Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Pre-Feasibility Report
For
Proposed Expansion of Synthetic Organic Chemicals Manufacturing unit
By
PRASOL CHEMICALS PRIVATE LIMITED
Project under – Activity 5(f)
Category - A
Prepared By
M/s Prasol Chemicals Private Limited Survey No. 8,13,15,16,25,75, Tal : Khalapur, Dist: Raigad Maharashtra, India Web: prasolchem.com
1 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Table of Contents
1 EXECUTIVE SUMMARY ...... 4 2 INTRODUCTION OF THE PROJECT ...... 7
IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ...... 7 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...... 7 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION ...... 9 DEMAND – SUPPLY GAP ...... 9 IMPORTS VS INDIGENOUS PRODUCTION ...... 9 EXPORT POSSIBILITY ...... 9 DOMESTIC / EXPORT MARKET ...... 9 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ...... 10 3 PROJECT DESCRIPTION ...... 11
TYPE OF PROJECT ...... 11 LOCATION ...... 12 DETAILS OF ALTERNATIVE SITES ...... 14 SIZE OR MAGNITUDE OF OPERATION ...... 14 PROJECT DESCRIPTION WITH PROJECT DETAILS ...... 15 RAW MATERIAL REQUIRED ...... 15 RESOURCE OPTIMIZATION ...... 18 WATER, ENERGY / POWER AVAILABILITY AND SOURCE ...... 18 Water ...... 19 Energy ...... 19 Power ...... 20 WASTE GENERATION, MANAGEMENT AND DISPOSAL ...... 20 Waste water ...... Error! Bookmark not defined. Non-Hazardous waste –...... 21 Hazardous waste - ...... 21 AIR EMISSIONS: ...... 21 MANPOWER ...... 22 SCHEMATIC OF EIA PURPOSE ...... 22 4 SITE ANALYSIS ...... 24
CONNECTIVITY ...... 24 LAND FORM, LAND USE AND LAND OWNERSHIP ...... 24 TOPOGRAPHY (ALONG WITH MAP) ...... 24 EXISTING LAND USE PATTERN ...... 24 EXISTING INFRASTRUCTURE ...... 24 GEOLOGY AND SOIL CHARACTERISTICS ...... 24 CLIMATE DATA FROM SECONDARY SOURCES ...... 28 SOCIAL INFRASTRUCTURE AVAILABLE ...... 29 5 PLANNING BRIEF ...... 30
PLANNING CONCEPT...... 30 POPULATION PROJECTION ...... 30 LAND USE PLANNING ...... 30 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ...... 30 AMENITIES / FACILITIES ...... 30 6 PROPOSED INFRASTRUCTURE ...... 31
INDUSTRIAL AREA (PROCESSING AREA)...... 31 RESIDENTIAL AREA (NON-PROCESSING AREA) ...... 31 GREEN BELT ...... 31
2 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
SOCIAL INFRASTRUCTURE ...... 31 CONNECTIVITY ...... 31 DRINKING WATER MANAGEMENT ...... 31 SEWERAGE SYSTEM ...... 31 INDUSTRIAL WASTE MANAGEMENT ...... 32 SOLID WASTE MANAGEMENT ...... 32 POWER REQUIREMENT AND SUPPLY / SOURCE ...... 32 7 REHABILITATION & RESETTLEMENT PLAN ...... 33 8 PROJECT SCHEDULE AND COST ESTIMATES ...... 34
LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION ...... 34 ESTIMATED PROJECT COST ...... 34 9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION) ...... 35
3 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
1 EXECUTIVE SUMMARY
Prasol Chemicals Private Limited (Prasol), form an integral part of the global chemical industry. Prasol is an ISO 9001:2008, ISO 14001:2004 and an OHSAS 18001:2007 certified company that is well aligned with its vision "To become a premier manufacturer of Specialty Chemicals and to provide Technical Services globally." Prasol is also A credit rated by SMERA.
Prasol has its own Research and Development and Manufacturing unit, with production facilities for Phosphorous Based, Acetone Based and Hydrogenated products, situated at Khopoli in Raigad district, Maharashtra state.
Prasol is prevalent in various sectors spanning Paints, Coatings, Thinners, Flavors & Fragrances, Agrochemicals, Lubricant Additives, Surfactants, Cosmetics and Pharmaceutical Industries.
Prasol’s global reach spans 45 countries along with local presence through multiple dedicated distribution channels across India.
With a team strength of over 400 employees, Prasol enforces the belief of "Customer first, Reputation first", through technical support and after sales service.
Prasol has established aggressive growth plans for its business with a well-defined pathway for the next several years. Lead by a strong and enthusiastic team of technocrats, the company is well underway in executing plans for organic growth in the near & medium term.
A few areas were considered in and around Maharashtra and found the existing plot most suitable due to its availability and proximity from the company’s existing manufacturing facility.
The site has obtained Prior Environment Clearance in past in the year 2014 for its expansion.
Plot area for the site is 68,644 m2.
Total cost of the expansion project will be approx. Rs. 50.0 Crores (based on present rates).
The total design capacity of the plant for various products will be 153,000 MTA (~ 510 TPD) on the basis of running the plant for 24 hrs., a day, seven days a week and 300 days / annum. The balance 65 days will be utilized for product change-over preparation and annual maintenance shutdown.
4 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
It is proposed to manufacture various inorganic and synthetic organic products.
The 7/12 or Land ownership document is attached at Annexure I
The Google image of the plot site is presented at Annexure – II
Proposed Layout Plan for new establishment is attached as Annexure–III.
Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide EIA Notification SO 1533, dated September 14, 2006 and its amendments. This project falls under Project activity 5 (f) and Category A.
The project brief is summarized in the table below Project summary at a glance
Table : Brief Project summary Sr No Particulars Details 1 Name of Company Prasol Chemicals Private Limited 2 Products Refer section 2 (Introduction of the project) 3 Location Survey No. 8,13,15,16,25,75 Tal. Khalapur, Dist Raigad. 4 Name of the project Expansion of Synthetic Organic Chemicals Manufacturing Facility 5 Total land area of the plot 68,644 sq m 6 Raw material Refer section 3.6 7 Water (estimate / Source) Existing – 710 cmd Proposed additional – 430 cmd Total – 1140 cmd Source of supply: Patalganga River Water (Permit Obtained) 8 Power Requirement / Existing – 2900 KVA Source Proposed additional – 2000 KVA Total – 4900 KVA Source : MSEDCL and captive generation 9 Manpower Existing - (Permanent + Contract) = 400 Nos Proposed: (Permanent + Contract) = 110 Nos Total (Permanent + Contract) = 510 Nos 10 Wastewater generation Total wastewater generation post expansion n (estimate) 391 cmd. (Domestic + trade effluent) Wastewater will be treated at site and will be totally recycled. 11 Air emissions Refer section 3.9 below 12 Solid Waste Refer section 3.9 below 13 Project cost (estimate) Estimate – 5,000 Lakhs
The Land shall be used as “Industrial” land thus there shall be no change in land use.
5 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Existing Unit has all basic infrastructure like Electrical Power, water supply, the internal road network, external approach road and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility).
There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological monuments, sanctuaries, etc.
The land and infrastructure is available for the existing unit and the raw material is easily available through the easy transport via road connectivity by local suppliers as well as imported one.
6 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
2 INTRODUCTION OF THE PROJECT
Identification of the Project and Project Proponent
Prasol Chemicals Private Limited (PCPL) is one of the leading & fastest growing chemical manufacturing companies in India. Incorporated in 1992, the manufacturing of unsaturated polyester resins was commissioned. In the year 1995, Prasol Chemicals became a deemed public limited company and set up a manufacturing unit at Khopoli near Mumbai, India.
PCPL is an ISO 9001: 2008, ISO 14001: 2004 and an OSHAS 18001:2007 certified company. PCPL has an in-house R&D and manufacturing facility, with production plants for Phosphorous based, Acetone based and hydrogenated products, situated at Khopoli, with their own warehouse for storage and distribution of specialty chemicals. The total occupied area at Khopoli is 16.96 Acres (around 68,644 sq. meters) with production plants for Phosphorous Pentasulphide, Diacetone Alcohol, Isophorone, Mesityl Oxide, Lubricant Additives, Phenol – Acetone and various Hydrogenated Products.
PCPL is prevalent in various sectors spanning Paints, Coatings, Thinners, Flavours & Fragrances, Agrochemicals, Lubricant Additives, Surfactants, Cosmetics, and Pharmaceutical Industries.
PCPL’s global reach spreads over 45 countries along with local presence in India through multiple dedicated distribution channels.
PCPL has established aggressive growth plans for its business with a well-defined pathway for the next several years. Lead by a strong and enthusiastic team of technocrats, the company is well underway in executing plans for organic growth in the near & medium term.
Brief Description of nature of the Project
Proposed project is a Expansion project consisting of manufacturing of Synthetic Organic Chemicals which will be widely used in several different applications.
List of Proposed Products and Production Capacity Existing Proposed Total (*) Additional S. No. Products / By Products Capacity Capacity Capacity (MT/Year) (MT/Year) (MT/Year) Products 1 Diacetone Alcohol 9,000 23,000 32,000 2 Nonyl Phenol 720 30 750 3 Phosphorous Pentasulphide 6,000 4,000 10,000
7 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
4 Phosphorous Acid Food Grade 600 0 600 5 Phosphorous Pentoxide 500 0 500 6 Dil. Phosphorous Acid 624 26 650 7 Isophorone 3,600 8,400 12,000 8 Phenol 20,000 0 20,000 9 Acetone 12,000 3,000 15,000 10 Zinc Diorgano Dithiophosphate 1,500 2,000 3,500 11 Mesityl Oxide 750 2,250 3,000 Hexylene Glycol, Trimethyl 1,800 13,200 15,000 12 Cyclohexanol, Trimethyl Cyclohexanone, 13 Methyl Isobutyl Ketone 0 5,000 5,000 14 Methyl Isobutyl Carbinol 0 3,000 3,000 15 Di-isobutyl Ketone 0 1,500 1,500 16 Di-isobutyl Carbinol 0 1,000 1,000 17 Cumene Hydroperoxide 0 5,000 5,000 18 3,5 Dimethyl Phenol 0 3,000 3,000 19 Methyl Pentadiene 0 2,000 2,000 20 Bisphenol-S 0 3,000 3,000 Lubricant Additives (Hydraulic 21 0 500 500 Packages/ Gear Oil Packages etc.) 22 Sodium Dithiophosphate 0 500 500 23 Sodium Dialkyl Dithiophosphate 0 500 500 24 Benzylidene Acetone 0 800 800 25 Benzyl Acetone 0 500 500 26 Dialkyl Dithiophosphoric Acid 0 500 500 27 PIBSA 0 1,500 1,500 28 PIBSI 0 750 750 29 Phosphate Esters 0 500 500 30 Amine Phosphates 0 300 300 31 Carbazole Esters 0 1,500 1,500 32 Ashless Lubricant Additive 0 300 300 33 Resorcinol 0 3,000 3,000 34 Dicumyl Peroxide 0 500 500 35 Cumyl Alcohol 0 250 250 Research and Development 36 - - - activities with Pilot Plant Sub Total (Products) 57,094 91,306 148,400 By-Products 1 Di-Nonyl Phenol 60 0 60
8 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
2 Alpha Methyl Styreme (AMS) 1,500 0 1,500 3 Acetophenone (ACP) 800 0 800 Sodium Hydrogen Sulphide 4 0 2000 2,000 (NaHS) 5 Dicarbinol 0 240 240 Sub Total (By Products) 2,360 2,240 4,600 Grand Total (Products + By 59,454 93,546 153,000 products) * As per existing consent to operate order no. Format 1.0/BO/CAC-cell/UAN No 0000016852/R/8th CAC – 1903001491 dated 26.03.2019 valid till 30.06.2021.
Need of the Project and Its Importance to the country and/or Region
All the products proposed above are imported to India on a regular basis. The quantum of imports varies from product to product, but the manufactured goods will be import substitutes.
Amongst the products proposed, hydrogenated products, Phosphorus Pentasulphide and ZDDP are already being manufactured at the company’s current facility near Khopoli, Dist: Raigad, Maharashtra.
The additional products proposed are forward integration of the company’s current products and have a great demand both global and domestic. The demand is envisaged to increase rapidly in the domestic market.
Demand – Supply gap
All the products Manufactured and proposed to be manufactured are being imported in the country and have a high demand in the domestic markets
Imports vs indigenous production
Currently India is a net importer of all the products proposed and thus the proposed expansion can lead to reduced foreign exchange and open opportunities in the domestic markets for other downstream products
Export Possibility
The products can be exported thus leading to forex revenues for the country
Domestic / Export market
All the products Manufactured and proposed to be manufactured are being imported in the country and have a high demand in the domestic markets. The demand is also high in the export market and can be catered to with the proposed expansion
9 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Employment Generation (Direct and indirect) due to the project
During the construction phase around 60 workers and during the operational phase around 110 workers including contractors will be required. Local skilled and semi- skilled workers will be engaged during construction phase. The positives impact includes enhanced direct employment for technical/ administrative works and indirect employment opportunities for transporters of raw materials and finished goods and downstream industries.
10 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
3 PROJECT DESCRIPTION
Type of Project
(Including interlinked and interdependent projects, if any)
The project is for manufacture of Prosperous based Chemicals as follows,
Existing Proposed Total Capacity Additional S. No. Products / By Products Capacity (*) Capacity (MT/Year) (MT/Year) (MT/Year) Products 1 Diacetone Alcohol 9,000 23,000 32,000 2 Nonyl Phenol 720 30 750 3 Phosphorous Pentasulphide 6,000 4,000 10,000 4 Phosphorous Acid Food Grade 600 0 600 5 Phosphorous Pentoxide 500 0 500 6 Dil. Phosphorous Acid 624 26 650 7 Isophorone 3,600 8,400 12,000 8 Phenol 20,000 0 20,000 9 Acetone 12,000 3,000 15,000 10 Zinc Diorgano Dithiophosphate 1,500 2,000 3,500 11 Mesityl Oxide 750 2,250 3,000 Hexylene Glycol, Trimethyl 1,800 13,200 15,000 12 Cyclohexanol, Trimethyl Cyclohexanone, 13 Methyl Isobutyl Ketone 0 5,000 5,000 14 Methyl Isobutyl Carbinol 0 3,000 3,000 15 Di-isobutyl Ketone 0 1,500 1,500 16 Di-isobutyl Carbinol 0 1,000 1,000 17 Cumene Hydroperoxide 0 5,000 5,000 18 3,5 Dimethyl Phenol 0 3,000 3,000 19 Methyl Pentadiene 0 2,000 2,000 20 Bisphenol-S 0 3,000 3,000 Lubricant Additives (Hydraulic 21 0 500 500 Packages/ Gear Oil Packages etc.) 22 Sodium Dithiophosphate 0 500 500 23 Sodium Dialkyl Dithiophosphate 0 500 500 24 Benzylidene Acetone 0 800 800
11 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
25 Benzyl Acetone 0 500 500 26 Dialkyl Dithiophosphoric Acid 0 500 500 27 PIBSA 0 1,500 1,500 28 PIBSI 0 750 750 29 Phosphate Esters 0 500 500 30 Amine Phosphates 0 300 300 31 Carbazole Esters 0 1,500 1,500 32 Ashless Lubricant Additive 0 300 300 33 Resorcinol 0 3,000 3,000 34 Dicumyl Peroxide 0 500 500 35 Cumyl Alcohol 0 250 250 Research and Development 36 - - - activities with Pilot Plant Sub Total (Products) 57,094 91,306 148,400 By-Products 1 Di-Nonyl Phenol 60 0 60 2 Alpha Methyl Styreme (AMS) 1,500 0 1,500 3 Acetophenone (ACP) 800 0 800 4 Sodium Hydrogen Sulphide (NaHS) 0 2000 2,000 5 Dicarbinol 0 240 240 Sub Total (By Products) 2,360 2,240 4,600 Grand Total (Products + By 59,454 93,546 153,000 products) * As per existing consent to operate order no. Format 1.0/BO/CAC-cell/UAN No 0000016852/R/8th CAC – 1903001491 dated 26.03.2019 valid till 30.06.2021.
Location
(Map showing general location, specific location, and project boundary and project site layout) with co ordinates
The proposed project site is at Honad, Chinchawli Gohe, Thanenhave, Dheku, Tembhewadi Group Grampanchayat, Taluka Khalapur, Dist Raigad.
Raigad District map showing proposed expansion project site location.
12 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Raigad District
Prasol Chemicals Private Limited Location
Details of Nearest Infrastructure Facilities Sr. No. Particulars Details 1. Group Gram Panchayat Honad, Chinchawli Gohe, Thanenhave, Dheku, Tembhewadi 2. Taluka Khalapur 3. District Raigad 4. Latitude Latitude: 180 46’ 34.90” N 5. Longitude Longitude: 730 18’10.60" E 6. Nearest water bodies Patalganga River 7. Nearest Highway Mumbai Pune Expressway 8. Nearest Railway station Khopoli 9. Nearest Airport/ Airbase Mumbai
The project expansion is proposed at Survey No. 8,13,15,16,25 and 75, Tal. Khalapur, Dist Raigad.
The Geographical Location of this plot is at Latitude 18° 46’ 34.90” N and 73° 18' 10.60" E with an elevation of 60 meter above sea level MSL.
Site coordinates are as follows: Location Latitude Longitude marked A 18°46'38.09"N 73°18'7.86"E B 18°46'36.96"N 73°18'12.79"E C 18°46'30.97"N 73°18'12.36"E D 18°46'30.29"N 73°18'7.24"E E 18°46'24.17"N 73°18'6.51"E F 18°46'21.60"N 73°18'10.93"E G 18°46'23.81"N 73°18'11.60"E H 18°46'22.35"N 73°18'15.38"E I 18°46'18.30"N 73°18'11.41"E
13 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
J 18°46'22.80"N 73°18'3.21"E K 18°46'24.86"N 73°18'5.20"E L 18°46'31.39"N 73°18'4.28"E M 18°46'34.86"N 73°18'8.78"E
GPS Location on Google Imagery of the proposed site is attached as Annexure I.
Land Form: Land is on plain contour; it is flat terrain.
Land Ownership: Land ownership is with project proponents (Prasol Chemicals Private Limited).
Existing Land use Pattern: The Land is for Industrial use & the proposed expansion project shall be at the same plot.
Existing Infrastructure: Presently there is an existing Infrastructure around the site.
Infrastructure like water, electricity, communication/telephone facility, roads already available. Other Infrastructure like, hospital, school, housing, entertainment, daily needs are available easily at nearby Khopoli Town (Which is at distance of about 7 km).
• There is no sensitive establishment in the vicinity such as health resort, hospital, and archaeological monuments.
Refer Annexure III for the proposed plant site layout plan.
Details of Alternative sites
(Sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be given)
No alternative site examined as the proposed expansion will be integrated with existing manufacturing site.
Size or magnitude of operation
Plot area of the project consists of ~ 68,644 m2 area.
The design capacity of the plant as given in the table below will be on the basis of running the plant for 24 hrs., a day, seven days a week and 300 days / annum. The balance 65 days will be utilized for product change-over preparation and annual maintenance shutdown.
It is proposed to manufacture Synthetic Organic Chemicals which will be widely used in several different applications.
Details of all the proposed products are listed in 3.1 above.
14 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Project description with Project details
(A schematic diagram / flow chart showing the project layout, components of the project etc should be given)
Proposed products, Brief description, Process Chemistry, Process Block diagram are given at Annexure V.
Raw material required
(Raw materials along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and finish products.)
Raw Materials: The basic raw material for the product capacity is submitted herein below.
Source for Raw Material Procurement: Raw Material is easily available in the local market.
Mode of Transport of Raw Materials: Few of the raw materials will be transported locally and few will be imported from the International Market. Mode of transport to site is by road truck/tankers.
Table: List of Raw Material required
Name of Raw Consumption Physical Means of S. No. Source Material (MTPA) State Storage Imports / 1 Acetone 50,000 L Tanks/Drums Local 2 Caustic 1,500 S/L Bags/ Tanks Local 3 Phosphorus 3,500 S Tanks/Drums Imports 4 Sulphur 8,000 S/L Bags/ Tanks Local Imports / 5 Cumene 28,000 L Tanks Local 6 ZnO 400 S Bags Local 7 Sulphuric Acid 1,500 L Tanks Local 8 Di-isopropyl Benzene 4,500 L Tanks/Drums Local 9 Benzaldehyde 650 L Tanks Local Cylinder 10 Hydrogen 300 G Local Banks 11 Polyisobutylene 430 L Tanks Local 12 Maleic Anhydride 120 L Tanks Local 13 Ethyl Acrylate 800 L Tanks Local 14 Phosphorus Pentoxide 500 S Bags Local 15 Methanol 2,000 L Tanks Local 16 Ethanol 2,000 L Tanks Local
15 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
17 Isopropanol 2,000 L Tanks Local 18 N-Butanol 2,000 L Tanks Local 19 Isobutanol 2,000 L Tanks Local 20 Pentanol 2,000 L Tanks Local 21 Octanol 2,000 L Tanks Local 22 Oleyl Amine 200 L Tanks Local 23 C12 Alcohol 100 L Tanks Local 24 C14 Alcohol 100 L Tanks Local 25 Methyl Acrylate 100 L Tanks Local 26 Carbazole Powder 100 S Bags Local NOTE: *RM requirement can be on the basis of the grade of ZDDP manufactured, the figure indicates maximum quantity per annum
Proposed bulk storages at site shall be as follows for finished goods and raw materials
Finished product storage details, Bulk Physical Storage Means of S. No. Products / By Products State Capacity Storage (MT) Products 1 Diacetone Alcohol Liquid 1,000 Tanks / Drums 2 Nonyl Phenol Liquid 40 Tanks / Drums Solid/ 3 Phosphorous Pentasulphide 300 Silo / Tote Bins Powder Phosphorous Acid Food 4 Liquid 40 Tanks / Drums Grade Solid/ 5 Phosphorous Pentoxide 40 Drums / Bags Powder 6 Dil. Phosphorous Acid Liquid 40 Tanks / Drums 7 Isophorone Liquid 300 Tanks / Drums 8 Phenol Liquid 300 Tanks / Drums 9 Acetone Liquid 1,000 Tanks / Drums Zinc Diorgano 10 Liquid 150 Tanks / Drums Dithiophosphate 11 Mesityl Oxide Liquid 100 Tanks / Drums Hexylene Glycol, Trimethyl 300 Tanks / Drums 12 Cyclohexanol, Trimethyl Liquid Cyclohexanone, 13 Methyl Isobutyl Ketone Liquid 100 Tanks / Drums 14 Methyl Isobutyl Carbinol Liquid 40 Tanks / Drums 15 Di-isobutyl Ketone Liquid 40 Tanks / Drums 16 Di-isobutyl Carbinol Liquid 40 Tanks / Drums
16 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
17 Cumene Hydroperoxide Liquid 40 Tanks / Drums 18 3,5 Dimethyl Phenol Liquid 50 Tanks / Drums 19 Methyl Pentadiene Liquid 40 Tanks / Drums Solid/ 20 Bisphenol-S 40 Silo / Bags Powder Lubricant Additives 21 (Hydraulic Packages/ Gear Oil Liquid 40 Tanks / Drums Packages etc.) 22 Sodium Dithiophosphate Liquid 20 Tanks / Drums Sodium Dialkyl 23 Liquid 20 Tanks / Drums Dithiophosphate 24 Benzylidene Acetone Liquid 20 Tanks / Drums 25 Benzyl Acetone Liquid 20 Tanks / Drums 26 Dialkyl Dithiophosphoric Acid Liquid 20 Tanks / Drums 27 PIBSA Liquid 40 Tanks / Drums 28 PIBSI Liquid 40 Tanks / Drums 29 Phosphate Esters Liquid 40 Tanks / Drums 30 Amine Phosphates Liquid 40 Tanks / Drums 31 Carbazole Esters Liquid 40 Tanks / Drums 32 Ashless Lubricant Additive Liquid 40 Tanks / Drums 33 Resorcinol Liquid 100 Tanks / Drums 34 Dicumyl Peroxide Liquid 30 Tanks / Drums 35 Cumyl Alcohol Liquid 10 Tanks / Drums By-Products 1 Di-Nonyl Phenol Liquid 10 Tanks / Drums 2 Alpha Methyl Styreme (AMS) Liquid 40 Tanks / Drums 3 Acetophenone (ACP) Liquid 20 Tanks / Drums Sodium Hydrogen Sulphide 4 Liquid 30 Tanks / Drums (NaHS) 5 Dicarbinol Liquid 10 Tanks / Drums
Raw material storage details,
Bulk Storage Physical Means of S. No. Name of Raw Material Capacity State Storage (MT)
1 Acetone L 1800 Tanks/Drums 2 Caustic S/L 50 Bags/Tanks 3 Phosphorus S 100 Tanks/Drums 4 Sulphur S/L 200 Bags/Tanks 5 Cumene L 1000 Tanks 6 ZnO S 10 Bags
17 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
7 Sulphuric Acid L 50 Tanks
8 Di-isopropyl Benzene L 100 Tanks/Drums
9 Benzaldehyde L 30 Tanks 10 Hydrogen G 5000 NM3 Cylinder banks 11 Polyisobutylene L 20 Tanks
12 Maleic Anhydride L 10 Tanks
13 Ethyl Acrylate L 30 Tanks
14 Phosphorus Pentoxide S 40 Bags
15 Methanol L 40 Tanks 16 Ethanol L 40 Tanks 17 Isopropanol L 40 Tanks 18 N-Butanol L 40 Tanks 19 Isobutanol L 40 Tanks 20 Pentanol L 40 Tanks 21 Octanol L 40 Tanks
22 Oleyl Amine L 20 Tanks
23 C12 Alcohol L 20 Tanks 24 C14 Alcohol L 20 Tanks 25 Methyl Acrylate L 10 Tanks 26 Carbazole Powder S 5 Bags
Resource optimization
(Recycling and reuse envisaged in the project, if any, should be briefly outlined)
Prasol Chemicals Private Limited intends to expand the manufacturing capacity of products. The resource optimization shall be carried out at the site and with other Prasol sites in order to reduce wastage and minimum transport needs.
Water, Energy / Power availability and source
(Availability of water, its source, Energy/power and requirement and source should be given)
18 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Water The total water requirement is for domestic, process, Boiler and cooling and greenery maintenance purpose.
The source of water shall be from Patalganga River, permit for which has been obtained by the company. Water requirement for proposed establishment is tabulated as below:
Table : Fresh Water requirement No Purpose Existing, Proposed additional, Total, cmd cmd(*) cmd 1 Domestic 27 8 35 2 Industrial 2.1 Industrial cooling / boiler feed 644 380 1018 2.2 Industrial processing 39 24 63 2.3 Gardening 0 18 18 Grand Total 710 430 1140 * As per existing consent to operate order no. Format 1.0/BO/CAC-cell/UAN No 0000016852/R/8th CAC – 1903001491 dated 26.03.2019 valid till 30.06.2021 and Consent to Establish order No Format 1.0/BO/CAC- cell/UAN No 0000043168/E/5th CAC – 1903000367 dated 07.03.2019 valid till commissioning of the unit or upto 5 years whichever is earlier.
Energy Steam/Process heat Requirement: Co-Generation Plant shall be sufficient for the Steam/Heat energy requirement of the proposed expansions.
Existing and proposed fuel requirement, APC system and stack details are as follows,
Sr Stack attached to APC System Height in Type of Fuel Quantity No meter and UoM Existing 1 Boiler – 2 and 3 (3 and 8 TPH) Mechanical dust 25 Imported coal 900 and collector, bag (common) 2000 kg/hr filter 2 Boiler 4 (16 TPH) Mechanical dust 35 Imported Coal 3200 kg/hr collector, bag filter, Cyclone separator 3 Boiler 5 (10 TPH) Mechanical dust 35 Imported Coal 2000 kg/hr collector, bag filter, 4 Thermic Fluid Heater - 1 Mechanical dust 30 Imported Coal 400 kg/hr collector, bag filter, 5 Thermic Fluid Heater – 2 Mechanical dust 35 Imported Coal 687 kg/hr collector, bag filter, Cyclone separator 6 Zinc Di Organo Alkaline 12 - - Dithiophosphate plant scrubber
19 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
7 Phosphorus Pentasulphide Alkaline 11 - - plant scrubber 8 DG set (250 KVA) Acoustic 3.6 above HSD 27.5 Lit/hr enclosure roof 9 DG set (380 KVA) Acoustic 3.6 above HSD 35 Lit/hr enclosure roof 10 Boiler (38 TPH for power ESP 47 Low ash 5625 kg/hr generation of 5 MW) (#) Imported Coal Proposed 11 Boiler 3N (5 TPH) Mechanical dust 35 Furnace Oil 255 Kg/ Hr collector, bag (Common) filter 12 Thermic Fluid Heater – 2N Mechanical dust 35 Furnace Oil 320 kg/hr collector, bag filter, 13 625 KVA (DG set) Acoustic 3.6 above HSD 125 Lit/hr enclosure roof Note: (a) (#) 38 TPH boiler is under construction. Once it is operational. Boilers mentioned in Sr No. 2 and 3 i.e. 16 TPH and 10 TPH will be standby. (b) Sr No 1 boiler (3 and 8 TPH- coal fired) operation will be discontinued once Sr No 11 boiler (5 TPH – Oil fired) is installed. (c) Sr No 5 TFH (coal fired) operation will be discontinued once Sr No 12 TFH (Furnace oil fired) is installed.
Power Existing Co-Generation Plant (of capacity 5 MW) shall be sufficient for the Power requirement of the proposed expansion.
DG Set:
Additional 1 DG sets of 625 KVA capacity is proposed to be installed at this site.
Its fuel requirement (only in case of emergency) shall be as follows:
Sr Capacity Nos Fuel requirement Source No 1 625 KVA 1 125 lit/hr (HSD) From local depot (emergency use only) /supplier
Waste generation, Management and disposal
(Quantity of waste to be generated (liquid and solid) and scheme of their management/disposal)
Wastewater Proposed wastewater generation, treatment and disposal shall be as follows,
N Descriptio Existing, cmd Proposed Total, Treatment and Disposal o n additional, cmd cmd 1 Domestic 21.6 5.4 27 Domestic and Trade effluent effluent shall be treated at site and
20 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
generation treated water will be 2 Trade 111.0 (Process 253 (Process 364 recycled within site. There effluent organic 31 Organic (53 (Process will be no discharge outside. generation cmd + cmd+ Organic (84 inorganic Inorganic 200 cmd+ effluent 80 cmd) Inorganic cmd) 280 cmd) Total 132.6 258.4 391 Note : 84 cmd Organic effluent (54 cmd + 30 cmd from IPH Plant).
The quantification of nonhazardous and hazardous waste estimated to be generated from proposed expansion activities is tabulated as below:
Non-Hazardous waste –
N Waste Type UOM Existing Proposed Total Disposal o Quantity quantity 1 Ion exchange resin TPA 1 0.5 1.5 Regenerate 2 Sand from water filtration TPA 11 6.5 17.5 CHWTSDF 3 Used cotton hand gloves Pairs per 10,000 2500 12500 CHWTSDF annum 4 Miscellaneous Kg/annum 500 200 700 CHWTSDF 5 Fly Ash TPD 20 0 20 Sale to Brick manufacture r (*) Note: Above quantities are rough estimate, will be firmed up during EIA study.
Hazardous waste -
No Waste Type Category UOM Existing Proposed Total Disposal (as per Quantity quantity HW rules 2016) 1 Used/Spent 5.1 KL/A 6.0 3.0 9.0 Sale to Oil authorized reprocessor 2 Filter residue 6.1 TPA 38.0 21.0 59.0 CHWTSDF/ 3 Tar 19.1 TPA 1500 - 1500 Sale to 4 Distillation 36.1 TPA 613.2 1225 1838.2 authorized residue reprocessor 5 Used barrels 33.1 Nos/A 6000 6000 12000 Sale to authorized reprocessor 6 ETP sludge 35.3 TPA 80 20 100 CHWTSDF from WWT 7 Spent 19.2 TPA 5 15 20 CHWTSDF/ catalyst Sale to authorized reprocessor (*) Note: Above quantities are rough estimate, will be firmed up during EIA study.
Air Emissions:
Environmental issues associated with proposed pesticides manufacturing, formulation and packaging includes:
21 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
The principal air pollutants will be volatile organic compounds (VOCs) and particulate matter (PM).
Likely air pollutants from proposed project shall be PM, H2S, NOx, SO2 & HC from various (~15 m to 35 m) process vents, boiler stack and DG Sets as point source.
Adequate APC equipment like scrubbers’ stacks & vents with adequate height will be provided. Vehicular Emissions like CO & HC’s will be generated as line source emissions. Fugitive emissions are also envisaged from proposed project.
Manpower
Manpower: Expected manpower requirement for the establishment (during operation phase) shall be as follows:
Description Existing, Nos Proposed additional, Nos Total, Nos Permanent 360 80 440 Contract 40 30 70 Total 400 110 510
Schematic of EIA Purpose
(Schematic representations of the feasibility drawing which give information of EIA purpose)
Figure : Schematic representation of the feasibility drawing which gives EIA purpose
22 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Project Concept and Site identification
Form 1 with proposed TOR to MoEF&CC (EAC)
Scoping by EAC
EC – rejected by MoEF&CCon TOR approved by EAC the recommendation of EAC
Draft EIA report to SPCB/UTPCC by Summary EIA and Form I – project proponent. display on SPCB / UTPCC website
Public Consultation Display on process by the MoEF&CC SPCB/UTPCC website
Proceedings of Public Display on the consultation SPCB/UTPCC website
To proponent for submission of Appraisal and final EIA report / Supplementary recommendation by report to draft EIA EAC Referred back to EAC under Approval by MoEF&CC communication to the project proponent
Rejected Approved Submission of half Display of compliance Post EC Monitoring yearly compliance report in MoEF&CC report to MoEF&CC / website Ro- MoEF&CC
23 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
4 SITE ANALYSIS
Connectivity
The proposed expansion of Prasol Chemicals Private Limited shall be located at its existing facility located at Survey No. 8,13,15,16,25,75, Tal Khalapur Dist Raigad, Maharashtra. The plant facility is located at 2 km from village Honad, and 3 km from Mumbai Pune Expressway. There is Khopoli town located on Mumbai-Pune NH4, which is considerably better developed in terms of infrastructural facilities, education, transport, hospital etc.
Landform, Land use and land ownership
Landform: Land is on plain contour; it is flat terrain.
Land Ownership: Land ownership is with project proponent (Prasol Chemicals Private Limited).
Topography (along with map)
The district has three physiographic divisions i.e. (i) Coastal zone in west covers about 20% percent of the district (ii) Central zone covers about 1/3 rd of the district, consisting of fertile land in low lying area (iii) Hilly zone in the eastern part highly uneven in altitude and covered with forest. This hill range is characterized by ruggedness and uneven topography, with Crestline of peaks and saddles forming the eastern horizon. Ulhas, Panvel and Patalganga are the three main rivers in northern part. Kundalika River is the main river in central part whereas in the southern part Savitri River is the main river. The soils in the district are formed from the Deccan Trap which is predominating rock formation with small out crops of Laterite at a few places in the Poladpur taluka and Matheran hill. The soils are grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium and Laterite as per the location and topographical situation.
Existing land use pattern
Existing land use is for industrial use owned by Prasol Chemicals Private Limited.
Existing infrastructure
Operating plant at the site.
Geology and Soil characteristics
GEOLOGY:
24 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
The rock of the district is trap. In the plains it is found in tabular masses a few feet below the soil and sometimes standing out from the surface. In the hills it is tabular and is also found in irregular masses and shapeless boulders varying from a few inches to several feet in diameter. In many places the surface of the trap has a rusty hue showing the presence of iron. Nala on West of the plant site is the main line of drainage which on going further meets Patalganga river near Mumbai Pune Highway (NH – 4). This nala has flowing water from Month of June to February. This helps in replenishment of ground water table. Soil Characteristics
There are four chief varieties of soil: Alluvial and Alluvia, Powdered Laterite and trap, clayey mould resting on trap, and soil containing marine deposits with, much sand and other matter in concretion. Of these the first, which is composed of various disintegrated rocks of the overlying trap formation, with a varying proportion of calcareous substances, is at once the richest and the most widespread. The soil in the vicinity of manufacturing plant is either black soil or red soil (rich in iron). As per the periodic soil analysis in year 2010, for area of village Honad and Khopoli, done by Agricultural department of Govt. of Maharashtra, soil has following characteristics; presented in table below.
Sr. No. Characteristic Observation Inference 1 pH 6.5 - 7.5 Slightly alkaline 2 Salinity (E.C) (mS/cm) 0.18 – 0.20 Average Sr. No. Characteristic Observation Inference 3 Organic Matter (%) 1.509 – 1.51 Very High 4 Nitrogen (kg/hector) -- -- 5 Sulphur (kg/ hector) 18.923 – 19.00 Below Average 6 Potassium 215.04 – 220 Average
(Source: Agricultural Dept., Govt. Maharashtra) The district is the second largest producer of rice in the Maharashtra State. The region is peculiarly terraced and, though the small strips in between the two terraces are levelled, it is difficult to get even a few gunthas of land in one piece in a levelled condition. The depth varies between two and six feet. They are loamy in texture, yellowish or reddish grey in color, neutral in reaction and almost devoid of lime. They are formed from the trap rock from the Sahyadri ranges under heavy rainfall and humid climatic conditions. The linear response of rice to the application of nitrogenous, phosphatic and potassic fertilizers is observed in these soils. Addition of bulky manures in these soils is also found to be advantageous from the point of view
25 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra of yield. There are some patches of manat soils in Mangaon taluka which are rich in clay and silt and which become stiff and hard when dry.
Khar soils.
These soils are situated on the flat, levelled land near the sea at the point of creeks formed due to the rivers. They are flat clay to clay loam in texture and reddish or yellowish grey in colour. These soils contain hardly more than one per cent of soluble salts. These soils are formed due to the deposition of salts by the sea or from lands reclaimed from the sea. Large tracts of land are going out of cultivation due to the ingress of the sea and, in order to reclaim these lands, the Government have formed the Khar Land Development Board which has undertaken ambitious projects of the reclamation of khar lands.
Coastal alluvium soils.
These soils are found all along the coast and at places where there are no creeks. They are deep soils developed on flat land and loamy in texture with reddish grey colour. They are devoid of clay fraction or humus and are open in nature. The profile is difficult to differentiate and is excessively drained. Calcium carbonate is found in abundance throughout the profile but calcium has not entered the clay complex. The sub-soil water level is only from ten to fifteen feet deep. The salt contents of the well water are higher in the proximity of the sea; but due to excellent drainage, its use has not produced any deleterious effects. The soils are almost neutral or slightly on the alkaline side of neutrality. Good garden crops like coconut, areca-nut, plantain, etc., are grown in these soils, depending upon the availability of water.
Laterite soils.
Out-crops of laterite rock are observed amongst the Sahyadri ranges amidst the trap rock mainly at Matheran and in the Poladpur taluka. These soils mostly occur on the mountain peaks. They are coarser in texture, wherever there are no forests. They are yellowish-red in colour and shallow in depth and yield coarse millets and niger. The heavy rains in the mountainous regions thoroughly leach the soils turning them acidic in reaction and devoid of calcium carbonate. They are rich in sesquioxides, the ratio of silica to sesquioxides being less than two. But they are generally poor in exchangeable bases or in fertility constituents. However, the soils from the forest region are well- supplied with nitrogen and organic matter. Typical soil analysis is as follows
26 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Description of Soils Chemical Coastal Salt land or Analysis Loamy Varkas Laterite Alluvial Khar land (1) (2) (3) (4) (5) (6) Yellowish Yellowish red Reddish or Reddish Colour to reddish to yellowish Yellowish red yellowish grey grey. grey. grey. Depth 1'—3' 1' - 2' 3' — 5' 5' — 10' 5' — 10' Per cent on drv matter oven Organic matter 0.7 — 1.8 0.5 — 1.0 2.0 — 3.0 0.7 — 1.5 0.5 — 1.5 Calcium Nil — 0.01 Trace Trace 5.0 — 10.0 0.05 — 2.00 Carbonate Sand (Coarse 5.0 — 10.0 60.0 — 70.0 8.0 — 10.0 20.0 — 35.0 20.0 — 30.0 and fine) Silt 30.0 — 35.0 10.0 — 15.0 40.0 — 60.0 30.0 — 40.0 25.0 — 30.0 Clay 30.0 — 40.0 10.0 — 20.0 30.0 — 40.0 15.0 — 30.0 10.0 — 20.0 Clay to Clay Textural class Loam Sandy Sandy loam Clay loam loam Total soluble 0.04 — 0.05 Trace 0.02 — 0.04 Trace 1.0 — 3.0 salts Organic carbon 0.4 — 0.9 0.27 — 0.67 1.5 — 3.0 0.4 — 1.6 0.5 — 1.05 Total Nitrogen 0.04 — 0.06 0.02 — 0.05 0.15 — 0.20 0.06 — 0.10 0.05 — 0.07 C/N 10—16 10—16 10—15 10—16 10—15 PH value 6.7 — 7.2 6.0 — 7.5 4.5 — 6.0 7.0 — 8.0 7.0 — 8.0 Mgm. per cent drv matter on oven Available P205 8—10 5.10 Trace—5 10—15 10—15 Available K20 12—20 10—20 5—10 20—25 10—15 millie equivalent dry matter per cent on oven. Exchangeable 20—25 18—25 5—10 30—35 20—30 Ca Exchangeable 7—8 7—10 1—2 5—7 10—11 Mg Exchangeable 0.08 — 2.0 2—3 0.01 — 0.02 2.3 7.5 — 12.0 Na Exchangeable 0.82 — 1.0 0.44 — 0.8 1—2 0.4 — 0.6 1.2 K Exchangeable -- -- 4—6 -- -- H Total Exchangeable 30—35 40—43 15—18 35—40 20 — 35 bases Base Exchange 20—35 40—45 19—24 35—40 30—35 Capacity
27 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Climate data from secondary sources
Climate and rainfall profile:
Village Honad (Raigad) being in region of Konkan the climate is warm and humid. The relative humidity levels in this region are high throughout the year. The relative humidity levels observed are in range of minimum 66% (Dec) to maximum 85% (July, August, September). The area receives rainfall for more than four months of the year, which provides main climatic variations. Out of total rainfall 90% is experienced during Monsoon season of months June to September. The details of monthly precipitation observed in Raigad district are given in Table below, Annual Rainfall Profile for Raigad District
Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec Month Rainfall 2.5 0.8 0.5 1.8 18.8 558.5 699.5 394.7 312.2 69.6 20.1 1.8 (mm)
(Source: Raigad Gazetteer, Government of Maharashtra) Being a coastal district the diurnal (daily) and seasonal variations of temperature are not large. The period from March to May is one of increasing temperatures. May is the hottest month with a mean daily maximum temperature at 31.7°C (89.1°F) and the mean daily minimum temperature at 26.4°C (79.5°F). Fresh breezes from the sea relieve the oppressive heat particularly in the coastal regions in the afternoons. The onset of the south-west monsoon early in June brings down the temperatures slightly. After the withdrawal of the south-west monsoon by the end of September the day temperatures increase slightly and the weather in October and November is almost like the summer months. In the period from December to February the weather is cooler than in the post-monsoon months. Humidity: The air is humid throughout the year. Relative humidity is on an average over 80 per cent during the south-west monsoon season. In the rest of the year the relative humidity is between 65 per cent and 75 per cent. Cloudiness: During the south-west monsoon season skies are heavily clouded to overcast. In May and October, the clouding is moderate. Clear or very lightly clouded skies are common in the rest of the year. Winds:
28 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Winds are very strong and blow from west or south-west during monsoon season. During the period from October to December winds are generally moderate but sometimes strong in October and blow from directions between north-east and south-east. In the three months from January to March the winds continue to be moderate and are predominantly from directions between north and east. In April while there is a slight strengthening of wind, the direction is variable. In May there is a further strengthening of winds and the directions are between south-west and north-west. Special weather phenomena: In association with cyclonic storms in the Arabian sea in the post-monsoon months and to a lesser extent in May, the district experiences very strong winds, sometimes reaching gale force, particularly very near the coast and also heavy widespread rain. Occasionally these storms may cross the coast in the northern part of the district and cause heavy damage. Thunderstorms occur in April and May and just before the onset of the monsoon and in the late September to the middle of November.
Social infrastructure available
Nearest town is Khopoli which is about 5 km from site towards east. Social infrastructure such as schools, Hospitals, market place and other amenities are easily available. Transport facilities by road are available.
29 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
5 PLANNING BRIEF
Planning Concept
• Existing operational unit in a well-established industrial area. • Water supply from Patalganga River. • Well-developed roads and connectivity. • Integration with the existing manufacturing facility.
Population Projection
In 2011, Raigad district had population of 2,634,200 of which male and female were 1,344,345 and 1,289,855 respectively. In 2001 census, Raigad had a population of 2,207,929 of which males were 1,117,628 and remaining 1,090,301 were females. Raigad District population constituted 2.34 percent of total Maharashtra population.
In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra population.
There was change of 19.31 percent in the population compared to population as per 2001. In the previous census of India 2001, Raigad District recorded increase of 20.99 percent to its population compared to 1991.
The initial provisional data released by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309 people per sq. km. Raigad district administers 7,152 square kilometers of areas.
Land use planning
For Industrial use
Assessment of Infrastructure Demand (Physical and social)
No major infrastructure demand is envisaged as the proposed site is in well-developed area.
Amenities / Facilities
No major amenities / facilities demand is envisaged as the proposed site is in well- developed area and has good site connectivity.
30 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
6 PROPOSED INFRASTRUCTURE
Since the expansion is planned at existing plant site, no special/specific development is anticipated. Company will have to do site development only. Company has not planned any residential area.
Industrial Area (Processing area)
Prasol Chemicals Private limited, Survey No. 8,13,15,16,25,75, Tal: Khalapur, Dist: Raigad Maharashtra, proposes to expand its existing facility for manufacture of Synthetic Organic Chemicals manufacturing based on demand and market projection.
Residential area (non-processing area)
No Residential area is proposed within the plant site.
Green Belt
Green belt of adequate area within and around the project site shall be carried out as per industries norms and requirement.
Social Infrastructure
Local people will be given preference wherever found suitable for all the jobs in the plant, direct as well as indirect. Thus, the project shall have a positive impact on the employment pattern of the region. Economic status of the local population will improve due to increased ancillary/business opportunities, thereby making positive impact. Educational, medical & housing facilities will improve due to the proposed project.
Connectivity
This proposed expansion project facility shall be located at company’s existing manufacturing area located at village Honad, in Raigad district, Maharashtra. The Site is 7 km from Khopoli town and 10 km from nearest railway Station, Khopoli. The land and infrastructure is available and the raw material is easily available through the easy transport via road connectivity.
Drinking water management
The total water requirement is about 1140 cmd for Domestic, boiler/cooling, Greenery and process. The source of water shall be from Patalganga river.
Sewerage System
Refer Annexure IV for trade effluent and sewerage water treatment scheme.
31 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Industrial waste management
Refer 3.9 above
Solid waste management
No specific infrastructure is required for the proposed expansion for solid waste management. Refer 3.9 above for additional waste generation and its disposal management.
Power requirement and supply / source
Power requirement shall be sourced from MSEDCL and by captive power generation (Cogen plant of 5 MW).
32 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
7 REHABILITATION & RESETTLEMENT PLAN
(Policy to be adopted (center/state) in respect of project affected persons including home oustees, land oustees and landless labors (a brief outline to be given)
The proposed expansion shall be within the plot owned of the company. It does not require acquisition of Land and the Infrastructure so there is no any kind of activity of Rehabilitation and Resettlement to be carried out.
33 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
8 PROJECT SCHEDULE AND COST ESTIMATES
Likely date of start of construction and likely date of completion
(Time schedule of the project to be given)
It is expected that the expansion project shall be completed within 9 to 12 months from date of grant of Environmental clearance.
Estimated project cost
(Along with analysis in terms of economic viability of the project)
Total estimated project cost is around Rs. 5000 Lacs
34 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION)
(Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area)
The proposed expansion project envisages
o For the growing domestic market and as Import substitution.
o Direct employment to locals and will prompt ancillary businesses.
o Export benefits.
35 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Annexure – I
Attached as Additional file
Annexure – II
36 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Location of Prasol Site
Goggle image of site
Goggle image of site with 1 km radius
Goggle image of site with 10 km radius
37 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
38 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Annexure – III
Proposed Plant site layout
AREA STATEMENT Sr No Description Area in sq m 1 Total Built up area 18,958 2 Total Green belt area 22,864 3 Total area for roads 14,215 4 Open land area 9,407 5 Total Co gen area 3,200 Total Plot area 68,644
39 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Annexure - IV
Proposed Effluent treatment scheme
Post expansion following quantities of effluent are expected.
• Domestic effluent – 27 cmd • Trade effluent – 30 cmd from IPH Plant - 54 cmd Organic effluent - 280 inorganic effluent Total – 391 cmd
The brief process of treatment of effluent will be as follow.
The proposed ETP will be designed to achieve “Zero Liquid Discharge”. Treatment scheme is as below: • Effluent will be segregate as per Low COD/ TDS & High COD/ TDS. • High COD/TDS effluent streams will be sent to Flotation tank after Neutralization. Sludge from filtration will be send to CHWTSDF for disposal. • After filtration, effluent will be sent to MEE & ATFD. Permeate from MEE & ATFD treatment will be send for Aerobic treatment. Sludge/ residue from reject stream of MEE & ATFD will be send to CHWTSDF for disposal. • Domestic effluent will be added in Aeration tank along with permeate stream of MEE & ATFD for biological treatment. After Biological treatment effluent will be send to clarifier. Active biological sludge from clarifier is send back to aeration tank to maintain MLSS & excess will be disposed of to CHWTSDF facility. • After secondary clarifier effluent passed through chlorination tank followed by Pressure sand filter/ Activated carbon filter. • Low COD/ TDS effluent will be treated in separate mixing tank with addition of Na2CO3 & Alum. Effluent will be passed through Multi grade sand filter to remove suspended solids from effluent. • The filtered effluent will be sent to RO plant to remove dissolved solids. RO reject stream will be sent back to MEE. • Treated effluent will be stored in Final storage tank & recycle back for gardening/cooling tower makeup.
40 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
PROPOSED ETP SCHEME
Effluent 1 Effluent 2 Effluent 3 In From IPH Plant Organic organic effluent effluent
Na CO Neutralisation Neutralisation 2 3 Mixing Alum
Bottom Residue Filtration Settling Multi grade sand filter
Sludge to CHWTSDF Back wash to Clarifier Filter press RO reject MEE + ATFD
Domestic Effluent Sludge to CHWTSDF
Sludge to Biological Treatment CHWTSDF UF/ RO
Secondary Clarifier Sludge to CHWTSDF PSF/ACF Chlorination
RO permeate Final storage Treated eff. for recycle 3
41 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Annexure - V
Proposed products, Brief description, Process Chemistry, Process Block diagram
1 Diacetone Alcohol
Diacetone Alcohol is produced by the Aldol Condensation of Acetone. The reaction is conducted in the reactive distillation mode. Acetone is passed over anionic catalyst to form diacetone alcohol after reaction. The reaction mass containing acetone and Diacetone alcohol is subjected to distillative separation to a) recover and recycle the unreacted acetone and b) recover diacetone alcohol in desired purities. The product will be stored in storage vessel prior to drumming
Diacetone Alcohol
(CH3)2CO Alcoholic Caustic Catalyst Acetone Diacetone Alcohol
FEED ACETONE (kg) CAUSTIC + CATALYST R (KG)
106.00 0.26
REACTION RECYCLE ACETONE 742.18 848.44
CATALYST NEUTRALIZATION REMOVAL 0.26 848.18
FLASHER 334.13 514.05
DISTILLATION 1 385.54 128.51
DISTILLATION 2 3.01 125.50
OFF-SPEC ACETONE(KG) DISTILLATION 3 RECOVERY 22.00 25.01 3.50 100.00
DAA PRODUCT ORGANICS 2.50 100.00
2) Phosphorus Pentasulphide (PPS)
Manufacturing Process In PPS plant, the manufacturing is done in 5 steps:
42 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Feed Preparation; Reaction; Distillation; Flaking; Grinding & Packaging.
Step 1: Feed Preparation
The solid Sulphur is sent to the melting tank for melting. After melting, the sulphur is sent to the Sulphur Feed Tank for reaction. The Phosphorus is molten and stored under water in the Phosphorus Feed Tank. Step 2: Reaction From feed tanks the liquid sulphur and phosphorus are fed to the reactor which is operated under Nitrogen blanket. In the reactor a simple addition reaction takes place at high temperatures to form Phosphorus Pentasulphide (PPS) product and then it is drained to the intermediate tank maintained at the desired temperature to be fed to the distillation furnace. The vapours formed (if any, during abnormal conditions) in the reactor and the intermediate tanks are sent to the H2S scrubber attached to the ZDDP plant / DATC Plant. Step 3: Distillation The reaction mass is heated and the vapours are collected in the distillation pot. The vapours are cooled in the pot and liquid PPS of 99.5% purity is obtained. Periodic maintenance shall be done, during which sludge will be removed. Step 4: Flaking The distillate mass is sent to the flaker. In flaker the distillate mass is solidified over a drum cooled with chilled water to form a thin solid layer which is scraped by a blade arrangement and collected in the form of flakes. Step 5: Grinding & Packaging These flakes are then conveyed through a pin mill arrangement to obtain the product in the required size of granules or powder. This product is then stored in Silos and packed in drums or Tote bins as per the requirement.
Reaction involved and process flow diagram is shown below:
4P4 + 5S8 4P4S10 Phosphorus Sulphur Phosphorus Pentasulphide (PPS)
43 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Phosphorus Sulphur
Figure : Block Diagram for PPS Manufacturing
Reactor
Furnace for Distillation
Sludg Distillation Receiver e Pot
Flaker
Grinding by Pin Mill
Packing of P2S5 Product
44 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
3) Phosphoric Acid (Food Grade) / Dil. Phosphoric acid
Phosphoric Acid is prepared by addition of water (dilution) of Polyphosphoric Acid in an Agitated Reactor. On further or excess Dilution, we get a dilute phosphorous Acid product
Phosphoric Acid
Polyphosphoric Acid Water MIXING 85.00 15.00 100.00
PHOSPHORIC ACID PRODUCT 100.00
Phosphoric Acid Water MIXING 85.00 15.00 100.00
DIL. PHOSPHORIC ACID PRODUCT 100.00
4) Isophorone Process:
Isophorone is produced by Aldol Condensation of Acetone.
Acetone with a catalyst mixture is fed in a continuous manner to a reactive distillation column system. The condensation reaction takes place in these reactors forming a mixture of Isophorone, Acetone, water and other organics. The Acetone is recovered and recycled back in the reaction section itself and is further sent for neutralization. The reaction mass, after neutralization, is washed & and then subjected to separation by distillation process to extract Isophorone in desired purities.
Isophorone
3 (CH3)2CO + 2H2O Caustic Catalyst Acetone Isophorone Water
45 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
0.069 CAUSTIC
155.88 ACETONE + REACTION WATER TO ETP WATER 110 70.16 323.44
195.726 85.726 WASHING AQ. DISTILLATION WATER FOR RECYCLE
127.7182
0.069 DISTILLATION 1 CAUSTIC RECOVERY 11.61075 116.1075
DISTILLATION 2 IPH PRODUCT 100 17.72 1.61252
RECOVERY
HEAVIES 85.726 16.10748 16.10748
5) Phenol / Acetone / Cumene Hydroperoxide (CHP) / Cumyl Alcohol (PDMC) / Dicumyl Peroxide / Alkyl Phenols Manufacturing of Phenol and Acetone is a two stage Cumene Peroxidation Process. First stage is oxidation of Cumene to Cumene Hydro Peroxide (CHP) followed by acid catalyzed decomposition (cleavage) of CHP to Phenol, Acetone, AMS, Acetophenone, and Tar etc. Second stage consists of series of distillation operations to separate Acetone, Phenol & other by products in stages. Firstly Acetone is separated followed by Phenol, Final stage separates out byproducts Acetophenone and Tar.
46 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Phenol – Acetone (Overall reaction):
+ O2 + (CH3)2CO
Cumene Oxygen Phenol Acetone
Reaction 1:
+ O2 (80–110oC) Cumene Oxygen Cumene Hydroperoxide (CHP)
Reaction 2:
H2SO4 catalyst + (CH3)2CO (80–85oC) CHP Phenol Acetone
PA Plant
CARBONATE VENT AIR (INERT) 0.30 157.47
CUMENE AIR OXIDATION 140.00 188.50 694.10
RECYCLE CUMENE CHP CHP PRODUCT optional draw 513.82 CONCENTRATION 180.29 PDMC PRODUCT optional draw
CATALYST WATER 5 CLEAVAGE 0.42 184.13 TO ETP 1.58
ACETONE PRODUCT ACETONE PHENOL PHENOL PRODUCT 100.00 60.00 60.00 DISTILLATION 109.13 DISTILLATION 100.00 15.00 9.13
ALKYL PHENOL OLEFIN AMS RECOVERY ACP RECOVERY 8.96 PROCESSING# 6.04 2.88
AMS PRODUCT ACP PRODUCT ALKYL PHENOL^ 6.042 2.88 TAR 6.25
ALL NUMBERS IN KGS EXCEPT MENTIONED OTHERWISE *CHP & PDMC Products can be drawn at a desirable quantity from the concentration stage as they are intermediates formed in the Oxidation reaction #All Alkyl Phenols will be manufactured from a Phenol Distillation stream to the desired quantity of the product mix ^Alkyl Phenols Include: Nonyl Phenol DiNonyl Phenol 3,5 Dimethyl Phenol
47 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
6) Zinc Diorgano Dithiophosphate (ZDDP) / Dialkyl Dithiophosphoric Acid
Manufacturing Process Zinc Diorgano-DithioPhosphate (ZDDP) is manufactured in two major steps. Step 1: Synthesis Step: The synthesis of Oxo-Alcohols and Phosphorus Pentasulphide takes place to form a Di-Alkyl Dithiophosphoric Acid with release of Hydrogen Sulphide gas. In this step, the oxo-alcohols are charged into the reactor, stirred and heated. Phosphorus Pentasulphide is added to this mass with continuous stirring which results in the evolving of gases which are to be absorbed in the 2 stage caustic scrubber.
Step 2: Neutralization Step: The neutralization of the acid is carried out with zinc oxide. Once neutralization is complete, the product mass is dried. Filter aid is added and the batch is filtered to obtain the product of desired quality. The residue is then removed from the filter in the form of solid cakes. The ZDDP product is then stored, packed and dispatched as required.
ZDDP Reactions:
Reaction 1: SH (95–100oC) 4 R-OH + P2S5 2(RO)2-P=S + H2S
Oxo-alcohols Phosphorus Diorganodithiophosphate Pentasulphide Acid
Reaction 2:
SH S S
2(RO)2-P=S + ZnO (RO)2-P=S-Zn-S=P-(OR)2 + H2O
Diorganodithiophosphate Zinc Zinc Diorganodithiophosphate Acid Oxide
48 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
5.12 NaOH (10%) 28.04 PPS
4.39 H2S Scrubber NaHS (30%) 9.47 Optional Draw DDP ACID PRODUCT Reaction Alcohol 47.06 71.70 48.06 To Flare 0.0439 11.00 16.00 ZnO Neutralization Base Oil 98.70
1.00 Drying Alcohol (Recovered)
97.70 Base Oil 3.00 Filter Aid 0.60 Mixing
101.30
Filtration Filter Cake 1.30 100.00
ZDDP Product 100.00
7) Mesityl Oxide Mesityl Oxide is manufactured by the dehydration of Di Acetone Alcohol (DAA) in presence of an acid catalyst followed by distillation to obtain the pure product. The raw material DAA is charged into an agitated reactor and the acid catalyst is added. The reaction is maintained at a constant temperature by use of steam for heating. The vapors are then passed through a distillation column to collect Crude MO at the top. The bottoms containing acetone & Di- acetone Alcohol (DAA) are recycled back into the reactor. The top product which is collected in a decanter is the fed to a distillation column where a Pure MO product is extracted from a mixture of MO, water and other lighter hydrocarbons. The pure MO is then stored in a product tank or packed as per requirements.
Mesityl Oxide
(CH3)2C(OH)(C0)CH3 CH3(CO)CH=C(CH3)2 + H2O Catalyst
Diacetone Alcohol Mesityl Oxide Water
DAA REACTION ACID
160.25 161.25 1.00
TO ETP WASHING 166.88 52.50 210.00 65.625
OFF SPEC DISTILLATION H2O 75.00 35 100.00 26.25
MO PRODUCT
100
49 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
8) Hydrogenated Products (Hexylene Glycol, Trimethyl Cyclohexanol, Trimethyl Cyclohexanone, Methyl Isobutyl Ketone , Methyl Isobutyl Carbinol, Di-isobutyl Ketone, Di- isobutyl Carbinol, Benzyl Acetone)
Initially the raw material is pumped from the feed tank into the loop reactor which operates at a preset temperature and pressure. The catalyst is fed into the reactor before the batch is initiated. The hydrogen gas in then introduced into the Loop reactor where the hydrogenation reaction takes place. The contents of the loop reactor are thoroughly mixed using a pump circulation system. After the reaction is completed, the reaction mass is emptied into a storage tank and a new batch is charged into the loop reactor.
The reaction mass from the tank is then passed through a filter system where the catalyst entrained in the product is removed / recycled. For some of the products a purification system based on distillation and special filtration is used. The product is then pumped into a tank from where the purified product can be packed and shipped.
Reactions
Hexylene Glycol
CH2COCH2C(CH3)2OH + H2 Ni Catalyst
DAA Hexylene Glycol (HG)
3,3,5 - Trimethyl Cyclohexanol
Catalyst C9H14O + 2 H2 C9H18O
IPH Trimethyl Cyclohexanol (TMCHnol)
3,3,5 - Trimethyl Cyclohexanone
Catalyst C9H14O + H2 C9H16O
IPH Trimethyl Cyclohexanone (TMCHnone)
MIBK Catalyst CH3(CO)CH=C(CH3)2 + H2 CH3(CO)CH2CH(CH3)2
Mesityl Oxide Methyl Isobutyl Ketone (MIBK)
50 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Note: DIBK is a By-Product in MIBK manufacture
MIBC
Catalyst CH3(CO)CH2CH(CH3)2 + H2 CH3CHOHCH2CH(CH3)2
Methyl Isobutyl Methyl Isobutyl Ketone (MIBK) Carbinol (MIBC)
DIBC
Catalyst (CH3)2CHCH2(CO)CH2CH(CH3)2 + H2 (CH3)2CHCH2CHOHCH2CH(CH3)2
Di Isobutyl Ketone (DIBK) Di Isobutyl Carbinol (DIBC)
Benzyl Acetone
C10H10O + H2 C10H12O
Benzylidene Acetone Benzyl Acetone
VENT GAS
RM HYDROGEN GAS REACTION CATALYST
CATALYST RECYCLE FILTRATION 0.00
DISTILLATION HBs (HW) OFF SPEC PRODUCT
HYDROGENATED PRODUCT
9) 3,5 Dimethyl Phenol
3,5 Dimethyl Phenol is prepared by thermal cracking of Isophorone. The process is carried out in 4 steps. Step 1 includes the thermal cracking of Isophorone in presence of a metallic catalyst.
51 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Step 2 involves distillation to remove the Impurities formed during cracking. Step 3 involves extraction of the product from the crude mass. Step 4 consists of final product purification to meet the quality requirements
O OH
+ CH4 CH3 H C 3 CH3 H C 3 CH3
isophorone 3,5-dimethylphenol
ISOPHORONE REACTION RECYCLE ISOPHORONE
IMPURITY REMOVAL DISTILLATION 1
EXTRACTION
DISTILLATION 2
DISTILLATION 3
3,5 DMP PRODUCT
10) Methyl Pentadiene
Methyl Pentadiene is manufactured by the dehydration of Hexylene Glycol (HG) in presence of an acid catalyst followed by distillation to obtain the pure product. The raw material HG is charged into an agitated reactor and the acid catalyst is added. The reaction is maintained at a constant temperature by use of steam for heating. The vapors are then passed through a distillation column to collect Crude MPD at the top. The product which is collected in a decanter is washed and then fed to a distillation column where a Pure MPD product is extracted from a mixture of MPD, water and other impurities. The pure MPD is then stored in a product tank or packed as per requirements.
52 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
HO H C CH CH OH 3 CH2 2 CH CH CH H3C CH C CH3 CH + 2H2O 2 CH3 CH3
2-methylpentane-2,4-diol 4-methyl1,3-pentadiene
MPD Plant
HG REACTION ACID
TO ETP WASHING
OFF SPEC DISTILLATION H2O
MPD PRODUCT
11) Bisphenol-S Bisphenol-S is prepared by the reaction of phenol with Sulphuric Acid. Phenol is reacted with Sulphuric Acid in presence of a catalyst to form Bisphenol-S. The product is then distilled from the crude mass after washing.
OH HO OH
O 2 + H2SO4 S phenol O Bisphenol-S
53 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
CATALYST
PHENOL REACTION SULPHURIC ACID
TO ETP WASHING
OFF SPEC DISTILLATION H2O
BISPHENOL-S
12) Lubricant Additives (Hydraulic Packages/ Gear Oil Packages etc.)
Lubricant Additives used in Hydraulic & Gear Oil Packages are generally prepared by mixing of multiple grades of additives (ZDDP & Ashless additives). It is simply a blending process with addition of base oils and other additives to form packages for Hydralic Oil & Gear Oil applications 13) Sodium Dithiophosphate
Sodium Dithiophosphate is prepared by a reaction of Sodium Hydroxide with Phosphorus Pentasulphide. The process involves evolution of H2S gas in the reaction. This H2S gas is then scrubbed with Caustic soda to form Sodium Hydrogen Sulphide (NaHS). Sodium Dithiophosphate is often used in the hydrated form.
P2S5 + 6 NaOH → 2 Na3PO2S2 + H2S + 2 H2O
14) Sodium Dialkyl Dithiophosphate Manufacturing Process Sodium Diorgano-DithioPhosphate (SDDP) is manufactured in two major steps. Step 1: Synthesis Step: The synthesis of Oxo-Alcohols and Phosphorus Pentasulphide takes place to form a Di-Alkyl Dithiophosphoric Acid with release of Hydrogen Sulphide gas. In this step, the oxo-alcohols are charged into the reactor, stirred and heated. Phosphorus Pentasulphide is added to this mass with continuous stirring which results in the evolving of gases which are to be absorbed in the 2 stage caustic scrubber.
Step 2: Neutralization Step: The neutralization of the acid is carried out with Caustic Soda. Once neutralization is complete, the product mass is dried. Filter aid is added and the batch is filtered to obtain the product of desired quality. The residue is then removed from the filter in the form of solid cakes. The SDDP product is then stored, packed and dispatched as required.
54 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
SDDP Reactions:
Reaction 1: SH (95–100oC) 4 R-OH + P2S5 2(RO)2-P=S + H2S
Oxo-alcohols Phosphorus Alkyldithiophosphate Pentasulphide Acid
Reaction 2:
SH S-Na
(RO)2-P=S + NaOH (RO)2-P=S + H2O
Alkyldithiophosphate Caustic Sodium Alkyl Acid Dithiophosphate
4.51 NaOH (10%) 23.74 PPS
3.87 H2S Scrubber NaHS (30%) 8.35 Optional Draw DDP ACID PRODUCT Reaction Alcohol 39.85 60.71 To Flare 0.0387 21.99 16.00 NaOH Neutralization Base Oil
98.70
1.00 Drying Alcohol (Recovered)
97.70 Base Oil 3.00 Filter Aid 0.60 Mixing
101.30
Filtration Filter Cake 1.30 100.00
SDDP Product 100.00
15) Benzylidene Acetone
Benzylidene Acetone is manufactured by Aldol condensation of Benzaldehyde & Acetone. Benzaldehyde & Acetone are fed to a reaction system along with a catalyst to form Benzylidene Acetone along with some impurities. The reaction mass is then washed and purified to form Benzylidene Acetone product
55 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
Benzylidene Acetone
CH3C(O)CH3 + C6H5CHO C6H5CH=CHC(O)CH3 + H2O
Acetone Benzaldehyde Benzylidene Acetone Water
1.00 CATALYST
BENZALDEHYDE REACTION ACETONE
94.00 153.75 58.75
TO ETP WASHING 166.88 52.50 202.50 65.625
OFF SPEC DISTILLATION H2O 75.00 27.5 100.00 26.25
BENZYLIDENE ACETONE 100.00
16) PIBSA
PIBSA is manufactured by the reaction of PolyIsobutylene & Maleic Anhydride. Polyisobutylene in presence of catalyst reacts with Maleic Anhydride forms Polyisobutylene Succinic Acid.
17) PIBSI PIBSA on further reaction with a polyamine forms Polyisobutylene succinimide (PIBSI)
56 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
18) Phosphate Esters Phosphate Esters are produced by a synthesis of Alcohols with Phosphorus Pentoxide. Phosphorus Pentoxide is added to a Alcohol mixture where reaction takes place at predetermined temperature & pressure conditions to form Phosphate Esters with liberation or water. Different grades of Phosphate Esters can be manufactured by varying the alcohols in the Alcohol mixture of the feed.
19) Amine Phosphates Phosphate Esters when reacted with and alkyl amine form amine phosphates. It is a simple addition reaction taking place at predetermined temperature & Pressure conditions.
20) Carbazole Esters Carbazole Esters are manufactured by a reaction of Ethyl Acrylate with Carbazole. Ethyl Acrylate and Carbazole at given temperature & pressure conditions in presence of catalyst form Carbzole Esters
21) Ashless Lubricant Additive Ashless Lubricant additive is manufactured in a manner similar to ZDDP. Alcohol (e.g Ethanol) reacts with Phosphorus Pentasulphide (PPS) to form the corresponding Dithiophosphoric Acid (Dirthyl Thiophosphoric Acid). H2S gas is evolved in the process. The Acid is the reacted with Ethyl Acrylate to form a Dithiophosphate Ester. This Dithiophosphate ester on refinement and addition of base oil act as an Ashless Lubricant Additive
57 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
NaOH (10%)
PPS
H2S Scrubber NaHS (30%)
Optional Draw DDP ACID PRODUCT Reaction Alcohol To Flare
Ethyl Acrylate Synthesis Base Oil
Drying Alcohol (Recovered)
Base Oil Mixing
Ashless Additive
22) Resorcinol Resorcinol can be manufactured by various routes. We have selected the manufacture of Resorcinol by Hydroperoxidation of m-Diisopropylbenzene (m-DIPB). M-DIPB is oxidized in a bubble column reactor to form the hydroperoxide mixture containing Dihydroiperoxide (DHP, Ketohydroperxide (KHP) & Hydroxyhydroperoxide (HHP). The mixture undergoes extraction to maximize the DHP concentration. This DHP then undergoes Cleavage to form Resorcinol & Acetone. The reaction mass is then distilled to obtain pure Resorcinol & Acetone in a series of distillation columns.
58 Prefeasibility Report Prasol Chemicals Private limited, Village Honad, Dist Raigad, Maharashtra
CARBONATE VENT AIR (INERT)
DIPB AIR OXIDATION
RECYCLE DIPB DHP CONCENTRATION
WATER CLEAVAGE
TO ETP
ACETONE PRODUCT ACETONE RESORCINOL RESORCINOL PRODUCT DISTILLATION DISTILLATION
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