proposed api & api intermediates in existing...

1

FORM-1

for

PROPOSED API & API INTERMEDIATES IN

EXISTING PIGMENT UNIT

of

M/s. AMAR PIGMENTS

PLOT NO. 3012-3013, PHASE – III, GIDC PANOLI,

DIST: BHARUCH-394116 (GUJ.)

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

2

APPENDIX I

(See paragraph - 6)

FORM 1

Sr.

No.

Item Details

1. Name of the project/s M/s. Amar Pigments

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

3. Proposed capacity/ area/ length/ tonnage

to be handled/ command area/ lease area/

number of wells to be drilled

Please refer Annexure – I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. Total Proposed Capacity: 40 MT/Month

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

7. Does it attract the general condition? If yes,

please specify.

Yes. Located within 5 km of critically

polluted area (Ankleshwar).

8. Does it attract the specific condition? If yes,

please specify.

No

Location

Plot/Survey/Khasra No. Plot No. 3012-3013

Village GIDC Panoli

Tehsil Ankleshwar – 394 116

District Bharuch

9.

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Railway Station: Ankleshwar (5 km)

Airport: Surat (60 km)

11. Nearest Town, city, District Headquarters

along with distance in kms.

Panoli Village (2 km),

Bharuch (20 km)

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Panoli Village, Taluka: Ankleshwar – 394 116,

Dist: Bharuch (Gujarat)

13. Name of the applicant M/s. Amar Pigments

14. Registered Address Plot No. 3012-3013, GIDC Panoli, Tal:

Ankleshwar, Dist: Bharuch-394116 (Guj)

Address for correspondence:

Name Mr. Vinubhai M. Dobaria

Designation (Owner/Partner/CEO) Partner

Address M/s. Amar Pigments

Plot No. 3012-3013, GIDC Panoli, Tal:

Ankleshwar, Dist: Bharuch (Guj)

Pin Code 394 116

15.

E-mail [email protected],

3

[email protected],

[email protected]

Telephone No. Phone : 02646 –650947, 272756

Mob. : +919824407734

Fax No. --

16. Details of Alternative Sites examined, if any.

Location of these sites should be shown on

a top of sheet.

NA

17. Interlinked Projects NA

18. Whether separate application of interlinked

project has been submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

21. Whether the proposal involves

approval/clearance under: if yes, details of

the same and their status to be given.

(a) The Forest (Conservation) Act, 1980?

(b) The Wildlife (Protection) Act, 1972?

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

No

22. Whether there is any Government

Order/Policy relevant/relating to the site?

No

23. Forest land involved (hectares) NA

24. Whether there is any litigation pending

against the project and/or land in which the

project is propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if any

and its relevance with the proposed

project.

NA

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

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

exploration, length for linear transport infrastructure, generation capacity for power

generation etc.,)

4

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes/No Details there of with approximate quantities

frates, wherever possible) with source of

information data

1.1 Permanent or temporary change in land

use, land cover or topography including

increase intensity of land use (with

respect to local land use plan)

No Proposed expansion is within the existing

premises of GIDC Panoli. Expected cost of the

project is Rs. 3.75 Crores.

Total Plot Area = 2,000 m2

Green Belt = 200 m2

1.2 Clearance of existing land, vegetation

and Buildings?

No Proposed expansion is within the existing

premises of GIDC Panoli.

1.3 Creation of new land uses? No

1.4 Pre-construction investigations e.g.

bore Houses, soil testing?

No

1.5 Construction works? Yes Plant Layout attached as Annexure - II

1.6 Demolition works? No

1.7 Temporary sites used for construction

works or housing of construction

workers?

No

1.8 Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

No Plant Layout attached as Annexure - II

1.9 Underground works mining or

tunneling?

No

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Off shore structures? No

1.13 Production and manufacturing

processes?

Yes For detail Please refer Annexure –III

1.14 Facilities for storage of goods or

materials?

Yes Specified storage area shall be provided for

storage of goods, Raw materials & Finished

products.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes For detail please refer Annexure – IV & V

1.16 Facilities for long term housing of

operational workers?

No

1.17 New road, rail or sea traffic during

Construction or operation?

No

1.18 New road, rail, air waterborne or other

transport infrastructure including new

or altered routes and stations, ports,

airports etc?

No

1.19 Closure or diversion of existing

transport routes or infrastructure

No

5

leading to changes in Traffic

movements?

1.20 New or diverted transmission lines or

Pipelines?

No

1.21 Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No

1.22 Stream crossings? No

1.23 Abstraction or transfers of water form

ground or surface waters?

No No ground water shall be used. The raw water

shall be supplied by GIDC Authority.

1.24 Changes in water bodies or the land

surface Affecting drainage or run-off?

No

1.25 Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel, raw material and

products will be primarily by road only

1.26 Long-term dismantling or

decommissioning or restoration works?

No

1.27 Ongoing activity during

decommissioning which could have an

impact on the environment?

No

1.28 Influx of people to an area either

temporarily or permanently?

No This is a well developed GIDC Estate and due to

the expansion of this project, M/s. Amar

Pigments will give direct employment to local

people based on qualification and

requirement. In addition to direct employment,

indirect employment shall generate ancillary

business to some extent for the local

population.

1.29 Introduction of alien species? No

1.30 Loss of native species or genetic

diversity?

No

1.31 Any other actions? No

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

Sr.

No.

Information/checklist confirmation Yes/No Details there of (with approximate quantities

frates, wherever possible) with source of

information data

2.1 Land especially undeveloped or

agricultural land (ha)

No GIDC land of 2,000 m2.

2.2 Water (expected source & competing

users) unit: KLD

Yes The entire water requirement will be met

through GIDC. Water available from GIDC. For

detail please refer Annexure – VI

2.3 Minerals (MT) No

6

2.4 Construction material: stone, aggregates,

and / soil (expected source – MT)

Yes Construction materials like crushed stones, sand,

rubble, cement, steel, etc. required for the

project shall be procured from the local market of

the region.

2.5 Forests and timber (source – MT) No

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes For detail please refer Annexure – VI

2.7 Any other natural resources (use

appropriate standard units)

No

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

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

Sr.

No.

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

quantities/rates, wherever possible)

with source of information data

3.1 Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes For detail please refer Annexure –VII.

3.2 Changes in occurrence of disease or affect

disease vectors (e.g. insect or water borne

diseases)

No

3.3 Affect the welfare of people e.g. by

changing living conditions?

No

3.4 Vulnerable groups of people who could

be affected by the project e.g. hospital

patients, children, the elderly etc.

No

3.5 Any other causes No

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

Sr.

No.




4.1 Spoil, overburden or mine wastes No

4.2 Municipal waste (domestic and or

commercial wastes)

No

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Please refer Annexure – V

4.4 Other industrial process wastes No

4.5 Surplus product No

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Please refer Annexure – V

7

4.7 Construction or demolition wastes No

4.8 Redundant machinery or equipment No

4.9 Contaminated soils or other materials No

4.10 Agricultural wastes No

4.11 Other solid wastes Yes

Please refer Annexure – V

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

Sr.

No.

Information/Checklist

confirmation

Yes/No Details there of (with approximate quantities/rates,

wherever possible) with source of information data

5.1 Emissions from combustion of

fossil fuels from stationary or

mobile sources

Yes For details Please refer Annexure – VIII

5.2 Emissions from production

processes

Yes For details Please refer Annexure – VIII

5.3 Emissions from materials handling

storage or transport

Yes All liquid raw materials shall be procured

in tankers and shall be transferred through a closed

circuit pipe lines.

Solid raw materials shall be charged through close

pipeline into reactors and the dust collection hopper

shall be connected to a bag filter and ID fan.

Also all the hazardous chemicals storage tanks will be

provided with flame arrestors & breather valves for

safety.

5.4 Emissions from construction

activities including plant and

equipment

Yes During construction work, only dust contamination will

be there, water sprinklers shall be utilized whenever

necessary.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Solvent vapors shall be cooled in appropriate

condensers and shall be passed through trap vessel

fitted with condensers. All the waste shall be stored in

designated place and shall be transported to TSDF site

in approved closed vehicles owned by the TSDF

authority.

Dust from drying will be collected in to dust collector

through cyclone separator & recovered powder will be

recycled back to process. Air Handling Unit will be

provided where ever applicable.

5.6 Emissions from incineration of No 5.7 Emissions from burning of waste

in open air e.g. slash materials,

construction debris)

No

5.8 Emissions from any other sources No

8

(III) Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.


quantities/rates, wherever possible) with

source of information data with source of

information data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes All machinery / equipment shall be well

maintained, shall be proper foundation with

anti vibrating pads wherever applicable and at

noise levels within permissible limits. DG set

shall have acoustic enclosure. Expected Noise

level at different locations in the plant is

enclosed as Annexure – IX

6.2 From industrial or similar processes Yes Please refer Annexure – IX

6.3 From construction or demolition No

6.4 From blasting or piling No

6.5 From construction or operational traffic No

6.6 From lighting or cooling systems Yes Please refer Annexure – IX

6.7 From any other sources No

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

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

Sr.

No.


quantities/rates, wherever possible) with

source of information data

7.1 From handling, storage, use or spillage

of hazardous materials

Yes Hazardous material shall be stored in designated

storage area with bund walls for tanks. Other

material will be stored in bags/drums on pallets

with concrete flooring and no spillage is likely to

occur. All liquid raw materials shall be

transported through pumps and closed pipelines

and no manual handling shall be involved. Spill

Container will be kept at appropriate places to

collect spillage. SOP for collection,

decontamination & disposal of spilled material

will be displaced at necessary locations. For

details please refer Annexure – VII

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes The neutralized low COD effluent after primary

treatment will be sent to the CETP of M/s PETL,

Panoli for the further treatment and final

disposal. The neutralize high COD effluent after

primary treatment will be sent to the Common

Spray Dryer of M/s PETL, Panoli for the further

9

treatment and final disposal.

7.3 By deposition of pollutants emitted to

air into the and or into water

No

7.4 From any other sources No

7.5 Is there a risk of long term build up of

pollutants in the environment from

these sources?

No

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

Sr.

No.


quantities/rates, wherever possible) with source

of information data

8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes For detail please refer Annexure – VII

8.2 From any other causes No

8.3 Could the project be affected by

natural disasters causing

environmental damage (e.g. floods,

earthquakes, landslides, cloudburst

etc)?

No

9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr.

No.

Information/Checklist confirmation

Yes/

No

Details there of (with approximate



9.1 Lead to development of supporting. utilities,

ancillary development or development stimulated

by the project which could have impact on the

environment e.g.

• Supporting infrastructure (roads, power supply,

waste or waste water treatment, etc.)

• housing development

• extractive industry

• supply industry

• other

Yes For detail please refer Annexure – X

9.2 Lead to after-use of the site, which could have an

impact on the environment

No

9.3 Set a precedent for later developments No

9.4 Have cumulative effects due to proximity to other

existing or planned projects with similar effects

No

10

(IV) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance (within 15km.) Proposed

project location boundary

1 Areas protected under international

conventions, national or local legislation

for their ecological, landscape, cultural

or other related value

No Proposed Expansion project site is within the

GIDC Estate of Panoli

2 Areas which important for are or

sensitive Ecol logical reasons –

Wetlands, watercourses or other water

bodies, coastal zone, biospheres,

mountains, forests

No

3 Area used by protected, important or

sensitive Species of flora or fauna for

breeding, nesting, foraging, resting,

over wintering, migration

No

4 Inland, coastal, marine or underground

waters

No No inland, costal or marine within 5 km from

the proposed project

5 State, National boundaries No 6 Routes or facilities used by the public

for access to recreation or other tourist,

pilgrim areas

No

7 Defense installations No

8 Densely populated or built-up area - Panoli Village

9 Area occupied by sensitive man-made

land uses Hospitals, schools, places of

worship, community facilities)

No

10 Areas containing important, high quality

or scarce resources (ground water

resources, surface resources, forestry,

agriculture, fisheries, tourism, minerals)

No

11 Areas already subjected to pollution

environmental damage. (those where

existing legal environmental standards

No

12 Areas susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquakes, subsidence, landslides,

flooding, erosion, or extreme or adverse

climatic conditions)

No

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

12

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products with their Production Capacity

II Layout Map of the Plant

III Brief Manufacturing Process Description

IV Description of Effluent Treatment Plant with flow diagram

V Details of Hazardous Waste

VI Water, Fuel & Energy Requirements

VII Details of Hazardous Chemicals Storage & Handling

VIII Details of Stacks and Vents

IX Expected Noise level at Different source within the premises

X Socio-economic Impacts

XI Proposed Terms of Reference for EIA studies

XII GIDC Letter for Water Consumption

XIII NCTL Membership Letter for Wastewater Disposal

13

ANNEXURE-I

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

Production Capacity (MT/Month) Sr.

No.

Name of Product

Existing Total After Proposed

Expansion

1 Pigment Beta Blue 3.5 0

2 α-Phenyl-2-Pyridyl Acetonitrile -

3 α-Phenyl-2-Pyridyl Acetamide -

4 L-(+) 4-Nitro Tartranilic Acid -

5 9-Methyl-1,2,3,9-Tetrahydro-4H-

Carbazol-4-One

-

6 2,2’,4’-Trichloro Acetophenone -

7 1-(2,4-Dichloro Phenyl)-2-(1H-

Imidazol-yl) Ethanol

-

8 Ritanilic Acid -

9 α-Phenyl-2-Piperidyl Acetamide -

10 P-Chloro Benzophenone -

11 P-Chlorobenzhydryl Chloride -

12 p-Chlorobenzhydryl Piperazine -

13 2-[4-(4-Chlorobenzhydryl)-1-

Piperazinyl] Ethanol

-

14 Lamotrigine -

15 Roxithromycin EP/BP -

40

Total 3.5 40

Note: Pigment Beta Blue (Existing Product) shall be discontinued after proposed expansion

14

LIST OF RAW MATERIAL

SR.

NO.

PRODUCT WISE RAW MATERIALS QUANTITY

(MT/MT)

1. Pigment Beta Blue

Crude CPC 1.20

Rosin 0.04

Xylene or MCB 0.01

Dispersing Agent 0.01

Caustic Flakes 0.06

HCl 0.09

2. α-Phenyl-2-Pyridyl Acetonitrile

2-Chloro Pyridine 0.67

p-Chloro Benzyl Cyanide 0.77

Sodamide 0.50

Toluene 2.70

Methanol 1.50

Sulfuric Acid 0.85

3. α-Phenyl-2-Pyridyl Acetamide

α-Phenyl-2-Pyridyl Acetonitrile 1.12

Sulfuric Acid 5.60

Sodium Hydroxide 4.50

Iso Propyl Alcohol 3.00

4. L-(+) 4-Nitro Tartranilic Acid

L-(+)-Tartaric Acid 0.85

Acetic Anhydride 2.70

P-Nitro Aniline 0.62

Ethylene Dichloride 6.00


Hydrochloric Acid 3.50

5. 9-Methyl-1,2,3,9-Tetrahydro-4H-Carbazol-4-One

1,3 Cyclohexane Dione 1.00

Phenyl Hydrazine Hydrochloride 1.65


Methanol 2.00

Dimethyl Sulphate 1.08

Methylene Dichloride 6.00


TBAB 0.05

15

6. 2,2’,4’-Trichloro Acetophenone

1,3 Dichloro Benzene 0.72

Chloro acetyl Chloride 0.63

Aluminum Chloride 0.65

7. 1-(2,4-Dichloro phenyl)-2-(1H-Imidazol-1yl)Ethanol

2,2’,4’-Trichloro Acetophenone 0.90

Sodium Borohydride 0.05

Methanol 0.30

Toluene 2.00

DMSO 0.70


Imidazole 0.26

8. α-Phenyl-2-Piperidyl Acetamide

α-Phenyl-2-Pyridyl Acetamide 1.10

Acetic Acid 6.60

Pd on Charcoal 0.10


9. DL-Ritanilic Acid

α-Phenyl-2-Piperidyl Acetamide 1.00

Iso Butanol 4.00



Activated Charcoal 0.05

10. P-Chloro Benzophenone

Benzoyl Chloride 0.83

Mono Chlorobenzene 0.67

Aluminum Chloride 0.80

Methanol 3.00


11. P-Chlorobenzhydryl chloride

P-Chloro Benzophenone 1.00

Methanol 1.00

Sodium Borohydride 0.07



12. P-Chlorobenzhydryl Piperazine

P-Chloro Benzhydryl Chloride 1.00

Piperazine 1.24

Toluene 3.00

16



13. 2-[4-(4-Chlorobenzhydryl)-1-Piperazinyl]Ethanol

P-Chloro Benzhydryl Piperazine 0.87

2-Chloro Ethanol 0.52

Toluene 3.20

Tri Ethyl Amine 0.80


14. Lamotrigine

Sulfuric Acid 20.10

Amino Guanidine bicarbonate 2.05

Acetonitrile 3.95

2.3 DBN 2.00


N-Propanol 73.40

Hyflow 0.20

15. Roxithromycin BP/EP

Methoxy Ethoxy Methyl Chloride 0.20

Sodium Methoxide 0.09

Oxime base 1.09

Acetone 5.44

17

ANNEXURE-II

LAYOUT MAP OF THE PLANT

N

18

ANNEXURE-III

BRIEF PROCESS DESCRIPTION

Pigment Beta Blue

Process Description

Charge the required quantity of CPC blue in the ball mill to prepare fine powder. Because of

heat generation while ball milling, it is required to be kept cooled through the jacketed

recirculation system of water. The mass thus prepared is refluxed. In a reactor the ground

CPC is refluxed with water, rosin, dispersing agent, caustic soda and solvent. On completion

of the reaction, the refluxed mass is distilled out to recover unreacted Xylene. The pH is

corrected to neutral using small quantity of HCL if required. Then slurry of each batch is

subsequently filtered and washed. The wet cake is dried, pulverized and packed.

Flow Chart

19

α-Phenyl-2-Pyridyl Acetonitrile

Process Description

In an S.S.Reactor 2-Chloro Pyridine reacts with Benzyl Cyanide in the presence of Sodamide

and the solution worked up to give Nitrile Compound.

Chemical Reaction

STAGE-1

N Cl

+

CN

+ NaNH2Toluene NH3NaCl

N

CN

+ +

M.Wt.:113.54 M.Wt.:117.15 M.Wt.: 39.01 M.Wt.: 194.23 M.Wt.: 58.44 M.Wt.: 17.03

NH3

M.Wt.:34.06

2

By Product Generate in Scrubber

+

M.Wt.:98.08

H2SO

4 (NH4)2SO

4

M.Wt.:132.14

Mass Balance

INPUTS for 100.0 Kgs Out Puts

RM QTY Product & By Product &

waste

QTY

2-Chloro Pyridine 67.0 Kgs α-Phenyl-2-Pyridyl Acetonitrile 100.0 Kgs

p-Chloro Benzyl Cyanide 77.0 Kgs Toluene Recovery 250.0 Lts

Sodamide 50.0 Kgs Toluene Loss 20.0 Lts

Toluene 270.0 Kgs Methanol Recovery 135.0 Lts

Methanol 150.0 Lts Methanol Loss 15.0 Lts

Water 400.0 Lts Residue 20.0 Kgs

Water For Scrubber 260.0 Lts Waste Water 469.0 Kgs

Sulfuric acid For Scrubber 85.0 Kgs Ammonium Sulfate Solution 350.0 Kgs

Total 1359.0 Kgs Total 1359.00 Kgs

20

α-Phenyl-2-Pyridyl Acetamide

Process Description

α-Phenyl-2-Pyridyl Acetonitrile hydrolyses with Sulfuric Acid which is treated with NaOH and

gives α-Phenyl-2-Pyridyl Acetamide.

Chemical Reaction

M.Wt.: 18.02

2N

CN

M.Wt.: 194.23

+

M.Wt.:98.08

H2SO

4

NaOH

IPA

OH2

M.Wt.:142.04

Na2SO4N

CONH2

+

M.Wt.: 212.25M.Wt.: 80.00

+ OH2

Mass Balance



waste

QTY

α-Phenyl-2-Pyridyl

Acetonitrile

112.0 Kgs α-Phenyl-2-Pyridyl Acetamide 100.0 Kgs

Sulfuric acid 260.0 Kgs IPA Recovery 270.0 Lts

Sodium Hydroxide 350.0 Kgs IPA Loss 30.0 Lts

Iso Propyl Alcohol 300.0 Lts residue 15.0 Kgs

Water 1000.0 Lts Waste water (Sodium Sulfite

solution)

1607.0 Kgs

Total 2022.0 Total 2022.0

21

L-(+) 4-Nitro Tartranilic acid

Process Description

Acetic Anhydride react with L-(+) Tartatic Acid and convert to Diacetate Tartaric Anhydride

which is reacted with p-Nitro Aniline and convert to L-P-Nitro Diacetyl Tartarate and after

hydrolyze with Sodium Hydroxide and acidify with HCl gives L-(+) 4-Nitro Tartranilic Acid.

Chemical Reaction

STAGE-1

COOH

COOH

OH H

H OH CH3

CH3

O

O

O

O

O

O

O

O

CH3

CH3

O

O3

CH3COOH4

M.Wt.: 240.22+

+

M.Wt.: 306.27M.Wt.: 150.09 M.Wt.: 216.14

STAGE-2

O

O

O

O

O

CH3

CH3

O

O

NH2

NO2

NH

COOH

O

O

O

CH3

CH3

O

O

NO2

+

M.Wt.: 138.12 M.Wt.: 354.26

EDC

M.Wt.: 216.14

+ NaOHNH

COONa

O

O

O

Na

Na

NO25 + CH3 COONa2

M.Wt.: 200.0 M.Wt.: 336.14

M.Wt.: 164.06

+

M.Wt.: 54.06

OH23

ClH

M.Wt.: 182.3

NH

COOH

O

OH

OH

NO2 + CH3 COOH2 Na Cl+ +5

5

M.Wt.: 270.20

M.Wt.: 120.1

M.Wt.: 292.2 M.Wt.: 54.06

OH23

22

Mass Balance



waste

QTY

Stage-1

L-(+)-Tartaric Acid 85.0 Kgs Stage-1 110.0 Kgs

Acetic Anhydride 270.0 Kgs Acetic Acid (R) 235.0 Kgs

Residue 10.0 Kgs


Stage-2

Stage-1 110.0 Kgs PNTA 100.0 Kgs

P-Nitro Aniline 62..0 Kgs EDC Recovery 540.0 Lts

Ethylene Dichloride 600.0 Lts Loss Of EDC 60.0 Lts

Sodium Hydroxide 105.0 Kgs Residue 10.0 Kgs

Hydrochloric Acid 350.0 Kgs Waste Water 710.00Lts

Water 600.0 Kgs

Total 1827.0 Kgs Total 1827.00

23

9-Methyl-1, 2, 3, 9-Tetrahydro-4H-Carbazol-4-One

Process Description

1,3 Cyclohexane Dione react with Phenyl Hydrazine HCl and convert in to 3-(2-

Phenylhydrazino) cyclohex-2-en-1-one which is cyclize in acidic media and convert to 9-

Methyl-1,2,3,9-Tetrahydro-4H-Carbazol-4-One and methylation of 1,2,3,9-Tetrahydro-4H-

Carbazol-4-One by Dimethyl Sulphate in Alkaline media is convert in to 9-Methyl-1,2,3,9-

Tetrahydro-4H-Carbazol-4-One.

Chemical Reaction

STAGE-1

O

O

NH

NH2

ClH

++

NH

O

ClH

M.Wt.: 112.13 M.Wt.: 144.60

M.Wt.: 36.46

M.Wt.: 185.22

+ ClH NH4Cl

M.Wt.: 18.02

OH2+

M.Wt.: 53.49M.Wt.: 36.46

STAGE-2

N

H

O

M.Wt.: 185.22

+ (CH3)2SO4 + NaOH

M.Wt.: 40.0M.Wt.: 126.13

N

O

CH3

MDC

M.Wt.: 199.25

+ CH3

OH

M.Wt.: 32.04

NaHSO4+

M.Wt.: 120.06

24

Mass Balance



waste

QTY

Stage-1

1,3 Cyclohexane Dione 100.0 Kgs Stage-1 100.0 Kgs

Phenyl Hydrazine

Hydrochloride

165.0 Kgs Methanol Recover 235.0 Kgs

Hydrochloric Acid 750.0 Lts Methanol Loss 10.0 Kgs

Methanol 200.0 Lts Residue 10.0 Kgs

Water 1000.0 Lts Waste Water 1860.0 Kgs


Stage-2

Stage-1 100.0 Kgs 9-Methyl-1,2,3,9-Tetrahydro-

4H-Carbazol-4-One

100.0 Kgs

Dimethyl Sulphate 108.0 Kgs MDC Recovery 540.0 Lts

Methylene Dichloride 600.0 Lts Loss of EDC 60.0 Lts

Sodium Hydroxide 42.0 Kgs Residue 5.0 Kgs

TBAB 5.0 Kgs Waste Water 650.0 Lts

Water 500.0 Kgs


25

2, 2’, 4’-Trichloro Acetophenone

Process Description

1, 3 Dichlorobenzene react with Chloro Acetyl Chloride in presence of Aluminum Chloride

and gives 2, 2’, 4’-Trichloro Acetophenone

Chemical Reaction

Cl

Cl

+ Cl CH2 COCl

M.WT.: 133.34

AlCl3

CCl CH2

Cl

Cl

O

+ AlCl3

M.WT.: 133.34

M.WT.: 223.48M.WT.: 112.94

M.WT.: 147.00

ClH

M.Wt.: 36.46

+

Mass Balance



waste

QTY

1,3 Dichloro Benzene 71.5 Kgs 2,2’,4’-Trichloro

Acetophenone

100.0 Kgs

Chloro acetyl chloride 63.0 Kgs AlCl3 Solution 500.0 Kgs

Aluminum Chloride 65.0 Kgs Water 599.5 Kgs

Water 1000.0 Kgs


26

1-(2, 4-Dichloro phenyl)-2-(1H-Imidazol-1yl) Ethanol

Process Description

Reduction of 2,2’,4’-Trichloro Acetophenone by Sodium Borohydride produce Alcohol

compound and there after react with Imidazole in Alkaline media gives 1-(2,4-Dichloro

Phenyl)-2-(1H-Imidazol-1yl)Ethanol

Chemical Reaction

C ClCH2

Cl

Cl

O

M.WT.: 223.48

+ NaBH4

M.WT.: 37.81

NaBH2

M.WT.: 35.81

MeOH

Toluene

CH ClCH2

Cl

Cl

OH

+

M.WT.: 225.50

NaOH

M.Wt.: 40.0

DMSON

NH

M.Wt.: 68.08

CH NCH2

Cl

Cl

OH

N

+ NaCl + OH2

M.Wt.: 257.12

M.Wt.: 58.44 M.Wt.: 18.02

27

Mass Balance



waste

QTY

Stage-1

2,2’,4’-Trichloro

Acetophenone

90.0 Kgs Stage-1 90.0 Kgs

Sodium Borohydride 5.15 Kgs Toluene (Recovery) 190.0 Lts

Methanol 30.0 Lts Toluene Loss 10.0 Lts

Toluene 200.0 Lts Water 335.15 Lts

Water 300.0 Lts


Stage-2

Stage-1 90.0 Kgs 1-(2,4-Dichloro phenyl)-2-

(1H-Imidazol-1yl) Ethanol

100.0 Kgs

DMSO 70.0 Lts Water 607.0 Kgs

Sodium hydroxide 21.0 Kgs

Imidazole 26.0 Kgs

water 500.0 Kgs


28

α-Phenyl-2-Piperidyl Acetamide

Process Description

Catalytic Reduction of α-Phenyl-2-Pyridyl Acetamide in presence of Pd gives α-Phenyl-2-

Piperidyl Acetamide

Chemical Reaction

N

CONH2

+ H2Pd on charcoal

Acetic Acid

NH

CONH2

M.Wt.: 212.25 M.Wt.: 218.29M.Wt.: 2.02

Mass Balance



waste

QTY

α-Phenyl-2-Pyridyl Acetamide 110.0 Kgs Stage-1 100.0 Kgs

Acetic Acid 660.0 Lts Pd on Charcoal reuse in next

batch

9.9 Kgs

Pd on Charcoal 10.0 Kgs Acetic Acid (Recovery) 600.0 Lts

Sodium Hydroxide 30.0 Kgs Acetic Acid Loss 60.0 Lts

Water 800.0 Lts Water 840.1 Lts


29

DL-Ritanilic Acid

Process Description

Hydrolysis of α-Phenyl-2-Piperidyl Acetamide in alkaline media gives Ritanilic Acid

Chemical Reaction

NH

CONH2

Na OH+

NH

COOH

ClH

M.Wt.: 72.92

+ OH2 + NH4Cl

M.Wt.: 53.49

+

M.Wt.: 58.44M.Wt.: 219.18M.Wt.: 218.29

M.Wt.: 40.0 M.Wt.: 18.02

+ OH2

M.Wt.: 18.02

2Na Cl

Isobutanol

Mass Balance



waste

QTY

α-Phenyl-2-Piperidyl

Acetamide

100.0 Kgs Ritanilic Acid 100.0 Kgs

Iso Butanol 400.0 Lts Iso Butanol 370.0 Lts

Sodium Hydroxide 150.0 Kgs Iso Butanol Loss 30.0 Lts

Hydrochloric Acid 375.0 Kgs Activated Charcoal 5.0 Kgs

Activated Charcoal 5.00 Kgs Water 1725.0 Kgs

Water 1200.0 Lts


30

p-Chloro Benzophenone

Process Description

In Glass line reactor charge Monochloro Benzene & Aluminium Chloride at RT then slowly

adds Benzoyl Chloride into reaction mass at 48ºC & Stir for 3 hrs. Then heat to 100ºC and

maintain for 2 hrs. Then add slowly water into reaction mass (during addition of water

generate HCl gas – scrub with NaOH soln. using scrubber) separate p-Chloro Benzophenone.

Chemical Reaction

Stage-1

ClO

+

Cl

M.WT.: 133.34

AlCl3

O

Cl

+

M.WT.: 140.57 M.WT.: 112.66M.WT.: 216.66

ClH

M.Wt.: 36.46

Mass Balance



waste

QTY

Benzoyl Chloride 415.0 Kgs p-Chloro Benzophenone 500.0 Kgs

Mono Chlorobenzene 333.0 Kgs Methanol 1430.0 Lts

Aluminum Chloride 400.0 Kgs Alcl3 Solution (25%) 1000.0 Kgs

Methanol 1500.0 Lts Water 1338.0 Kgs

Water (Scrubber) 600.0 Lts Residue 30.0 Kgs

Sodium Hydroxide (Scrubber) 120.0 Lts

Water 900.0 Lts


31

p-Chlorobenzhydryl Chloride

Process Description

In Reactor charge MeOH and p-Chloro Benzophenone and cool to 25˚C ,then slowly add

Sodium Borohydride and maintain for 4 hr, there after distilled out MeOH and charge

hydrochloric acid and stir the mass for 6 hr. discard acidic layer and collect p-

Chlorobenzhydryl Chloride.

Chemical Reaction

O

Cl

M.WT.: 216.66

+ NaBH4

M.WT.: 37.81

OH

Cl

M.WT.: 218.68

NaBH2+

M.WT.: 35.81

MeOH

ClH

M.Wt.: 36.46Toluene

Cl

Cl

M.WT.: 237.12

Mass Balance



waste

QTY

p-Chloro Benzophenone 500.00 Kgs p-Chloro Benzhydryl chloride 500.0 Kgs

Methanol 500.0 Lts Methanol 470.0 Lts

Sodium Borohydride 35.0 Kgs Water 1735.0 Kgs

Hydrochloric Acid 1000.0 Kgs Residue 30.0 Kgs

Sodium Hydroxide 200.0 Kgs

Water 500.0 Lts


32

p-Chlorobenzhydryl Piperazine

Process Description

IN reactor charge Toluene, p-Chlorobenzhydryl Chloride and Piperazine into heat to 70ºC &

maintain for 3 hrs. Then add HCl at RT & product extract with HCl & side up Toluene layer

and recover for next batch. Product contains HCl charge into reactor & adjusts 9 pH by

NaOH soln. & centrifuge the product and dry at 50ºC.

Chemical Reaction

Cl

Cl

M.WT.: 237.12

NH

N

H

+

M.WT.: 86.14

TolueneNaOH

M.Wt: 40.00

Na Cl OH2

M.Wt.:58.44 MWt: 18.02

+

N

Cl

NH

+ +

M.WT.: 286.80

Mass Balance



waste

QTY

P-Chloro Benzhydryl chloride 500.0 Kgs P-Chloro Benzhydryl

Piperazine

500.0 Kgs

Piperazine 620.0 Kgs Toluene 1420.0 Lts

Toluene 1500.0 Lts Piperazine 400.0 Kgs

Hydrochloric acid 500.0 Kgs NaOH Sol 900.0 Kgs

Sodium Hydroxide 500.0 Kgs Water 1380.0 Kgs

Water 1000.0 Lts Residue 20.0 Kgs


33

2-[4-(4-Chlorobenzhydryl)-1-Piperazinyl] Ethanol

Process Description

S.S.R. to be clean and dry. Charge Toluene, p-Chloro Benzhydryl Piperazine, Triethyl Amine

and 2-Chloro Ethanol at RT. Then heat up to reflux and maintain reflux for 8 hr. Then

distilled out toluene completely & collect product.

Chemical Reaction

Stage-1

N

Cl

NH

+

M.WT.: 286.80

NaOH

M.Wt: 40.00

OH Cl +

M.WT.: 80.51

Toluene

Tri Ethyl AmineN

Cl

N

OH

OH2

M.Wt.:58.44

MWt: 18.02

+ Na Cl

M.WT.: 330.85

+

Mass Balance



waste

QTY

p-Chloro Benzhydryl

Piperazine

435.00 Kgs p-Chloro Benzhydryl

Piperazine

500.0 Kgs

2-Chloro Ethanol 260.0 Kgs Toluene 1520.0 Lts

Toluene 1600.0 Lts TEA reuse in Next Batch 380.0 Kgs

Tri Ethyl Amine 400.0 Lts Water 1345.0 Kgs

Sodium Hydroxide 50.0 Kgs

Water 1000.0 Lts


34

Lamotrigine

Process Description

Amino Guanidine bicarbonate is reacted 2,3 DBN & then purified in n-Propanol.

Chemical Reaction

35

Mass Balance

Stage - 1

Raw Material In Put Quantity

Kgs

Product Out Put Quantity

Kgs

Out Put Details

4113.0

9326.0

2512.5

15359.8Aqueous Effluent Process water

Process water for cake

wash Sulphuric Acid

256.3 752.0Aqueous Wash

Dichloro Benzoyl Nitrile 250.0 115water loss in drying

Acetonitrile 4.0 235Output

235

Total 16461.8 16461.8

Stage - 2


Kgs


Kgs

Out Put Details

1026.2 6.1

3.1 1026.2

62.0 8.06

Spent carbon + Hyflow

Dilute n-Propanol

vapor loss on Drying

n-Propanol

Activated carbon

Lamotrigine (Stage-I)

Hyflo 3.0 53.94 Output

53.94

Total 1094.3 1094.3

Stage - 3


Kgs


Kgs

Out Put Details

n-Propanol 5192.1 21.8 Spent carbon + Hyflow

Activated carbon 18.8 5192.1 Dilute n-Propanol

Lamotrigine (Stage-I) 375.0 48.75 vapor loss on Drying

Hyflo 3.0 326.25 Output

Total 5588.8 5588.8

36

Roxithromycin

Process Description

Erythromycin Thiocyanate reacts with liq. Ammonia in presence of methylene chloride to

give Erythromycin base. Methylene chloride is separated and distilled off. Residual

Erythromycin base reacts with Hydroxyl Amine Hydrochloride and Triethyl Amine in

presence of Methanol to give Erythromycin Oxime Hydrochloride. Methanol is distilled out

and Erythromycin Oxime Hydrochloride reacts with Liq. Ammonia in presence of

Isopropanol to give Erythromycin Oxime Base.

Erythromycin Oxime Base reacts with sodium Methoxide and Methoxy Ethoxy methylene

chloride in presence of acetone to give Roxithromycin Crude. Roxithromycin crude is

purified in methanol to give Roxithromycin pure.

Chemical Reaction

37

Mass Balance

38

ANNEXURE-IV

TREATMENT PROCESS

Details of Effluent Treatment Plant along with flow diagram

Stream I (Low COD & TDS Stream) = 17.33 KL/Day

First all non-toxic and biodegradable streams (low & medium COD & TDS) of wastewater

shall pass through Screen Chamber where floating material shall be removed with help of

Screen. Then effluent shall be passed through Oil & Grease Removal Tank. Automatic

mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and grease

from the wastewater to Oil & Grease Collection Tank. Then effluent shall be collected in

Collection cum Equalization tank-1. Pipe grid is provided at bottom of the CET-01 to keep all

suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1W+1

stand-by) shall supply air through to pipe grid.

Then after, equalized wastewater shall be pumped to Neutralization Tank-1 where the

continuous addition and stirring of Caustic solution is done to maintain neutral pH of

wastewater from Caustic Dosing Tanks as per requirement by gravity. Then after,

neutralized wastewater shall go to Flash Mixer-1 by gravity. Alum and Polyelectrolyte shall

be dosed from Alum Dosing Tank and Polyelectrolyte Dosing Tank respectively by gravity

into FM-1 to carry out coagulation by using a Flash Mixer. Then after, coagulated

wastewater shall be settled in Primary Clarifier. Treated effluent will be sent to CETP of

PETL, Panoli for further treatment.

Stream II (High COD & TDS Stream) = 1.67 KL/Day

High COD effluent shall be passed through collection cum neutralization tank where the

continuous addition and stirring of Caustic solution is done to maintain neutral pH of

wastewater from Caustic Dosing Tanks as per requirement by gravity. Treated neutral

effluent will be sent to Common Spray Dryer facility of PETL, Panoli for further treatment.

39

FLOW DIAGRAM OF ETP:

Screen Chamber Oil & Grease

Trap

Collection cum

Equalization

Tank

Neutralization

Tank

Primary Settling

Tank

CETP of PETL,

Panoli

Common

Spray Dryer

of PETL,

Panoli

Raw Effluent

Low COD

Collection cum

Neutralization

Tank

High COD

40

SIZE OF TANKS

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

Stream I (Low COD & TDS Stream) 17.33 KL/Day

1 Screen Chamber 2.5 x 1.0 x (0.05 +0.3 FB) 1 RCC M25+A/A Bk.

Lining

2 Collection cum Equalization

Tank-1

3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

3 Neutralization Tank 3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

4 Flash Mixer-1 0.8 x 0.8 x (1.5 LD +0.5 FB) 1 RCC M25

5 Primary Clarifier 2.0 x 1.2 x (2.0 LD + 0.75

HB+ 0.5 FB)

1 RCC M25

6 Aeration Tank-1 7.0 x 5.2x (3.5 LD +0.5FB) 1 RCC M25

7 Secondary Clarifier-1 2.0 x 1.2 x (2.0 LD + 0.75

HB+ 0.5 FB)

1 RCC M25

Stream II (High COD & TDS Stream) 1.67 KL/Day

1 Collection cum

Neutralization Tank-1

3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PCC = PLAIN CEMENT CONCRETE

PP = POLYPROPELENE

MSEP = MILD STEEL EPOXY PAINTED

SS = STAINLESS STEEL

41

EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-I)

Sr.

No.

Category of Wastewater Before Treatment After Treatment

1 pH 3.5-6.5 6.5-8.0

2 COD (mg/L) 5,500 1,000

3 BOD3 (mg/L) 1,700 300

4 TDS (mg/L) 3,500 3,200

5 Ammonical Nitrogen (mg/L) 30 20

EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-II)

Sr.

No.

Category of Wastewater Before Treatment

1 pH 2-10

2 COD (mg/L) 55,000

3 BOD3 (mg/L) 12,000

4 TDS (mg/L) 40,000

5 Ammonical Nitrogen (mg/L) 300

42

ANNEXURE-V

HAZARDOUS WASTE GENERATION AND DISPOSAL

Generation Sr.

No

Type of Waste Category

Existing Total

Proposed

Mode of Treatment & Disposal

1. ETP Waste 35.3 0.017

MT/Month

5

MT/Month

Collection, Storage, Transportation &

Sent to TSDF site of M/s. PSWML,

Panoli or M/s. BEIL, Ankleshwar

2. Used Oil 5.1 1.67

Lit/Month

18

Lit/Month


Sale to registered re-processor or use

for lubrication within premises

3. Spent Carbon 28.3 - 0.09

MT/Month


co-processing in cement industries or

Send to TSDF of M/s. PSWML, Panoli

or M/s. SEPL, Jambusar or M/s. BEIL,

Ankleshwar

4. Empty Bags 33.1 12

Nos/Month

40

Nos/Month

Collection, Storage, Transportation,

Decontamination & sale to

registered vendors

5. Discarded Containers

33.1 - 30

Nos/Month



registered vendors

6. Discarded Liners

33.1 - 50

Nos/Month



registered vendors

7. Distillation Residue 36.1 - 3

MT/Month


Sent to Common Incineration of M/s.

SEPPL, Dahej or M/s. BEIL,

Ankleshwar or cement industries for

Co-Processing

8. AlCl3 Soln. - - 80

MT/Month

Collection, Storage & Sold to end

users

43

ANNEXURE-VI

_______________________________________________________________________

WATER, FUEL & ENERGY REQUIREMENT

WATER CONSUMPTION AND WASTEWATER GENERATION

Water Consumption

(KL/Day)

Waste Water

Generation (KL/Day)

Sr.

No.

Category

EXISTING TOTAL

PROPOSED

EXISTING TOTAL

PROPOSED

1. Domestic 1 2 0.7 1.4

2. Other (Gardening) NIL 1 NIL NIL

3. Industrial

Process 1.5 21.5 1.2 19

Boiler 1.5 2 0.2 0.3

Cooling NIL 0.5 NIL 0.3

Washing 11 12 11 12

Total Industrial 14 36 12.4 31.6

Grand Total 15 39 13.1 33.0

44

WATER BALANCE DIAGRAM (EXISTING)

Domestic

1

Boiler

1.5

Washing

11

Water Consumption

15

Domestic

0.7

Wastewater

13.1

Boiler

0.2

Washing

11

ETP

Process

1.5

Sent to PETL, Panoli

Process

1.2

All Figures in KL/Day

Septic Tank/Soak Pit

45

WATER BALANCE DIAGRAM (TOTAL PROPOSED)

All Figures in KL/Day

Domestic

2

Boiler

2

Washing

12

Water Consumption

39

Domestic

1.4

Cooling

0.5

Wastewater

29.93

Boiler

0.3

Washing

12

Cooling

0.3

ETP

Process

21.5

Sent to PETL, Panoli

Process

19

Gardening

1

High COD &

High TDS �

1.67

Common Spray

Dryer of PETL,

Panoli for further

treatment

Septic Tank/Soak Pit

46

TOTAL POWER REQUIREMENT & SOURCE OF POWER

Power requirement will be 125 HP which will be taken from DGVCL. 1 No. of 62 KVA DG Set

will be kept for emergency power back up.

FUEL REQUIREMENT

SR.

NO.

NAME OF FUEL QUANTITY

1 Natural Gas 700 Nm3/day

2 LDO 500 Lit/day

47

ANNEXURE-VII

STORAGE DETAILS OF HAZARDOUS CHEMICALS

Quantity Sr.

No.

Name of Hazardous

Chemicals Max.

That can be

stored

State Operating

Pressure &

Temp.

Type of

Hazard

Possible

(Fire, Explosion, etc.)

Remarks

1 2-Chloro Pyridine 500 kg NTP Harmful HDPE DRUM

2 Benzyl Cyanide 500 kg NTP Harmful HDPEDRUM

3 Sodium Amide 250 kg NTP Flammable MSDRUM

4 Toluene 1000 kg NTP Flammable MSDRUM

5 Methanol 1000 kg NTP Flammable MSDRUM

6 Sulfuric Acid 1000 kg NTP Corrosive CARBOYS

7 Sodium Hydroxide 300 kg NTP Corrosive BAGS

8 Iso Propyl Alcohol 1000 kg NTP Flammable MSDRUM

9 L-(+)-Tartaric Acid 500 kg NTP Harmful BAGS

10 Acetic Anhydride 1000 kg NTP Flammable MSDRUM

11 P-Nitro Aniline 500 kg NTP Harmful BAGS

12 Ethylene Dichloride 1000 kg NTP Flammable MSDRUM

13 Hydrochloric Acid 1000 kg NTP Flammable MSDRUM

14 1,3 Cyclohexane Dione 250 kg NTP Corrosive, Harmful BAGS

15 Phenyl Hydrazine

Hydrochloride

250 kg NTP Corrosive, Harmful BAGS

16 Dimethyl Sulphate 500 kg NTP Corrosive, Harmful HDPEDRUM

17 Methylene Dichloride 1000 kg NTP Flammable MSDRUM

18 1,3 Dichloro Benzene 1000 kg NTP Flammable MSDRUM

19 Chloro acetyl chloride 1000 kg NTP Flammable MSDRUM

20 Aluminium Chloride 500 kg NTP Corrosive, Harmful BAGS

21 Sodium Borohydride 50 kg NTP Corrosive,

Flammable

MS CARBOY

22 DMSO 500 kg NTP Flammable MSDRUM

48

23 Imidazole 500 kg NTP Corrosive, Harmful BAGS

24 Acetic Acid 1000 kg NTP Flammable MSDRUM

25 Pd on Charcoal 20 kg NTP Flammable CARBOY

26 Iso Butanol 750 kg NTP Flammable MSDRUM

27 Activated Charcoal 100 kg NTP - BAGS

28 Monochlorobenzene 750 kg NTP Irritant MS DRUM

29 Benzoyl Chloride 250 kg NTP Corrosive, Irritant HDPE DRUM

30 Piperazine 500 kg NTP Corrosive, Irritant BAGS

31 2-Chloro Ethanol 500 kg NTP Harmful HDPEDRUM

32 Tri Ethyl Amine 500 kg NTP Harmful MSDRUM

49

ANNEXURE-VIII

_______________________________________________________________________

DETAILS OF STACKS & VENTS

Details of Flue Gas Emissions

Sr. No. Source of

Emission

Type of

Emission

Stack Height

(meter)

Stack

Diameter

(meter)

Pollution Control

Equipment

1 Boiler SPM, SO2,

NOx

15 0.5 -

2 Process Vent-1 SO2,

HCl, HBr

15 0.3 Two stage

Scrubber

3 Process Vent-1 NH3 15 0.3 Two stage

Scrubber

50

ANNEXURE-IX

_______________________________________________________________________

EXPECTED NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES

Various sources of noise in industry have been identified as under,

• Pumps

• Boiler

• Reaction vessel

The typical noise levels of equipments, as indicated by the equipments manufacturers are

given below:

Sr. No. Name of Machinery / Units Noise level, dB(A)

1 Pumps 60 – 65

2 Boiler 65 – 75

3 Reaction Vessel 55 – 60

EXPECTED NOISE LEVELS:

SR.

NO.

SOURCE OF NOISE PERMISSIBLE LIMIT

(DAY/NIGHT)

dB (A)

EXPECTED NOISE

LEVEL dB (A)

1. Near Security Gate 75/70 60

2. Near Administration Building 75/70 60

3. Near Boiler & Utility Block 75/70 65

4. Near ETP 75/70 65

5. Near Process Plant 75/70 65

6. Near Canteen 75/70 50

• DG set with acoustic enclosure, housed in a separate room, erected on anti vibrating

pad.

• Ear muffs are provided to the operators.

• Regular preventive maintenance of equipments will be carried out.

51

ANNEXURE-X

_______________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

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

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

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

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

manpower requirement for the proposed diversification is expected to generate some

permanent jobs and secondary jobs for the operation and maintenance of plant. This will

increase direct / indirect employment opportunities and ancillary business development to

some extent for the local population. This phase is expected to create a beneficial impact on

the local socio-economic environment.

2) INDUSTRIES

During construction of the project, the required raw materials and skilled and unskilled

laborers will be utilized maximum from the local area. The increasing industrial activity will

boost the commercial and economic status of the locality, to some extent.

3) PUBLIC HEALTH

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

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

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

uncontrolled from process and utility stacks may cause discomfort, burning of eyes to the

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

equipment / process. The company regularly examines, inspects and tests its emission from

sources to make sure that the emission is below the permissible limit. Hence, there will not

be any significant change in the status of sanitation and the community health of the area,

as sufficient measures will be taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the new factory will have proper linkage for the transport and communication, the

development of this project will not cause any additional impact. In brief, as a result of the

project there will be no adverse impact on communication, as sufficient measures will be

proposed to be taken under the EMP. The proposed project is not expected to make any

significant change in the existing status of the socio - economic environment of this region.

52

ANNEXURE-XI

_______________________________________________________________________

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

1. Project Description

• Justification of project.

• Promoters and their back ground

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

industries, surface water bodies, forests etc.

• Project cost

• Regulatory framework

• Project location and Plant layout.

• Existing infrastructure facilities

• Water source and utilization including proposed water balance.

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

• List of hazardous chemicals with their toxicity levels.

• Mass balance of each product along with the batch size

• Storage and Transportation of raw materials and products.

• Existing environmental scenario

2. Description of the Environment and Baseline Data Collection

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

in 5 km area.

• Study of Data from secondary sources.

• Other industries in the impact area

• Prevailing environment quality standards

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

site. For SPM, RSPM, SO2, NOx.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

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

the study area were surveyed.

4. Impacts Identification and Mitigatory Measures.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

53

6. Risk Assessment

• Objectives, Philosophy and methodology of risk assessment

• Details on storage facilities

• Identification of hazards

• Consequence analysis through occurrence & evaluation of incidents

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

• Safety precautions for the storage of Chemicals and vapour condensation.

7. Information for Control of Fugitive Emissions

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

9. Occupational Health and Safety Program for the Project.

10. Information on Rain Water Harvesting

11. Green Belt Development Plan

54

ANNEXURE-XII

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GIDC LETTER FOR WATER CONSUMPTION

55

ANNEXURE-XIII

_______________________________________________________________________

PETL MEMBERSHIP LETTER

57

ANNEXURE-XIV

_______________________________________________________________________

BEIL MEMBERSHIP LETTER

proposed api & api intermediates in existing...

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