M/s. Chemtech Intermediates Pvt. Ltd. G.I.D.C., Nandesari, Vadodara. M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 1 CHAPTER -1 INTRODUCTION 1.1 PURPOSE OF THE REPORT AND REGULATORY FRAMEWORK M/s. Chemtech Intermediates Pvt. Ltd is already engaged in manufacturing of organic chemicals at plot C1-128/14-15, GIDC Estate, Nandesari, Dist. Vadodara, Gujarat. The Unit is having valid Consolidated Consent & Authorization (CC&A) from Gujarat Pollution Control Board vides CC&A order no.: AWH-85623 with validity up to 31/12/2021 for manufacturing of organic chemicals. Unit has granted consent before 2006 and it is attached as Annexure-I A. Now, unit has purchased new two adjoining plots for proposed expansion. The expansion will be carried out at plot C1-128/13,14,15,16 GIDC Estate, Nandesari, Dist. Vadodara, Gujarat, existing plot & new adjoining plots located in GIDC. The unit is going for expansion for range of products like pharma advanced Intermediates. The existing production quantity is 90 MT/Month of synthetic organic chemicals. The total production quantity after expansion becomes 1080 MT/Month. The details of products are given in Table no.1.1.The product proposed by the unit fall in the Schedule attached to the EIA Notification, i.e. Project No. 5(f). The purpose of this report is to: Establish a pre-project baseline with respect to environmental indicators. Identify environment related impacts Evaluate safety related risk factors associated with project Propose appropriate mitigation measures for minimizing the adverse impacts to the extent possible Suggest Environment Management Plan Recommend Risk Management Plan This report is also made in the overall frame work of the Environmental Impact Assessment (EIA) Notification dated 14 th September, 2006 (and subsequent amendments to the same) issued by the Ministry of Environment and Forests and climate change (MoEF&CC), by providing required information with regards to the project as mentioned in the Terms of Reference issued by the State Level Environment Impact Assessment Committee.
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CHAPTER -1 INTRODUCTIONenvironmentclearance.nic.in/writereaddata/EIA/23112019...M/s. Chemtech Intermediates Pvt. Ltd. G.I.D.C., Nandesari, Vadodara. M/S. JYOTI OM CHEMICAL RESEARCH
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M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 9
Main industries are petrochemicals, chemicals, fertilizer, Dyes and intermediates and
pharmaceuticals in the industrial area.
1.4 LOCATION OF THE PROJECT
Proposed expansion of project will be carried out at the existing plant C1-128/14/15 and two
new adjoining plots no. C1-128/13/16, GIDC-Estate, GIDC Nandesari and Dist. Vadodara-
391 340. The plot allotment letter from GIDC is attached as Annexure-II. It is approximately
10 km distance from Dist Vadodara. Vadodara is third largest city in the State of Gujarat and
is one of the focal point of industrial growth in western India. Numerous major, medium and
small scale industries are situated in this area. The national highway 8 connecting Nandesari
to Ahmedabad and lies approx.2.97 km NE of the site and it is well connected by rail and
road. Water is available from the GIDC water supply scheme. Mahi River, a perennial river,
flows approx. 2.45 km west of the site.
The approximate geographical positioning of the project site is at Latitude: 22°24'21.15"N,
Longitude: 73°05'47.66"E. The salient features of the location of the project site are presented
in Table no. 1.4. Layout plan of the factory premises clearly demarcating various units within
the plant. Provision of separate entry & exit and adequate margin all-round the periphery for
unobstructed easy movement of the emergency vehicle / fire tenders without reversing back
is attached as Annexure-III.
The location of project site can be identified from the location map shown in Figure no. 1.1
and Figure no.1.2.The industry is located in an area, which is already industrialized. The
industries in the vicinity of the proposed project are given in the table no-1.4.
TABLE: 1.4
NEARBY INDUSTRIES IN THE VICINITY
Name of Industry Direction w.r.tproject site
Address
Supra Combines South C-1/128/16, GIDC, Nandesari, Vadodara.Jineshwar Chemicals North C-1/128/08, GIDC, Nandesari, Vadodara.Ester India East C-1/128/29-30 GIDC, Nandesari,
Ministry of Environment, Forests & ClimateChange, CPCB and SPCB/UTPCC.
7. Hazardous & Other Wastes(Management and TransboundryMovement) Rules 2016
MoEF&CC, CPCB, SPCB/UTPCC, DGFT,Port Authority and Customs Authority.
8. Manufacture Storage and Import ofHazardous Chemicals Rules, 1989amended 2000
Ministry of Environment & Forests, ChiefController of Imports and Exports, CPCB,SPCB/UTPCC, Chief Inspector of Factories,Chief Inspector of Dock Safety, Chief Inspectorof Mines, AERB, Chief Controller ofExplosives, District Collector or DistrictEmergency Authority, CEES under DRDO.
9. Chemical Accidents (EmergencyPlanning, Preparedness andResponse) Rules, 1996
CCG, SCG, DCG, LCG and MAH Units.
10. Ozone Depleting Substances(Regulation and Control) Rules,2000
Ministry of Environment, Forests & ClimateChange.
11. EIA Notification, 2006 as amendedtimely (2009, 2011)
13. Public Liability Insurance Act,1991 amended 1992
Ministry of Environment, Forests & ClimateChange, District Collector.
14. Public Liability Insurance Rules,1991 amended 1993
Ministry of Environment, Forests & ClimateChange, District Collector.
15. Factories Act, 1948 Ministry of Labour, DGFASLI and Directorateof Industrial Safety and Health/FactoriesInspectorate.
16. The Explosives Act, 1884 Ministry of Commerce and Industry(Department of Explosives).
17. The Explosive Rules, 1983 Ministry of Commerce and Industry and ChiefController of Explosives, port conservator,customs collector, railway administration.
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Legal Instrument Concern Authority or Bodies
18. The Gas Cylinder Rules, 2004 * Ministry of Commerce and Industry and ChiefController of Explosives, port conservator,customs collector, DGCA, DC, DM, Police (subinspector to commissioner)
19. The Static and Mobile PressureVessels (Unfired) Rules, 1981
Ministry of Commerce and Industry and ChiefController of Explosives, port conservator,customs collector, DGCA, DC, DM, Police (subinspector to commissioner)
20. The Motor Vehicle Act, 1988 Ministry of Shipping, Road Transport andHighways.
21. The Central Motor Vehicle Rules,1989
Ministry of Shipping, Road Transport andHighways.
22. The Custom Act, 1962 CBEC, Ministry of Finance.(Note: * the rules are not directly applicable to the proposed project but during operation itmay be applicable timely depending up on allied operations like welding, fabrication &shipping of raw materials & products.)
1.10 STRUCTURE OF EIA REPORT
The generic structure of the EIA report, as per the guideline provided by MoEF & CC is
illustrated in the following Table no.1.7.
TABLE: 1.7STRUCTURE OF EIA REPORTSr.No.
EIA Structure Contents
1. Introduction Purpose of the report and regulatory frame work Identification of the project and project proponent Key Information of project Regulatory Frame work Scope & Objective of EIA study Structure of EIA report Terms of reference & Its Compliance
2. Project Description Condensed description of those aspects of the project (basedon project feasibility study), likely to cause environmentaleffects. Description contains the details of the following: Type of project Need for the project Location details showing general location, specific location,project boundary & project site layout) Technology and process description Project description. Including drawings showing projectlayout, components of project etc. Schematic representationsof the feasibility drawings which give information importantfor EIA purpose Description of mitigation measures incorporated into theproject to meet environmental standards,
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EIA Structure Contents
3. Description of theEnvironment
Study area, period, components & methodology Establishment of baseline for valued environmentalcomponents, as identified in the scope Base maps of all environmental components
Details of Investigated Environmental impacts due to projectlocation, possible accidents, project design, projectconstruction, regular operations, final decommissioning orrehabilitation of a completed project Measures for minimizing and / or offsetting adverse impactsidentified Irreversible and Irretrievable commitments of environmentalcomponents Assessment of significance of impacts (Criteria fordetermining significance, Assigning significance) Mitigation measures
5. Analysis ofalternatives(technology & site)
Need for alternatives with respect to technology and siteselection, give details of each alternative, summary ofadverse impact of each alternative and propose mitigationmeasures for each alternative.
6. EnvironmentalMonitoring Program
Technical aspects of environmental monitoring for theeffectiveness of mitigation measures (incl. Measurementmethodologies, frequency, location, data analysis, reportingschedules, emergency procedures, budget & procurementschedules)
7. Additional Study:Risk Assessment &DisasterManagement Plan
8. Project Benefits Detail of the Socioeconomic & other tangible benefits of theproject
9. Environmental CostBenefit Analysis
Environmental cost benefit analysis to be carried out ifrequired.
10. EnvironmentManagement Plan
Description of the administrative aspects of ensuring thatmitigation measures are implemented and their effectivenessmonitored, after approval of the EIA. The Chapter consist of: Mitigation measures for impacts Pollution Prevention Plan Greenbelt Development Plan Mangrove Management Plan Dredging management PlanWaste management planEnvironment Management CellBudgetary Provisions for EMS
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1.11 TERMS OF REFERENCE BY SEAC, GANDHINAGAR AND ITS
COMPLIANCE
TABLE: 1.8SPECIFIC TOR GIVEN BY SEAC, GANDHINAGAR
Sr.No.
Terms of Reference TOR Compliance
1. Installation of Cyanide gas emission sensor in production plantarea.
Details given in chapter-2 section no.2.3.2.3 pageno.49.
2. Segregation of cyanide bearing system from other stream of plantand specific treatment for cyanide bearing stream in ETP plant.
Details given in chapter-2, Table 2.19 on pageno.144.
3. Safety precautions for cyanide stream and cyanide compoundhandling as per PESO standards and provide antidotes for cyanidehandling in plant area.
Details given in chapter-7 section no 7.4.7 onpage no.261.
4. Isolated storage of various solvents at ground floor area. Isolated storage area forvarious solvents ismentioned in plant layoutin Block No.5. Details ofland breakup is given intable no 2.9 in chapter-2on page no.126.
5. Details with respect to justification for proposed expansion(1) To address proportionate availability of space for productionplant.(2) To address proportionate availability of storage area for rawmaterials finished goods, utilities and goods carrier movementwithin premises.(3) To address proportionate captive/common infrastructureavailable to accommodate additional load due to proposedexpansion.(4) Environment impact and its mitigation measures forcommon/captive infrastructure due to proposed production.
Details covered inchapter-2 section no.2.5.1 from page no.126to 127.
6. Compliance of MoEFCC’s OM dated 01/05/2018 regarding“Corporate Environment Responsibility” (CER). Fund allocationfor Corporate Environment Responsibility (CER) shall be made asper MoEFCC’s OM No.22-65/2017-IA. III dated 01/05/2018 forvarious activities therein. The details of fund allocation andactivities for CER shall be incorporated in EIA/EMP report.
Attached as Annexure-XIX.
7. Explore the use of renewable energy to the maximum extentpossible. Details of provisions to make the project energy-efficientthrough of energy efficient devices and adoption of modes ofalternatives eco-friendly sources of energy like solar water heater,solar lighting etc. Measures proposed for energy conservation.
Details covered inchapter-10 section no.10.4.2.1. on page no.376point no. b.
8. Qualitative & Quantitative analysis of hazardous waste streamsgeneration from the manufacturing process (Product wise). Explorethe possibility to reuse such waste streams within premises as rawmaterials for other products or to convert it into valuable productsinstead of selling outside. Sound management of such waste
No such waste streamswill be reused as rawmaterials withinpremises.
10. Address spent solvents as hazardous waste management and itsdisposal in hazardous waste matrix.
There will be nogeneration of any spentsolvents. Solvents suchas Toluene, Cyclohexane,Methanol, Chloroform,MDC, Pyridine, andDMF will be used andrecovered. It will recyclewithin premises in sameprocess. Unit willperform solvent recoverymore than 95%. Therewill be only 5%generation of residue &loss. Residue generationwill be less than 5% andwill go for co-processingfacility of NandesariEnvironment Control Ltd(NECL).
11. Leak detection and repairing Programme (LDAR) for all thevolatile organic solvent proposed for use in-house with detailedchemical properties including vapour pressure. LDAR shallendeavor prevention of losses of solvents to the best minimumextent.
Details covered inchapter-7, in section no.7.8.1 from page no. 295to 297.
12. Safety precautions including flame proof electric fittings to betaken to avoid fire hazard during unloading, storage, transportation,handling and processing of solvents.
Details covered inchapter-7, section 7.4 &7.5 from page no 254 to273.
13. Segregation of waste water streams based on characteristics and itsproper management keeping in view direction under section 18(1)(b) of the water (Presentation and control OF Pollution) act, 1974issued by CPCB dated 31/03/2016 regarding compliance of CETP
Segregation of wastewater streams is given inchapter-2, section no.2.6.1.1 on page no, 140.Compliance of CETPkeeping in view directionunder section 18(1) (b) ofthe water (Presentationand control OF Pollution)act, 1974 is attached asAnnexure-V.
14. MOU for final disposal of above mentioned solutions which aregoing to be generated as Hazardous waste as per HWR-2016, (1)
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Terms of Reference TOR Compliance
Sodium bromide, (2) Hydrobromic acid, (3) Spent nitric acid and(4) spent catalyst at the time of appraisal of Environmentalclearance.
acid is attached asAnnexure-VI.MOU for spent Nitricacid is attached asAnnexure-VII. MOU forspent catalyst is attachedas Annexure-VIII.
TABLE: 1.9TOR GIVEN BY SEAC, GANDHINAGAR
Sr.No.
Terms of Reference Section no. Covered Under
1. A tabular chart with index for point-wisecompliance of below mentioned TORs.
Details are covered in Chapter-1.
2. Executive summary of the project – giving aprima facie idea of the objectives of theproposal, use of Resources, justification, etc. Inaddition, it should provide a compilation of EIAreport, including EMP and the Post-projectmonitoring plan in brief.
Details are covered under Chapter-11from page no 388 to 398.
3. Justification for selecting the proposed productand unit size.
Details are covered under section no.1.3.1 in Chapter-1 on page no. 6.
4. Land requirement for the project including itsbreak up for various purposes, its availabilityand Optimization.
Details of Land are covered undersection no.2.5.1 of Chapter-2 frompage no. 126 to 127.
5. Land possession documents. Copy of NA ordershowing permission to use the project land forindustrial purpose. If located in GIDC, copy ofplot holding certificate obtained from GIDCAuthority.
Copy of plot holding certificate isattached as an Annexure-II.
6. Location of the project site and nearest habitatswith distances from the project site to bedemarcated on Toposheet (1: 50000 scale).
Toposheet is attached as an Annexure-IX.
7. Topography details of the project area. Details covered in chapter-3 sectionno 3.1.1 on page no 169.
8. Geological features and geo-hydrological statusof the study area.
Details are covered under section no.3.7.2 of Chapter-3 from page no.193.
9. In case of project located outside notified area:Legal Undertaking stating that unit is
This is existing unit located in GIDCNandesari. Hence undertaking is not
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complying the three conditions [i.e. waterconsumption less than 25 M3/day; Fuelconsumption less than 25 TPD; and not coveredin the category of MAH units as per theManagement, Storage, Import of HazardousChemical Rules (MSIHC Rules), 1989] as perthe amendment to EIA Notification, 2006 videSO 1599 (E) dated 25/06/2014.
applicable.
10. Present land use pattern of the study area shallbe given based on satellite imagery.
Details are covered under section no.3.7of Chapter-3 from page no 189 to192.
11. Layout plan of the factory premises clearlydemarcating various units within the plant.Provision of separate entry & exit and adequatemargin all round the periphery for unobstructedeasy movement of the emergency vehicle / firetenders without reversing back. Mark the samein the plant layout.
Plant layout is attached as anAnnexure-III.
12. Technical details of the plant/s along withdetails on best available technologies (BAT),proposed technology and reasons for selectingthe same.
Details are covered under sectionno.2.4.1of Chapter-2 on page 60.
13. Product spectrum (Proposed products alongwith production Capacity) and processes.
Details of products are given in tableno.1.1 in Chapter-1 on page no. 2.Details of process are covered undersection no.2.4.2 of Chapter-2 frompage no 60 to 125.
14. Chemical name of each proposed product to bemanufactured. Details on end use of eachproduct. (Provide CAS number of all theproducts & raw materials. In case of Dyes, CInumber).
Details are covered under table 1.1 ofChapter-1 from page no 2 to 5.
15. Details on raw materials, source and storagewithin the premises.
Details of raw materials source isgiven in chapter-2, table no. 2.8 onpage no 58 to 59.
16. Details of complete manufacturing process /operations of each product along with chemicalreactions, process flow diagram describing eachunit processes and unit operations along withmaterial balance, consumption of raw materialsetc.
Details of process are covered undersection no.2.4.2 of Chapter-2 frompage no 60 to 125.
17. Details on strategy for the implementation ofcleaner production activities.
Details are covered under section no.10.4.2. (J) Of Chapter-10 on page no371.
18. Assessment of source of the water supply withadequacy of the same to meet with therequirements for the project. Permissionobtained from the concern authority for supply
Water will be supplied by Nandesariwater & Utilities Ltd. Waterpermission letter is attached as anAnnexure-X.
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of raw water.19. Undertaking stating that no bore well shall be
dug within the premises (If project is locatedwithin the Industrial estate).
Undertaking is attached as anAnnexure-XI.
20. Details on water balance including quantity ofeffluent generated, recycled & reused. Detailsof methods to be adopted for the waterconservation.
Details are covered under section no.2.5.2 of Chapter-2 from page no 127to 130.Water conservation program iscovered under section no.10.4.2. (N)of Chapter-10 from page no 377 to378.
21. Effort to minimize effluent discharge and tomaintain quality of receiving water body.
Details covered in chapter-10, sectionno 10.4.2. (B).2 on page no. 363.
22. Explore the possibilities for Zero LiquidDischarge (ZLD) or Efforts to minimizeeffluent discharge and to maintain quality ofreceiving water body.
Due to high COD of treated effluentZLD is not practically implementable.The unit will send final treatedeffluent to CETP of NandesariIndustrial Association (NIA).Thequality of effluent will be maintainedas per inlet norms of CETP.
23. Segregation of waste streams, characterizationand quality with specific treatment and disposalof each stream including action plan formaximum recycle of treated waste water andminimum discharge for effluent
Details of waste stream are shown insection no. 2.6.1.1 in Chapter-2 onpage no. 139.
Details of characterization, quality andtreatment are given in section no.10.4.2. (B).1 in Chapter-10 from pageno 357-360.
24. Capacity of ETP in KL/day. Details of ETPincluding dimensions of each unit along withschematic flow diagram. Inlet, transitional andtreated effluent qualities with specific efficiencyof each treatment unit in reduction in respect ofall concerned/regulated environmentalparameters. Inlet effluent quality should bebased on worst case scenario consideringproduction of most polluting products that canbe manufactured in the plant concurrently.
ETP is designed for 78 KLD. Detailsof ETP are covered under sectionno.2.6.1.2 in chapter-2 from page no140-145.Worst case scenario is covered undertable 2.17 of Chapter-2 on page no135-138.
25. In case of discharge into GIDC drainage /Pipeline:1. Copy of permission letter with quantity
(KL/day) from the concern authority ofdrainage network /pipeline withconfirmation for spare capacity available totake additional effluent.
2. Characteristics of the combined effluentand treated water to be sent to Commonpipeline with reference to the
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MoEFCC/CPCB/GPCB discharge norms.3. Provision for continuous monitoring
system for waste water discharge.26. In case of waste water sent to Common
Facilities (CF) like CETP, MEE, Spray Dryeretc.a. Details of Common facilities including (1)
Total capacity of the CF (2) Copy of CC&Aof the CF. (3) Actual load at present(Qualitative and Quantitative – KL per day)(4) Booked quantity & Spare capacity of CF(5) Copies of XGN generated Inspectionreports with analysis reports of thewater/Air/Hazardous samples collected byGPCB (Last 2 year). Copies of instructionsissued by GPCB in last 2 year and pointwise compliance thereof. (6) Copies ofShow- cause notices, closure notices etc.served by the GPCB and its compliance(6)Recommendations and suggestions of thelast two Environment Audit reports ofCETP and its compliance report. (7)Common Facility Up gradation scheme, ifany.
b. Status compliance to the 18(1) (b) directionissued by the CPCB with respect tocompliance & CEPI area action plan alongwith relevant supportive document.
c. Give status of compliance of Environmentalnorms of existing Common Infrastructurei.e. CETP, MEE & Spray Dryer (Whicheveris applicable) in which you are a member.
d. Submit adequacy of Common infrastructurei.e. CETP, MEE & Spray Dryer foradditional load (Whichever is applicable)along with writtenconfirmation/membership certificatementioning the same (Total consentedquantity, total quantity booked so far,quantity booked for the unit, spare quantityavailable).
Details of CETP are attached as anAnnexure-V.
27. In case of Zero Liquid Discharge (ZLD) :1. Action plan for ‘Zero’ discharge of effluent
shall be included. Notarized undertaking forassuring that underground drainageconnection will not be taken in the unit.
2. Economical and technical viability of theeffluent treatment system to achieve Zero
Not Applicable.ZLD is not practically implementable.Quality of effluent will meet inletnorms of receiving body (CETP).
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Liquid Discharge (ZLD).3. Certification of adequacy of proposed ZLD
scheme through credible institutes ofNational repute.
4. To estimate & monitor ground water quality& its contamination status, piezometer wells,one on up gradient of the groundwater flowand other three on the down gradient side ofthe ground water flow of the proposedproject at different depth based on availableground water depth shall be established andall the parameters mentioned in IS 10:500for potable water standard shall bemonitored.
28. In case of in-house MEE for waste watertreatment: Capacity of MEE in KL/hr.Technical details of MEE including evaporationcapacity, steam required for evaporation,adequacy of the proposed boiler to supply steamfor evaporation in addition to the steam requiredfor the process etc. Techno economical viabilityof the evaporation system. Control measuresproposed for the evaporation system in order toavoid/reduce gaseous emission/VOC fromevaporation of industrial effluent containingsolvents & other chemicals.
Not applicable
29. Technical details of ATFD/Crystallizer/Dryer,RO/NF system etc. (If any).
Not Applicable.
30. Details of the treatability and feasibility ofwastewater to be disposed off means of spraydryer and its impact on environment andHuman Health.
Not Applicable.
31. Undertaking stating that a separate electricmeter will be provided for the waste watertreatment system viz.ETP, RO, MEE, Spraydryer etc. (Whichever is applicable)
Undertaking is attached as anAnnexure-XI.
32. Economical and technical viability of theeffluent treatment system.
Details are covered under section no.10.4.2 (B).3 of Chapter-10, on page no361.
33. Plans for management, collection and disposalof waste streams to be generated from spillage,leakages, vessel washing, used containerwashing etc. Measures proposed for preventingeffluent discharge during unforeseencircumstances.
All the waste streams will be collectedseparately and sent to ETP fortreatment. It will not be allow in stormwater drain. Detailed decontaminationis given under section no. 10.4.2. (B).6of Chapter-10 on page no.363.
34. Action plan for reuse of waste streams likeSpent acids, Poly Aluminium Chloride etc.within premises to convert into valuable
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products instead of sending outside to actualend-users.
35. Adequacy of the proposed EMS with respect tothe pollution load envisaged in terms of Air,Water and hazardous waste.
Details are covered in section no. 2.15of Chapter-2 on page no. 164.
36. One season Site-specific micro-meteorologicaldata using temperature, relative humidity,hourly wind speed and direction and rainfallshould be incorporated.
Details are covered under table no. 3.2of Chapter-3 on page no. 169.
37. Anticipated environmental impacts due to theproposed project/production may be evaluatedfor significance and based on correspondinglikely impacts VECs (Valued EnvironmentalComponents) may be identified. Baselinestudies may be conducted within the study areafor all the concerned/identified VECs and likelyimpacts will have to be assessed for theirmagnitude in order to identify mitigationmeasures.
Details of impact are covered undersection no. 4.2 of Chapter-4 from pageno 213 to 233.
38. One complete season base line ambient airquality data (except monsoon season) to begiven along with the dates of monitoring. Theparameters to be covered shall be in accordancewith the revised National Ambient Air QualityStandards (NAAQS) as well as project specificparameters like NH3, HCl, Cl2, HBr, VOC etc.Locations of the monitoring stations should beso decided so as to take into consideration thepre-dominant downwind direction, populationzone and sensitive receptors. There should be atleast one monitoring station in the upwinddirection. There should be at least onemonitoring station in the predominantdownwind direction at a location wheremaximum ground level concentration is likelyto occur.
Details are covered under sectionno.3.3 of Chapter-3 from page no 172to 177.
Monitoring dates are attached as anAnnexure-XX.
39. Modeling indicating the likely impact onambient air quality due to proposed activities.The details of model used and input parametersused for modeling should be provided. The airquality contours may be shown on location mapclearly indicating the location of sensitivereceptors, if any, and the habitation. The windrose showing pre-dominant wind directionshould also be indicated on the map. Impact dueto vehicular movement shall also be includedinto the prediction using suitable model. Resultsof Air dispersion modeling should be
Details are covered under section no.no 4.2.2 of Chapter-4 from page no214 to 227.
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superimposed on satellite Image / geographicalarea map.
40. Base line status of the noise environment,impact of noise on present environment due tothe project and proposed measures for noisereduction including engineering controls.
Details are covered under section no.3.5 of Chapter-3 from page no 185 to189.Details are covered under section no.no 10.4.2 (C) of Chapter-10 from pageno.
41. Specific details ofA. Process gas emission from each unit process
with its quantification.B. Air pollution Control Measures (APCM)
proposed for process gas emission.Adequacy of the air pollution controlmeasures (APCM) for process gas emissionmeasures to achieve the GPCB norms.
C. Details of the utilities required.
D. Type and quantity (MT/hr & MT/Day) offuel to be used for each utility.
E. Flue gas emission rate emission from eachutility.
F. Air Pollution Control Measures (APCM)proposed to each of the utility along with itsadequacy
G. List the project specific sources of fugitiveemission along with its quantification andproposed measures to control it.
H. Details on tail gas treatment.(If any)
A. Details are covered under table2.21 of Chapter-2 on page no147.
B. Details are covered under table2.21 on page no. 147 and figure2.6 & 2.6 of Chapter-2 from pageno
C. Details of utilities are coveredunder table no. 2.5.4 of Chapter-2on page no 131.
D. Details of fuel quantity arecovered under section no. 2.5.3 ofChapter-2 on page no 131.
E. Details are covered under table2.20 of Chapter-2 on page no 146.
F. Details are covered under table2.20 of Chapter-2 on page no 146.
G. Details are covered under table no.10.3 of Chapter-10 on page no356.
H. No such treatment.42. Provision of CEMS (Continuous Emission
Monitoring System)Undertaking is attached as anAnnexure-XI.
43. Action plan for odour control to be submitted. Details are covered under section no.10.4.2. (L) of Chapter-10 from pageno 374 to 375.
44. Management plan for solid/hazardous wasteincluding storage, handling, utilization and safedisposal as per the Hazardous and Other Wastes(Management and Transboundary Movement)Rules 2016. CPCB guidelines in respect ofspecific treatment, such as solar evaporation,incineration, etc., need to be followed.
Details are covered under section no.10.4.2. (D).2 of Chapter-10 from pageno 364 to 365.
45. How the manual handling of the hazardouswastes will be minimized? Methodology ofdecontamination and disposal of discarded
Details are covered under section no.10.4.2. (D).3 of Chapter-10 from pageno 365-366.
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containers and its record keeping.46. Management of by-products which fall under
the purview of the Hazardous and Other Wastes(Management and Transboundary Movement)Rules 2016 as per the rules and necessarypermissions from the concern authority.
Not Applicable.
47. Membership of Common EnvironmentalInfrastructure like TSDF, Common IncinerationFacility (CHWIF), MEE, Spray dryer etc.
Membership of Common TSDF isattached as an Annexure-XII.
48. Name and quantity of each type of solvents tobe used for proposed production. Details of in-house solvent recovery system including massbalance, solvent loss, recovery efficiency (%recovery), feasibility of reusing the recoveredsolvents etc. for each type of solvent.
Details of solvent storage andrecovery efficiency are given in table2.2 & 2.3 of Chapter-2 on page no 41& 42.
Details of solvent recovery system arecovered under section no. no 10.4.2.(K) of Chapter-10 from page no 371 to373.
49. Appropriate monitoring network has to bedesigned and proposed, to assess the possibleresidual impact son VECs.
Details are covered under section no.6.3 of Chapter-6 from page no 237.
50. A detailed EMP including the protection andmitigation measures for impact on humanhealth and environment as well as detailedmonitoring plan and environmentalmanagement cell proposed for implementationand monitoring of EMP. The EMP should alsoinclude the concept of waste-minimization,recycle/reuse/recover techniques, energyconservation, and natural resource conservation.Total capital cost and recurring cost/annumearmarked for environment pollution controlmeasures.
Details are covered under Chapter-10section 10.3 from page no 351 to 387.
51. Details of in-house monitoring capabilities andthe recognized agencies if proposed forconducting monitoring.
Details are covered under section no.6.4 of Chapter-6 from page no.
52. Permission from PESO, Nagpur for storage ofsolvents, other toxic chemicals, if any.
PESO licence is attached asAnnexure-XIII.
53. Occupational health impacts on the workers andmitigation measures proposed to avoid thehuman health hazards along with the personalprotective equipment to be provided. Provisionof industrial hygienist and monitoring of theoccupational injury to workers as well as impacton the workers. Plan for periodic medicalcheckup of the workers exposed. Details ofwork place ambient air quality monitoring planas per Gujarat Factories Rules.
Details are covered under section no.7.7 & 7.8 of Chapter-7 from page no285 to 294.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 27
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Terms of Reference Section no. Covered Under
54. Details on volatile organic compounds (VOCs)from the plant operations and occupationalsafety and health protection measures. Proposalfor Leak Detection and Repair (LDAR)program as per the CPCB guidelines.
Details are covered under table 10.3 ofChapter-10 from page no 356 to 357.
Details are covered under section no.7.8.1 of Chapter-7 from page no. 395to 297.
55. Risk assessment including prediction of theworst-case scenario and maximum credibleaccident scenarios should be carried out. Theworst-case scenario should take into account themaximum inventory of storage at site at anypoint of time. The risk contours should beplotted on the plant layout map clearly showingwhich of the facilities would be affected in caseof an accident taking place. Based on the same,proposed safeguard measures including On-Site/ Off-Site Emergency Plan should be provided.
Details are covered under section no.7.12 to 7.19 of Chapter-7 from pageno 302 to 321.
On-site/off-site emergency plan arecovered under section no. 7.20 ofChapter-7 from page no 322 to 337.
56. MSDS of all the products and raw materials. MSDS are attached as soft copy57. Details of hazardous characteristics and toxicity
of raw materials and products to be handled andthe control measures proposed to ensure safetyand avoid the human health impacts. This shallinclude the details of Antidotes also.
Characteristics and toxicity of rawmaterials and products are covered inannexure – XI.Antidotes are covered under table 7.8,of Chapter-7 on page no 274 to 284.
58. Details of quantity of each hazardous chemical(including solvents) to be stored, Material ofConstruction (MoC) of major hazardouschemical storage tanks, dyke details, thresholdstorage quantity as per schedules of theManufacture, Storage & Import of HazardousChemicals Rules of major hazardous chemicals,size of the biggest storage tank to be providedfor each raw material & product etc. How themanual handling of the hazardous chemicalswill be minimized?
Details are covered under table 7.2 ofChapter-7 from page no 253 to 254.
59. Details of the separate isolated storage area forflammable chemicals. Details of flame proofelectrical fittings, DCP extinguishers and othersafety measures proposed. Detailed fire controlplan for flammable substances and processesshowing hydrant pipeline network, provision ofDG Sets, fire pumps, jockey pump, toxic gasdetectors etc.
Details are covered under section no.7.9 of Chapter-7 on page no 298.
60. Submit checklist in the form of Do’s & Don’tsof preventive maintenance, strengthening ofHSE, manufacturing utility staff for safetyrelated measures.
Details are covered under section no.7.10 of Chapter-7 from page no 298 to299.
61. Specify safety precaution to be taken forChemical storage, process, and handling &
Details are covered under section no.7.5 of Chapter-7 from page no 262 to
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 28
Sr.No.
Terms of Reference Section no. Covered Under
transportation hazard. 273.62. Details on workers training before engaging
work, periodical, in-house, outside etc.Safety Training provided to allworkers as per Section 111 A of theFactories Act.
63. Details on various SOP to be prepared. Details are covered under section no.7.21 of Chapter-7 on page no 346.
64. Details on safety audit to be carried out andtheir compliance status.
Safety Audit conducted on 10.02.2018and compliance report is attached asAnnexure-XIV.
65. Specific safety measures to be taken for generalPublic living in the vicinity.
Safety Manual prepared as per rule41(B) & 41(C) and distributed to allthe nearby employees.
66. Details on hazardous identification i.e. HAZOP,HAZAN, Fault tree analysis, Event treeanalysis, Checklist, Audit etc. to be adopted forthe safety operation of the plant.
Details are covered under section no.7.5.5 of Chapter-7 from page no 274.
67. Detection and monitoring if VOC’s / gases. Details are covered under table 6.2 ofChapter-6 from page no 239 to 242.
68. Detailed five year greenbelt developmentprogram including annual budget, planningschedule, species, width of plantations, numberof trees to be planted, area under green beltdevelopment [with map],budgetary outlay etc.along with commitment of the management tocarry out the tree plantation activities outsidethe premises at appropriate places in the nearbyareas and elsewhere.
Details are covered under section no.10.4.2. (F) of Chapter-10 from pageno 368 to 369.
69. Action plan for the greenbelt development –species, width of plantations, planningschedule, etc., in accordance to CPCBpublished guidelines
Details are covered under section no.10.4.2. (F) of Chapter-10 from pageno 368 to 369.
70. Detailed socio-economic development measuresincluding community welfare program mostuseful in the project area for the overallimprovement of the environment. Submit adetailed plan for social corporateresponsibilities, with appropriate budgetaryprovisions for the next five years and activitiesproposed to be carried out; specific to thecurrent demographic status of the area.
Details are covered under Chapter-8from page no.
71. (a) Does the company have a well laid downEnvironment Policy approved by its Board ofDirectors? If so, it may be detailed in the EIAreport.(b). Does the Environment Policy prescribe forstandard operating process / procedures to bringinto focus any infringement / deviation /violation of the environmental or forest norms /
Environment and quality policy isattached as an Annexure-XV.
Details are covered under section no.10.3 of Chapter-10 from page no 351to 353.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 29
Sr.No.
Terms of Reference Section no. Covered Under
conditions ? If so, it may be detailed in the EIA.72. What is the hierarchical system or
administrative order of the company to dealwith the environmental issues and for ensuringcompliance with the EC conditions. Details ofthis system may be given.
Details are covered under section no.10.3 of Chapter-10 from page no 351to 353.
73. Does the company have a system of reportingof non compliances / violations ofenvironmental norms to the Board of Directorsof the company and / or shareholders orstakeholders at large? This reportingmechanism should be detailed in the EIAReport.
Details are covered under section no.10.3 of Chapter-10 from page no 351to 353.
74. Phase wise project implementation schedulewith bar chart and time frame, in terms of sitedevelopment, infrastructure provision, EMSimplementation etc.
Details are covered under section no.10.6 of Chapter-10 from page no 386to 387.
75. Certificate of accreditation issued by theNABET, QCI to the environmental consultantshould be incorporated in the EIA Report.
High court stay order is attached as anAnnexure-XVI.
76. An undertaking by the Project Proponent on theownership of the EIA report as per theMoEF&CC OM dated 05/10/2011 and anundertaking by the Consultant regarding theprescribed TORs have been complied with andthe data submitted is factually correct as per theMoEF&CC OM dated 04/08/2009.
Under taking by project proponent isattached as an Annexure-XI.
Under taking by consultant is attachedas an Annexure-XVII.
77. All documents to be properly referenced withindex and continuous page numbering.
Noted and complied
78. Where data are presented in the Reportespecially in Tables, the period in which thedata were collected and the sources should beindicated.
Noted and complied
79. Project Proponent shall enclose all the analysis/testing report of water, air, soil, noise etc. usingthe MoEF& CC/NABL accredited laboratories.All the original analysis/testing reports shouldbe available during appraisal of the Project.
Nil
80. In case of Expansion of the projecta. Need for the proposed expansion should be
justified in detail.b. Adequacy of existing EMS (Environment
Management System).c. Explore the possibility to achieve Zero
Liquid Discharge (ZLD) for existing as wellas proposed activity.
d. Records of any legal breach ofEnvironmental laws i.e. details of show-
a. Details are covered under sectionno. 2.2 of Chapter-2 on page no32.
b. Details of are given in section no.2.15 of chapter-2 on page no 164to 165.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 30
Sr.No.
Terms of Reference Section no. Covered Under
cause notices, closure notices etc. served bythe GPCB to the existing unit in last fiveyear and compliance of its point wisecompliance report.
e. Copies of Environmental Clearancesobtained for the existing plant, its point wisecompliance report.
f. Environmental audit reports for last 3 yearsand compliance of itsrecommendations/Suggestions.
g. Copy of Consent to Operate (CC&A)obtained along with point wise compliancestatus of all the conditions stipulatedtherein.
h. Compliance of MoEFCC circulars vide No:J-11011/618/2010-IAII (I) dated 30/05/2012and J-11013/41/2006-IA-II(I) dated20/10/2009.
i. Copies of XGN generated Inspection reportswith analysis reports of thewater/Air/Hazardous samples collected byGPCB (Last 2 year). Copies of instructionsissued by GPCB in last 2 year and pointwise compliance thereof.
d. Details of Show cause notices,closure etc and their reply aregiven in table no. 10.17 ofchapter-10 on page no 381.
e. Not Applicable
f. Not Applicable
g. Copy of CCA and compliance areattached as an Annexure-I.
h. Not Applicable
i. Nil
81. In case of project is located in Ankleshwar-Panoli, Vatva -Narol & Vapi GIDC.(A) Compliance of MOEFCC’s OM no. J-11013/5/2010-IA.II (I) dated 25/11/2016regarding lifting of moratorium on theconsideration of projects for environmentalclearance.(B) Compliance of direction under section 18(1) (b) of the Water (Prevention and Control ofPollution)act, 1974 issued by CPCB dated31/03/2016 regarding compliance of CETP.a) Action initiated by GPCB, if any, againstproposed unit regarding non-compliance ofprescribed standards under the variousenvironmental laws.b) Performance of CETP with respect to currenthydraulic load& prescribed standards with NoObjection Certificate of CETP regardingincorporation of the proposed unit foracceptance of waste water.c) Performance of TSDF site with respect tocurrent load& prescribed standards with NoObjection Certificate of TSDF site regardingincorporation of the proposed unit for
Proposed expansion will be carried outin GIDC Nandesari.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 31
Sr.No.
Terms of Reference Section no. Covered Under
acceptance of hazardous waste to the commoninfrastructure.d) Copies of quarterly action report taken forthe above points submitted to the CPCB.e) Report of GPCB which have conductedmonitoring as per the said direction by CPCBdated31/03/2016.
*Unit shall not be manufacturing more than fifteen products at a time.*This is a worst case scenario. If these products are manufactured only those raw materialswill be stored at site.
2.3.2.1 MANAGEMENT PLAN FOR SOLVENTS WITH DETAILS OF STORAGE,HANDLING AND RE-USE:
For storage of the solvents, storage drums are provided. The storage drums area installed
within flammable liquid storage yard.
At Storage drums area following measures are taken to minimize the vapour loss.1. FLP (Flameproof) type light fittings will be provided.2. Proper ventilation will be available in Drum storage area.3. Proper label and identification board /stickers will be provided in the storage area.4. Conductive drum pallets are provided.5. Drum handling trolley / stackers/fork lift are used for drum handling.6. Separate dispensing room with local exhaust and static earthing provision will beavailable.7. Materials are stored as per its compatibility study and separate area will be
available for flammable, corrosive and toxic chemical drums storage.8. Smoking and other spark, flame generating item are banned from the Gate.9. NFPA (National Fire Protection Association) labels are provided on drums forhazard identification of the chemicals.10. Exhaust will be provided at ground level in drum storage area.11.Drum loading unloading procedures are prepared and implemented.
*Unit will not be manufacture more than fifteen products at a time.*This is a worst case scenario. If these products are manufactured only those raw materialswill be stored at site.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 49
2.3.2.3 INSTALLATION OF CYANIDE GAS EMISSION SENSOR IN PRODUCTION PLANTAREA.
Cyanide streamline are kept separate. For safety point of view, separate dissolution reactor throughpump-line addition tank is provided. We have provided personal protective safety suit and three antidotekit to three shifts. Our team is working under safety guidelines of production in-charge and maintainingregister as per PESO system. Photographs of dissolving tank, safety suit & antidote kits are as givenbelow.IMAGE: 2.1CYANIDE GAS EMISSION SENSOR
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 50
Physical & Chemical Property / Characteristics of Product & Raw Materials:The Characteristics of Product & Raw materials is given in below Table.TABLE: 2.6
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 59
28 Methyl Cyanoaceate Imported By Road
29 Liqour Ammonia (25%) Surat / Mysor Ammoina By Road
30 Cyclohexane Fresh GSFC By Road
31 Cyanoacetic Acid Imported By Road
32 2-Ethyl Hexanol Imported By Road
33 Meyhylene Chloride GACL By Road
34 Catalyst Amine Amines & Plasticisers By Road
36 sodium hypochloride GACL By Road
37 N N dimethylformamide Imported By Road
38 Hydrobromic acid Dwarkesh/Fulk International By Road
41 Bromine Dwarkesh/Fulk International By Road
42 Para formaldehyde Simaline Chemicals By Road
45 Sodium Bicarbonate Unique Enterprise By Road
46 Cuprous chloride Ratna Nico chem By Road
49 Carbon Anand Carbon By Road
53 Vaniline Rohdia By Road
562,5-dimethyl phenylacetonitrile
Chemtech By Road
57 Sulfuric acid Panoli intermediates By Road
59 alpha-napthyl acetonitrile Sabri/Chem tech By Road
61 Hydrogen gas Inox By Road
62 2 chloro benzyl cyanide Chemtech/Imported By Road
63 4chloro benzyl cyanide Chemtech/Imported By Road
641- [cyano-4-(methoxyphenyl)-methyl]cyclohexanol
Interpharmachem By Road
65 Ethyl alcohol Andhra Sugars By Road
66 Phenyl ethyl alcohol Kedac Chemicals By Road
67 Chloroform GACL By Road
68 veratrol Camline Ltd. By Road
69 1-2 diethoxy benzene Solvey Speciality Chemicals By Road
70 p-xylene Reliance Ltd. By Road
71 Potassium cyanide Imported By Road
73 o- chloro benzoic acid Chemcrux/Imported By Road
74 4 -chloro benzoic acid Chemcrux/Imported By Road
*Unit shall not be manufacturing more than fifteen products at a time.*This is a worst case scenario. If these products are manufactured only those raw materials
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 60
2.4 PROCESS DESCRIPTION
2.4.1 BEST AVAILABLE TEHCNOLOGY SELECATION
The unit will adopt latest and best technology available so far in the market. Moreover, the
unit is very conscious about the product quality and equally about the environmental
protection and resource conservation; and hence they put their efforts for replacing/upgrading
their plant and machineries from time to time with the best available technology. The unit’s
processes are efficient and are tailor made to reduce the effluent as well as are based on green
chemistry wherever possible. Sustainable Competitive Advantage in the bulk Drug industry
can be attained mainly by way of continuous product & process innovations. The atom
economy will be achieved. The average percentage of yield obtained will be more than 98%.
Only Stoichiometric amount of raw materials will be used. The process control steps will be
introduced to check the full conversion of main raw materials.
2.4.2 PRODUCT MANUFACTURING PROCESS
Details of manufacturing process & Chemical Reaction & Material balance:
Group: A
1. Phenyl Acetonitrile :
Process Description:
The Benzyl chloride and Sodium Cyanide are taken into reactor and reacted in presence ofwater. Then reacted mass is separated from aqueous layer & wash with water. The crudeproduct distilled to get pure product phenyl Acetonitrile.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 61
Material Balance:
2. 4- Methoxy Phenyl acetonitrile :
Process Description:
p- anisyl alcohol reacted with concentrated hydrochloric Acid in glass lined reactor give p –anisyl chloride. The product extracted with toluene and Toluene layer cyanated by sodiumcyanide solution using phase transfer catalyst gives 4–Methoxy Phenyl Acetonitrile. Thetoluene layer separated washed with water. The toluene distilled and reused in next batch.The final product distilled under vacuum gives pure product.
Chemical Reaction:
ReactorCompound Qty (KGS) Compound Qty (KGS)Benzylchloride 114 Reaction Mass 105DM Water 140 Efluent 195.5Sodium Cyanide 44.5TEA 1Sodium Carbonate 1Total 300.5 Total 300.5
Compound Qty (KGS) Compound Qty (KGS)Reaction Mass 105 Reaction Mass 105DM Water 50 Effluent 50Total 155 Total 155
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 64
Process Description:
2-chloro benzyl chloride is reacted with sodium cyanide in presence of water make crude 2-chloro Benzyl Cyanide. The crude product separated from aqueous layer & washed withwater. The pure product obtained by high vacuum distillation.
Chemical Reaction:
CH2Cl
Cl
2-CHLORO BENZYL CHLORIDE M.W.161
+
CH2CN
Cl
2-CHLORO PHENYLACETONITRILE M.W.151.5
+NaCl
SODIUM CHLORIDE M.W58.5
NaCNSODIUM CYANIDE
M.W.49
Material Balance:
4. 4- Chlorophenyl Acetonitrile:
Process description:
4-chloro benzyl chloride is reacted with sodium cyanide in presence of water make crude 4-chloro Benzyl Cyanide. The crude product separated from aqueous layer & washed withwater. The pure product obtained by high vacuum distillation.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 65
Chemical Reaction:
CH2Cl
Cl
+
4-CHLORO BENZYL CHLORIDE M.W.161
Cl
CH2CN
4-CHLORO PHENYLACETONITRILE M.W.151.593
+ NaClSODIUM CHLORIDE M.W58.5
NaCNSODIUM CYANIDE
M.W.49
Material Balance:
5. 2-4 –Dichloro Phenyl acetonitrile :
Process Description:
2-4 Di chloro Benzyl Chloride is reacted with sodium cyanide in presence of water givescrude 2-4 Di chloro Benzyl Cyanide. The crude product separated from aqueous layer &washed with water. The crude product distilled under vacuum gives pure product.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 67
GROUP ( B ) ACIDS
1. Phenylacetic Acid :
Process Description:
The pure Phenyl aceto nitrile is reacted with sulphuric Acid in presence of water to makephenyl acetic Acid. The crude product layer separated and distilled to get pure phenyl AceticAcid. Flaking is done with the flaker to get phenyl Acetic Acid chips.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 68
Process Description:
4- Methoxy Phenyl acetonitrile hydrolysed by sodium hydroxide in water under reflex gives,solution of sodium salt and 4-Methoxy Phenyl acetic Acid. (The Ammonia gas evolvedscrubbed in water and dilute solution which we make adjustment of pH of sulphuric acid usedin phenyl acetic acid. Finally we make ammonium sulphate Crystals and sale. ) The sodiumsalt and product salt solution treated with carbon filtered and Acidify in glass Lined reactorgives 4-Methoxy phenyl acetic Acid. The solid material centrifugal and dry. The motherliquor goes to ETP plant.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 70
Process Description:
2- Chloro phenyl Acetonitrile hydrolysed by sodium hydroxide in water under reflux givessolution of sodium salt of 2 – chloro phenyl acetic Acid.
The sodium salt of product solution treated with carbon filtered and treated with acid in glasslined reactor gives 2 – chloro phenyl acetic Acid. The solid product centrifugal and dry. Themother liquor goes to ETP plant.
The ammonia gas evolved during reaction scrubbed in to water dilute ammonium solution.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 72
Process Description:
4 Chloro phenyl Acetonitrile hydrolysed by sodium hydroxide in water under reflux givessolution of sodium salt of 4–Chloro phenyl acetic Acid.
The sodium salt product solution treated with carbon filtered and acidify in glass lined reactorgives 4 –Chloro phenyl acetic Acid. The solid product centrifuge and dry. The mother liquorgoes to ETP plant.The ammonia gas evolved during reaction scrubbed into water dilute ammonium solution.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 74
Process Description:
2-4 Di chloro phenyl acetonitrile hydrolysed by sodium hydroxide in water under reflux givessolution of sodium salt of 2-4 –Di chloro phenyl acetic Acid.
The sodium salt of product treated with carbon, filtered and treated with acid in glass linedreactor gives 2-4 –di chloro phenyl acetic acid. The solid product centrifuge and dry.Themother liquor goes to ETP.
The ammonia gas evolved during reaction scrubbed in to water dilute ammonium solution.
Chemical Reaction:
CH2CN
Cl
CI
+WaterNaoH
Sodium Hydroxide M.W. 40
CH2COONa
Cl
CI
+ NH3Ammonia M.W.17
2,4-DICHLORO BENZYL CYANIDE M.W.186
2.4-DICHLORO PHENYLACETIC ACIDSODIUM SALT M.W. 227
CH2COONa
Cl
CI2.4-DICHLORO PHENYLACETIC ACIDSODIUM SALT M.W. 227
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 75
6. 3,4 Di methoxy phenyl acetic Acid:
Process Description:
3, 4-dimethoxyphenylacetonitrile hydrolysed by sodium hydroxide in water under refluxgives solution of sodium salt of 3-4 – Di methoxy phenyl acetic Acid.
The sodium salt product solution treated with carbon, filtered and acidify in glass linedreactor gives 3-4 Di methoxy phenyl acetic Acid. The solid product centrifuge and dry. Themother liquor goes to ETP plant. The ammonia gas evolved during reaction scrubbed in towater dilute ammonium solution.
Chemical Reaction:
ReactorCompound Qty (KGS) Compound Qty (KGS)2,4-DichloroPhenylacetonitrile 94 Reaction Mass 238
48% Aq. NaOH 65Ammonium SulfateSolution 40 %
100
DM Water 87Sulfuric acid (Scrubber) 32Water For Scrubber 60Total 338 Total 338
Compound Qty (KGS) Compound Qty (KGS)Reaction Mass 238 Wet Product 115Carbon 2 Carbon 3Aq. HCl (28%) 100 Effluent 272DM Water 50Total 390 Total 390
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 78
7. 3,4-Diethoxy phenyl acetic Acid:
Process Description:
3-4 di ethoxy phenyl aceto nitrile hydrolysed by sodium hydroxide in water under refax givessolution of sodium salt of 3-4 – Di ethoxy phenyl acetic Acid.
The sodium salt of product solution treated with carbon, filtered and acidify in glass linedreactor gives 3-4 Di methoxy phenyl acetic Acid. The solid product centrifuge and dry. Themother liquor goes to ETP plant.
The ammonia gas evolved in hydrolysed stage scrubbed in dilute sulphuric Acid givesammonium sulphate solution.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 80
8. 2,5–Dimethyl Phenyl acetic Acid:
Process Description:
2, 5-dimethylphenylacetonitrile hydrolysed by sodium hydroxide in water under refax givessolution of sodium salt of 2,5-dimethylphenylacetic acid.
The sodium salt product solution treated with carbon, filtered and acidify in glass linedreactor gives 2, 5-dimethylphenylacetic acid. The solid product centrifuge and dry. Themother liquor goes to ETP plant.
The ammonia gas evolved in hydrolysed stage scrubbed in dilute sulphuric Acid givesammonium sulphate solution.
Chemical Reaction:
CH2CN
+WaterNaoH
Sodium Hydroxide M.W. 40
CH2COONa
+ NH3Ammonia M.W.17
2,5-DMETHYL BENZYL CYANIDE M.W.145
2.5-DIMETHYL PHENYLACETIC ACIDSODIUM SALT M.W. 186
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 83
Group (C) CYANOACETIC AICD DERIVATIVES
1. Methyl Cyano acetate :
Process Description: -
Methyl Chloro acetate reacted with Sodium Cynamide solution in water along with phaseTransfer catalyst gives methyl Cyano acetate. Product layer separated & distilled to give thepure product.
Chemical Reaction:
CLCH2COOCH3 + NaCN = CNCH2COOCH3 + NaCl
M.W.108.5 M.W. 49 M.W.99 M.W.58.5
Material balance:
ReactorCompound Qty (KGS) Compound Qty (KGS)Methyl Chloroacetate 118 Reaction Mass 104Sodium Cyanide 50 Effuent 224DM Water 160
Total 328 Total 328
Compound Qty (KGS) Compound Qty (KGS)Reaction Mass 104 Reaction Mass 104Water 50 Effluent 50
Total 154 Total 154
Compound Qty (KGS) Compound Qty (KGS)Reaction Mass 104 Product 100
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 84
2 Ethyl cyano acetate:
Process Description:
Ethyl cyano acetate reacted with sodium cyanide in water as media along with phase transfercatalyst gives crude product crude product layer separated from aq. Layer and washed withwater. The crude product distilled to give pure product.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 85
3. Cyano acetamide:
Process Description: -
Methyl cyano acetate reacted with 25 % ammonia solution gives cyano acetamide.Centrifuge the product and wash the cake with chilled methanol dry the product.Collect the mother liquor for methanol recovery.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 86
1. Octorylene:-
Process Description: -
In 1st step ester formed by the condensation of a Cyanoacetic acid with 2-ethylhexanol inpresence of PTSA as catalyst, which is worked up & fractionally distilled to get pure 2-Ehtyhexyl cyanoacetate (2-EHCA). In 2nd step 2-Ethylhexyl cyanoacetate (2-EHCA),Benzophenone (BP), ammonium acetate,acetic acid and Cyclohexane are mixed. The mixtureis heated under stirring to reflux temperature andwater is distilled out azeotropically. Thereaction mass is cooled and worked up. Crude product is fractionally distilled to get pureOctacrylene.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 88
2. N-N Di ethyl amino cyano acetoamide:
Process Description: -
Chloro acetyl chloride reacted first with Di ethyl amine in presence of sodium carbonate intoluene as solvent gives di ethyl amino chloro acetamide intermediates product. Intermediatesproduct reacted with sodium cyanide in water and phase transfer catalyst gives N-N-DiethylCyano acetamide. The solvent toluene distilled & reused. Finally product purified by highvaccune distillation.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 89
Material balance:
ReactorCompound Qty (KGS) Compound Qty (KGS)Fresh Toluene 30 Reaction Mass 513Recovered Toluene 370 vapour loss 8 chloroacetylChloride 86 effulent 136 Diethylamine 58 Carbon Dioxide 35Sodium Carbonate 68DM WATER 80Total 692 Total 692
Compound Qty (KGS) Compound Qty (KGS)Reaction Mass 513 Reaction Mass 495DM Water 103 Effluent 160hypo 5 vapour loss 6Sodium Cyanide 40Total 661 Total 661
Compound Qty (KGS) Compound Qty (KGS)Reaction Mass 495 Product Pure 109
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 90
Group (D) AMINES
1. Phenyl ethyl amine
Process Description: -
Benzyl cyanide is treated with hydrogen under pressure in presence of Raney Nickle ascatalyst in methanol as solvent gives Phenyl ethyl amine. The catalyst is filtered and solventdistilled get crude product. The crude Phenyl Ethyl amine distilled to give pure Phenylethylamine.
Chemical Reaction:-
CH2CN
+
PHENYL ACETONITRILE M.W. 117
H2HydrogenM.W. 2
METHANOL
Raney Nickle
CH2CH2NH2
PHENYETHYLAMINE M.W. 121
Material balance:
ReactorCompound Qty (KGS) Compound Qty (KGS)Benzyl Cyanide 107 Reaction Mass 488.4Methanol fresh 38 Raney Nickel recocered 0.6Methanol Recoverd 362 vapour loss 20Raney Nickel 0.6Ammonia 0.3Hydrogen Gas 1.1
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 91
2. 4-Methoxy Phenyl ethyl amine:-
Process Description: -
Benzyl cyanide is treated with hydrogen under pressure in presence of Raney Nickle ascatalyst in methanol as solvent gives Phenyl ethyl amine. The catalyst is filtered and solventdistilled get crude product. The crude Phenyl Ethyl amine distilled to give pure Phenyl ethylamine.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 92
3. 2 – Cyclohexenyl Ethylamine :-
Process Description: -
p-Methoxyphenylacetic Acid is reacted Thionyl Chloride and this intermediate further reactorwith 2- ( 1 – cyclohexenyl) ethylamine and reacted mass crystallized in solvent to obtainrequired product.
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4. 3,4- Di methoxy Phenyl amine:-
Process Description: -
3,4-Dimethoxy Phenyl aceto nitrile reduces by hydrogen in presence of catalyst Ammonia inMethanol. 3,4-Diethoxy phenyl ethyl amine is isolated by filtration & high vacuumDistillation and recovered catalyst & solvent recycled.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 95
5. 3-4 Di ethoxy Phenyl ethyl amine:-
Process Description: -
3, 4-Di ethoxy Phenyl acetonitrile reduces by hydrogen in presence of catalyst Ammonia inMethanol. 3,4-Diethoxy phenyl ethylamine is isolated by filtration & high vacuumDistillation and recovered catalyst & solvent recycled.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 96
6. 2-Chloro phenylethylamine :-
Process description:
2 Chloro benzyl Cyanide is reacted under pressure with hydrogen in autoclave in presence ofRaney nickel catalyst to produce 2 Chloro phenyl ethyl amine. Crude product distilled givepure product.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 97
7. 4 – Chloro Phenyl ethyl amine:-
Process description:-
4-Chlorobenzyl Cyanide is reacted under pressure with hydrogen in autoclave in presence ofRaney nickel catalyst to produce 4-Chlorophenylethyl amine. Crude product distilled givepure product.
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Process Description:-
Phenylethylalcohol & phenyl acetic acid reacted in toluene media using PTSA. To removewater azeotropically gives product. The toluene distilled & reused. Finally product distilledunder vaccume.
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1. 3,4–Di methoxy Phenyl acetonitrile:
Process Description:
1,2-Dimethoxy Benzene taken in chloroform and treated with para-formaldehyde andhydrochloric acid gives 3-4 Di methoxy Benzyl chloride. The water acid layer separated fromorganic layer. Organic layer washed with water and treated with sodium cyanide in waterusing phase transfer catalyst give 3-4 Di methoxy Benzyl cyanide.
The chloroform distilled and reused obtained crude product. The Crude product purified byhigh vacuum distilled gives pure product.
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Process Description:
1,2-Diethoxy Benzene taken in chloroform and treated with para-formaldehyde andhydrochloric acid gives 3-4 Di ethoxy Benzyl chloride. The water acid layer separated fromorganic layer. Organic layer washed with water and treated with sodium cyanide in waterusing phase transfer catalyst give 3-4 Di ethoxy Benzyl cyanide. The chloroform distilled andreused obtained crude product. The Crude product purified by high vacuum distilled givespure product.
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Process Description:
p- Xylene reacted with Para-formaldehyde in presence of Hydrochloric acid gives 2-5 –Dimethyl benzyl chloride. The water acid layer separated from organic layer. Organic layerseparated from acid layer. Organic layer reacted with sodium cyanide in water using phasetransfer catalyst gives 2- 5- Dimethyl phenyl acetonitrile. The solvent p-Xylene remove andfinal product distilled under vacuum gives pure product.
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Process Description:
Refined naphthalene and paraformaldelyde is reacted with hydrochloric Acid produce Alpha–Chloro methyl napthalene.
The Chloro methyl napthalene reacted with sodium cyanide in water gives alpha- Napthylacetonitrile. The crude product separated from water & purified by high vacuum distillation.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 110
Group (G) MIS PRODUCTS
1. 2,3-Di Chloro Benzoyl Cyanide:
Process Description:
In a clean and dry reactor charged Toluene and cuprous cyanide and reflux to remove watercontent if any. Cooled to room temperature then 2, 3 Di Chloro Benzoyl Chloride and Tetrabutyl Ammonium bromide is added and heated to the reflux temperature.
Maintain at temperature for several hrs. After completion of reaction, cool the reaction massto room temperature. Filtered the solid cuprous chloride and the filtrate containing product istaken for distillation assembly. Distilled all Toluene under vacuum completely. Then Distillout product under high vacuum. The product is purified using hexane. Product was filtered,suck dry.
Cuprous cyanide Recovery Process:
Cuprous chloride reacted with sodium cyanide in presence of water gives cuprous cyanide.The product filtered and washed with water.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 110
Group (G) MIS PRODUCTS
1. 2,3-Di Chloro Benzoyl Cyanide:
Process Description:
In a clean and dry reactor charged Toluene and cuprous cyanide and reflux to remove watercontent if any. Cooled to room temperature then 2, 3 Di Chloro Benzoyl Chloride and Tetrabutyl Ammonium bromide is added and heated to the reflux temperature.
Maintain at temperature for several hrs. After completion of reaction, cool the reaction massto room temperature. Filtered the solid cuprous chloride and the filtrate containing product istaken for distillation assembly. Distilled all Toluene under vacuum completely. Then Distillout product under high vacuum. The product is purified using hexane. Product was filtered,suck dry.
Cuprous cyanide Recovery Process:
Cuprous chloride reacted with sodium cyanide in presence of water gives cuprous cyanide.The product filtered and washed with water.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 110
Group (G) MIS PRODUCTS
1. 2,3-Di Chloro Benzoyl Cyanide:
Process Description:
In a clean and dry reactor charged Toluene and cuprous cyanide and reflux to remove watercontent if any. Cooled to room temperature then 2, 3 Di Chloro Benzoyl Chloride and Tetrabutyl Ammonium bromide is added and heated to the reflux temperature.
Maintain at temperature for several hrs. After completion of reaction, cool the reaction massto room temperature. Filtered the solid cuprous chloride and the filtrate containing product istaken for distillation assembly. Distilled all Toluene under vacuum completely. Then Distillout product under high vacuum. The product is purified using hexane. Product was filtered,suck dry.
Cuprous cyanide Recovery Process:
Cuprous chloride reacted with sodium cyanide in presence of water gives cuprous cyanide.The product filtered and washed with water.
In a reactor prepare a 70% Sulphuric acid solution v/v by diluting with water stir well, nowcharge amino guanidine bicarbonate slowly and in portion, during this time lots of frothingoccur stir well to get clear solution. Now add solid 2,3 Di Chloro Benzoyl cyanide slowly.The suspension is stirred at 40-45�C for several hrs. After completion of reaction sulphatesalt product is filtered washed well with D.M. Water to removed excess of Sulphuric acidsucked well & proceed further. Transfer above wet cake into another reactor add D.M. Waterstart stirring to get homogeneous mass. Now, carefully bring pH 7-7.5 with the help of liquorammonia or caustic soda, stirred well to get uniform pH filtered the mass, sucked dry well.Dry the product.
In the clean dry reactor, charge 2-Cyanoacetamide followed by D. M. Water and addIsoValeraldehyde and stir till completion of reaction. Add Sulphuric acid, heat the reactionmass to reflux. Cool, Extract with toluene and separate Toluene layer. Distill out Toluene toget 3-Isobutylglutaric acid. In the clean dry reactor charge 3-Isobutylglutaric acid followedby Ammonium Carbamide, heat the reaction mass and stir. Add D.M. Water and filter thesolid product. In a clean dry reactor charge wet product followed by D.M. Water, Causticsoda lye & Activated carbon and heat. Filter the reaction mass and collect the filtrate. Add
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 114
Hydrochloric acid in to the filtrate and stir. Cool and filter the reaction mass to get wetproduct. Dry the product to get (±)-3-(Carbamoyl methyl)-5-methyl Hexanoic acid.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 117
Material Balance:
5. 3,4-DihydroxyBenzaldehydeProcess Description:
Vaniline reacted with nitric Acid in MDC as solvent gives 4-Hydroxy- 3- methoxy-benzaldebyde. The 4-Hydroxy- 3- methoxy-benzaldebyde.byAlluminium Chloride inpresence of pyridine catalyst gives 3-4-Dihydroxy-benzaldelyde crude product. The crudeproduct purified by methanol solvent gives pure product.
Charge nitric Acid 100 % 2000 kg and OCBA 1000 KG IN SS Reactor and start pumpcaustic solution for circulation and start blower and water circulation start heating temp 60 cto 65 c. for 8 hrs and then cool it to 40 c Add water 2000 kg and start stirring for 2 hrs. Andfilter it in nutch filter and collect wet cake and wash with water. Mother liquor will use innext batch and wet cake dry and packing in 50 kg. bags.
Cyanohexanone& 4 – methoxy phenyl acetonitrile reacted in alkaline medium in water givescrude product. Product centrifuge and washed with water and purified by recyclatization fromtoluene gives pure product.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 120
Chemical Reaction
Material Balance:
8. 4 – Bromo Phenyl Acetic Acid:
Process Description:
4-bromo toluene reacted with bromine in water media give 4-bromo benzyl bromide. 4-Bromo benzyl bromide is reacted with sodium cyanide to make 4 – Bromo benzyl cyanide. 4-Bromo benzyl cyanide is then hydrolyzed with caustic to make 4 – Bromo phenyl aceticAcid.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 123
9. 4 – Cyano Benzoic Acid:
To the stirred solution of 4- Chloro benzoic acid in DMF was added catalytically amount ofpotassium iodine and sodium cyanide under reflux for completion of reaction. Recover theDMF and add water. Filter the product, wash with water. Purified product from withcyclohexane centrifuge and cylo hexane recover from the filtrate.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 126
2.5 RESOURCE REQUIREMENT
2.5.1 INFRASTRUCTURE FACILITIES (LAND)
The unit is located at Plot No. C1-128/13/14/15/16, GIDC Estate, Nandesari, Dist-Vadodara-391340. The GIDC plot allotment document is attached as Annexure-II. The total plot area ofthe unit is 3096.85 Sq. m. Inside green belt area will be 681.21 Sq. m. is approximately 22 %of total plant area. Unit will provide greenbelt of 774.21 Sq. meter outside the premises isapproximately (25 %). The letter for the same is attached as Annexure-XVIII. The existingplant area is 1480 sq. m. and unit has proposed additional plant area for expansion 1616.85sq. m., separate entry & exit and adequate margin all-round the periphery for unobstructedeasy movement of the emergency vehicle / fire tenders without reversing back is also takencare.
ADEQUACY OF THE PROPOSED AREA
A. To address proportionate availability of space for production plant.
Unit has purchased new two adjoining plots nos. 128/13 & 16 for proposedexpansion.
Plot No. 128/13 have 876.85 sq. m of land and plot No. 128/16 have 740 sq. m ofland.
The total production capacity will be 1080 MT/month. Products will be manufacturedon campaign basis and at a time not more than 15 products will be manufactured. Rawmaterials will only be purchased as per requirement of the production campaigns. Theproduction area is divided into two blocks-plant building 1 and plant building 2, withground floor plus 2 floors of construction. Reactors installed on 1st, and 2nd floor ofboth blocks.
8-10 reactors on each floor of plant building-1 and plant building 2, reactor size willbe 10 KL and 1 batch time will be 20 hrs. The area provided for production area-1will be 162.01 m2 on ground floor. Plant building -1 having 2 floors of construction,the area provided for production area-2 will be 76.81 m2 on ground floor hence therequired space for production is sufficient.
As the total floor area available will be adequate for installation of productionequipment.
B. To address proportionate availability of storage area for raw materials, finished
goods, utilities and goods carrier movement within premises.
Storage area for Raw material and finished goods will be in multi-tier racks; as aresult less floor area is occupied to store more raw materials with safe handlingstorage systems. Raw material will be stored on pallets to facilitate ease of handlingand goods movement. Unit has proposed plant-1 of 83.1 m2 & plant-3 of 607.23 m2
area on ground floor and 2 more floors for storage of raw material and products. So,required space for proposed raw materials & product storage is sufficient.
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Utility
Unit has 1 Nos. of boiler (2 TPH), 1 Nos. of Thermo pack and D.G. Set (300 KVA)and also 1 Nos. of boiler (5TPH) 2 Nos. of Thermo pack (10 Lac Kcal) as proposedutility and for that unit will provide total 160.26 sq. m. area. This area is sufficient.
Goods Carrier Movement
Unit has proposed 5 to 8 m vide road and two gates for easily Goods CarrierMovement.
Common infrastructure:
Unit will discharge effluent to CETP, Nandesari. And Membership certificate forwastewater discharge to NIA is attached as Annexure-V.
Plant Layout is attached as Annexure-III.
This is sufficient to store all the raw materials required for the proposed expansion.Additionally, space is provided at the site for the day-storage of raw materials. The Details ofbreakup of plot area are covered under following table.
TABLE: 2.9LAND USE BREAK UP OF TOTAL PLOT AREA
Sr.No.
Particular Land Area (sq.m.) Land Area in %
1 Admin Building 218.79 7.072 Ware House Area 138.81 4.483 Plant I & II 1568.5 50.654 Engineering & Utility Block 135.26 4.375 Drum Solvent Storage Area* 130.72 4.226 ETP Area 39.43 1.277 Hazardous Waste Storage
Area38.27
1.248 Green Belt Area** 681.21 22.009 Open Area 145.51 4.70
Total 3096.5 100.00
* Solvent storage area will be kept on the ground floor only.
** Unit will develop additional 25% greenbelt area outside the factory premises. The NIA
(Nandesari Industrial Association) has allotted the land and the copy of the letter is attached
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2.5.3 ENERGY REQUIREMENT
The energy requirement in terms of power and fuel for proposed unit is shown in below table.
TABLE: 2.11
FUEL & ENERGY REQUIREMENT
Sr.No.
Fuel Existing quantity Proposed Total
1. Fire wood (forexisting boiler)
1.5 MT/day -1.5 00 MT/Day
2. Bio Coal/coal(for new boiler)
2.5 MT/Day 8.5 MT/Day 12.5MT/Day
3. Bio coal/coal(for new TFH)
1.5 MT/Day
4. LDO/Diesel (fornew D.G. Set)
50 Lit/Hr 50 Lit/Hr 100 Lit/Hr
5. Connected load 100 KVA 300 KVA 400 KVA*Coal will be used during monsoon where availability of bio coal is less.MOU for coal is attached as Annexure-2.5.3.1 DETAILS OF ENERGY DISTRIBUTION/UTILISATION
Details of energy distribution are covered in below table.
* In worst case, 13.03 KL/Day effluent will generate from Group A.** In worst case, 7.46 KL/Day effluent will generate from Group C.*** In worst case, 1.425 KL/Day effluent will generate from Group F.
****In worst case, 0.80 KL/Day effluent will be generated from Group G.
2.6.1.3 TREATMENT PROCESS DESCRIPTION FOR CYANIDE STREAMFIGURE: 2.5
HYPOCHLORITE TREATMENT FOR CYANIDE REMOVAL
If the qualities of Cyanide to be destroyed are small enough. It is perfectly acceptable to usesodium hypochlorite. The following equation shows the reaction pattern.
5NaOCl + H2O + 2NaCN → 2NaHCo3 + N2 + 5 NaCl
Effluent from CyanideStream 30KL → Transfer to primary treatment
NaOCl 200 Kgs →
PROCESS DESCRIPTION:-
The effluent from cyanide Stream is collected in a separate collection tank i.e.; Storage tankfrom plant. Then it is batch wise transfer to the 30KL treatment tank facilitated with stirrerafter testing the cyanide content which is almost between the ranges of 30 to 40 PPM.
Now add approx 200 Kgs of Sodium Hypochlorite solution to the effluent under stirring forfirst 3 hours and then check the sample for the absence of Cyanide content. After the QCCheck transfer the effluent to primary treatment tank where it is further treated.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 147
2.6.2 GASEOUS EMISSIONAs per CCA order no. AWH-85623, the unit has one stack of Baby Boiler having 11 mheight. One common stack of Boiler and Thermo pack having capacity of 2 TPH & height 37m, and D.G. Set (300 KVA).
Now, the unit has proposed one boiler having capacity of 5 TPH & two Thermo Pack havingcapacity of 10 lacs K Cal/Hr.
Details of stack height, fuel consumption, air pollution control system etc, for flue gas
emission and process gas emission are shown in below Table no. 2.16.and Table no.2.17
TABLE: 2.20DETAILS OF FLUE GAS EMISSION
Sr.No.
StackAttached To
StackHeight(M)
Type ofFuel
FuelConsumption
Type ofEmission
Permissible Limit
APCM
EXISTING As Per CCA No.-AWH-856231. Baby Boiler 11 Fire
Wood1.5 MT/Day SPM
SO2
NOx
150mg/NM3
100 PPM50 PPM
---
2. Boiler (2TPH)
37 BioCoal/coal
2.5 MT/ Day SPMSO2
NOx
150mg/NM3
100 PPM50 PPM
MultiCycloneSeparator +wet scrubber3 Thermo pack Bio
Coal/coal
1.5 MT/ Day
4. D.G. Set(300 KVA)
11 LDO/Diesel
50 Lit/ Hr SPMSO2
NOx
150mg/NM3
100 PPM50 PPM
Adequatestack heightand acousticenclosure
Proposed1. Boiler
( 5 TPH)37 Bio
Coal/coal5 MT/Day SPM
SO2
NOx
150mg/NM3
100 PPM50 PPM
MultiCycloneSeparator +Bag filter+waterscrubber
2. Thermo pack(2 Nos.) (10Lac Kcal)
37 BioCoal/coal
3.5 MT/Day SPMSO2
NOx
150mg/NM3
100 PPM50 PPM
MultiCycloneSeparator +Bag filter+waterscrubber
* Existing baby boiler will be dismantled.
Note: The flue gas emission will be 70% to the permissible limit.
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FIGURE 2.7DIAGRAM OF ACID SCRUBBER
The scrubbing system consists of Scrubber (packed column absorber) an exhaust Blower andscrubbing media circulation via pumps. The gases vapors from the process enter the scrubberwhere they are absorbed. The solution which is coming from scrubber is subjected to Effluenttreatment plant completely. Thus, the air leaving from scrubber is clean. The details ofscrubber system and features of scrubber system are given below in Table no. 2.19 and Tableno. 2.20.
2.6.3 HAZARDOUS WASTE GENERATION
The following type of hazardous waste will be generated from the operational activities. All
the waste will be stored separately in a designated storage area. The details of hazardous
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use any agriculture land.2. Coal handling unit/Agency shall be
minimum 500 meters away fromthe residential area, school/colleges,Historical Monuments, ReligiousPlaces, Ecological sensitive area aswell as forests area.
There is no residential area, school/colleges,Historical Monuments, Religious Places,Ecological sensitive area of 500 m radialdistance from project site.
3. Coal handling unit/Agency shall belocated at a minimum 500 metersaway from the Railway line,Express ways, National Highways,State ways and District Roads andfrom water bodies like River, Nala,Canal, Pond etc.
There is no Railway line, Express ways,National Highways, State ways and DistrictRoads and from water bodies like River, Nala,Canal, Pond of 500 m radial distance fromproject site.
The unit will keep 9 m height of compoundwall around coal handing area.
6. Coal handling unit/Agency shallensure adequate water supplythrough pipe/ surface water beforeselection of the site.
Not applicable.
7. Coal handling unit/Agency shallensure that stacking of coal in heapsdoes not get higher than thecompound wall of premises Coalhandling unit/ Agency shall strictlyobserve itself and ensure thecompliance of all the conditions/Environmental stipulation laid outin the permission to be granted tothe local authority, or any otherauthority etc.
It will be complied.
8. Continuous water sprinkling shallbe carried out on the top of the heapat regular intervals to preventdusting, fire & smoke. Duringloading/unloading, fixed pipenetwork with sufficient waterstorage and pump shall be installed.
It will be complied.
9. Coal handling unit/Agency shallensure maximum sprinkling ofwater at each and every stage oftransportation to avoid generationof coal dust or other dust.
It will be complied.
10. Coal handling unit/Agency shallensure that all trucks before leavingthe storage yard shall be coveredwith tarpaulin and also that trucks
The unit will ensure that truck should beproperly covered and should not beoverloaded.
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are not over loaded as well as thereis no spillage during transportation.
11. Coal handling unit/Agency shallensure regular sweeping of coalfrom internal and main road andalso ensure that there is adequatespace for free movement of vehiclesat the surrounded area.
It will be complied.
12. The following adequate AirPollution Control Measures shall beinstalled and to be operatedefficiently.(a) Dust containment cumsuppression system for theequipments.(b) Construction of wind breakingwall.(c) Construction of metal road &RCC Pucca flooring in the plotarea/ godown etc.(d) System for regular cleaning andwetting of the floor area within thepremises.(e) Entire coal storage area/ godownshould be covered with Permanentweather shed roofing. In case ofcrushing/sieving/grading activity iscarried out (i.e. G. I. Sheet).(f) Fixed pipeline should beinstalled for sprinkling of water andto ensure that total plot area iscovered with adequate water tank ofcompatible storage.(g) In case of mechanical crushing,adequate additional APCM shouldbe installed. And such crushingactivity should carry out in closeshed.
There will be provision of all mentioned airpollution control measures.
13. There shall be no use of fuel hencethere shall be no flue gas /processemission.
There will be no flue gas/process emission instorage area.
14. Coal handling unit/Agency shallprovide adequate fire fightingmeasure to avoid any fire and shallensure that there is no explosive orchemical reaction in storage yard.For this purpose an onsiteemergency plan shall be preparedand implemented by coal handlingunit.
Onsite emergency plan is already prepared tocontrol fire.
15. Coal handling unit/Agency shall It will be complied.
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carryout three rows plantation withtall growing trees all along theperiphery of the coal handlingpremises, inside & outside of thepremises along with road
16. There should be mechanizedloading/ unloading system from theloading /unloading area to thestacking yards and in to thevehicles.
This will be provided.
17. Coal handling unit/Agency shallimprove housekeeping in the yardand nearby approach areas leadingto the any road. They shall take alladequate steps under the provisionsof Air (Prevention & Control ofPollution) Act, 1981 andEnvironment(Protection) Act -1986and submit an action taken report inthis regard.
The unit will maintain good housekeeping andprovide air pollution control measures.
18. Coal handling unit/Agency shalltake all corrective steps to resolvethe issue of air pollution atpermitted coal storage/handlingarea where coal is being stored.
The unit will provide air pollution controlmeasures.
19. Coal handling unit/Agency shallprepare EMP (EnvironmentManagement Plan) and implementthe same in true spirit and thusmaintain overall environment ofthat area.
This will be complied.
20. Coal handling unit/Agency shall notcarry out the operation ofloading/unloading of coal/coal dustat any place, till adequate airpollution control equipment for dustcontrol/suppression are installedand efficiently operated and theconsent under the provisions of Air(Prevention & Control of Pollution)Act, 1981 is obtained by the coalyard owners/ Coal handlingunit/Agency / coal importers.
The unit will carry out the operation ofloading/unloading of coal/coal after obtainingconsent and installing air pollution controlmeasures.
21. Coal handling unit/Agency shallstore coal in such a way that coalheap should not be higher than 15feet and clear distance between twoadjoining heap at G.L. should be 5meters ,so that in case of fire,approach is available.
The unit will follow these criteria.
22. Proper drainage system shall be There will be provision of drainage system
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provided in all coal storage area sothat water drained from sprinklingis collected at a common tank andcan be reused after screeningthrough the coal slit.
with collection tank to reuse water.
23. Coal handling unit/Agency shallobtain transport permission fromthe local Administration under therelevant rules.
Not applicable as coal will be used withinpremises.
24. Coal handling unit/Agency shalltake measures to control the airpollution while loading/handlingcoal. Specific measures shall beunder-taken to avoid fugitiveemission at the time ofloading/unloading of coal byindividual coal yard unit.
It will be complied.
25. Coal handling unit/Agency shallsubmit details to GPCB at HeadOffice and Regional Office,regarding the capacity of coal yardand with probable height of the coalheaps in the storage yard.
Area, storage quantity and height heap notmore than 5 m.
26. Coal handling unit/Agency shalloperate continuous Ambient AirQuality Monitoring Stations as perCPCB guideline. The results ofparameters like SPM, RSPM,SO2shall be submitted to the SPCBevery month.
The unit will submit ambient air monitoringreport every month to GPCB.
27. The concentration of the followingparameters in the ambient air withinthe premises and a distance of10meters from the source (otherthan the stack/vent) shall not exceedthe following levels.
The unit will provide adequate controlmeasures to keep concentration of PM10,PM2.5, SO2 and NOx within permissiblelimit.
PARAMETERS PERMISSIBLE LIMITAnnual 24 Hrs Average
Particulate Matter-10(PM10)
60 Microgram/M3
100 Microgram/M3
Particulate Matter-2.5 (PM2.5)
40 Microgram/M3
60 Microgram/M3
SO2 50 Microgram/M
380 Microgram/M
3
NOx 40 Microgram/M
380 Microgram/M
3
28. Coal handling unit/Agency shalltake adequate measures for controlof noise levels from its own sourceswithin the premises so as to
The unit will provide adequate controlmeasures to control noise levels.
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2.9 Fly Ash Storage, Handling and Disposal:The fly ash generated from Boiler, bag filter and Multi cyclone separator will be collected.
Fly ash is stored in bags and disposal at authorised traders.
2.10 PROJECT IMPLIMENTATION SCHEDULE
Implementation of Project within a pre-determined time frame is an important factor for the
success of a project. Timely implementation saves on various costs like interest,
administrative overheads and helps to realize the goals as per pre-determined objectives.
Implementation of Project involves co-ordination of different activities at various levels of
the firm and amongst different outside agencies. The project implementation schedule is
given in table no.2.27.
This will start immediately after getting Environment Clearance. From the date of start, the
implementation schedule envisages completion of project in 6 months. It is considered that
preliminary activities such as obtaining necessary statutory clearance for proposed project
and financial arrangements for the implementation of the project will be made at proper
dates.
The major activities to be carried out at site during project work are as follows:
TABLE: 2.27
PROJECT IMPLEMENTATION SCHEDULE
Project implementation schedule after getting NOC from GPCB
Sr. No. Activity Required Period
maintain ambient air qualitystandards in respect of noise to lessthan 75dB(a) during day time and70 dB (A) during night time.Daytime is reckoned in between 6a.m. and10 p.m. and night time isreckoned between 10 p.m. and 6a.m.
29. Coal handling unit/Agency Youshall strictly adhere with theapplicability of Hazardous Waste(Management and Handling &Transboundary Movement) Rules -2008“and ensure that there shall be nogeneration of any type ofHazardous Waste.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 165
Sr.
No.
Probable Source Proposed Control Measures
and instrument connection. Suitable gasket material to be used.
Suitable gland packing will be used in valves.
Periodic inspection and maintenance of pipes and
pipe fittings.
7. Chemical vapours from wet cake
in filtration and drying area
Filtration will be done out in Agitated Nutch filter.
Transfer and drying of wet-cake done in system
shall be adopted, worker shall be provided PPEs,
fume extraction system shall be provided, whenever
require.
8. Warehouse storing drums and
bags
Spillages shall be strictly prevented by providing dip
pans, proper handling equipment, minimum manual
operation, local exhaust and roof top ventilators.
Spill control procedures and equipment shall be
provided.
2.15 ADEQUACY OF THE PROPOSED EMS
AIR:
The unit is using fire wood in existing baby boiler. Bio coal/lignite is being used in common
stack of Boiler (2 TPH) & thermo pack with adequate APMC like multi cyclone separator
and wet scrubber.LDO/Diesel is being used on existing D.G. SET (300 KVA) with adequate
stack height & acoustic enclosure.
Bio coal/ coal/ lignite will be used in proposed Boiler (5 TPH) & Thermo pack (2 Nos.) (10Lac Kcal) with adequate APCM like Multi Cyclone Separator, Bag filter & water scrubber.
Acid scrubber and water venturi scrubber followed by alkali scrubber will be used forproposed reactors in process gas emission.
The fugitive emission of VOC will be from solvent recovery plant, VOC will be control as
per the CPCB Guidelines. Existing baby boiler will be dismantled after proposed expansion.
WATER:
The source of water is GIDC Nandesari. In the existing scenario, the unit is using 3 KLD
fresh water for domestic purpose, 48 KLD of fresh water for industrial purpose and 1.5 KLD
11. COD in mg/l APHA(22nd Edition)– 5220 B Open Reflux Method 412. BOD in mg/l IS: 3025 (Part – 44) 1993
(Reaffirmed 1999)1
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13. MPN ColiformCount
APHA -9221 C --
14. E.coli APHA- 9221 D (Presence Absence Test) --15. Nitrate in mg/l Spectrophotometer 116. Iron (as Fe) in mg/l By NOVA 60 spectrophotometer (Triazine) 0.0117. Fluoride (as F) in
mg/lBy NOVA 60 spectrophotometer 0.1
18. Residual FreeChlorine in mg/l
Iodometric method 1
19. Sodium in mg/l Flame photo meter --20. Potassium in mg/l Flame photo meter --21. Ammonical
Nitrogen in mg/lAPHA-4500 N ORG BnC macro and semi-microKJELDHAL
2.8
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In view of the above mentioned chemical analysis of groundwater samples reveals that the pH varies from 6.7 to 7.90, Calcium and Magnesium content varies
between 65.8 to 114.23 mg/l and 68 to 90 mg/l respectively. Total hardness and alkalinity expressed as CaCO3 ranges between 34 to 800 mg/l and 50 to 900
mg/l respectively. Chlorides and Sulphate are found to be in the range of 32.34 to 670 mg/l and 25 to 200 mg/l respectively. Nitrates and Fluorides are found
to be in the range of 4 to 9.9 mg/l and 0.15 to 0.8 mg/l. The heavy metal contents are found to be well within the limit. The TDS contents are found to be well
within the permissible limit. The physico-chemical and biological analysis revealed that all the parameters are well within the prescribed limits of IS: 10500-
2012.
EIA OF M/S. CHEMTECH INTERMEDIATES PVT. LTD, GIDC NANDESARI, VADODARA
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 184
TABLE: 3.7WATER QUALITY PARAMETERS (SURFACE WATER SOURCES)
Parameter Sampling locationUnit IS 10500: 2012 Bhetasi
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CONCLUSION
In view of the above mentioned chemical analysis of surface water samples reveals that the pHvaries from 7.8 to 8.24, Calcium and Magnesium content varies between 30 to 115 mg/l and 28to 44 mg/l respectively. Total hardness and alkalinity expressed as CaCO3 ranges between 150to 915 mg/l and 145 to 352 mg/l respectively. Chlorides and Sulphate are found to be in therange of 35 to 270 mg/l and 26 to 260 mg/l respectively. Nitrates and Fluorides are found to bein the range of 3.5 to 8.9 mg/l and not detected respectively. The heavy metal contents are foundto be well within the limit. The TDS contents are found to be well within the permissible limit.The physico-chemical and biological analysis revealed that all the parameters are well within theprescribed limits of IS: 10500-2012.
3.5 NOISE ENVIRONMENT
To estimate background noise level, noise measurement was done within the study area
using the sound level meter. The locations where noise level measurements were done are
shown at Figure no. 3.8. The result of measurement is given in Table no. 3.9.
FIGURE: 3.8LOCATION OF NOISE MONITORING STATIONS
TABLE: 3.8CPCB RECOMMENDATIONS FOR COMMUNITY NOISE EXPOSURE (1989)
Category of area Leq (dBA) (Day Time)(06:00 to21:00 Hrs.)
Ldn (dBA) (Night Time)(21:00 to 06:00 Hrs.)
Industrial area 75 70
EIA OF M/S. CHEMTECH INTERMEDIATES PVT. LTD, GIDC NANDESARI, VADODARA
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 187
Commercial Area 65 55Residential Area 55 45Silence Zone 50 40
TABLE: 3.9NOISE LEVEL DATA
Sr.No.
Location AreaCategory
LEQ (dB (A)) CPCB Limit (dB(A))
Latitude Longitude
DayTime
NightTime
DayTime
NightTime
Min
Max
Min
Max
Max Max
1. Project site(N1)
Industrial 62 64 59 61 <75 <65 22°24'21.15"N
73°05'47.66"E
2. Village:Nandesari(N2)
Residential
48 49 41 43 <55 <4522°24'48.4
1"N73°05'14.02"
E
3. Village:Bhetasi (N3)
Residential
52 53 41 43 <55 <45 22°25'5.31"N
73°02'31.21"E
4. Village:Ambali (N4)
Residential
50 52 41 42 <55 <45 22°23'23.11"N
73°02'15.27"E
5. Village:Kotna (N5)
Residential
46 49 41 43 <55 <45 22°21'38.74"N
73°03'29.70"E
6. Village:Anagad(N6)
Residential
51 53 39 42 <55 <4522°23'14.0
6"N73°04'43.21"
E
7. Village:Undera (N7)
Residential
51 53 40 42 <55 <45 22°20'59.80"N
73°08'0.54"E
8. Village:Padamla(N8)
Residential
49 51 40 42 <55 <4522°24'54.0
7"N73°07'31.25"
E
9. Village:
Ajod (N9)
Residential
52 54 42 44 <55 <45 22°24'12.39"N
73°09'41.41"E
During monitoring period, the LEQ (dB (A)) noise levels varied between 46-62 (dB (A))
and 49-64 (dB (A)) during day time in industrial area and residential area respectively.
Noise levels varied between 40-59 (dB (A)) and 42-61 (dB (A)) during night time in
industrial area and residential area respectively.
EIA OF M/S. CHEMTECH INTERMEDIATES PVT. LTD, GIDC NANDESARI, VADODARA
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 188
3.6 SOIL
3.6.1 BASELINE DATA
Description of soil environment has become vital particularly when the treated effluent is to
be discharge on land for disposal or treatment. The soil environment is usually described by
determining the physical and chemical characteristics of soil samples collected from site
with the help of auger/spade. The composite soil sample was collected from project site and
the villages within 10 km radius. The samples were collected to determine physical and
chemical characteristic of soil. The selected soil sampling locations are given in Table no.
3.10 and shown in Figure no. 3.9. The results are given in Table no. 3.11.
TABLE: 3.10LOCATIONS OF SOIL QUALITY MONITORING WITH RESPECT TO THE
PROJECT SITE
Sr.No.
Location Latitude Longitude Distancefrom projectsite in km
Bird’s diversity of the area shows diversity as the area has various ecosystems. A total 72
bird species were reported from the area. The bird species are representative of wetlands,
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M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 200
forests and grassland habitat. Important species in the study area include lesser flamingo
reported from river mahi. The locals reported presence of vultures seen only during certain
time of the year.
TABLE: 3.14LIST OF BIRDS
Sr.No.
Common Name Scientific Name
Grebes1. Little Grebe TachybaptusruficollisCormorants and darters2. Little Cormorant Phalacanusniger3. Darter Anhinga melanogasterHerons & Egrets4. Little Heron Butoridesstriatus5. Indian pond heron Ardeolagrayii6. Purple heron Ardeapurpurea7. Grey heron Ardeolacinerea8. Little egret Egrettagularis9. Intermediate egret Mesophoyxintermedia10. Great Egret CasmerodiusalbusStorks11. Asian openbilled stork Anastomusascitans12. Painted strock Mycterialeucocephala13. White stork CiciniaciconiaIbis & spoonbills14. Black ibis Psudibispapillosa15. White ibis Threskiornisaethiopica16. Glossy ibis Plegadisfalcinellus17. spoonbill Platalealeucorodia18. Lesser flamingo Phoeniconanias minor19. Common crane Grusgrus20. Sarus crane Grusantigonewaders21. Black winged stilt HimantopusHimantopus22. Red- wattled lapwing Vanellusindicus23. Little stint Calidrisminuta24. Wood sandpiper TringaglareolaHawks25. Black kite Milvusmigrans26. Short toed eagle Circaetusgallicus27. shikra Accipiterkingfishers
EIA OF M/S. CHEMTECH INTERMEDIATES PVT. LTD, GIDC NANDESARI, VADODARA
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Sr.No.
Common Name Scientific Name
28. Common kingfisher Alcedoathis29. Lesser pied kingfisher Cerylerudis30. White throated kingfisher Halcyon smyrnensisWagtails & pipits31. White wagtail Motacilla alba32. Yellow wagtail MotacillaflavaPheasants, quails and33. Jungle bush quail Perdiculaasiatica34. Common peafowl PavocristatusGeese & Ducks35. Cotton pigmy goose Nettapuscoromandelianus36. Lesser whistling duck Dendrocygnajavanica37. Purple swamphen Porphyrioporphyrio38. Cotton teal NettapuscoromandelianusRails and coots39. Common moorhen Gallinule chloropus40. Common coot Fulicaatra41. Water cock GallicrexcinereaOther birds42. Common redshank Tiringa tetanus43. Bronze-winged jacana Metopidiusindicus44. Pheasant –tailed jacana Hydrophasianuschirugus45. Green bea- eater Merposorientalis46. Barn owl Tyto-alba47. Spotted owlet Athenebrama48. Blue rock pigeon Columba livia49. Rose ringed parakeet Psittaculakrameri50. Indian cukoo Cuculusmicropterus51. Common hoopoe Upupaepops52. House crow Corvussplendens53. House sparrow Passer domesticus54. House swift Apusaffins55. Indian Myna Acridotherestristis56. Warbler Prinia57. Pied avocet Recurvirostraavosetta58. Crested lark Galeridacristata59. Indian bush lark Mirafraassamica60. Ashy crowned sparrow lark Eremopterixgrisea61. Indian roller Coraciasbenghalensis62. Golden oriole Oirolusoriolus63. Bar- tailed godwit limosalapponica
EIA OF M/S. CHEMTECH INTERMEDIATES PVT. LTD, GIDC NANDESARI, VADODARA
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Sr.No.
Common Name Scientific Name
64. Rufous tree pie Dendrocittavagabunda65. Blue tailed bee eater Meropsphilippinus66. White napped woodpecker Dendrocopsleucopterus67. Red vented bulbul Pycnonotuscafer68. White browed fantail Rhipiduraalbicollis69. Sand martin Ripariariparia70. Purple sunbird Nectariniasperata71. House swift Nectariniasperata72. Common jungle night jar Caprimulgusaffinis73. Vultures (occasional) --
3.9 SOCIO-ECONOMIC ENVIRONMENT
As assessment of socio-economic environment forms an integral part of an EIA study,
baseline information for the same was collected during the study period. The baseline socio-
economic data collected for the study region, before the proposed expansion is operational,
has been identified for the four major indicators viz. demography ,civic amenities, economy
and social culture. The baseline status of the above indicators is compiled in forthcoming
sections.
3.9.1 DEMOGRAPHIC DATA WITHIN THE REGION OF INTEREST
Demography covers the information related to population density, sex ratio and literacy level
of the public in the study area. Table no.3.15 provides the data on inhabitations of the
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 214
4.2.2 AIR ENVIRONMENT
4.2.2.1 CONSTRUCTION PHASE IMPACTS
Dust will be generated during excavation and hauling operation and vehicle transportation on
unpaved tracks at the site. Other exhaust gases like NOx, SO2, VOC and HC may be also
slightly released into the local ambient air due to vehicular traffic movement. Thus, the local
ambient air quality may be temporarily affected. It will be confined within the project
boundary and expected to be negligible outside the plant boundaries.
Mitigative Measures
Water sprinkling and provision of enclosures will allow the particles to settle down prior to
discharge. There will be provision of enclosures to construction area to allow the particles to
settle down prior to discharge.
4.2.2.2 OPERATION PHASE IMPACTS
As per CCA order no. AWH-85623, there is flue gas emission (SPM, SO2 and NOx) from one
baby boiler based on fire wood fuel, Boiler (2 TPH) & Thermo pack based on Bio coal/ coal/
lignite fuel, and D.G. Set (300 KVA). There is no process gas emission from the existing
manufacturing activities. Existing baby boiler will be dismantled.
The proposed expansion project will result flue gas emission, process emission and fugitiveemission. Flue gas emission will be from boiler having capacity of 5 TPH & two ThermoPack having capacity of 10 lacs K Cal/Hr. Bio coal/ coal/ lignite will be used as fuel in Boiler(5 TPH) & Thermopack. Process gas emission will be from Reactors. There will be emissionof HBr, NH3, and Br2 from reactor vent. There will be fugitive emission of VOC duringmaterial handling, transferring and at storage area.
Mitigative Measure
The unit is using fire wood in existing baby boiler. Bio coal/lignite is being used in common
stack of Boiler (2 TPH) & thermo pack with adequate APMC like multi cyclone separator
and wet scrubber. LDO/ Diesel is being used on existing D.G. Set (300 KVA) with adequate
stack height & acoustic enclosure.
Bio coal/ coal/ lignite will be used in proposed Boiler (5 TPH) & Thermo pack (2 Nos.) (10 Lac
Kcal) with adequate APCM like Multi Cyclone Separator, Bag filter & water scrubber.
Acid scrubber and water venturi scrubber followed by alkali scrubber will be used for
proposed reactors in process gas emission.
The NH3 will be absorbed in Acid Scrubber; Br2 & HBr will be absorbed in Water Venturi
Scrubber Followed by Alkali Scrubber before venting out to achieve GPCB norms. Adequate
stack height will further help in dispersion of pollutants. Closed feeding and transferring
system, proper local or exhaust ventilation and more solvent recovery efficiency will control
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR.236
CHAPTER -5
ANALYSIS OF ALERNATIVES (TECHNOLOGY & SITE)
5.1 INTRODUCTIONM/s. Chemtech Intermediates Pvt. Ltd is already engaged in manufacturing of organicchemicals at plot C1-128/14-15, GIDC Estate, Nandesari, Dist. Vadodara, Gujarat. The Unitis having valid Consolidated Consent & Authorization (CC&A) from Gujarat PollutionControl Board vides CC&A order no.: AWH-85623 with validity up to 31/12/2021 formanufacturing of organic chemicals. Now, unit has purchased new two adjoining plots forproposed expansion. The expansion will be carried out at plot C1-128/13,14,15,16 GIDCEstate, Nandesari, Dist. Vadodara, Gujarat, existing plot & new adjoining plots located inGIDC.The products manufactured by unit are established since last long developed in the R&D labby the proponent. Necessary modification will be done based on the R & D activities. All theproducts are tailor made products based on literature review and set in R&D. Hence noproposal of alternate process or technology and currently it is best technology available withthe proponent.The unit didn’t opted for any alternatives as Nandesari GIDC site was very well connected byroad & rail and close to Vadodara city. The Nandesari-GIDC has lots of other chemicalindustries and hence the required infrastructure and resources are readily available.GIDC Location
Nandesari GIDC is in Vadodara Taluka and District of Gujarat, India. Nandesari GIDCis a part of Chemicals industries. Site is very well connected by road & rail and closeto Vadodara city.
Availability of power facilities – MGVCL.
Availability of water facilities from GIDC – Nandesari. Raw materials will be available easily. Transportation cost will be cheap, availability of CETP - NECL, Nandesari for
effluent treatment & discharge Availability of TSDF site- NECL, Nandesari for disposal of Hazardous Waste All infrastructure facilities are available.
Connectivity Site is very well connected by road & rail and close to Vadodara city. It is well connected with National Highway (NH-8). Road and Railway both are having
the connectivity to New Delhi, the National Capital and Mumbai, the commercialCapital of India.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR349
The Unit will use latest STATE OF ART technology. Thus man power will be exposed to
new technology.
8.4 ACTION PLAN FOR BUDGETARY ALLOCATION
The unit has planned to spend 1.5 % of the total cost of the proposed project (Rs. 7.10
crore) over a period of five years towards CER activity. The 1.5 % is as per the Office
Memorandum- Compliance of Hon'ble NGT order dated 19.08.2019 (published on
23.08.2019) in O.A. No. 1038 2018 - reg. Date:31/10/2019.So, as per the proposed
project cost Rs.10.65 Lakhs will be used in the CER activities. Budgetary allocation is
given in below table.
TABLE: 8.1BUDGETARY ALLOCATION FOR CER ACTIVITIES
Sr.No.
Activity Fund EarmarkedFor Activity
TimeSchedule
1. Contribution in installing RO plant forDrinking Water supply in industries ofNandesari GIDC, adjacent GIDC colony,School situated in the colony and nearbypopulated areas.
10.65 lacks 5 Year
Letter from Nandesari water & utilities ltd for CER activities is attached as annexure – XIX.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 351
CHAPTER -10ENVIRONMENTAL MANAGEMENT PLAN
10.1 INTRODUCTION
Environmental protection is an issue that no organization can neglect and hope to survive.
The key to the success of the integrated approach to pollution prevention and control is the
management and operation of the organization. Effective committed management delivers a
successful industry. A total commitment to the environment, not just for compliance with
legal or regulatory compliance will be the essence of environment management of an
industry. Many companies have recognized the benefits of implementing an effective
environmental management system.
10.2 AIM AND OBJECTIVE
The aim of environment management plan is to conserve natural resources and water, to
prevent pollution of environment, to ensure effectiveness of control measures and
monitoring programme, to ensure safety, welfare and good health of worker, to minimize
generation of waste.
The objectives of EMP are as under:
Pollution will be prevented or reduced at the source,
Pollution that cannot be prevented will be recycled in to the system,
Pollution that cannot be prevented or recycled will be subjected for recovery of chemicals
using best technologies,
Pollution that cannot be prevented or recycled or recovered will be treated in
environmentally safe manner, and
Disposal and other releases into the environment will be used “only as a last resort” and
will be conducted in an environmentally safe manner.
10.3 ENVIRONMENTAL MANAGEMENT CELL
M/s. Chemtech Intermediates Pvt. Ltd. G.I.D.C., Nandesari, Vadodara has assignedresponsibility to officers from various disciplines to co-ordinate the activities concerned withmanagement and implementation of environmental control measures. Environmentmanagement cell is shown in below Figure no.10.1.
Effluent Recycling of effluent/ washings/scrubber water – wheneverpossible. Adequate Effluent treatment plant havingprimary.
Proper housekeeping preventing contamination of groundwater and storm water drainage. Record of hazardouswaste generation during the treatment of waste water andits disposal.
Record of water consumption will be maintained for eachusage in future. Record of waste watergeneration/treatment/disposal
Record of chemicals utilization at ETP2. Domestic Sewage
waterDisposed to soak pit/ septic tank.
10.4.2 (B) 1. EFFORTS TO MINIMIZE EFFLUENT DISCHARGE
Following action will be taken to minimize effluent discharge.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 372
All reasonably practical measures will be adopted by the unit to minimize the risk ofaccidents within a chemical manufacturing unit
All building plans and installations will be as per relevant laws and approved by competentauthority Training is imparted to all workers for all the hazardous process operations within the plantand will be supervised by experienced supervisors Suitable personnel protective equipments and fire extinguishers at strategic locations andsuitable personal protective equipmentswill be provided
Flame proof electrical fittings, flame arrestors etcwill be installed All the raw materials & solvents will be stored in designated storage area equipped withnecessary safety features.
Physical and chemical properties of raw materials and products as MSDS is provided assoft copy in CD. The solvent storage area will be restricted for unauthorized persons. Proper earthling willbeprovided in all electrical equipment whenever solvent handling is done. Flame arrester cumbreather valve and flame proof fitting will be provided at tank farm. Periodic inspection & testing of pressure vessels, equipments, and machineries will bedone. Good housekeeping will be ensured within the factory premises All designated staff & workers will be trained for the fire fighting, work permit system, firstaid and safe handballing of hazardous chemicals. Incident/accident reporting system will be developed and all the employees are made awarefor the same.
Suitable notices/boards will be displayed at designated locations indicating appropriatehazard warnings. Antidotes as well as MSDS for all the chemicals will be made available within the factorypremises. Pre-employment medical check up at the time of employment will be carried out. In orderto safe guard the health of the employees, all the employees undergo periodic health checkupat every six month.10.4.2. (J) CLEANER PRODUCTION
Discarded containers/bag will be sent back for raw material filling/selling to authorizerecycler after decontamination.
The unit will be using green chemistry for manufacturing of bulk drugs, which willresult in energy savings.
All steam condensate will be recycled. Cleaner production options will be explored further. The unit will try to recover the chemicals in the effluent in near future.
Unit will use natural gas as a clean fuel. Vacuum cleaner will be used to recover spilled material.
Housekeeping will be regularly maintained. Dedicated staff for the purpose will beemployed.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 373
Products will be manufactured on campaign basis to reduce repeated cleaning ofreactors.
Whenever possible, extra filter cloths for centrifuges will be stocked to avoid/minimize the washings.
Solvents recovery will be maximized and uncondensed solvent will be scrubbed inwater. The scrubbed water will be subjected to further solvent recovery.
10.4.2. (K) SOLVENT RECOVERY SYSTEM WITH SCRUBBER TO
CONTROL VOC
A solvent recovery system comprises of two stage heat exchangers. Cooling tower water is
circulated in primary heat exchanger and in secondary heat exchanger chilled water
circulation is done. The uncondensed solvent after the secondary heat exchanger will be
diverted to water scrubber the traces of solvent will get dissolved in water. On getting
saturation, the solvent mix water will be subjected for recovery of solvent (if feasible) and/or
water will be diverted to ETP plant for further treatment the process will ensure no VOC
emission from solvent recovery system.
The scrubbing system consists of a scrubber (packed column absorber), an exhaust blower
and scrubbing media circulation via pumps followed by carbon adsorption tower. The vapors
coming from the process vents and raw material storage area enters the primary scrubber
where they are absorbed in water. Thus, the air leaving from the scrubber is clean, which is
again feed into the secondary tower consists of carbon to trap any remaining VOC. The figure
of scrubber system is given below as figure. The details of scrubber system and features of
scrubber system are given below in Table no. 10.14 and Table no. 10.15.
TABLE 10.14
DETAILS OF WATER SCRUBBER SYSTEM FOR VOCSr. No. Name of Units Capacity Quantity MOC1 Water Scrubber 5 KL 1 HDPE/PP FRP
TABLE 10.15SPECIFICATIONS OF WATER SCRUBBER SYSTEM
Description DetailsVelocity gas 10 Kg/HrGas flow 10 Kg/HrBlower Capacity 75 CFMPump Capacity 250 L/HrsScrubbing media WaterColumn diameter 300 mmColumn packed height 3 MTotal column height 4.5 M
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 376
Sr.No.
Probable Source Proposed Control Measures
5. Emission from bulkstorage tank duringunloading
Breather valve, PSVs, Rupture disc will beprovided.
Vapor recovery system will be installed forprocess and storage vent tank.
6. Leak from valves,flanges, plugs andinstrument connection.
Welded pipes will be used wherever feasible.
Suitable gasket material to be used.
Suitable gland packing will be used in valves.
Periodic inspection and maintenance of pipes andpipe fittings.
7. Chemical vapors fromwet cake in filtration anddrying area
Filtration will be done out in Agitated Neutchfilter. Transfer and drying of wet-cake done insystem shall be adopted, worker shall be providedPPEs, fume extraction system shall be provided,whenever require.
8. Warehouse storingdrums and bags
Spillages shall be strictly prevented by providingdip pans, proper handling equipment, minimummanual operation, local exhaust and roof topventilators.
Spill control procedures and equipment shall beprovided.
10.4.2. (M) RAIN WATER HARVESTING SCHEME
Rainwater harvesting is a mechanism involved in collecting, storing and using rainwater
when it is most needed. A rainwater harvesting system comprises of various stages –
transporting rain water through pipes or drains, filtration, and storage in tanks for reuse or
recharge. There are five components in a rainwater harvesting system namely catchment,
conveyance, filtration, storage and recharge.
Advantages of Rain Water Harvesting
There are various advantages of Rain Water recharging from which some of those are listed
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 383
for the adequate treatment.9. We assure you, sir we will take all
the precautions to process oureffluent at the best land.Further we request you sir, lookingto the above fact please not to takeany further action and oblige us.
2. 10.
The copy of the show-cause & closer notice with reply is attached as Annexure – XX.
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 385
10.6 PROJECT IMPLIMENTATION SCHEDULE
Implementation of Project within a pre-determined time frame is an important factor for the
success of a project. Timely implementation saves on various costs like interest,
administrative overheads and helps to realize the goals as per pre-determined objectives.
Implementation of Project involves co-ordination of different activities at various levels of
the firm and amongst different outside agencies. This will start immediately after getting
Environment Clearance. From the date of start, the implementation schedule envisages
completion of project in 8 months. It is considered that preliminary activities such as
obtaining necessary statutory clearance for proposed project and financial arrangements for
the implementation of the project will be made at proper dates.
The major activities to be carried out at site during project work are as follows:
TABLE: 10.18PROJECT IMPLEMENTATION SCHEDULE
Project implementation schedule after getting NOC from GPCBSr. No. Activity Required Period1. Civil work Immediately after getting NOC-3 Months2. Procurement of machinery 1 month after getting NOC3. Eraction& installation of
machineryImmediately after competition of activity no.2- 2 month
4. Trial of machinery &equipment
Within 1 months after competition of activity no.3
5. Commercial activity 1 months after competition of activity no.4
FIGURE 10.7BAR CHART
0 0.05 0.1 0.15 0.2 0.25
Civil Work
Procurement of machinery
Erection & installation of machinery
Trial of machinery & equipment
Commercial Activity
Civil Work Procurement ofmachinery
Erection &installation of
machinery
Trial ofmachinery &equipment
CommercialActivity
Year After Getting NOC from GPCB 0.2 0.1 0.1 0.1 0.1
M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 390
In existing scenario, Fire wood is used 1.5 MT/Day, it will be discontinued after proposed expansion;Bio Coal/coal is used 4 MT/Day in existing scenario, total consumption of Bio Coal/coal will be 12.5MT/Day after proposed expansion. Existing requirement of LDO/Diesel is 50 Lit/Hr, totalrequirement of LDO/Diesel after proposed expansion will be 100 Lit/Hr.
UTILITIES
The existing utilities are cooling tower, boilers, Thermopack, Chilling Plant, Air Compressor, Pumps,
Motors, Storage tanks etc. New utilities will be installed in proposed expansion such as boiler, cooling