PRE FEASIBILITY REPORT
FOR OBTAINING ENVIRONMENTAL CLEARANCE For the Proposed Synthetic Organic Chemicals Manufacturing Unit of
M/s. AWAKE CHEMICALS PVT. LTD. Survey No. : 610, Sayla-Muli By-pass Road, Bh. Sarvoday Jin Mill, Sayla-363430, Taluka: Sayla, District: Surendranagar, Gujarat.
Himanshubhai Mesvaniya: 90675 72622 E-mail: [email protected]
Prepared By:
T. R. ASSOCIATES
C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S. G. Highway, Ahmedabad. Mo. No.: 98253 71099 Email ID: [email protected]; [email protected]
February 2016 1. Introduction
M/s. Awake Chemicals Pvt. Ltd. is a proposed new project to be located at Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin Mill, Sayla-363430, Ta: Sayla, Dist: Surendranagar, Gujarat for manufacturing of synthetic organic chemicals including pharmaceutical and dyes and intermediates with total production capacity of 62 MT/Month.
It may be noted that Proponent had obtained Consent To Establish for manufacturing inorganic products with the company name Shree Sarvasiddhi Chemicals at above stated location and constructed shed but the production never started and now the proponent intends to obtain EC for new above stated organic chemical products. Proposed production details are given below:
Sr. Capacity Product No. ( MT/Month) 1. Diethyl Safranine 5 2. Safranine-O 5 3. Janus Green B 5 4. Methylene Blue Zn free 5 5. Titan Yellow 5 6. Succinimide 5 7. N-Bromo Succinimide 2 8. N-Chloro Succinimide 2 9. Bromohexine HCl (BP) 2 10. Bronopol 2 11. Niclosamide 4 12. Oxo-O-Tolyl Acetonitrile 5 13. 4 Nitro 3,5 Dimethyl Pyridine 7 14. Dichloro Pyrimidine 5 15. 2-Amino 5-Methyl Thiozole 2 16. Oil Mustard (Allyal Isothlocyanate) 1 By-Product 1. Zn Carbonate 1.6 2. Sodium Bromide 0.2 3. Sodium Bromide Solution 2.1 4. Sodium Acetate 1.2 5. Ammonium Chloride 0.6
The proposed products fall under Category 5(f) as stated in Environment Impact Assessment Notification Published on 14th September, 2006. Further, the location of the proposed project is outside the notified industrial estate. Hence, the project proponent has to obtain the EC from the Ministry of Environment & Forests, New Delhi. M/s. T. R. Associates has been appointed to carry out EIA/EMP studies for Environmental Clearance.
The total land area of company is 11,129 Sq. Mt. out of which 3,680 Sq. Mt. (33.1% of total land) area will be used for greenbelt development. The estimated cost of the proposed project is 3 Crores. Total budget allocation towards Environmental Management Facilities will be Rs. 50 Lacs. Total 30 persons will be employed including skilled persons, unskilled persons and office staff.
2. Project Proponent and their back ground
Company is promoted by its directors namely Mr. Himanshubhai Mesvaniya having enough experience in field of manufacturing of inorganic and organic chemicals.
3. Brief description of nature of the project:
It is a small scale project for production of synthetic organic chemicals including pharmaceutical and dyes and intermediates which will be sold in domestic market as well exported.
Need for the project and its importance to the country and or region:
Looking to the product profile, it is required to take Environmental Clearance. In India, good quality raw materials are available at cheap rates, enabling the manufacturing at low cost. This increases the profit margin as compared to other players in the world. To meet the current and future market demand, the project proponent intends to start a new unit. Looking to the market demand, the proposed project is feasible at stated location.
Imports v/s Indigenous production:
Indian market is open and big that is why every kind of import is booming. Indian industrialist must understand the fact that its no more a regional shift, it is a global shift. Indian technology should be upgraded an updated at par with international standards.
The working environment in India has changed tremendously. Earlier the trade fairs were hardly participated by foreign chemical manufacturing companies where as now it is flooded with global suppliers.
Export Possibility:
There is good possibility for export. But currently we are focused on local sale market for distribution.
Employment Generation (Direct and Indirect) due to the project:
This project will provide direct employment to 30 people whereas it will provide employment to many others indirectly.
4. Project Description
(i) Type of project including interlinked and interdependent projects: Chemicals, Dyes & stains are frequently used in biology and medicine to highlight structures in biological tissues for viewing, often with the aid of different microscopes. So it is an individual Industry having no direct dependency on others.
(ii) Location Proposed project is to be located at Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin Mill, Sayla-363430, Ta: Sayla, Dist: Surendranagar, Gujarat at Latitude: 22° 32' 56.51" N and Longitude: 71° 29' 43.57" E
Google image showing proposed project site is given below;
Google Image of Proposed Location:
Nearest Residential Area of Sayla
0.3 km Proposed Project Site
0.3 km
0.9 km SH 21
NH 8A
Salient features in the surroundings area of the proposed site within 10 km radius are as follows:
Sr. Important Features Description No. 1 Location Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin Mill, Sayla-363430, Ta: Sayla, Dist: Surendranagar, Gujarat. 2 GPS Coordinates
3 Mean Sea Level 127 m 4 Nearest power station Paschim Gujarat Vij Company Ltd., Sayla 5 Proponent Name Mr. Himanshubhai Mesvaniya (Director) Contact No. 09067572622 6 Corporate office address Survey No.: 610, Sayla-Muli by-pass road, Bh. Sarvoday Jin, Sayla-363430, Ta: Sayla, Dist: Surendranagar. 7 Temperature range 120 C to 450 C 8 Annual Rain fall 803 mm 9 Nearest Road SH21 @ 0.3 Km, West NH 8A @ 0.9 Km, South 10 Nearest Railway station Nearest Railway station: Muli Road Railway station @ 15.3 Km, NNW 11 Nearest city Sayla @ 0.3 Km, West 12 Nearest village Sayla @ 0.3 Km, West 13 National Highway NH 8A @ 0.9 Km, South 14 State Highway SH21 @ 0.3 Km, West 15 Nearest River/water body 1) Bhogava River (Seasonal) @ 5.3 Km, SE 2) Nibhani River (Seasonal River) @ 7.0 Km, SE 3) Check dam on Bhogava River @ 9.0 Km, SSW, Near Village Juna Jashapar 16 Seismic Zone Zone-III (Less Active) 17 National Parks / Sanctuary None within 10 Km radius.
(iii) Project description with process details
List of Products & By-products
Sr. Name of Product Quantity (MT/Month) No. 1 Diethyl Safranine 5 2 Safranine-O 5 3 Janus Green B 5 4 Methylene Blue Zn Free 5 5 Titan Yellow 5 6 Succinimide 5 7 N-Bromo Succinimide 2 8 N-Chloro Succinimide 2 9 Bromohexine HCL(BP) 2 10 Bronopol 2 11 Niclosamide 4 12 Oxo-O-Tolyl Acetonitrile 5 13 4 Nitro 3,5 Dimethyl Pyridine 7 14 Dichloro Pyrimidine 5 15 2 Amino 5 Methyl Thiozole 2 16 Oil Mustard 1 By-product 1 Zn Carbonate 1.6 2 Sodium Bromide 0.2 3 Sodium Bromide Solution 2.1 4 Sodium Acetate 1.2 5 Ammonium Chloride 0.6
List of raw materials
Sr. Quantity in Name of the product Name of Raw Materials No. KG/Month Diethyl Aniline 4445 HCL 2223 Sodium Nitrite 1600 Zn Dust 1556 1 Diethyl Safranine Calcium Carbonate 2223 Aniline 2223 Sodium Dichromate 1778 Salt 6667 Garnet GB 3572 HCl 1786 Sodium Nitrite 1286 Fe Dust 1608 2 Safranine - O ICE 7143 Calcium Carbonate 715 Aniline 1786 Sodium Dichromate 1072 Salt 5000 Sr. Quantity in Name of the product Name of Raw Materials No. KG/Month Safranine 5000 HCl 2500 Sodium Nitrite 1750 3 Janus Green B Sodium Acetate 1750 Dimethyl Aniline 2500 Soda Ash 1500 Salt 5000 Methylene Blue 2B 6250 Soda Ash 1000 4 METHYLENE BLUE ZN FREE EDTA 313 ICE 25000 Salt 625 Dehydro Thio Para Toludine 5264 Sulphonic Acid HCl 1579 5 Titan yellow Sodium Nitrite 922 ICE 5264 Sodium Carbonate 2106 Salt 7895 Succinic acid 5960 6 Succinimide Ammonia 860 Succinimide 1116 7 N bromo succinimide Caustic 449 Bromine 1794 Succinimide 1480 8 N CHLORO SUCCINIMIDE Sodium hypochloride 1100 Acetic acid 900 2Nitro N Cyclohexyl Methyl Benzyl 1600 Amine Hydrogen 11 Methanol 5334 9 Bromohexine HCL (BP) Carbon 27 Bromine 1734 HCl 240 Ethanol 3734 Nitro Methane 667 Methanol (Fresh) 500 Caustic 467 10 Bronopol Formaldehyde 1467 Carbon 34 Bromine 1767 Xylene 11429 Ortho Chloro para nitro aniliine 2058 11 Niclosamide Thiohyl chloride 1543 5 Chloro salicylic acid 2000 12 Oxo-O-Tolyl Acetonitrile Xylene (Fresh) 3334 Sr. Quantity in Name of the product Name of Raw Materials No. KG/Month Ortho toluic acid 4584 Thionyl chloride 3750 Sodium cyanide 1667 3,5 lutidine 6731 Sulphuric acid 11005 4 Nitro 3,5 Dimethyl Acetic acid (Fresh) 1347 13 Pyridine Nitric acid 7337 Ammonia Gas 6512 Hydrogen Peroxide 4712 Di hydroxyl Pyridimine 5233 MDC (Fresh) 5070 14 Dichloro pyrimidine Phosphorus Oxochloride 9303 TEA (Fresh) 1675 Caustic 7256 Propenaldehyde 2400 Sulphuryl Chloride 6000 Methanol 5300 15 2 amino 5 methyl thiozole Caustic 2700 Toluene 6000 Thiourea 2000 HCL 400 Allyl Chloride 820 16 Oil Mustard Ammonium Thiocyanate 824
Detailed Manufacturing Processes
1. DIETHYL SAFRANINE:
Manufacturing Process Charge Diethyl Aniline, conc. HCl and water in open watt. Charge ice for chilling. Charge sodium nitrite for diazotized it. Charge Zn-powder & Aniline into it then complete reaction by addition of sodium dichromate & calcium carbonate then heat & filter product. Take clear filtrate & charge salt. Pure Diethyl Safranine is isolate then dry & pulverized to get finished product.
Reaction Chemistry
Process Flow Diagram Diethyl aniline 200 KGS OPEN WATT D M WATER 200KGS
Sodium nitrite 72 kgs Chilled up to 0⁰C Zn-dust 70kg
Zn-Powder 2 kg to be Filtration reused in next batch
Calcium Carbonate 100 kgs Stir mass under chilling Aniline 100kgs for 4-5 hrs
Salt 300kgs Heat Mass 90°C
Centrifuge 900 kgs wastewater
Drying 95kgs Drying loss
Pulverizing
Packing 225kgs
Mass Balance
Sr. Qty Per Qty Per Input Output No. Batch (Kg) Batch (Kg) 1. Diethyl Aniline 200 Zn powder (To be reused in 2 next batch) 2. Water 200 Wastewater (To be treated 900 in ETP) 3. HCl 100 Drying loss (To atmosphere 95 through vent) 4. Sodium Nitrite 72 Diethyl Safranine 225 5. Zn Dust 70 6. Calcium Carbonate 100 7. Aniline 100 8. Sodium Dichromate 80 9. Salt 300 Total 1222 1222
2. SAFRANINE-0:
Manufacturing Process Charge Garnet GB, Conc. HCl and water in open watt. Charge ICE for chilling. Charge sodium Nitrite for diazotised it. Charge Fe-Powder & Aniline into it then complete reaction by addition of sodium Dichromate & Calcium Carbonate then heat & filter product. Take Clear filtrate & Charge Salt. Pure Diethyl Safranine is isolate then dry & pulverised it.
Reaction Chemistry
Process Flow Diagram with Mass Balance
Garnet GB 200 KGS D M WATER 1000KGS OPEN WATT HCl 100kg
Sodium nitrite 72 kgs Chilled upto Fe-dust 90kg 0°C Ice 400kgs
Filtration Fe-Powder 12kg
Calcium Carbonate 40 kgs Stir mass under Aniline 100kgs chilling for 4-5hrs Sodium Dichromate 60kgs
Salt 280kgs Heat Mass at 90°C
Centrifuge 1990 kgs Wastewater
Drying 60kgs Drying loss
Pulverising
Packing 280kgs (25 kgs *11 drum)
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Fe powder (To be reused Garnet GB 200 12 in next batch) 2. Wastewater (To be Water 1000 1990 treated in ETP) 3. Drying loss (To HCl 100 60 atmosphere through vent) 4. Sodium Nitrite 72 SAFRANINE 0 280 5. Fe Dust 90 6. ICE 400 7. Calcium Carbonate 40 8. Aniline 100 9. Sodium Dichromate 60 10. Salt 280 TOTAL 2342 2342
3. JANUS GREEN B:
Manufacturing Process Safranine, conc. HCl and water charge in open watt. Charge ice for chilling. Charge sodium nitrite for diazotised it. Charge Dimethyl Aniline into it then complete reaction by addition of Sodium Acetate & soda ash heat & filter product. Take clear filtrate & charge salt. Pure Janus Green-B is isolate then dry & pulverised it.
Reaction Chemistry
Process Flow Diagram
Safranine 200 KGS Open watt 500 D M WATER 200KGS kgs HCl 100kg
Chilled upto 0⁰C Sodium nitrite 70kgs 570KGS
Sodium Acetate 70kgs Stir for 2hrs Dimethyl Aniline 100kgs 800 kgs Soda Ash 60kgs
Stir R .mass under chilling for 4‐5hrs 800 kgs
Salt 200kgs Heat 800kgs R. Mass 90°C
Centrifuge 700 kgs Water 1000 KGS
Drying 300 kgs 100kgs drying loss
Pulverising 200 kgs
Packing 200kgs (25 kgs*8 drum)
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Safranine 200 Wastewater (To be treated 700 in ETP) 2. Water 200 Drying loss (To atmosphere 100 through vent) 3. HCl 100 Janus Green B 200 4. Sodium Nitrite 70 5. Sodium Acetate 70 6. Dimethyl Aniline 100 7. Soda Ash 60 8. Salt 200 TOTAL 1000 1000 4. METHYLENE BLUE ZN FREE:
Manufacturing Process
Methylene Blue to be charged in open watt & purify it by Soda ash & EDTA. Then filter & Salt Out done by pure salt. The purified material is isolated which is Methylene Blue Zn Free.
Reaction Chemistry
Process Flow Diagram
Open watt Methyl blue‐2b 200 kgs 1200 kgs D m water 1000kgs
SODA ASH 32 kgs HEAT upto EDTA 10kg 90⁰C 1242KGS
Salt 20kgs Filtration Zn‐CARBONATE 1242 kgs 50kg
800KGS ICE Stir R. mass under chilling for 1‐2hrs 1992 kgs
2012kgs R. Mass
Centrifuge 350 1662 kgs Water KGS
Drying 160 kgs 190kgs drying loss
Pulverising 160 kgs
Packing 160kgs (25 kgs *6 drum)
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Methylene Blue 2B 200 Zn carbonate (by-product) 50 2. Water Wastewater (To be 1000 1662 treated in ETP) 3. Soda Ash Drying loss (To 32 190 atmosphere through vent) 4. EDTA 10 Methylene Blue Zn Free 160 5. ICE 800 6. Salt 20 TOTAL 2062 2062
5. TITAN YELLOW:
Manufacturing Process Dehydro Thio is diazotised in the presence of sodium nitrite under Conc. HCl & chilling condition, the reaction mixture is then coupled with the Dehydro Thio. The final product is filtered & centrifuged. Before packing material is dried in tray dryer & pulverised.
Reaction Chemistry
Process Flow Diagram
Dehydrothio para toluedene sulphonic acid (DTPT) 100 KGS Open watt 460 D M WATER 300KGS kgs HCl 60kg
Sodium nitrite 35 kgs Chilled upto 0⁰C 695KGS Ice 200kgs
100 kgs DTPT Stir R. mass under Sodium Carbonate 80kgs chilling 875Kgs
Stir R. mass under chilling for 4‐5hrs 875kgs
Salt 300kgs Heat R. Mass
Centrifuge 795 kgs Water 380 KGS
Drying 190 kgs 190 kgs Drying loss
Pulverising 190kgs
Packing 190kgs (25 kgs *7 drum) Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Dehydro Thio Para Wastewater (To be Toludine Sulphonic Acid 200 treated in ETP) 795 (DTPT) 2. Water Drying loss (To 300 190 atmosphere through vent) 3. HCl 60 Titan Yellow 190 4. Sodium Nitrite 35 5. ICE 200 6. Sodium Carbonate 80 7. Salt 300 TOTAL 1175 1175
6. SUCCINIMIDE
Manufacturing Process . Charge Recycle water with Succinic acid in to reactor, then slowly purge Ammonia gas & heat to 200⁰C and maintain for 2 hours. . After 100⁰C collect he water and same will be use in to next batch as raw water. . Cool to 70-80⁰C unload the molten mass in to trays. . This material will become solidifying after Cooling.
Reaction Chemistry H
N O O HOOCCH 2CH2COOH + NH3 Succinic acid Ammonia Water Succinimide Mol Wt: 118 g / Mol Mol Wt: 17 g / Mol Mol Wt: 36 g / Mol Mol Wt: 99 g / Mol
Process Flow Diagram:
Succinic acid 596 kg Charge Into reactor & Heat Up 364 Kg. 182 Kg. to 200 ⁰C for 2 Hrs. Ammonia 86 kg Wastewater
Tray Dryer 500 kg
Finished Product
Mass Balance:
SR. QTY PER INPUT BATCH (KG) OUTPUT NO. BATCH (KG) 1 Succinic acid 596 Wastewater (To be 182 recycled in next batch) 2 Recycled Water 182 Wastewater (To be 182 treated in ETP) 3 Ammonia 86 Succinimide (Product) 500 Total 864 864
7. N BROMO SUCCINIMIDE
Manufacturing Process . Charge water with succinimide in the reactor. In this solution add caustic and bromine solution. . In second reactor prepare sodium hypo bromide solution and transfer in to 1st reactor to dissolve succinimide (slowly at 20⁰C) and maintain it for 1 hr at 10 ⁰C. . Centrifuge the solution after reaction take place. Glue water wash & dry in to try dryer @ 65⁰C temp. Finish product is ready for packing.
Reaction Chemistry
Process Flow Diagram
Succinimide 184 kg Charge into Water 1000 kg reactor Caustic 74 kg +Water 150 lit 1704 kg Bromine 296 Kg
Centrifuge Sodium Bromide ‐ 34 kg 1704 kg Wastewater – 1150 kg Sodium Bromide Solution 190 Kg (Send to Bromine Recovery plant) Product 330 kg
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) Sodium Bromide Solution 1. Succinimide 184 (by-product) 190
2. Water 1150 Waste water 1150 3. Caustic 74 Sodium bromide (by-product) 34 4. Bromine 296 N Bromo Succinimide 330 TOTAL 1704 1704
8. N CHLORO SUCCINIMIDE
Manufacturing Process . Charge water & Succcinimide in the reactor. Add acetic acid to the solution. . Maintain temperature up to 20⁰C. . Further sodium hypo chloride is added slowly to make pH 8.5. . Precipitation observed. . Stir for 1 hr and then centrifuge & dry it for packing.
Reaction Chemistry
N N
O O O O + NaOCl + CH3COOH +CH3COONa + H2O
Succinimide Sodium Hypo chloride Acetic acid N Chloro Succinimide Sodium acetate Water Mol Wt: 99 g/Mol Wt: 74 g/Mol Mol Wt: 60 g/Mol Mol Wt: 134 g/Mol Mol Wt: 82 g/Mol 18 g/Mol
Process Flow Diagram
Succinimide 148 kg Water 27 Lit Charge into Reactor
Sodium Hypochloride 110 kg 375 kg Acetic Acid 90 kg
Centrifuge Waste Water – 54 lit 375 kg Sodium Acetate – 121kg
Product 200 kg Mass Balance
SR. INPUT QTY PER OUTPUT QTY PER NO. BATCH (KG) BATCH (KG) 1 Succinimide 148 Waste water 54 2 Water 27 Sodium acetate (by-product) 121 3 Sodium hypo chloride 110 N Chloro Succinimide 200 4 Acetic acid 90 TOTAL 375 375
9. BROMOHEXINE HCL (BP)
Manufacturing Process . Charge methanol in reactor then charge nitro cyclohexyl methyl benzyl amine in reactor, then charge catalyst. Then hydrogen gas is introduced to the reactor at 60C. . After the reaction catalyst is filtered. To the filtrate bromine is added slowly at 15C after complete addition, reaction mass is stirred for 6 hours at room temperature. This is again chilled to 20C and centrifuged ml is collected for recycle. . The centrifuge cake is charged in reactor in ethanol to this dissolved mixture carbon is added and is stirred for 2 hours. This is then filtered. To the filtrate HCl is added at 10C and stirred for 3 hours, this is then centrifuged and ml is recycled after distillation. Then product is dried and packed.
Reaction Chemistry
2 NH2 NH NO2 Br 2Br2 2 H2 CH2 CH N + 2HBr CH2 N •HCl N + HCl + 2H2O 316 CH3 CH3 CH3 Br + 36 + 36 C14H20ClN2O2HCl C14H21N2 C14H20Br2N2 + 158 284.78 + 4 376.13 216 288 534
NH2 NH2 Br Br CH2 CH2 N + HCl N •HCl
CH3 36.5 CH3 Br Br
C14H20ClN2O2HCl C14H20ClN2O2HCl
260 412.5 412
Process Flow chart
2 Nitro n Cyclohexylmethyl Benzylamine HCL – 300 Kg Methanol – 1000 kg Reactor Hydrogen Gas- 2 Kg Catalyst Ranickel
Bromine – 325 Kg
Centrifuge 1000 Kg Mother Liquor Recycle
Ethanol 700 lit Carbon 5 Kg Reactor
Filter 812 Kg Mother Liquor HCL 45 Kg Recycle
Centrifuge
Drying and packing 375 Kg
Mass Balance
QTY PER SR. QTY PER INPUT BATCH OUTPUT NO. BATCH (KG) (KG) 1. 2 Nitro N Cyclohexyl 300 Mother liquor (To be 1000 Methyl Benzyl Amine recycled) 2. Hydrogen 2 Drying Loss 190 3. Methanol 1000 Mother liquor (To be 812 recycled) 4. Carbon 5 Bromohexine HCl 375 5. Bromine 325 6. HCL 45 7. Ethanol 700 TOTAL 2377 2377
10. BRONOPOL (BP)
Manufacturing Process
. Charge methanol in Reactor then charge nitro methane, formaldehyde, caustic lye slowly to the mixture. This is maintained for 3 hours at 20C, after that charge bromine and maintain for 4 hours at 60C, then methanol is recovered. . After total methanol recovery, charge water& Carbon this is then stir for 1 Hr. Then carbon is filtered & water is distilled. The reaction mixture is chilled to 10C & centrifuge & dry. Ml is sodium bromide solution & is collected separately.
Reaction Chemistry
NO2 CH3NO2 + 2HCHO + Br2 + NaOH HO Br OH + NaBr + H2O + NaBr + H2O 61 + 2*30 + 79*2 + 40 C3H6O4NBr
61 + 60 + 158 + 40 119 + 101 + 18
318 318
Process Flow chart
Nitro Methane 100 kgs Methanol 425 kg Methanol 500 kgs Reactor Distillation Residue 50 kg Distillation loss 150 kg Caustic 70 kgs
Water 500 Kgs
Cb 5 k Filter Water Recycle 500 Kg
Sodium Bromide Centrifuge Solution 130 kg
Dryer Drying loss 105 Kg
Product 300 Kg
Mass Balance
SR. INPUT QTY PER OUTPUT QTY PER NO. BATCH (KG) BATCH (KG) 1. Water 500 Wastewater 500 2. Nitro Methane 100 Methanol (Recovered) 425 3. Methanol 500 Sodium Bromide Solution 130 4. Caustic 70 Distillation residue 50 5. Formaldehyde 220 Distillation loss 150 6. Carbon 5 Drying Loss 105 7. Bromine 265 Bronopol (BP) 300 TOTAL 1660 1660
11. NICLOSAMIDE-BP
Manufacturing Process . Charge xylene in reactor and then add 5 nitro salicyclic acid at room temperature. . This is stir for 1 hour and chilled to 10C. then slowly charge thionyl chloride at 15C and maintain for 3 hours. . Then slowly charge orthochloro para nitro aniline then stir for 6 hours at 85C. This is then cooled to room temperature and centrifuged. . ML is collected and recycled. Then extra water is drained to ETP and product is dried and packed.
Reaction Chemistry
Cl Cl 2NaOH COOH + 2SOCl2 COCl + NaCl + H2O + NaHSO3 2 * 40 OH OH
C7H5ClO3 + 2SOCl2 C7H4O2Cl2 + NaCl + H2O + NaHSO3 172.57 + 118.57 + 80 191 + 58 + 18 + 104
371 371
Cl Cl Cl OH
COCl + H2N NO2 O2N NHOC + HCl OH Cl
C7H4O2Cl2 + C6H5N2O2Cl C13H8Cl2N2O4 + HCl
191 + 172.5 172.57 + 36
363.5 363.5
Process Flow chart
Xylene 1000 kgs
O.C.P.N.A 180 kgs Reactor
Thionylchloride 135 kgs ML Recycle 1200 Kg
Centrifuge Wastewater 440 kg
Dryer Drying loss 100 Kg
Product 350 Kg
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Water 600 Waste Water 440 2. Xylene 1000 Water ML Re Use 1200 3. Ortho Chloro Para Nitro 180 Drying loss 100 Aniline 4. Thionylchloride 135 Niclosamide BP 350 5. 5 Chloro Salicyclic Acid 175 TOTAL 2090 2090
12. OXO-O-TOLYL ACETONITRILE
Manufacturing Process . Charge Xylene to the reactor then charge orthotoulic acid. Add thionyl chloride at 15C with controlled temperature. . To this solution sodium cyanide and water is added at room temperature. . Then stirred for 8 hours and separated. Then xylene is recovered and reused and a finished product is packed in drums.
Reaction Chemistry
OH OH C=O C=O CH3 CH3 + 2SOCl2 + 2NaOH + NaCl + H2O + NaHSO3
136.2 + 118.57 + 80 154 + 58 + 18 + 104
334 334
OH CN C=O C=O CH3 CH3 + NaCN + NaCl
154 + 49 145 + 58
203 203
Process Flow chart
Xylene 700 Kg O Toluic acid 275 Kg Thionylchloride 225 Kg Reactor
Xylene (Recovered & reused in next batch) 500 Kg Sodium Cyanide 100 Kg Stirring and Wastewater 500 Kg Water 700 Kg Separation Drying & distillation loss 550 Process waste 100 Kg Distillation residue 50 kg
Final Product 300 kgs.
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Water 700 Waste Water 500 2. Xylene (Recovered+ Fresh) 700 Xylene (Recovery) 500 3. Ortho toluic acid 275 Drying & distillation loss 550 4. Thionyl chloride 225 Distillation residue 50 5. Sodium cyanide 100 Process waste 100 OXO-O- Tolyl 300 Acetonitrile TOTAL 2000 2000
13. 4 NITRO 3, 5 DIMETHYL PYRIDINE :
Manufacturing Process Charge Acetic acid and 3,5 lutidine .This mixture is stir for 1 hr. After this in prepared solution hydrogen peroxide is added. Then acetic acid is recovered. This is unloaded into drums. Sulphuric acid and Nitric acid mixture is prepared. In the same nitrating mixture above N-oxide mixture is added between the temperature 65 ˚C .This is then stir for 3 hrs. Then slowly water is added at room temperature .After maintaining is to be neutralized by ammonia gas. This is then centrifuged and dry.
Reaction Chemistry
NO2 3 3 H3C H C 3 H C 3 CH3 2 4 CH CH Acetic Acid H SO
N N 3 N H3C H2O2 H3C HNO3 H C O O
Process Flow chart
3, 5 Lutidine 400 Kg Acetic acid 380 Kg Reactor Hydrogen Peroxide 280 Kg
Acetic Acid Recovery
300 kg Sulphuric Acid 654 Kg Nitric acid 436 Kg Ammonia gas 387 Kg Reactor Water 1150 lit Mixing
Water 200 Lit
Centrifuge 1350 Kg wastewater
Dried & Packing 416 Kg 1821 Kg wastewater
Mass Balance
SR. INPUT QTY PER OUTPUT QTY PER NO. BATCH (KG) BATCH (KG)
1. 3,5 lutidine 400 Aqueous layer (wastewater to ETP) 1350 2. Sulphuric acid 654 Acetic Acid recovery 300 3. Acetic Acid 380 Emission and Drying Loss 1821 4. Nitric acid 436 4 Nitro 3,5 Dimethyl Pyridine 416 5. Ammonia gas 387 6. Hydrogen Peroxide 280 7. Water 1350 TOTAL 3887 3887
14. DICHLORO PYRIMIDINE
Manufacturing Process . In a glassline reactor Di hydroxy pyrimidine is dissolved in phosphorous oxychloride and MDC as a solvent. . This mixture is treated with tri ethyl amine.The above mixture is maintained at 40˚C for 6 hrs. . This is then chilled to 10˚C, then water is added slowly. Then the mixture is stir for 1 hr. . Then layer is separated, organic layer is taken for MDC recovery and final product is packed in drums. . Aqueous layer contains TEA, which is recovered by treating with caustic flakes.
Reaction Chemistry
HO Cl OH Cl + 2POCl3 + 8 NaOH N N N N + 2Na2PO4 + 8H2O + 4NaCl
112.13 + 307 + 320 146 + 142 *02 + 8 * 2 + 4 * 58.5
735 735
Process Flow chart
Phosphorous Oxichloride 400 kgs Di Hydroxy Pyrimidine 225 kgs Reactor MDC 1218 kgs
Water 1000 kgs TEA 72 kgs Reactor
MDC Layer Aqueous Layer 1840 kgs TEA 1075 kgs
Caustic 312 kg MDC Distillation MDC Recovery 1000
Distilation loss 400 Aqueous effluent 925 kg Pack 215 kg Mother liquor + TEA 462kg
Mass Balance
SR. INPUT QTY PER OUTPUT QTY PER NO. BATCH (KG) BATCH (KG) 1. Di hydroxyl Pyridimine 225 Aqueous Effluent 925 2. MDC 1218 MDC Recovery 1000 3. Phosphorous Oxychloride 400 Mother liquor + TEA (To 462 be recycled innext batch) 4. TEA 72 Dichloro Pyridimine 215 5. Caustic 312 Distillation Loss 550 6. Water 1000 Distillation residue 75 TOTAL 3227 3227
15. 2-AMINO 5-METHYL THIOZOLE
Manufacturing Process In a glassline reactor sulphuric chloride is charged .It is chilled to 20˚C then propenaldehyde is added in 5 hours. Then addition of 265 lit of Methanol in to solution. For adjusting pH there is addition of caustic for 10 pH. Then two layers separated aqueous layer send to ETP and organic layer treated with thiourea and HCL mixture. This is then reflux for 3 hour. Then cooled and adjust ph to 9 by dilute caustic solution. It is then centrifuge and dry.
Reaction Chemistry
CH3CH2CHO + 2SO2Cl2 + CH3OH + 5NaOH CH3CHClCOOCH3 + 2NaHSO3 + 3NaCl + H2O
122.5 + 2 * 134 + 76 + 2 * 40 122 + 2 * 104 + 3 * 58 + 5 * 18
558 558
S N CH3CHClCOOCH3 + H2N‐C‐NH2 + 2NaOH + 2NaCl + NaOOH3 + 2H2O H2N S CH3 122.5 + 76 + 2 * 40 114 + 2 * 49.5 + 70 + 2 * 18 315 315
Process Flow chart
WATER 200 LITS
Propenaldehyde 120 kgs Sulphuryl chloride 300 kgs Methenol 265 kgs Reactor Caustic 85 kgs + 200 lits water
400 lits SEPARATION Aqueous
Caustic 50 kgs + 120 lits water
Toluene 300 kgs Reactor HCl 20 kgs Thiourea 100 kgs
190 lits CENTRIFUGE Aqueous
DRYER Drying Loss 1070
Product 100 Kg
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Propenaldehyde 120 Aqueous layer Effluent 590 2. Sulphuryl Chloride 300 Emission and Drying Loss 1070 3. Methanol 265 4. Caustic 135 5. Toluene 300 6. Thiourea 100 7. HCL 20 8. Water 520 2 amino 5 methyl 100 thiozole TOTAL 1760 1760
16. ALLYAL ISOTHIOCYANATE ( ALLYAL MUSTARD OIL)
Manufacturing Process Charge water and ammonium thiocynate in reactor with continuous stirring. Stir for 4 hours at maintained temperature between 10˚C to 15˚C. add slowly Allyl chloride within 1 hour. Then reflux for 4 hours at 45˚C to 50˚C. cool to room temperature and then stop stirring and separation for 3 hours. Separate two layers. Upper layer is product (crude) and lower layer is wastewater. Take crude product in glass distillation unit and start distillation under vaccum. Distilled out pure allyl isothiocynate.
Reaction Chemistry
CH2=CHCH2Cl + NH4SCN → CH2=CHCH2NCS + NH4Cl Allyl Chloride Ammonium Allyl Iso Ammoinium Thiocyanate thiocynate Chloride
(76.5) + (76.0) → ( 99 ) + (54)
Process Flow chart
Ammonium Thiocyanate 206 kg Water 386 kg Condensation Ammonium Thiocyanate 2 kgs
Allyl Chloride 205 kg
Ammonium Chloride 148 kgs Separation Wastewater 387 kgs
Crude Allyl Thiocyanate
Distillation Distillation residue 10 kgs
Final Product
Mass Balance
SR. QTY PER QTY PER INPUT OUTPUT NO. BATCH (KG) BATCH (KG) 1. Allyl Chloride 205 Allyl Iso Thiocyanate 250 2. Ammonium Thiocyanate 206 Ammonium chloride 148 3. Water 386 Ammonium Thiocyanate 2 (To be reused in next batch) Wastewater (To be 387 treated in ETP) Distillation residue 10 TOTAL 797 797
5. Resource optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined.
Latest Process technology will be adopted as available in market with optimum resources requirement with highest yield and less waste and pollution generation. Treated industrial effluent will be reused in cooling activities. In addition to this, all the feasible cleaner production technologies will be adopted.
6. Availability of water its source, Energy/ power requirement and source should be given.
Energy/power requirement will be 150 KVA which will be procured through Paschim Gujarat Vij Company Limited.
The total water requirement will be 30 KL/day which will be fulfilled by own Open well. Water balance diagram is given here under;
Water balance diagram
Source of Water Supply: Open well Total: 30 KL/day
2 Industrial Domestic KL/day 26.5 KL/day 1.5 KL/day
To Septic Tank & Soak pit 1.3 KL/day
Scrubbing Washing RO Plant Reject 6 Greenbelt 0.5 KL/day 0.5 KL/day 21 KL/day 11.5 KL/day Development KL/day 8 KL/day Permeate Scrubbed 9.5 KL/day Ammonia to be Recycled Boiler DM Plant 2.5 KL/day 7 KL/day 4.5 Reject KL/day 5.5 KL/day Cooling Process Reject 1 20 KL/day 0.5 0.2 6 KL/day KL/day 0.8 KL/day KL/day 9 KL/day KL/day
Effluent Treatment Plant followed by Evaporator and condenser system 15.5 17 KL/day KL/day ZERO DISCHARGE
Sludge to TSDF 7. Quantity of wastes to be generated (liquid and solid) and scheme for their Management/disposal.
HAZARDOUS WASTE GENERATION AND DISPOSAL
Sr. Quantity Description Category Management No. (MT/Annum) Collection, storage and ETP Sludge & Evaporation 1 34.3 150 disposal at approved TSDF Residue Site Collection, storage and used 2 Used / Spent Oil 5.1 0.1 within premises as a lubricant / sold to registered recycler. Discarded bags/ drums/ Collection, storage & sell to 3 33.3 65 containers authorized vendor 4 Distillation residue 20.3 36 Collection, storage and disposal at approved CHWIF 5 Process waste 28.1 20 Site
WASTEWATER GENERATION AND DISPOSAL FACILITY
Industrial Wastewater:
Waste water having Ammonical Nitrogen content (about 300 liters/day having Ammonical Nitrogen 200-300 mg/l) will be collected separately and given Ammonia stripping. Ammonia water will be recycled in process. Wastewater after Ammonical nitrogen removal and other Industrial wastewater generated from manufacturing process and washing activities will be collected in Collection tank. Then this wastewater will be given chemical treatment. Then it will be then pumped to filter press from where the sludge separated will be sent to TSDF site. The filtrate separated from the filter press will be then collected in intermediate holding tank. Boiler & Cooling Tower blow-down and R.O & DM reject will be added in this holding tank. Reverse osmosis will be provided to this water and will be reused in cooling tower, washing and gardening purpose Reject from this R.O will be evaporated in evaporator.
Name of the units Volume (m3) No. of Unit Collection tank and stripper system Capacity 500 liters/day 1 set Collection cum Neutralization Tank 10 1 Chemical (Fenton) Treatment Tank 10 1 Filter Press 2 m3/hr 1 Intermediate Water Collection Tank 20 1 Evaporator followed by Condenser 1 m3/hr 1 Treated Water Storage Tank 20 1 ETP Flow Diagram:
Wastewater High from Ammonical Process and blowdown Nitrogen washing and reject effluent Filter Press (2m3/Hr) Intermediate Holding Evaporator Collection Chemical Holding Tank for Ammonia and Tank Treatment Tank Reuse Stripper condenser (10 KL) (10KL) (20 KL) (20 KL) (0.5 KL)
Sludge and evaporation residue to TSDF Pump
Stream-wise Quality of Effluent:
Composite After Chemical Particular Unit Process Washing Effluent (Before Treatment & Treatment) Sludge Removal Quantity KL/day 9.0 0.5 9.5 9.5 pH -- 3.0-5.0 6.0-7.0 3.0-6.0 6.5-8.0 Total Suspended Solids mg/l 100-200 200-300 100-200 40-50 Total Dissolved Solids mg/l 3000-4000 1100-1200 3000-4000 3500-4500 Chemical Oxygen Demand mg/l 3000-4000 100-150 3000-4000 200-300
Process & After Cooling & washing effluent RO & DM Composite evaporation Particular Unit Boiler blow after chemical Reject Effluent (Condensate down treatment water) Quantity KL/day 9.5 1.0 6.5 17 15.5 pH -- 6.5-8.0 6.5-7.5 6.5-7.5 6.5-7.5 6.5-7.5 TSS mg/l 40-50 70-80 20-30 30-40 <10 TDS mg/l 3500-4500 2000-2500 6000-8000 4000-5000 <500 COD mg/l 200-300 40-50 10-20 100-150 <100
8. Schematic representations of the feasibility drawing which give information of EIA purpose.
9. Site Analysis
(i) Connectivity Nearest Railway station Muli road railway station 15.3 Km Nearest National highway NH 8A 0.9 Km Nearest Airport Rajkot 77.4 Km Nearest State highway SH 21 0 km
(ii) Existing Infrastructure (1) Power: 150 KVA from Paschim Gujarat Vij Company Limited, Sayla. (2) Water: Source of the water will be own Open well. (3) Basic amenities; Good Road connectivity with state and National highway. (4) Post Office: at Sayla which is 1.2 km away from project site
(iii) Land Form, Land use and Land ownership. Proposed project site has already been procured by proponent and it is having an existing shed in one corner and other is an open area which is presently not being used for any purposes.
(iv) Soil classification of Surendranagar In this region, major area falls into 'very deep' soil. However, ‘deep’ soil is in major area of Surendranagar district. There are 'moderately deep' soils in few area of Surendranagar. There are 'very shallow' to 'shallow' soil in North-East part (Surendranagar district) and South West (Surendranagar district) part of the region. Rocky outcrops are also found in some part of the region especially in South - West (Surendranagar District) of the region. A major texture of the soil in the region is 'Loamy'. However, in South-West part (in Ahmedabad and Surendranagar district) a soil texture in few area is found to be 'Clayey'.
Major area of the region is having 'Well’ drained soil. However, in some area of region especially in central part and Western part of Surendranagar district is representing 'Some what excessively' drained soil. A very few area of southern part of the region (Adjoining area of Ahmedabad and Surendranagar district) is showing 'moderately well' drained soil.
In few area in Eastern part of Surendranagar district is 'Slightly Saline'. Also Slight sodicity is found in North-East part of Surendranagar district. In west part of the Surendranagar region 'Moderate’ to ‘strong‘ sodicity of the soil is found in the region.
(v) Social Infrastructure available. Sayla is the nearest residential area from the project site which is at only 0.3 km far. This Sayla is a Taluka place which is having all the social and infrastructure facilities.
(vi) Climate data from Indian Meteorological Department
Air Temperature oC Humidity % Monthly Mean Wind Month Rainfall Daily Max. Daily Min. Max. Min. Speed kmph Total, mm March 2015 42.9 12.2 100.0 11.0 16.7 9.9 April 2015 44.3 22.0 92.0 6.0 0 14.5 May 2015 44.4 24.7 93.0 7.0 6.0 17.7 Source: IMD, Rajkot
10. Planning Brief
(i) Planning Concept (type of industries, facilities transportation etc) Town and Country Planning/Development authority Classification.
Proposed Project site is located near to the State highway 21 and National Highway 8A which is well connected to the Rajkot and Ahmedabad having all the infrastructural and transportation facilities. There is no any similar type of industry in nearby area.
(ii) Land use planning (breakup along with green belt etc).
Sr. Particular Area (Sq. Mt.) No. 1 Built Up Area 2791.0 2 Green belt area 3680.0 3 Open/ Road area 4658.0 Total 11129.0
Plant Lay-out is given hereunder; Plant Lay-out
(iii) Assessment of Infrastructure Demand (Physical & Social). Sayla is the nearest residential area from the project site which is at only 0.3 km far. This Sayla is a Taluka place which is having all the social and infrastructure facilities.
(iv) Amenities/Facilities. Sayla is the nearest residential area from the project site which is at only 0.3 km far. This Sayla is a Taluka place which is having all the social and infrastructure facilities.
(v) Proposed Infrastructure a. Industrial Area Industry will provide 2791 Sqmt. built up area for industrial process activity. Which provide all needed facility including proper ventilation, safe handling system, etc. b. Residential Area There will not be any provision of labor quarters within the premises. c. Green Belt. 3,680 Sqmt. (33.1%) area will be proposed for greenbelt development. In addition to this, project proponent will participate in greenbelt development programs in nearby areas under their CSR. d. Social Infrastructure The Project proponent Industry will contribute annually 2% of total profit towards CSR (Corporate Social Responsibility) activity like following in nearby villages; Education Facilities:- Facilities for village schools like game kits, drawing kits, table- chairs; school construction (classroom/toilet/school boundary), ceiling fans or books for school library Health Facilities:-to provide assistance to existing health facilities in Nearest Hospital, for improvement in health facilities or services.
11. Project Schedule & Cost Estimates
(i) Likely date of start of construction and likely date of completion
Start construction work: 1st September, 2016 Completion of construction work: 15th October, 2016
(ii) Estimated project cost along with analysis in terms of economic viability of the project.
Total project cost is around 3 Crores