EC Notification SO 1543 dated 14th September 2006. The product quantities (existing & proposed) details are given in Table 2-1 of Chapter 2.
5 By-products Total 3 no’s of by products are proposed to be generated after expansion. All by-products will be sold to market or disposed as per rule 9 of Hazardous and other wastes (Management & Transboundary Movement) Rules 2016 based on applicability. The total quantities generation is tabulated below.
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S. No.
Description Proposed Project Details
Sr. No
Existing By Product Generation Quantity in MT/Month
Additional By Product Generation Quantity in MT/Month
Total By Product Generation Quantity in MT/Month
1 26 2767.4 2793.4
All details about By-product are given in Table 2-2 of Chapter 2.
6 Raw Materials The major raw materials consists of following items.
Organic Chemicals
In Organic Chemicals
Solvents and
Catalysts The product wise consumption details of raw materials have been given in Table 3-11.
7 Resource Requirement
a. Land The unit has total Land area 60702.82 sq. m (15 acre) sq.m. The area details are tabulated as below.
Sr. No
Existing Land Area in Sq.m
Additional Land Area Requirement in Sq m
Total Land Area Requirement in Sq m
Land Use Type
1 60702.82 Existing site, No additional new land required
60702.82 Industrial
b. Water The entire water requirement is proposed to be met through Haldia Development Authority (HDA) supply.
Existing Total water requirem ent in KLD
Additional Water requirement in KLD
Total Water requirement in KLD
Water Sources (Existing & Proposed)
60 271 331
Haldia Development Authority (HDA) supply
The unit is having valid EC letter no J-11011/914/2008-IA II(I) dated 29th April 2009 having approval of 453 KLD, which will not be increased. Hence no additional water will be sourced as per previous EC letter no J-11011/914/2008-IA II(I) dated 29th April 2009. Additionally, Unit is having One existing bore well as per EC letter no J-11011/914/2008-IA II(I) dated 29th April 2009 for which the approval from State Water Investigation Directorate, Kolkata has been obtained for 30 KL/hr with maximum 02 Hours withdrawal period. The copy of certificate is also attached as Annexure 02. The unit will not supplement any additional water requirement from Existing bore well for proposed expansions in construction & operational phase. No proposal for additional bore well for proposed expansions hence No ground water will be used for proposed expansions. Water quantity Details are given in a Table 3-13 of Chapter 3.
c. Electricity & Fuel Requirements
The power requirement details for existing & proposed expansion are given below. The power requirement will be met through West Bengal State Electricity Distribution Company Limited (WBSEDCL).
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S. No.
Description Proposed Project Details
Existing Power Requirement in KW
Additional Power Requirement in KW
Total Power Requirement in KW
4250 43530 47780
The Fuel requirements for operation of Boilers, and DG sets is given below.
Sr No
Fuel Name
UOM Existing Qty.
Additional Proposed Quantity
Total after Expansion
Consumption Area
1 Coal MT/Day
60 225 285 Boiler
2 HSD Lit/ Day
250 455 705 DG Sets
d. Backup power The DG sets are installed at existing plant premises for emergency power back up only. The details of existing and proposed DG sets are tabulated as below.
Sr. No
Existing DG Set Capacity (KVA)
Additional DG Set Capacity (KVA)
Total Power Back up Capacity in KVA
1 1 X 500 KVA 1X2000 KVA
1 X 500 KVA 1 X 600 KVA 1 X 2000 KVA
2 1 X 600 KVA
The fuel for all DG sets : High Speed Diesel (HSD)
e Steam Requirements The steam generation capacity expansion is proposed as follows.
Sr. No
Existing Boiler Capacity in TPH
Additional Boiler Capacity for proposed expansion in TPH
Total Boiler Capacity after expansion in TPH
1 1 X 8 TPH Coal Fired Boiler
2 X 15 TPH Coal Fired Boilers
1 X 8 TPH 2 X 15 TPH Coal fired boilers
f. Man power Total required Manpower would be around 2046 and the details are given below:-
Sl. No. Particulars Manpower Details
Existing Proposed Total after Expansion
1 Staff 54 100 154
2 Contract 80 225 280
Total 134 325 459
The company will encourage local employment for proposed expansion.
8 Source of Pollution
a. Waste Water Generation The total existing and proposed waste water generation rates in KLD are tabulated below.
Source Total Existing waste water generation
Additional waste water generation
Total waste water generation after expansion
Industrial & Domestic
20 KLD 200 KLD 220 KLD
The details of waste water generation are given in Table 3-14 of Chapter 3.
b. Air Emission The point source emissions will be from Process and Flue stacks. The emission parameters for Flue stacks and Process stacks have been tabulated below.
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S. No.
Description Proposed Project Details
Source of Emissions (Point Source)
Existing Parameters Proposed Parameters
Flue Gas PM, SO2 , NOx & CO
PM, SO2 , NOx & CO
Process HCl, NH3, H2S, HC. HCl, NH3, H2S, HC.
The details of stack emissions are given in Error! Not a valid result for table. & Table 3-16 of Chapter 3.
c. Solid Waste / Hazardous Generation
The Major Waste Generation from Proposed Expansion is from following sources. Organic distillation residues Toxic and High COD Aqueous waste Expired / Off Specific Products ETP Sludge Used Oil Packaging Materials Lead Acid Batteries Details of all waste with generation quantity and disposal method are given in Table 6-1 & Table 6-2.
9 Mode of Treatment
a. Waste water
Existing effluent treatment facility: The company has existing adequate effluent treatment plant (25 KLD) with Primary, secondary & tertiary treatment facility. Additional Capacity of Proposed ETP : Approx. 200 KLD. Total Capacity of ETP After Expansion: 220 KLD. Final Disposal Facility: Treated effluent will be discharged to green belt canal for further disposal to hooghly river which ultimately meets to bay of bengal. Recycling Proposed : The unit has proposed recycle/reuse of treated effluent part in cooling and green belt development before discharge to green belt canal. The details of Effluent generation & disposal are given in Table 3-14 of Chapter 3.
b. Air Existing APCM: company has adequate Air pollution control devices for control of Flue gas & Process gas emission like process scrubber, bag filter. Proposed APCM: company will provide adequate APCM like process scrubber, bag filter to achieve WBPCB norms. The details of air pollution sources and control devices are given in Table 3-16 of Chapter 3.
c. Hazardous/Solid Waste/municipal solid waste
Hazardous Waste /Solid Waste - Collection, storage and disposal to be carried out as per hazardous and other waste (management & transboundary movement) rules 2016. The details of solid/ hazardous waste generation and disposal method are given as Table 6-1 of Chapter 6.
10 Resource Recovery
a. Solvent The solvent used in Production Process are recycled / recovered during production process and UPL has maintained minimum recovery of 95 % for solvents. Detail of solvent usage and solvent recovery are given in Table 3-12 of Chapter 3.
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2 INTRODUCTION
2.1 BACKGROUND
UPL Limited (formerly known as United phosphorous Limited), popularly known as ‘UPL’, is an International company started its operation in the year 1969. It`s almost 48 years ago, they had started as a small scale unit to manufacture Red Phosphorus. Since then it has established well-equipped manufacturing units with corporate office at Mumbai. Through backward and forward integrations respectively, today they are a leading global producer of crop protection products, intermediates, specialty chemicals and other industrial chemicals. Being the largest manufacture of agrochemicals in India, they offer a wide range of products that includes Insecticides, Fungicides, Herbicides, Fumigants and Rodenticides. UPL of late has made a significant entry in Seed business as well. M/s UPL Limited have major manufacturing facilities at Vapi, Ankleshwar, Jhagadia, Haldia and major products are Pesticides, Caustic Soda, Chlorine, Intermediate Chemicals, Phosphorus based chemicals and Specialty Chemicals. UPL Limited started operations at Vapi Estate in 1969 with manufacturing of Red Phosphorus first time in India. Mr Rajnikant D Shroff, an industrialist, is the Chairman of the Company. The Company has acquired several Units in India and abroad, and modernized them; and are in operation. UPL Limited have a strong manufacturing base supported by engineers and scientists. The R&D team of the Company develops various products as per the market requirements. Most of the products manufactured are agrochemicals used by the farmers. UPL have 25 manufacturing sites and customer base in 123 countries all over the world. The company has marketing network in 25 countries including America, Europe, Africa, besides in all states of India. They rank amongst the top 5 post patent agrochemical industries in the world. The Unit has implemented Environmental Management System Standard i.e. ISO 14001, Occupational Health & Safety Assessment Standards i.e. OHSAS 18001 and Quality management System Standards i.e. ISO 9001. UPL voluntarily adopted the Codes of Practice of Responsible Care (RC) initiatives. UPL is one among the few industries permitted to use Responsible Care logo by Indian Chemical Council (ICC). UPL Limited Management have taken up various CSR activities and major activities are in the field of education, health protection and improvement of infrastructure facilities. The important organizations under the umbrella of UPL Limited are Sanskardeep Vidyalaya (Ankleshwar), Gyam Dham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology (Ankleshwar). 2.1.1 CSR Activity at Haldia
The CSR activity in the UPL Haldia unit are providing infrastructure and facilities in schools like (i) toilets, (ii) computers and (iii) school uniforms. 2.1.2 Key Personnel
Mr Rajnikant D Shroff, Chairman & Managing Director
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Mrs Sandra R Shroff, Vice Chairman
Mr Jaidev R Shroff, Group CEO- Director
Mr Vikram R Shroff, Executive Director
Mr Kalyan Banerjee, Director
Mr Arun C Ashar, Director
Mr Raj K Tiwari, Global SCM Director
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT.
UPL Limited (Unit-09) is an operational manufacturing unit, located at leased land of Kolkata Port Trust, Haldia, East Midnapur District, West Bengal. The Unit is manufacturing pesticides technical, and pesticides formulation products. UPL- Haldia Units (Unit No. 9) had accorded the Environmental Clearance (EC) from Ministry of Environment and Forests (MoEF) for 460 metric tons per month (MTPM) vide F.No. J-11011/914/2008-IA II(I) dated 29.04.2009. Now UPL has proposed to expand the Pesticide technical, Intermediate & Formulation products to 1980 MTPM. The existing and proposed product and by-products is provided in following table.
Table 2-1 List of existing Products & Proposed Products with expansion quantities
Sl. No
.
Building Status (No of
Buildings)
Products
Production Quantity in (Metric Tonne Per Month)
CIB Status
EC Notification 2006, category
Change in
Production
Process (Yes / NO)
Existing Capacity as per EC Granted
Additional
Capacity
Total Capacity
after Expansio
n
A) Pesticide Technical Grade
1 1
(Existing + Proposed in New Plant
Adjacent to Existing Plant)
Acepate 100 1400 1500 Not
Banned 5(b) Yes, New
Route
OR OR OR OR OR OR OR
Metamitron 100 NIL 100 Not
Banned 5(b) No
2
Di-Methoate
60 NIL 60 Not
Banned 5(b) No
OR OR OR OR OR OR OR
Ethion 60 NIL 60 Not
Banned 5(b) No
3
1 (No
Expansions Proposed)
Methyl Sulfanilyl Caramate (Asulam)
200 NIL 200
Not Banned
5(b) No
4 Not
Implemented
Pretilachlor 50 NIL 50 Not
Banned 5(b) No
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Sl. No
.
Building Status (No of
Buildings)
Products
Production Quantity in (Metric Tonne Per Month)
CIB Status
EC Notification 2006, category
Change in
Production
Process (Yes / NO)
Existing Capacity as per EC Granted
Additional
Capacity
Total Capacity
after Expansio
n
5 Not
Implemented
Methoxy Ethyl
Mercuric Chloride
(Bagalol)*
50 NIL NIL
Banned except
The use of
MEMC is banned
completely except for seed treatmen
t of potato
and sugarcan
e S.O.681
(E) dated 17thJuly,
2001
5(b) No
6
New Plant – 1 No for DESMP +
ACEPHATE
Expansions
Diethyl P -toluene Methyl
Sulphonyloxy
Phosphonate (DESMP)
0 240 240 Not
Banned 5(b)
New Product
Total Capacity 460 1640 2100
B) Pesticide Formulation – Solid – No Expansions Proposed
1 Existing Plant No
Expansion
Acepate – 75% (Stthene)
130 MT/Mon
th NIL
130 MT/Mon
th
Not Banned
Not Applicabl
e
Not Applicabl
e
2 Existing Plant No
Expansion
Metamitron—50%
100 MT/Mon
th NIL
100 MT/Mon
th
Not Banned
Not Applicabl
e
Not Applicabl
e
3 Existing Plant No
Expansion
Bagalol (MEMC 15%)
100 MT/Mon
th NIL
100 MT/Mon
th
Not Banned
Not Applicabl
e
Not Applicabl
e
Total in MT/Month 330
MT/Month
NIL 330
MT/Month
Not Applicabl
e
Not Applicabl
e
C) Pesticide Formulation – Liquid – No Expansion Proposed
1 Existing Plant No
Expansion
Asulam (Methyl Sulfanilyl Caramate- 50 w/v solution)
250 KL/Mont
h NIL
250 KL/Mont
h
Not Banned
Not Applicabl
e
Not Applicabl
e
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Sl. No
.
Building Status (No of
Buildings)
Products
Production Quantity in (Metric Tonne Per Month)
CIB Status
EC Notification 2006, category
Change in
Production
Process (Yes / NO)
Existing Capacity as per EC Granted
Additional
Capacity
Total Capacity
after Expansio
n
2 Existing Plant No
Expansion
Asulam (Methyl Sulfanilyl Caramate- 40 w/v solution) Asulox
320 KL/Mont
h NIL
320 KL/Mont
h
Not Banned
Not Applicabl
e
Not Applicabl
e
3 Existing Plant No
Expansion
Qninolphos- 25% EC (Starlux)
30 KL/Mont
h NIL
30 KL/Mont
h
Not Banned
Not Applicabl
e
Not Applicabl
e
4 Existing Plant No
Expansion
Dimethoate – 30 EC (TARA 909)
200 KL/M
NIL 200
KL/M
Not Banned
Not Applicabl
e
Not Applicabl
e
5 Existing Plant No
Expansion
Ethion -50% EC (MIT 505)
150 KL/M
NIL 150
KL/M
Not Banned
Not Applicabl
e
Not Applicabl
e
Total in KL/Month 950
KL/Month
NIL 950
KL/Month
Not Applicabl
e
By-products like Methanol, Acetic Acid and Ammonium Sulphate will be generated from the process. However, for Formulation products, Environmental Clearance is not required as per the EIA Notification 2006. The list of by-products has been shown in the following table.
Table 2-2 List of By-products
Sl. No.
By Product Name Source/Plant Existing Generation (MTPM)
Additional Generation (MTPM)
Total Generation after expansion (MTPM)
1 Methanol Asulam 26 0 26 2 Acetic Acid Acephate 0 2025 2025 3 Ammonium
Sulphate Acephate 0 742.4 742.4
Total 26 2767.4 2793.4
The Following By Products are expected from existing process which are not implemented. Sl. No.
By Product Name Source/Plant Existing Generation (MTPM)
Additional Generation (MTPM)
Total Generation after expansion (MTPM)
1 Ammonium Bromide
Ethion 132.7 0 132.7
2 Ethanol Metamitron 96.4 0 96.4 3 Sodium Bi
sulphide Pretilachlor 193.8 0 193.8
4 HCl Pretilachlor 14.95 0 14.95 Total 437.85 0 437.85
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2.3 JUSTIFICATION FOR THE PROJECT:
2.3.1 Need for the Project and its Importance to the Country and or Region,
Proposed expansion in project is needed to serve increasing demand from export market. Benefits of the project are many fold: The proposed expansion project for manufacturing of various products are based on the market surveys. India imports Diethyl P -toluene Methyl Sulphonyloxy Phosphonate (DESMP) -2800 MT per year. Its current price is $7/kg and total value for import is around 150 Cr. There are no manufacturers in India. Therefore producing 120 MT/ month; i.e. 1440 MT per year will reduce the import cost of Diethyl P -toluene Methyl Sulphonyloxy Phosphonate (DESMP). 2.3.2 Demand-Supply Gap.
Indian Pesticides is one of the rapidly growing markets and has emerged a strong export oriented business. Out of the present business of 180 Billion markets, the export accounts 100 billion and is steadily growing at a rate of 6.7%. This is 2.5 times more than the world market. With the introduction of genetically modified crops in India, the consumption of Insecticides decreased marginally. But the other sectors such as weedicides & herbicides, fungicides etc. are rapidly growing. UPL is focuses on the sectors of Fungicides and herbicides and strong in export of these group molecules (Source: India Pesticide Industry Analysis to 2018; Ken Research]. 2.3.3 Imports vs. Indigenous Production.
Company is always focusing on manufacturing all products locally with backward integration so that Country will get benefits like Growth, employment, infrastructure etc. UPL Limited R & D team is constantly engaged in identifying & evaluating new molecules. After a very careful scrutiny of the developments of R & D, the company is ready to enhance the production capacity. Company is importing only such products for which, either the technology is not available in India or, the manufacturing cost is higher than the import cost. 40% Raw materials will be imported to manufacture proposed products. 2.3.4 Export Possibility.
Pesticide Product- The products of UPL Limited are mainly for rice, wheat, cotton, vegetables, fruits, tea, tobacco etc., which are the main crops in India and in many countries as well. That’s why these products have worldwide market. The global marketing network of UPL Limited is mainly, America sales 37%, Europe & Africa 28.%, Indian subcontinent & Asia Pacific 35 %. Intermediates & specialty Chemicals - Indian Specialty Chemicals poised to be $ 80-100 billion industry by 2020. Asia-Pacific region now is nearly 42 % of the global market for chemicals. India is emerging as manufacturing and export hub for specialty and knowledge chemicals. Key advantages include re-engineering capabilities and relatively low cost of production. Innovation and Scale will be the key differentiators, going forward. The continuous growth of this sector saw demand – supply gap and sometimes, molecules are not available both for the domestic and export market. Like the above many products are made in India and exported to all the European Countries and all other countries. Continuous growth of exports and increase in the Indian market demand off set the local competitions. Some
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manufacturing capacities cleared for the manufacture are neither installed nor operated. Some products are not available at the peak demand time of the local season. To support the above projections, promoters have propelled to set up new manufacturing facility in chemical zone. 2.3.5 Domestic / export Markets
Rest of the approx. 20-30 % of total production will be sold to domestic market. 2.3.6 Employment Generation (Direct and Indirect) due to the Project
For proposed project direct & indirect employment generation will be as follows:
Table 2-3 Manpower Requirement
Sl. No. Particulars Manpower Details
Existing Proposed Total after Expansion
1 Staff 54 100 154
Contract 80 225 280
Total 134 325 459
Locally employed manpower shall be utilized.
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3 PROJECT DESCRIPTION
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY
The focus of the company is on the development of agriculture and better products through use of pesticides so essential for growth and prosperity of agriculture economy for that company wishes to manufacture various Fungicides, Herbicides, Insecticides, Specialty Chemicals and Intermediates Products and Formulations (Solid / Liquid). 3.2 LOCATION & ACCESSIBILITY
The proposed expansion unit is located at Haldia. Haldia is an industrial town located in the Purba Medinipur District of West Bengal. The region has been developed with the Haldia port as the focal point in the District. The Regional setting map of the site is provided in Figure 3.1. The site is located in the Survey of India Toposheet No. F45K4. The site location has been indicated on topographic map of 1:50000 scale (Refer Figure 3.2). The google imagery map with geographical coordinates of the site is shown in Figure 3.3. The site can be accessed from Kolkata through Vidyasagar Setu then Kona Express Way which ultimately joins with NH-6 up to Kolaghat. The site can be accessed from NH 6 via. Kolaghat- Haldia road (NH 41) to Rani Chowk (Haldia). From Rani Chowk, the site can be accessed by Link Road to Durgachak and site. Haldia is well connected with Kolkata through rail also; daily trains are available from Haldia to Howrah via. Panskura. The nearest Railway Station is Durgachak, 0.6 km from the site. The nearest Airport of Netaji Subhas Chandra Bose, Kolkata is approximately 140 km from site. The capital city Kolkata is approximately 130 km from site.
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Figure 3-1 Regional Setting Map of the Site
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Figure 3-2 Site Location Map on Topomap
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Figure 3-3 Site Location of Satellite Imagery with Geographical Coordinates
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3.3 ENVIRONMENTAL SENSITIVITY
The UPL Haldia site is located on the southern side of the Haldia Industrial area. The proposed expansion unit will be constructed within the existing plant area. The environmental setting of the site has been provided in following table.
Table 3-1 Environmental Settings of the Site
Sl. No. Component Location and Distance
1. Industries South Bharat Petroleum Corporation Limited Oil Terminal- adjacent
North Exide Industries Ltd- 0.2 km
Hindustan Petro-chemical Limited – NW, 2.3 km
Reliance MCT East Indorama Chemical Limited- 1.0 Km
Green Belt Canal
Mitsubishi Chemicals-3.5 km West Himadri Chemicals;
Tata Power
Indian Oil Corporation- 2.7 km
Haldia Port- 5.5 km 2. River South Hooghly River- 0.45 km
West Haldi River- 10 km
3. Settlement/ Town
North Durgachack town- 0.6 km
Chaul Khola – NW- 6.5 km
Jamal Chak- 5.7 km West Baishnabchak – 4.5 km
4. Forest No natural forest in the 10 km of the study area
5. Mangrove vegetation Nayachar- Riverine Island of Hooghly River is located 4.2 south of the site has mangrove plantation area;
Mangrove plantation along the Hooghly River side- BPCL oil Terminal to Hooghly Met Coke ; which is approximately 0.4 km from site
6. Ecological Sensitive area like National Park, Wildlife Sanctuary, Biosphere Reserve, etc
No ecological sensitive area in the 10 km radius of the proposed site
7. Estuary Hooghly estuary- 0.45 km from the site
The environmental settings of the site is presented in Figure 3-4
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Figure 3-4 Environmental Setting Map of the site
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3.4 SITE ALTERNATIVE STUDY
No alternative site study will be carried out as proposed project will be located in a well-developed Industrial Estate, Haldia. Following points are considered for proposed project site selection. The proposed expansion will be constructed in the available land of existing plant. No additional land will be required for proposed expansion unit. The existing unit is located in the Haldia Industrial area. The existing unit is well connected through Port (Haldia), Railway (nearest station Durgachak), Road (NH-41) for transport of raw material and finished products. Same facilities will be utilised for the proposed expansion unit. The existing water requirement and additional required water will be supplied from Haldia Development Authority (HDA). The power requirement for the existing unit is being sourced from West Bengal State Electricity Distribution Company Limited (WBSEDCL); the additional power requirement for proposed expansion unit will be sourced from WBSEDCL. 3.5 SIZE OR MAGNITUDE OF OPERATION.
The existing capacity (Pesticide technical, Intermediate & Formulation products) of UPL- Haldia is 460 MTPM. It is proposed to expand the Pesticide technical to 1980 MTPM. As per the proposed project cost, the project is covered under Medium Scale category of manufacturing industries. 3.6 PROJECT DESCRIPTION WITH PROCESS DETAILS
Detailed project description with process details has been provided in the following section. 3.6.1 Acephate (Existing Route)
3.6.1.1 Process Description
Step 1 : Isomerization (Preparation of O, S, dimethyl Phosphoramidothioate) O, O - dimethyl phosphoramidothioate is isomerised in presence of catalyst, dimethyl sulphate. Dichloroethane is used as solvent.
Step 2 : Acetylation O, S, dimethyl phosphoramidothioate is reacted with acetic anhydride in presence of sulphuric acid as catalyst to produce Acephate.
CH3O S (CH3)2 SO4 CH3O O
P P
CH3O NH2 CH3S NH2
CH3O O CO-CH3 CH3O O
P + O P + CH3COOH
CH3S NH2 COCH3 CH3S NH-C-CH3
O
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Step 3 : Neutralization The acetic acid formed during acetylation in Step 2 and the sulphuric acid, which was used as catalyst, are neutralized with ammonia and water. The aqueous phase and organic phase are separated. Step 4 : Extraction of Aqueous Phase The aqueous phase after neutralization is extracted with dichloro methane to extract the dissolved Acephate. Extraction is a batch process and the process is repeated 8 to 9 times till all the Acephate is being taken out. Step 5 : Stripping The organic phase after neutralization and the extract of aqueous phase is stripped to remove excess dichloro methane and to maintain desired concentration. Step 6 : Crystallisation
The stripped mass in Step 5 is chilled to produce acephate crystals.
Step 7 : Centrifugation
The crystallized mass of Step 6 is centrifuged to produce wet acephate cake.
Step 8 : Drying The Acephate cake as obtained in Step 7 is dried in screw drier by Fluidised Bed drier to produce final product dried Acephate.
3.6.1.2 Mass Balance- ACEPHATE
Mass balance of Acephate has been provided in following Table
Table 3-2 Mass Balance for Acephate (Existing Route)
INPUT Kg/MT
Acephate
Output in Kg/MT
Methylene di Chloride 10774 PRODUCT
DMPAT 1113 Acephate 1000
DMS 133 WASTE WATER TO ETP
Sulphuric Acid 98% 25 WASTE WATER 2223
Acetic anhydride 777 WASTE TO INCINERATION
Ammonia Solution 25% 808 INCINERABLE WASTE 10
Water 980 WASTE TO LAND FILLING
LAND FILLING WASTE 0
SOLVENT RECOVERY
SOLVENT RECOVERY(MDC) 10235
BY PRODUCT
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RECYCLE / REUSE
Centrate + MDC 1137
EMISSION TO AIR
Vapour loss 5
TOTAL 14610 TOTAL 14610
Figure 3-5 Acephate Process Flow Diagram with Existing Route
Acephate Technical
MDC
Organic Part
Effluent
MDC to
Recycle
Centrate Wash NH3
H2O
MDC
H2SO4
DMS
AC2O
MDC
Isomerization
Acetylation
Centrifugation
Neutralization
Organic Part
Extraction
Drying
.
Stripping
Crystallisation
Aqueous Part
DMPAT
Centrate to Recycle
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3.6.2 Acephate (Proposed New Route – After Expansions)
3.6.2.1 Process Description
Dimethyl Phosphorous Amido Thionate (DMPAT) is isomerized to Methamediphos by catalytic reaction at 50 degree C and atmospheric pressure in the presence of Dichloro methane as solvent. After isomerisation, the mass is reacted with acetic anhydride at 40 degree C. It is then neutralized with aqueous ammonia. Ammonia vapour Scrubbed through scrubber & all scrubber mass reuse in neutralizer. The layers are separated and aqueous layer is extracted from Acephate and react with H2SO4 which generate Ammonium sulphate & acetic acid. The organic layer is feed to FFE for dichloromethane recovery and concentrated Acephate + MDC is then taken for vacuum recovery. Recovered dichlormethane is Distilled and recycled in process. After vacuum recovery of all MDC crude Acephate is dissolved in ethyl acetate .After then it is crystalized and slurry is feed into agitated nutche filter. Ethyl acetate is recovered from the mother liquor of crude. Acephate cake is feed to spin flash dryer for purification. The dry Acephate is filled in bags as final packing.
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Figure 3-6 Stoichiometric Balanced Chemical Reaction
3.6.2.2 Raw Material & Mass Balance
Raw material requirement and mass balance of Acephate has been provided in following Table
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Table 3-3 Mass Balance for Acephate (Proposed Route)
INPUT QUANTITY Kg/Ton
Acephate (1500 kg)
OUTPUT QUANTITY Kg/Ton
PRODUCT
MDC 8371.5 Acephate 1500
DMPAT 1612.5 RECOVERY
DMS 199.5 Ethyl Acetate Solvent 3649.5
H2SO4 (98%) 37.5 MDC Solvent 8296.5
Acetic Anhyd 1149 BY-PRODUCT
NH3 Solution(17%) 1212 Ammonium Acetate(35%)
H2SO4 (98%) 612 OR
Ethyl Acetate 3724.5 Acetic Acid (30%)OR
Water 345 Acetic Acid (45%) OR
Water for scrubber 1 30 Acetic Acid (99%)
Water for scrubber 2 7.5 AND
H2SO4 for Scrubber 2 1.5 Ammonium Sulphate (90%)
Caustic (48%) for Sodium Acetate conversion
1178.22 OR
Ammonium Sulphate (90%) 1072.785
Sodium Acetate (27%) 3148.935
EFFLUENT GENERATION
Stream:1 Organic waste to incinerator
DMS+DMPAT+MDC+Acetic Anhydrate
780
AIR POLLUTION
NH3 Vapour 18
MDC Solvent Traces 7.5
Ethyl Acetate Solvent Traces 7.5
SOLID WASTE GENERATION
Nil Nil
TOTAL 18480.72 TOTAL 18480.72
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Figure 3-7 Acephate Process Flow Diagram
3.6.3 Di Ethyl P-Tosyloxym Ethylphosphonate ( DESMP - New)
3.6.3.1 Process Description
Diethyl Phosphite(DEP) react with formaldehyde in presence of catalyst under nitrogen atmosphere at temp 15 degree centigrade to produce DEHMP. Then this DEHMP react with PTSCL in presence of caustic lye solution by maintaining pH 10-11 and mass temperature 0-5 degree centrigrade. After reaction water addition and layer separation. Then again water addition followed by Hydrochloric acid addition by maintaining pH 6-6.5.Proper stirring,
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settle the mass and separate organic layer that is finally fed for removal of solvent and moisture by vacuum 725-730 mm Hg and temperature 60-65 degree centigrade. Stoichiometric Balanced Chemical Reaction for DESMP
Diethylphosphite
P
OO
OH
+
Formaldehyde
C HH
O
Diethyl p-tosyloxymethylphosphonate
P
O
O
OOS
O
O
P OO
O
OH
Hydroxymethyl-phosphonic acid diethyl ester
+
p-TolueneSulphonyl Chloride
S
O
O
Cl
Table 3-4 Mass Balance for DESMP
INPUT KgMT
DESMP
Output in Kg/MT
Di Ethyl Phosphite 538 PRODUCT
Formaldehyde 372 DESMP 1000
Catalyst 34 WASTE WATER TO ETP
PTSCL 671 WASTE WATER 4020
C.S.Lye 566 WASTE TO INCINERATION
Toluene 2692 No incinerable waste 0
Water 2692 WASTE TO LAND FILLING
Hydrochloric Acid 39 No land filling waste 0
SOLVENT RECOVERY
Solvent recovery (Toluene) 2584
BY PRODUCT
No By Product Recovery 0
RECYCLE / REUSE
No Recycling 0
EMISSION TO AIR
No Emissions 0
TOTAL 7604 TOTAL 7604
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Figure 3-8 DESMP Process Flow Diagram
3.6.4 Metamitron ( Existing – No Expansion)
3.6.4.1 Manufacturing Process
Step 1 : Preparation of Acetyl Hydrazine
Acetyl Hydrazine is prepared by reacting ethyl acetate with Hydrazine Hydrate under refluxing temperature. Ethanol and water so produced during reaction is removed by distillation.
O CH3 – COO.C2H5 + H2N – NH2.H2O CH3–C–NH–NH2+C2H5OH+ H2O (Ethyl Acetate) (Hydrazine Hydrate) (Acetyl Hydrazine) (Ethanol)
Step 2 : Preparation of Hydrazone
Hydrazone is prepared by reacting acetyl hydrazine with EPG in presence of ethanolic HCl medium. This reaction is carried out at low temperature for long time. Wet cake of Hydrazone is recovered through filtration and mother liquor is recycled till it has rejected and sent for recovery.
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N-NH-C-CH3 CH3 – C – NH – NH2 + C6H5 – CH – C C6H5 – C – C – OC2H5 + H2O OC2H5 O (Acetyl Hydrazine) (EPG) (Hydrazone)
Step 3 : Preparation of MMZ (Phenyl Glyoxylic Acid Hydrazide Acetyl Hydrazone)
MMZ is prepared by reaction of Hydrazone with hydrazine hydrate at low temperature in alkaline medium. Here ethanol is used as carrier / solvent. Wet cake so obtained is dried under vacuum at 70oC.
N – NH – C – CH3 N – NH – C – CH3 C6H5–C–C–OC2H5 + H2N–NH2.H2O C6H5–C–C–HN–NH2 + HOC2H5 + H2O (Hydrazone) (MMZ)
Step 4 : Preparation of Metamitron
Metamitron (MMT) is prepared by dehydrating MMZ in presence of sodium acetate under refluxing temperature. Here ethanol is used as medium / solvent. After completion of reaction the mass is cooled at 0oC centrifuged to get wet cake of MMT. Then final product is dried under vacuum at 65oC.
N – NH – C – CH3 N – N C6H5 – C – C – HN – NH2 + CH3 – COONa C6H5 – C C – CH3 + H2O O = C – N - NH2 (MMZ) (Metamitron)
O
O
OO
OO
OO
OO
OO
OO
O
O
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Table 3-5 Mass Balance for Metamitron
INPUT Kg/MT
Metamitron
Output in Kg/MT
Ethyl Phenyl Glyoxalate 1271 PRODUCT
Ethyl Acetate 844 Metamitron 1000
Hydrazine Hydrate 1043 WASTE WATER TO ETP
Ethanol Solvent 4348 WASTE WATER 0
Hydrochloric Acid 117 WASTE TO INCINERATION
Acetic Acid 15 WASTE 1604
Sodium Acetate 43 WASTE TO LAND FILLING
Water 322 NO LAND FILLING WASTE 0
Ammonia Solution 25% 247 SOLVENT RECOVERY
SOLVENT RECOVERY(ETHANOL) 4174
BY PRODUCT
ETHANOL 964
RECYCLE / REUSE
CONDENSATE WATER 507
EMISSION TO AIR
VAPOUR LOSS 1
TOTAL 8250 TOTAL 8250
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Figure 3-9 Process Flow Diagram for Metamitron
MMZ Preparation
Reaction Mass
Metamitron
Wet Cake
EtOH (F/R)
Reaction Mass
EtOH (F/R)
Na Acetate
MMZ
H2O
EtOH (F/R)
EPG
HCl
EtOH (F/R)
NH3
EtOH (F/R)
Ethyl Acetate
Hydrazine Hydrate
Acetyl Hydrazine
Preparation
MMZ Preparation
Filtration
Alcohol
Recovery
Acetyl Hydrazine
Hydrazine Hydrate
Wash H2O
Alcohol
Recovery
MMZ
Meta
am
mm
ami
tro
nmi
tro
nmi
tro
n
Pre
par
atio
n
MMT Reaction
Crystallization
Alcohol
Recovery
FBD Drying
Centrifugation
Aqueous
Effluent
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3.6.5 Di Methoate (Existing – No Expansion)
3.6.5.1 Manufacturing Process of Dimethoate
Step 1 : Neutralization
The dimethyl dithio phosphoric acid is neutralized with diluted ammonium hydroxide solution. The aqueous layer
containing the ammonium salt of dimethyl dithio phosphoric acid is taken in another reactor for condensation
reaction and organic phase sent for toluene recovery.
CH3O S CH3O S
P + NH4OH P + H2O
CH3O S – H CH3O S – NH4
STEP 2 : PREPARATION OF METHYL CHLORO ACETATE
It is an ester and prepared by reacting mono chloro acetic acid with methanol in presence of catalyst
at required temperature.
Cl – CH2 – COOH + CH3OH Cl – CH2 – CO – CH3 + H2O
Step 3 : Condensation
Salt of dimethyl dithio phosphoric acid, is condensed with methyl chloro acetate formed in Step 2.
CH3O S CH3O S
P + Cl.CH2.COOCH3 P + NH4Cl
CH3O S – NH4 CH3O S – CH2 – CO – CH3
Step 4 : Amidation
O
O
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Table 3-6 Mass Balance for Di-Methoate
INPUT KgMT
Dimethoate
Output in Kg/MT
Di Methyl Di thio phosphoric Acid
1159 PRODUCT
Ammonia Solution 25% 76 Dimethoate 1000
Mono chloroacetic Acid 382 WASTE WATER TO ETP
Methanol 127 WASTE WATER 1647
Sodium Bi Carbonate 13 WASTE TO INCINERATION
Water 1480 INCINERABLE WASTE 0
Monomethyl Amine 276 WASTE TO LAND FILLING
LAND FILLING WASTE 0
SOLVENT RECOVERY
SOLVENT RECOVERY 0
BY PRODUCT
BY PRODUCT 0
RECYCLE / REUSE
Mother Liquor 642
Organic Part for Recycle 225
EMISSION TO AIR
NO VAPOUR LOSS 0
TOTAL 3514 TOTAL 3514
Step 4 : Amidation
The condensed produced formed in Step 3 is amidated by reacting with mono methylamine to produce
Dimethoate. This dimethoate is then filtered, washed and transferred to drier.
CH3O S CH3O S
P + CH3NH2 P + CH3OH
CH3O S – CH2 – CO – CH3 CH3O S-CH2-C-NH-CH3
Step 5 : Drying
Dimethoate is then dried under vacuum to remove moisture and Dimethoate technical is obtained.
O O
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Figure 3.10: PROCESS FLOW DIAGRAME FOR DI METHOATE
3.6.6 ETHION (Existing – No Expansions)
3.6.6.1 PROCESS DESCRIPTION FOR ETHION
STEP 1 - NEUTRALISATION
The diethyl dithio phosphoric acid is neutralized with diluted ammonium hydroxide
solution. The aqueous layer containing the ammonium salt of diethyl dithio
phosphoric acid is taken in another reactor for condensation reaction and sent for
toluene recovery.
Dry Dimethoate
Mother Liquor for
Recycle
H2O
H2O
MMA
CP
H2O
Effluent
Effluent
Effluent
Effluent
H2O N3HCO3
MCA
H2O
Neutralization
Layer Separation Neutralization
Condensation
MCA Preparation
Amidation
Drying
.
Filtration
Washing &
Layer Separation
MCAA BOUNDARY
MeOH
Layer Separation
NH3
Organic part for
Toluene Recovery
and Recycle
Effluent
DMTA
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Step 2 : Condensation
Ammonium salt of diethyl dithio phosphoric acid is condensed with methylene dibromide to
get ethion.
Step 3 : Drying
Ethion produced in Step 2 is dried under vacuum to get Ethion Technical.
Table 3-7 Mass Balance – ETHION
INPUT KgMT
ETHION
Output in Kg/MT
Di Ethyl thio phosphoric acid 1309 PRODUCT
Ammonia 25% 512 ETHION 1000
Water 1785 WASTE WATER TO ETP
Toluene 17 WASTE WATER 879
Methylene Di Bromide 495 WASTE TO INCINERATION
INCINERABLE WASTE 10
WASTE TO LAND FILLING
LAND FILLING WASTE 0
SOLVENT RECOVERY
SOLVENT RECOVERY (TOLUENE) 16.5
BY PRODUCT
AMMONIUM BROMIDE 2212
RECYCLE / REUSE
RECYCLE OR REUSE
EMISSION TO AIR
WATER VAPOUR 0.5
TOTAL 4118 TOTAL 4118
C2H5O S C2H5O S
P + NH4OH P + H2O
C2H5O S – H C2H5O S- NH4
C2H5O S
P
C2H5O S-NH4
C2H5O S
P
C2H5O S - CH2
S OC2H5
P
- S OC2H5
+ CH2Br2 + 2NH4Br
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Figure 3-10PROCESS FLOW DIAGRAM FOR ETHION
3.6.7 Methyl Sulfenilyl Caramate (ASULAM - EXISTING – No Expansions)
3.6.7.1 Process description of Asulam :
Raw materials Dimethyl carbonate, Sodium methoxide and Sulfanilamide are charged in the
reaction vessel at room temperature. And then the mass are heated to reflux temp of 68°c
slowly and is being maintained at reflux temperature for some time. After completion of the
reaction, the mass which contains methanol are recovered by steam and vacuum distillation.
The recovered methanol along with water is sent for methanol distillation where methanol is
purified and the waste water is sent for treatment.
The product from the reaction vessel are sent for mixing vessel where required quantities of
hydrochloric and caustic are added to achieve the product quality specified and then it is
stored in the final storage tank from there it shall be loaded in tankers.
Reaction chemistry:
1st stage C6H8N2SO2 + NaOCH3 --------- C6H7N2SO2Na + CH3OH 172 54 194 32 Sulfanilamide sodium methoxide methanol
CH2Br2
H2O
Condensate
Effluent
Effluent
H2O
DDPA
Neutralization
Layer Separation
Condensation
Drying
Stripping
NH3
Organic part for
Toluene Recovery
and Recycle
Ethion Technical
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2nd stage C6H7N2SO2Na + C3H6O3------- C8H9O4N2SNa + CH3OH 194 90 252 32 Di methyl ASULAM
carbonate
Table 3-8 Mass Balance for ASULAM
INPUT KgMT
ASULAM
Output in Kg/MT
Sodium Methoxide 130 PRODUCT
Sulphanilamide 313 ASULAM 1000
Di methyl carbonate 192 WASTE WATER TO ETP
Caustic 11 WASTE WATER NOT GENERATED 0
Water 605 WASTE TO INCINERATION
Hydrochloric acid 89 INCINERABLE WASTE 0
Solvent Methanol 301 WASTE TO LAND FILLING
LANDFILLING WASTE 0
SOLVENT RECOVERY
Recovered Solvent(Methanol) 286
BY PRODUCT
Methanol 125
RECYCLE / REUSE
WATER +Methanol TO PROCESS 228
EMISSION TO AIR
HCl 2
TOTAL 1641 TOTAL 1641
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Figure 3-11 PROCESS FLOW DIAGRAM FOR ASULAM
3.6.8 PRETILACHLOR (EXISTING – No Expansions)
3.6.8.1 Manufacturing Process of Pretichlor
1st stage : PEC
1 Ready a MSGL Reactor provided with a agitator, condenser, Feed tank, TP etc.
2 Check whether the equipment is clean and free of any extraneous matter.
3 Check whether all utilities required for the process is available with the Utilities department.
4 Charge n - Propoxy Ethanol and DMF
5 Heat the mass to 110ºC
6 Feed Thionyl Chloride at110ºC through dip tube over a period of 3 Hrs such that the temperature of the reaction mass is maintained around 110ºC and scrubber can take the load.
8 Maintain the temperature of the reaction mass at 120ºC for a period of 1 Hr
9 Submit a sample for unreacted n - Propoxy Ethanol and Chlorosulfite ( < 1.0%)
(Take out an aliquot in test tube , add MDC,such that 10% solution is obtained)
10 If EOR is OK then proceed for the next step , otherwise continue the reaction
till PEA and Chloro sulfite is in desired limit.
11 Distill out the reaction mass at atmos. pressure and collect first cut upto 125 deg C and
then the main cut between 125 to 135º C
12 Analyze all the cuts for Area Profile and note the quantities of each.
13 The residue left over after distillation is to be disposed off.
14 The yield of the Main cut is about 92.0%
2ND STAGE PEDA
1 Charge DEA, NMP
2 Heat the mass to 150ºC over a period of 1 Hr
3 Feed PEC via the additional tank to the reaction mass over a period of 3 Hrs at a temperature between 148 - 152 ºC (Not to exceed 155 deg C)
4 If the EOR is OK , proceed for work up. If not OK, then continue cooking for further 2.0 Hrs.
Sodium Methoxide
Solution
Sodium Methoxide Powder
Methanol
Asulam Reaction
Sulphanilamide
Dimethyl Carbonate
Methanol Generation
ASULAM TECHNICAL
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5 Cool the reaction mass to 100 ºC, and distill out NMP and DEA (part) at 10 mmHg vacuum
at max pot temp. 140 deg C
6 Transfer contents to SS wash vessel and cool to RT
7 add 15% Caustic solution, agitate the mass for 20 to 30 mins to attain pH 10-11.
8 Pass this through hyflow bed or body feed and allow to settle and separate the layers at RT
9 HETP of 9 stages. After the 2nd cut, the mass is preferably taken to smaller vessel for the 3rd cut
10 Distill off the crude organic mass under 10 to 1 Torr during the first cut to third cut
11 First cut 110-122º C Vapor Temp DEA (6 mmHg)
12 Middle cut 122-142ºC Vapor Temp Mixture of DEA + PEDEA (6 mmHg)
12 Main cut 133-142 ºC Vapor Temp PEDEA (2 mmHg)
14 And mid cut to next distillation batch. The yield of the PEDEA is around 78%
3rd stage Pretichlor
1 Ready the SS reactor for the step
2 Charge PEDEA
3 Charge toluene
4 Heat the contents to 80 deg C
5 Feed CAC via the additional tank to the reaction mass over a period of 3 - 3.5 Hrs at a temperature
between 80 ºC
6 Submit a sample of the reaction mass for absence of PEDEA (< 0.5%)
7 If the EOR is OK , cool mass to 30°C. proceed for work up. If not OK, then continue cooking for further 1.0 to 2.0 Hrs.
Add fresh water (200ml/mol) and stir and allow the layer to separate
8 Allow to settle and separate the bottom aqueous layer
9 Wash the organic layer with 5% NaHCO3 soln (100 ml/mol), separate the layers.
10 Allow to settle and separate the bottom aqueous layer
11 Wash the organic layer with water again (100 ml/mol), separate the layers.
12 Organic layer is taken for solvent recovery
13 Distill out the Toluene from reaction mass at 10 torr
14 Towards the end subject the organic layer at maximum vacuum and remove all traces of the solvent.
Chemical Reactions 1st stage C5H12O2 + SOCL2 --------- HCL + SO2 + C5H11CLO 104 119 36.5 64 122.5 PEA TC PEC 2nd stage C5H11CLO + C10H13N ------- HCL + C15H25NO 122.5 149.5 36.5 235.5 PEC Aniline PEDEA 3rd stage C15H25NO + C2H2CL2O + NAOH -------- C17H26NCLO2 + NaCL + H2O 235.5 113 40 312.5 58.5 18 PEDEA CAC Pretilachlor
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Table 3-9 Mass balance for Pretilachlor
INPUT Kg/MT
Pretilachlor
Output in Kg/MT
PEA 495 PRODUCT
DMF 5 Pretilachlor 1000
SOCL2 571 WASTE WATER TO ETP
DEA 3368 WASTE WATER 2808
NMP 1408 WASTE TO INCINERATION
Sodium Hydroxide 15% 1299 INCINERABLE WASTE 77
CAC 432 WASTE TO LAND FILLING
Toluene 1356 LAND FILLING WASTE 0
Water 1016 SOLVENT RECOVERY
Sodium Bi Carbonate 339 NMP 1338
Sodium Hydroxide 10% 3605 DEA 3199
Toluene Recycle 1296
BY PRODUCT
Sodium Bi Sulphite 3877
HCL 299
RECYCLE / REUSE
RECYCLE OR REUSE 0
EMISSION TO AIR
Vapour loss (Water) 0.6
TOTAL 13894 TOTAL 13894
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Figure 3-12 PROCESS FLOW DIA FOR PRETILACHLOR
NaOH 10% 3605
ALL QUANTITY IN KGS
PEA 495 SO2
Sodium Sulphide
DMF 5.4 271.5 3876.5 By product
water 699
SOCL2 571
175 30% HCL (By-Product)
PEC 998
624
77
547
DEA 3368
NMP 1408
3780
15% NAOH 1299 Aq effluent to ETP
1471
PEDEA
3608
2543
DEA RECYCLE
796
CAC 432 124
HCL
Toluene 1356
2460
Water 1016 1459
Aq effluent
NAHCO3 339 ETP
5%
2356
loss atm 60
Toluene recy
1296
1000
Product
Residue for Incineration
NMP +DEA RECYCLE
1543
PEA
to
PEC
PEC
Distillation
PEC
to
PEDEA
Separation
Caustic Scrubber
HCl
scrubber
Distillation
of DEA
Condensation
Washing
Ist water
2nd NaHCO3
Toluene
Distillation
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3.6.9 Methoxy Ethyl Mercuric Chloride (BAGALOL - EXISTING – No Expansions)
3.6.9.1 Process description of Bagalol
Take Methanol and Acetic acid in 2KL cap Glass lined Reactor.
Charge Mercury Oxide slowly with continuous agitation for 2 Hrs.
After mixing, purge ethylene gas in the mixture. Ethylene gas is generated in Silver Cracker Unit. Total conversion is required min 40 to 56 Hrs.
Maintain the reaction mass at room temperature by circulating cool water in Jacket. Distillation
Take reaction mass in Distillation vessel. Distilled out excess methanol under vacuum at low temp.
Neutralize the remaining mass after distillation with NaOH solution.
Take reaction mass in wooden tub and cool it using Ice.
Slowly add NACL solution in reaction mass and precipitate it.
Filter reaction mass in centrifuge.
Mix MEMC cake with soda ash and soda bicarbonate to get 15% MEMC in Ballmill.
Recover Mercury from Mother liquor.
HgO + 2 CH3COOH (CH3COO)2Hg + H2O
(216.6) (60) (318.6) (18)
Mercury Oxide Acetic Acid
2) H H
Hg(OOC-CH3)2 + H-C = C-H + CH3OH CH3OC2H4CH3COOHg + CH3COOH
(318.6) (28) (32) (318.6) (60)
3) H H
CH3OC2H4CH3COOHg + NaCl CH3O C C HgCl + CH3 COONa
H H
(318.6) (58) (294.6) (82)
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Table 3-10 Mass Balance for BAGALOL
INPUT Kg/MT
Bagalol
Output in Kg/MT
Methanol 2857 PRODUCT
Acetic Acid 371 Bagalol 1000
Mercury Oxide 571 WASTE WATER TO ETP
Ethylene Gas 234 WASTE WATER 1434
Sodium Hydroxide 57 WASTE TO INCINERATION
Sodium Chloride 143 INCINERABLE WASTE 0
Water 143 WASTE TO LAND FILLING
Ice 514 LAND FILLING WASTE 0
SOLVENT RECOVERY
NO SOLVENT RECOVERY 0
BY PRODUCT
BY PRODUCT 0
RECYCLE / REUSE
EXCESS METHANOL + ACETIC ACID 2457
EMISSION TO AIR
NO EMISSION 0
TOTAL 4891 TOTAL 4891
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Figure 3-13 Process Flow Diagram For BAGALOL
INPUT Consumption/MT OUTPUT Generation/MTMethanol 2857
Acetic Acid 371
Mercury Oxide 571
Ethylene Gas 234
Sodium Hydroxide 57
Methanol and Acetic Acid
Sodium Chloride 143
Water 143
Ice 514
Centrifuge Mother Liquor to ETP 3863
Drying Evaporation Loss 29
Yield 1000Bagalol
Technical
Reactor
Distillation
Precipitation
(pH = 7.0)
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3.7 RAW MATERIAL REQUIREMENT
Raw materials required for existing project, proposed expansion project, transport and storage facility is provided in following table.
Table 3-11 Raw Material Requirement Details
Sr no Product name Raw material Name Existing Consumption in MT/ Month
Additional Consumption in MT/Month
Total consumption
after Expansion in MT/Month
Existing Product (Pesticide Technical Grade)
1 Acephate (Existing
Route)
Methylene di Chloride 1077.4 0 1077.4
DMPAT 111.3 0 111.3
DMS 13.3 0 13.3
Sulphuric Acid 98% 2.5 0 2.5
Acetic anhydride 77.7 0 77.7
Ammonia Solution 25% 80.8 0 80.8
1 Acephate (Proposed
New Route)
MDC 0 8371.5 8371.5
DMPAT 0 1612.5 1612.5
DMS 0 199.5 199.5
H2SO4 (98%) 0 37.5 37.5
Acetic Anhyd 0 1149 1149
NH3 Solution(17%) 0 1212 1212
H2SO4 (98%) 0 612 612
Ethyl Acetate 0 3724.5 3724.5
H2SO4 for Scrubber 2 0 1.5 1.5
Caustic (48%) for Sodium Acetate
conversion
0 1178.22 1178.22
OR OR OR OR OR
2 Metamitron
Ethyl Phenyl Glyoxalate 127.1 0 127.1
Ethyl Acetate 84.4 0 84.4
Hydrazine Hydrate 104.3 0 104.3
Ethanol Solvent 434.8 0 434.8
Hydrochloric Acid 11.7 0 11.7
Acetic Acid 1.5 0 1.5
Sodium Acetate 4.3 0 4.3
Ammonia Solution 25% 24.7 0 24.7
3 Di-Methoate
Di Methyl Di thio phosphoric Acid 69.6 0 69.6
Ammonia Solution 25% 4.6 0 4.6
Mono chloroacetic Acid 22.9 0 22.9
Methanol 7.6 0 7.6
Sodium Bi Carbonate 0.8 0 0.8
Monomethyl Amine 16.6 0 16.6
OR OR OR OR OR
4 Ethion Di Ethyl thio phosphoric
acid 78.5 0 78.5
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Sr no Product name Raw material Name Existing Consumption in MT/ Month
Additional Consumption in MT/Month
Total consumption
after Expansion in MT/Month
Ammonia 25% 30.7 0 30.7
Toluene 1.0 0 1.0
Methylene Di Bromide 29.7 0 29.7
5 Methyl Sulphenilyl
Carbamate (Asulam)
Sodium Methoxide 26.0 0 26.0
Sulphanilamide 62.6 0 62.6
Di methyl carbonate 38.4 0 38.4
Caustic 2.2 0 2.2
Hydrochloric acid 17.8 0 17.8
Solvent Methanol 60.2 0 60.2
6 Pretilachlor
PEA 24.8 0 24.8
DMF 0.3 0 0.3
SOCL2 28.6 0 28.6
DEA 168.4 0 168.4
NMP 70.4 0 70.4
Sodium Hydroxide 15% 65.0 0 65.0
CAC 21.6 0 21.6
Toluene 67.8 0 67.8
Sodium Bi Carbonate 17.0 0 17.0
Sodium Hydroxide 10% 180.3 0 180.3
7
Methoxy Ethyl Mercuric Chloride
(Bagalol)
Methanol 142.9 0 142.9
Acetic Acid 18.6 0 18.6
Mercury Oxide 28.6 0 28.6
Ethylene Gas 11.7 0 11.7
Sodium Hydroxide 2.9 0 2.9
Sodium Chloride 7.1 0 7.1
8
Di Ethyl P-Tosyloxym
Ethylphosphonate (DESMP)
Di Ethyl Phosphite 0 129.1 129.1
Formaldehyde 0 89.3 89.3
Catalyst 0 8.2 8.2
PTSCL 0 161.0 161.0
C.S.Lye 0 135.8 135.8
Toluene 0 646.1 646.1
Hydrochloric Acid 0 9.4 9.4
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3.8 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE
Resource optimization/recycling and reuse envisaged in the project (solvent recovery system) in detail are as mentioned below.
The raw materials will be stored in closed containers and will be handled through closed system to avoid the handling losses.
The solvents are reused in the manufacturing of pesticides. Details of solvent use & recovery are as under.
Condensate from Boiler will be recycled in the process to minimize the water consumption.
Recovery of valuable by-products like MDC. Toluene, and Methanol.
The UPL has maintained standard of solvent recovery more than 95% for solvents used in production of Acephate & DESMP.
The Recovery details of Solvents are Tabulated below.
Table 3-12 Solvent Recovery Details
Sr. No
Name of Product Name of Solvent Consumed
Quantity of Consumption in Kg/MT
Recovered Quantity in Kg/MT
% Solvent Recovery
1 Acephate (Existing Route)
MDC 10774 10235 95
Acephate (Proposed Route)
Ethyl Acetate 3724.5 3649.5 98
MDC 8371.5 8296.5 99
2 DESMP Toluene 2692 2584 96
3 Asulam Methanol 301 286 95
4 Ethion Toluene 17 16.5 97
5 Metamitron Ethanol 4348 4174 95
6 Pretilachlor
NMP 1408 1338 95
DEA 3368 3199 95
Toluene 1356 1296 96
3.9 RESOURCE REQUIREMENT
3.9.1 Land
The total land of the plant is 60702.82 sq. m (15 acre). This land has been taken long term lease from Kolkata Port Trust Haldia Dock Complex; the possession letter is attached in Annexure -3. The total build-up area of the plant is 23986.557 sq. m. and greenbelt area is 18,211 sq. m. (30% of the total plant area). The plant has demarcated 1821 sq. m for greenbelt plantation. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant. The site layout plant with proposed expansion unit has been provided in following figure.
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Figure 3-14 Plant Layout Map
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3.9.2 Water
The existing fresh water requirement of the plant is 60 KLD. The additional water requirement for the proposed expansion unit is 211 KLD; therefore total fresh water requirement after expansion will be 271 KLD. Water is being sourced from Haldia Development Authority (HDA), the future required water will be sourced from HDA. The detailed water balance is given below.
Table 3-13 Water Balance Details
Sr No
Source of Water Consumption Existing Water Consumption
(KLD)
Additional Water Consumption (KLD)
Total water Consumption
After Expansion (KLD)
1 Domestic 10 42 52
2 Industrial
2.a Process Water including Scrubber and R & D & Washing
12 62 74
2.b Boiler Feed Water
20 45 65
2.c Cooling, DM Plant, Chilling Water
8 52 60
2.e Gardening* 10 10 20
Total 60 211 271
3.9.3 Power
The existing power requirement is 4250 KW. Additional power requirement for proposed expansion unit is 43530 KW. Therefore, total power requirement will be 47780 KW. The power is being sourced from West Bengal State Electricity Distribution Company Limited (WBSEDCL); additional required power will be sourced from WBSEDCL. There are two (2) diesel generator (DG) sets having capacity of 1 x 500 KVA and 1 x 600 KVA. Additional 2000 KVA DG set will be installed for proposed expansion unit. 3.9.4 Fuel
Coal fired boiler (8 TPH capacity) is being utilised for generation of steam for the process. The existing coal requirement is 60 Mt/Day Exported coal is being used for boiler and is being sourced from Haldia Port through truck. For proposed expansion unit additional 2 x 15 TPH capacity boiler will be required and additional coal requirement will be 225 Mt/Day. Exported coal will be sourced from the Haldia port for proposed expansion unit. The existing HSD requirement is 250 lit/Day; additional requirement will be 455 lit/Day. HSD is being sourced from nearest oil terminal. 26 days HSD storage facility has been provided within the plant.
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3.10 POLLUTION SOURCES, TREATMENT AND DISPOSAL
3.10.1 Effluent & Sewage
Effluent has been generated from the process as well as boiler and cooling tower blowdown. The total effluent generated from the plant is 20 KLD. The effluent is being treated through effluent treatment plant (ETP) of 25 KLD capacity. After expansion, approximately, 200 KLD effluent will be generated from the plant. The effluent will be treated through 230 KLD capacity ETP. Part of the treated effluent will be used as cooling tower makeup water and remaining treated water will be discharged into Green Canal after meeting the discharge standard. Sewage is being generated from the office and plant area. Sewage generated from the existing plant is 5.8 KLD. After expansion, 17.8 KLD sewage will be generated from the plant. Sewage is presently being treated through ETP; same system will be continued for proposed expansion project. The Waste Water Balance is given in a Table Below.
Table 3-14 Waste Water Balance
Waste Water Generation Source Existing Waste
Water Generation in KLD
Additional Waste water
Generation in KLD
Total Proposed Waste water
generation in KLD
Process 7.4 120.6 128
Cooling Water Blow Down from CT 4.8 40.2 45
Boiler Blow Down 2 27.2 29.2
Domestic Waste Water 5.8 12 17.8
Total Waste Water Generation in KLD 20 200 220
3.10.2 Air Emission
3.10.2.1 Flue Gas Emission
At present, the unit is having one number of 8 TPH steam boiler. The proposed expansion unit will install additional two number of Steam Boiler having capacity 15 TPH each. Coal will be utilised as fuel.
The details of Flue gas stack have been given in a Table Below.
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Table 3-15 Existing and Proposed Air Emissions Details (Flue Gas)
Sr. No
Stack Attached To Dia of Stack in MM
Stack Height in M
Parameters Air Pollution Control Device
Monitoring Device
EXISTING FLUE GAS STACKS
1 Boiler – 8 TPH 1000 30 PM. SO2, NOx Bag Filter Opacity Meter Connected to CPCB Server
2 DG Sets – 1 X 500 KVA
250 10 PM, SO2 & NOx Adequate Stack Height
Only used in Emergency
3 DG Sets – 1 X 650 KVA
250 10 PM, SO2 & NOx
PROPOSED STACK EMISSIONS
1 Boiler 1 X 15 TPH 1875 51 PM, SO2 & NOx Bag Filter Opacity Meter & Flue Gas Analyser
2 Boiler 1 X 15 TPH 1875 51 PM, SO2 & NOx Bag Filter
3 1 X 2000 KVA DG Set
800 30 PM, SO2 & NOx Adequate Stack Height
Only used in Emergency
3.10.2.2 Process Emission The emission from the process are HCl, NH3, H2,S, CH3Cl. The process emission will be controlled through following air pollution control systems. The details of existing and proposed process emissions with stack details are given below.
Table 3-16 Existing and Proposed Process Stack Emissions
Sr. No
Stack Attached To Dia of Stack in MM
Stack Height in M
Parameters Air Pollution Control Device
EXISTING PROCESS GAS STACKS
1 Asulum Plant Vent 80 5 HCL Caustic Scrubber
2 Ethion Vent
25 18 H2S, NH3 Caustic & NaOCl Scrubber
3 Acephate Plant IsoMer Reactor Vent
40 9 CH3Cl Water Scrubber
4 Fluidised Bed Drier – FBD 350 18 PM Bag Filter
5 Spin Flush Drier - SFD 200 19 PM Bag Filter
PROPOSED PROCESS STACK EMISSIONS
1 Asulum Plant Vent 80 5 HCL Caustic Scrubber
2 Ethion Vent 25 18 H2S, NH3 Caustic & NaOCl Scrubber
3 Acephate Plant IsoMer Reactor Vent
560 9 CH3Cl Water Scrubber
4 Fluidised Bed Drier – FBD 350 18 PM Bag Filter
5 Spin Flush Drier - SFD 200 19 PM Bag Filter
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Presently the unit has installed two numbers of two stage water scrubber followed by alkali scrubber to scrub HCl gas generated from the process. After proposed expansion, the unit will install additional three numbers of two stage water followed by alkali scrubbers to scrub HCl, gas generated from the process. Adequate height of process vent will be provided. 3.10.3 Solid Waste / Hazardous Generation
The discarded drums /bags /Liners are decontaminated, detoxified by using water/caustic/HYPO and will be sold to scrap processors.
Used oil shall be sold to State Pollution Control Board (SPCB) authorized recycler / re-processor.
ETP Sludge; MEE salts shall be sent to Treatment, Storage and Disposal Facility (TSDF) site at Haldia- Ramkey for final disposal
Organic waste / distillation Residue, Aqueous waste, Off specification product / date expired product, is/will be sent for incineration.
After expansion total Landfilling waste generation will be 0 MTM (Existing: 00 MTM + Proposed: 00 MTM). Generated landfilling wastes will be sent to Ramkey, Haldia for landfilling.
After expansion total Incineration waste generation will be 15 MTM (Existing: 1.5
MTM + Proposed: 13.5 MTM). Generated incineration waste will be sent for co-processing first and remaining quantity will be sent to Ramkey, for incineration.
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4 SITE ANALYSIS
4.1 CONNECTIVITY
The port of Haldia acts as the guiding factor to trade and commerce of vast hinterland comprising the entire Eastern India including Bihar and Eastern Uttar Pradesh and the two land locked Himalayan Kingdoms of Nepal and Bhutan. The near by Aminities to the site have been given in Table 3.1 of PFR Report. 4.1.1 Road Connectivity
The National Highway 41 connects the port city with National Highway 6 (part of Golden Quadrilateral) at Kolaghat. From Kolaghat NH-6 connects Orissa, Jharkhand, Kharagpur, Bankura and Purulia and also Durgapur, through NH-34 to North Bengal, Bangladesh via Petrapole and Bhojadanga.
Figure 4-1 Accessibility Map of the Haldia Industrial Area
4.1.2 Rail Connectivity
Haldia port is connected with the broad-gauge line of the South-Eastern Railways. Panskura-Haldia electrified rail route is highly suitable for the daily commuters. Also a circular railway connecting the core industrial areas to provide additional facilities to the industries are among the plans for the future.
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4.1.3 Air Connectivity
The Netaji Subhash Chandra Bose International Airport, Kolkata, connects the port city to the rest of the India and world by air. Available road transport from the airport to the port city provides an easy means of communication in spite of the distance. 4.1.4 Water Connectivity
The Allahabad-Haldia stretch of the Ganga-Hooghly River serves as national waterways No 1. With Haldia Dock Complex, the country's 5th largest port with all modern facilities for industrial growth. Bulk cargo-handling facilities, full-fledged container facilities, an oil jetty to handle tankers with liquid cargo are a few of the facilities that the Haldia Dock provides. Along with these the city is also equipped with river ferry services between Kukrahati-Raichak and Kukrahati - Diamond Harbor. 4.1.5 Land Form, Land use and Land Ownership :
The plot of land is located at a land of KoPT – Kolkata Port Trust – A Nodal agency owing a land has given permission to UPL for 30 Years Lease utilisation for Industrial Purpose. The “Haldia Development Authority (HDA) is nodal agency constituted by government of West Bengal who is responsible for support infrastructure development at Industrial area like Water, Road & Other Amenities. Thus, landuse pattern is non-agricultural it is used for industrial activities only and belongs to KoPT. Land possession document is attached as Annexure-03. The total land described above is owned (acquired) by the project proponent and has declared as Industrial zone. The total land of the plant is 60702.82 sq. m (15 acre). This land has been taken long term lease from Kolkata Port Trust Haldia Dock Complex. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant. 4.2 TOPOGRAPHY (ALONG WITH MAP)
There is a general gradual slope towards Southern side i.e. towards the 45 meter Service Corridor (Nananjuli), running parallel to the HPL Link Road, on the way to City Centre from Durgachak at Haldia Township area. The most prevalent soil in the region is black cotton soil. However, sandy, light grey, reddish and brown soil also occurs in the area. Major portion of the area is black and red sandy loam soil. Geological formations are of Khodalites, Chamockites, Quartzite and quartz veins origin occurring in elongated bands. 4.3 LAND USE
The total land used UPL Haldia unit is 60702.82 sq. m (15 acre. The total build-up area of the plant is 23986.557 sq. m. (39.5%) and greenbelt area is 18,211 sq. m. (30% of the total plant area). The plant has demarcated 1821 sq. m for greenbelt plantation. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant. The identified land was built-up area. Therefore, land filling and tree felling would not be required. The detailed land use table for existing site and proposed expansions is given as below.
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Table 4-1 Existing and Proposed Land Use Details
Sr. No
Particulars Existing m2 Proposed area in m2 Remarks
A Production Plant Area with
Utility 23987 25187
No Additional Land Requirement since
Expansion is proposed within
existing plant premises.
B Rain Water Harvesting
Pond Area 11476 11476
C Circulation Areas (Roads) 3500 3500
D Green belt /Land scrapings 18,211 20,032
E Open Areas /Non Processing Areas
3,529 508
TOTAL AREA IN Sq. M 60702.82 60702.82
The Proposed Land has already been defined as a classified Industrial zone by Haldia Development Authority. Hence, there is no change in the character of the land to be used for the Industry. 4.3.1 CRZ applicability
The proposed expansion site is approximately, 450 m from high tide line. As per CRZ Notification 2011, CRZ is applicable up to 100 m from HTL. Therefore proposed project does nor attract CRZ. 4.4 EXISTING INFRASTRUCTURE
The details on the existing core infrastructure facilities are dealt in the above paragraph some additional important aspects are dealt below 4.4.1 Water
Water at Haldia is served by rivers like Rupnarayan, Haldi and Hooghly that ensure abundant water supply for irrigation of the agricultural farms. The Authority has made requisite arrangements to ensure treated industrial and domestic water supply round-the-clock. Due to current water demand of industries, HDA augmented 25 MGD Water Treatment Plant beside its existing 25 MGD Water Treatment Plant at Geonkhali. For fulfillment of future demand to a tune of 25 MGD the treatment plant has been started operating recently on BOT basis. 4.4.2 Power
West Bengal State Electricity Distribution Corporation Ltd. (WBSEDCL) is primarily responsible for a stable and quality power supply to the Haldia Planning Area.
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4.4.3 Telecommunication
For instantaneous communication to any part of the globe, Haldia port city is well equipped with the latest telecom facilities provided by BSNL, Reliance, Airtel, Vodafone etc. and postal services. 4.4.4 Drainage
The Irrigation and Waterways Department of West Bengal plays a significant role in the planning and execution of the comprehensive drainage scheme for Haldia. To supplement, this scheme HDA has undertaken a number of projects like construction of drainage culverts and RCC Box type culverts over Manasatala Canal. Also some secondary drainage schemes for Storm Water Drainage have been taken. 4.5 SOIL CLASSIFICATION
General soil classification of the area is as under : Soil Characteristics & Land use classification: The study area is located at Haldia Industrial area. Major part of the study area has been developed for industrial use and township. The quality of East Midnapur district area soil had been identified as coastal alluvial type. Proposed expansion project is within existing site and located in Kolkata Port Trust industrial Area Haldia, where land is already developed for industrial purpose. Quality of soil is not considerably fertile for agriculture activities and no evidence of any influence of soil contaminant has been noticed. 4.6 CLIMATE
The climate of Haldia is a typical moderate one with winter temperatures ranging from a low of around 9.6 degrees Celsius to a high of 29.3 degrees Celsius. Summers on the other hand can be very hot and humid. Usual summer temperatures in May range from a low of 24 degrees to highs around 42 degrees. Rainfall is heavy during monsoons, and the rainy months are between May and September.
Table 4-2 Climatic Condition in the Study Area
Sl. No. Parameter
1. Temperature
Summer 41.7 C to 24.0 C
Winter 29.3 C to 9.6 C
2. Humidity 68 to 80%
3. Rainfall (Annual average) 1580 mm
4. Wind speed Mean speed – 5.5 to 9.9 km per hour
5. Wind Direction
Predominant From South & south west
Winter season From North & North-West
[IMD, Haldia]
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4.7 DEMOGRAPHY OF THE PROJECT INFLUENCE AREA
In the 2011 census, Haldia had a population of 200,827, out of which 104,841 were males and 95,986 were females. The 0–6 year’s population was 21,945. Effective literacy rate was 79%.
Figure 4-2 Decadal Population Growth at Haldia
Table 4-3 Demography of Haldia at a Glance
Demographic parameter Total Male Female
Total No. of Household 44065
Total Population 200827 104841 95986
Sex Ratio 916
In the age group 0-6 years 21945 11194 10751
Child Sex Ratio 960
Literates 158380 87334 71046
79% 55% 45%
Table 4-4 Working Population of Haldia
Workforce Participation Parameter Total Male Female
Total workers 61216 54477 6739
30% 89% 11%
Main Worker 50792 46004 4788
25% 91% 9%
Marginal Worker 10424 8473 1951
5% 81% 19%
Non Worker 139611 50364 89247
70% 36% 64%
4.8 SOCIAL INFRASTRUCTURE AVAILABLE
The infrastructure resource base of the area with reference to education, medical facilities, water supply, post and telegraph, transportation and communication facilities and power
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supply etc. are briefly described below for 5 km Core Area of Influence around the site (that comprises of Haldia Municipality, Dihsibram Nagar, Anantapur and Kismat Sibramnagar) : Education: The villages and sub-urban towns located within the 10 km study area have access to 86 govt. primary schools, 20 middle schools, 19 secondary schools and 15 senior secondary schools. Other than that, there are several private educational facilities imparting education from primary to higher education lying within the Haldia Municipal Corporation area. Communities within the study area are mostly dependent on Haldia for fulfilling the needs of higher education. Drinking Water: As per Census 2011 data, treated water supply is available from Geonkhali Water Supply Station. Communication and Transportation: The area is well connected with road network. The Kolaghat Nandkumar Road and Haldia Tamluk Mecheda Road connects the core area with other parts of the District. Public transportation such as buses and autos are available. Power Supply: Power supply is available in all of the villages and sub-urban areas within the study area. Medical/Primary Health Care: Primary Health Centre, Block Primary Health Centre and Sub-Divisional Hospital is present within Haldia Municipality Area. Other than that Primary Health Sub Centre is present in Kismat Shibramnagar.
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5 PLANNING BRIEF
5.1 PLANNING CONCEPT
Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification is as follows UPL has a thorough knowledge of worldwide market of Pesticides (Technical & Formulations) as well as organic intermediates and is already exporting these products. After a very careful scrutiny of the developments of R & D, UPL is ready to launch new intermediates as well as several new pesticides. To support the above projections, it is decided to make optimal use of the facilities at existing site by providing additional supporting infra-structure & hence this project for addition & expansion. Land required for the proposed project is already owned by proponent and no additional land is required for proposed project. Additional Power, Fuel and water will also be available through same existing sources. Proposed project activities will address all the applicable rules and regulations. There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like petro-chemicals, chemicals, oil & gas storage and bottling, thermal power plant. Haldia Dock complex, etc. in the Haldia Industrial area. 5.2 POPULATION PROJECTION
Not applicable 5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC
The existing unit is located in the HDA Industrial area; the proposed expansion unit will be constructed within the existing plant area; hence there will not be any change in Land use of core zone and buffer zone. The total land used UPL Haldia unit is 60702.82 sq. m (15 acre. The total build-up area of the plant is 23986.557 sq. m. (39.5%) and greenbelt area is 18,211 sq. m. (30% of the total plant area). The plant has demarcated 1821 sq. m for greenbelt plantation. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant.
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Table 5-1 Existing and Proposed Land Use Details
Sr. No
Particulars Existing m2 Proposed area in m2 Remarks
A Production Plant Area with
Utility 23987 25186.557
No Additional Land Requirement since
Expansion is proposed within
existing plant premises.
B Rain Water Harvesting
Pond Area 11476 11476
C Circulation Areas (Roads) 3500 3500
D Green belt /Land scrapings 18,211 20,032
E Open Areas /Non Processing Areas
3,529 508
TOTAL AREA IN Sq. M 60702.82 60702.82
Figure 5-1 Photographs of Existing Greenbelt
While selecting the plants species to be grown in the green belt zone, following points will be taken into account:
Climatic condition and soil characteristics of the region.
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The air pollution emitted by the industry – gaseous and particulate matter. Plant interaction with both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere.
Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles.
Height of the plants should not be too high to be lethal.
For absorbance of gases, the duration of the foliage should be longer.
Vegetation controls soil erosion rates significantly. The decrease of water erosion rates with increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked.
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ( PHYSICAL & SOCIAL) :
There is no need for any infrastructure demand in terms of physical or social needs for the proposed expansion. 5.5 AMENITIES/ FACILITIES
HDA industrial area of Haldia has the available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.
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6 PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA (PROCESSING AREA).
The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety. The proposed project is an expansion within existing unit. Approx. 60702.82 Sq. meter land will be used for proposed expansion. 6.2 RESIDENTIAL AREA (NON PROCESSING AREA) :
No residential area is involved in the proposed expansion project. 6.3 GREENBELT
Green belt will be provided and maintained at the tune of 33% of the total land area of factory. 6.4 SOCIAL INFRASTRUCTURE
Not applicable. 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/ WATER WAYS ETC)
The project site is very well connected by road through National Highway no. 41, eastern railways. 6.6 DRINKING WATER MANAGEMENT ( SOURCE & SUPPLY OF WATER ) :
Source of water is from HDA water supply services for proposed expansions. 6.7 SEWERAGE SYSTEM
HDA has provided drainage facility for disposal of treated effluent and sewage. 6.8 INDUSTRIAL WASTE MANAGEMENT
Industrial liquid effluent generated during the manufacturing of proposed products will be segregated. Concentrated (high TDS) effluent will be treated in the primary, secondary & tertiary ETP and will be discharged through HAD drainage to Hooghly after meeting the discharge standard. Generated domestic liquid waste is being treated through ETP and then disposed off through drainage system. 6.9 SOLID/HAZARDOUS WASTE MANAGEMENT
Generation, treatment and disposal of solid/hazardous waste has been provided in following table.
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Table 6-1 Solid/Hazardous Waste Management
Sl. No.
Type of Solid /Hazardous waste
Quantity in MT/Month
Mode of Disposal Existing as per EC
Actual Generation
Additional Quantity After Expansion
Total Quantity (Actual Generation + Additional)
1 ETP sludge 1.465 0.7 4.9 5.6 Disposed off into TSDF, Haldia
2 Used oil 1.00 0.11 0.64 0.75 Sell to authorized recycler
3
Solid waste from industrial process (Salt from MEE & Process residue
6.5 0 0 0 Disposed off into TSDF, Haldia for Incineration
4 Waste from MMT Process
166.25 4.83 178.18 182.94
Disposed off into TSDF, Haldia for Incineration
5 Asulum formulations
2 2 2 2 No Generation
177.215 7.64 185.72 191.29
Table 6-2 Non Hazardous Waste Management
Sl. No.
Type of Solid /Hazardous waste
Category Quantity TPD Place of Storage
Disposal
Existing as per EC
Actual Generation
Additional After Expansion (Actual +Additional)
1 Fly Ash 34.3 15 2.1 68.1 70.2 HDPE Drums
Disposed off into Low laying area or Given to Local Brick Manufacturers
6.10 POWER REQUIREMENT & SUPPLY / SOURCE
Power requirement for proposed expansion project will be taken from West Bengal State Electricity Distribution Corporation Ltd. (WBSEDCL).
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7 REHABILITATION AND RESETTLEMENT (R&R) PLAN
7.1 POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS
INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEF OUTLINE TO
BE GIVEN):
Proposed expansion will be carried out at existing site located in Industrial zone of Kolkata Port Trust which is developed for industrial purpose and there is no population or local inhabitant at the proposed expansion at existing site. Thus Rehabilitation & Resettlement (R&R) Plan is not applicable to propose expansion
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8 PROJECT SCHDULE & COST ESTIMATION
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION
The proposed expansion project will be started after getting Environmental clearance from Ministry of Environment, Forest and Climate Change (MoEF &CC) & Consent to Established (CTE) from State Pollution Control Board (SPCB). 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF
THE PROJECT
The estimated approx. capital cost of the expansion project shall be INR 165.31 crores & detail
Table 8-1 Project Cost Breakup
Sl. No. Component Amount (INR in Crore)
1 Equipment Cost 47.17
2 Piping Cost 25.47 3 Electrical Cost 10.43 4 Instrumentation Cost 8.68 5 Civil & structure Cost 37.67
6 Insulation Cost 5.15 7 Painting Cost 5.15
8 Safety Equipment Cost 2.00 9 Utility Cost 9.09 10 Miscellaneous Cost ( HAZOP, Service) 14.50 11 Cost of Environment Management System (APCM, Waste
Management cost, Effluent Treatment & Green Belt)
(25.14 crore) included in the project
cost
Total 165.31
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9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL
PEOPLE INCLUDING TRIBAL POPULATION ANY IN THE AREA
The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to be purchased.
From The proposed expansion project, there shall be increase to foreign exchange generated by Exports.
Reduce dependence on Imports hence reducing forex risks.
There shall be direct or indirectly increase in employment generation for the local people and lead to ensure continued employment to existing workforce without affecting work conditions and hence supporting their families.
The company has allocated some budget for CSR activities, which can lead to improved social infrastructure, if planned properly.
The proposed expansion project shall not have any adverse environmental impacts because adequate protection measures will be provided to achieve permissible norms of MoEF&CC /WBPCB.
UPL Management have taken up various CSR activities and major activities are in the field of education, health protection and improvement of infrastructure facilities. The important organizations under the umbrella of UPL are Sanskardeep Vidyalaya (Ankleshwar), Gyan Dham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology (Ankleshwar). In CSR, UPL spent 10.62 Crores in the year of 2014-15; 11.56 Crores in 2015.16 and 23.79 Crores in 2016-17.
CSR Activity at Haldia The CSR activity in the UPL Haldia unit are providing infrastructure and facilities in schools like (i) toilets, (ii) computers and (iii) school uniforms 9.2 CONCLUSION:
The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to be purchased. From The proposed expansion project, there shall be increase to foreign exchange generated by exports and reduced dependence on Imports hence reducing forex risks. Moreover, existing site is located inside Industrial zone of Kolkata Port Trust. As summarized in above sections, it has been noticed that the proposed expansion in existing production capacity (Pesticides Technical) and addition of new products (Pesticides Technical products) will not have any major impacts, which can lead to serious issue of environmental pollution or any other hazards. Considering the probability of impacts, proponent has planned adequate mitigation measures and EMP. There shall be direct or indirectly increase in employment generation for the local people which will lead to ensure continued employment to existing workforce without affecting work conditions and hence supporting their families. The company has allocated some budget for CSR activities, which can lead to improved social infrastructure. In addition, UPL Management have taken up various CSR activities and shall continue to do so in the field of education, health protection and improvement of infrastructure facilities.
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Annexure
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Annexure 1: Environmental Clearance
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Annexure 2: Ground water Withdrawal Permission
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Annexure 3: Land Possession Certificate