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PRE FEASIBILITY REPORT OF M/S. Jayveer Pharma Chem. Survey No. : 621, Jagudan Kochva Road, Village: Jagudan, Taluka & District: Mehsana. Mr. Ritesh R. Chaudhary (M) 09825095477 E-mail: [email protected] Prepared By: T. R. ASSOCIATES C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S. G. Highway, Ahmedabad. Mo. No.: 98253 71099 Email ID: [email protected] ; [email protected]
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M/S. Jayveer Pharma Chem. - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0_08_Jul... · M/s. Jayveer Pharma Chem is proposing to manufacture Pharmaceutical

Apr 01, 2018

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Page 1: M/S. Jayveer Pharma Chem. - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0_08_Jul... · M/s. Jayveer Pharma Chem is proposing to manufacture Pharmaceutical

PRE FEASIBILITY REPORT

OF

M/S. Jayveer Pharma Chem.

Survey No. : 621, Jagudan – Kochva Road, Village: Jagudan,

Taluka & District: Mehsana.

Mr. Ritesh R. Chaudhary

(M) 09825095477

E-mail: [email protected]

Prepared By:

T. R. ASSOCIATES

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,

S. G. Highway, Ahmedabad.

Mo. No.: 98253 71099

Email ID: [email protected];

[email protected]

May 2015

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1. Executive summary

M/s. Jayveer Pharma Chem is proposing to manufacture Pharmaceutical Drugs

& their Intermediates at Survey No. : 621, Jagudan – Kochva Road, Village:

Jagudan, Taluka & District: Mehsana. Proposed unit will manufacture

Pharmaceutical Drugs for sell purpose.

The total land area of company is 6779 m2 out of which 2873 Sq. Mt. land will be

used for greenbelt area development. The estimated cost of the Resin project is

11.0 Crores. Total budget allocation towards Environmental Management

Facilities will be Rs. 75 Lacs. Total 12 persons will be employed including skilled

persons, unskilled persons and office staff.

M/s. T. R. Associates is carried out EIA/EMP studies for Environmental Clearance.

Production details are given below:

Sr. No. Name of Product Quantity

1 N - Methyl 4 Piperidone 7.5 MT/M

2 N – Methyl 4 Chloro Piperidine (NMCP) 2 MT/M

3 5 Chloro 1 (4 Piperidyl) 2 Benzimidazolonone

(D-7) 5 MT/M

4 1 – (3 – Chloropropyl) -1- Dihydro – 2 –H –

Benzimidazolone (D-2) 4 MT/M

5

Dompiridone 5 – Chloro – 1 – (1 – (3 – (2 – Oxo

– 1 – Benzimidazolinyl) Propyl) – 4 –

Piperidyl) – 2- Benzimidaz

5 MT/M

6 Chlorzoxazone (5 – Chloro – 3 – H Benzooxa-

zolonone) OR 5 – Chloro – 2 – Benzoxazolione 10 MT/M

7 4 CAP (4 Chloro 2 Amino Phenol) 25 MT/M

8 Peraphenylene Diamine 50 MT/M

9 2.5 Dichloro Peraphenylene Diamine 10 MT/M

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Salient Features with in 10 km radius surroundings area as follows:

S.No Important Features Description

1 Location Survey No. : 621, Jagudan – Kochva Road,

Village: Jagudan, Taluka & District: Mehsana

2 Topomap F43A7

3 Longitude 72°24'32"E

4 Latitude 23°30'40"N

5 MSL 127 m

6. Nearest power station UGVCL (Uttar Gujarat Vij Company Ltd.)

7 Proponent Name Mr. Ritesh R. Chaudhary

8 Corporate office address Jayveer Pharma Chem, Near Sarvajanik

Vidhyalaya, Panch Limdi, Mehsana – 384001.

9 Temperature range 140 C to 430 C

10 Annual Rain fall 900 mm

11 Nearest Road SH 41 (0.75 Km)

12 Nearest Railway station Jagudan Railway Station– 0.68 Km

13 Nearest city Mehsana – 8.5 Km

14 Nearest village Jagudan – 0.5 Km

15 National HW NO NH 8 (43 Km)

16 State HW No SH 41 (0.75 Km)

17 Seismic Zone Zone-III (Less Active)

18 National Parks / Sanctuary None within 10 Km radius.

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2. Project back ground.

Pharmaceutical Drugs & their Intermediates used in treating different diseases

and health issues. For e.g: Domperidone is used to relieve symptoms of feeling sick

(nausea) and sickness (vomiting). The proposed product have good market

demand.

Export Possibility.

There is good possibility for export. But currently we are focused to local sale

market for distribution.

Employment Generation (Direct and Indirect) due to the project.

This project will provide direct employment to 12 people whereas it will provide

employment to many others indirectly.

3. Project Description

(i) Type of project including interlinked and interdependent projects.

Pharmaceutical Drugs & their Intermediates used in treating different

diseases and health issues. It is sometimes dependent on units producing

Intermediate products.

(ii) Location

Longitude: 72°24'32"E

Latitude : 23°30'40"N

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Google Image of Proposed Location.

Key Plan of proposed site

Project site

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(iii) Project description with process details

MANUFACTURING PROCESS

1. N-METHYL – 4- PIPERIDONE (NMP)

Take 630 Kg Methyl Acrylate in dry reactor at 25 – 30 °C.

Charge 30% Mono Methyl Amine solution of 360 Kg (108 kg MMA in 252 kg

Methanol) in reactor at 20 ° C for 3 hrs. Keep stirring.

Maintain 20-25 °C temp for 6 to 8 hrs.

Check sample. If G.C. is ok than maintain temperature 30-35 °C for 2-4 hrs

Send sample for G.C. if G.C. is ok than cool reaction mass to 0°C.

Now charge weight wise Sodium Methoxide powder 200 Kg at temp 0-10 ° C in

8 hrs.

After completion of addition, heat the reaction mass to 40 °C.

Maintain 40 °C for 6 hrs and check T.L.C.

After this charge 1500 Lit of D.M. Water & 1500 L Chloroform. Slowly temperature

rises up to 55-60 °C. Maintain temperature for 2 hrs.

Send sample for T.L.C., if T.L.C. is ok than cool up to 35-40 °C.

Reaction mass extract with chloroform at 40-45 °C.

Total 1500 Lit chloroform extract (5x300 Lit).

Collect total chloroform extract in other distillation reactor.

Distilled out total chloroform.

Cool up to 25-30 °C. Transfer the materials in vacuum distillation reactor.

Start vacuum distillation and collect materials at temperature 90-120 °C.

Finally get product N-METHYL – 4- PIPERIDONE up to 250 Kg.

Mass Balance Table:

Input per batch Output per batch

Methyl Acrylate 630 NMP 250

MMA 30% 110 Effluent 2125

(Methanol) 252 Chloroform 1500

Sodium Methoxide 200 Methanol 252

D.M Water 1500 Waste Residue 65

Chloroform 1500

TOTAL 4192 4192

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PROCESS FLOW DIAGRAM OF N-METHYL – 4 - PIPERIDONE

S.S. Reactor 630 Kg Methyl Acrylate

360 Kg 30% MMA soln

(108 kg MMA in 252 Kg methanol)

200 Kg Sodium Methoxide powder

1500 Lit D.M Water

1500 Lit Cloroform

1500 Lit Chloroform

250 Kg Methanol for reused

250 kg Methanol

1500 lit Chloroform

315 Crude

250 Kgs Finished NMP

Vaccum Distillation

1500 lit wastewater

(2125 Kgs)

65 Kg Waste Residue

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REACTION FLOW

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2 N-METHYL – 4- CHLORO – PIPERIDINE (NMCP)

Charge N- Methyl 4- Piperidone 500 Kg (Aqueous Solution of 500 KG NMP and

500 Kg D. M. Water in hydrogenator at 25 – 30 °C) in hydrogenator. Then charge

Ranny Nickle catalyst of 20 Kg and close the main hole.

Purge N2 gas for removal of O2 gas and purge H2 gas for removal of O2 & N2 gas.

Pass & purge hydrogen gas at 4-6 Kg pressure.

Start hydrogenator and pass H2 gas up to consumption of H2 should be nil.

Check sample for G.C. & T.L.C. if ok than filter the materials and collect catalyst.

Collect mother liquor in vacuum distillation reactor.

Start vacuum distillation up to 110 °C. Recovered 500 Lit of water and reused.

500 Kg of N- Methyl – 4- Hydroxy Piperidine (NMHP) is obtained.

Take 150 Lit of toluene and 500 Kg NMHP and mix it.

Charge 800 Kg of Thionoyl Chloride in glass line reactor with 2000 L toluene at

25-30 °C.

Start charging of mixture of toluene and NMHP in glass line reactor at below 60 °C

for 5-6 hrs.

Raise the temperature up to 60-65 °C for 1 hr and maintain it for 6 hrs. Now cool it

at 20-25 °C.

Charge slowly D. M. Water of 700 Lit at 25-30 °C and stir for 1 hr.

Settle and separate product (aqueous) layer. Now take this aqueous layer in

another reactor.

Slowly add 600 Lit of soda solution 25 % (150 Kg soda ash in 500 Lit water) for 3-

4 hrs.

Add 200 Kg of caustic lye up to 50° C for 1-2 hr and add 1050 Lit chloroform for

extraction.

Collect extract chloroform in distillation reactor and distil out chloroform up to

110°C. Cool up to 30-35 °C.

Now start high vacuum distillation and collect final product NMCP at 80-110 °C.

Final output 450 Kg of NMCP is obtained.

Liquid Effluent 1300 lit. is also obtained.

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Mass Balance Table:

Input per batch Output per batch

NMP 500 NMCP 450

DM Water 1700 Spent Catalyst 20

R. Nickle 20 Distilled Water 500

Thionyl chloride 800 Toluene 2150

Toluene 2150 Effluent 2350

Soda 150 Chloroform 1050

Caustic Lye 200 Residue 50

Chloroform 1050 NMCP 450

TOTAL 6570 TOTAL 6570

PROCESS FLOW DIAGRAM OF N-METHYL – 4- CHLORO PIPERIDINE

Hydrogenetor 500 Kg NMP

500 Kg DM water

20 Kgs Ranny Nickle

H2 Gas

N2 Gas

Reactor

Glass Lined Reactor 800 Kg Thionyl Chloride in

2150 litres Toluene

700 Lit D.M water

20 Kg Spent Catalyst for resell

500 Litres Distilled Water

Vaccum Distillation

NMCP 450 Kg

1050 Litre Chloroform

distilled and reused

1300 Litre Effluent

(2350 Kg)

Distillation reactor

Separation of Aqueous

Layer

2150 litre Toluene distilled for reuse

50 Kg Residue

Vaccum Distillation

Final Product NMHP

500 Kg

25% 600 Litres Soda Soln

(150 Kgs in 500 litres water)

200 Kg Caustic Lye

1050 litre Chloroform

Distillation

O2 Gas

N2 Gas

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REACTION FLOW

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3 D-7 (5- CHLORO – 1 (4 – PIPERIDYL) 2 - BENZIMIDAZOLONONE

Stage 1 – D3 N-CARBETOXY 4-PIPERIDONE (NCP)

Charge 1500 Lit toluene and 300 Kg Ethyl chloroformate (ECF) & 30 kg

Caustic lye in reactor at 25-30 °C .

Raise the temperature up to 40-45 °C.

Start addition of mixture of 250 Kg (N-METHYL -4-PIPERIDONE) and 200 lit

Toluene at 40-45 °C within 8 hrs. Maintain temperature up to 50-55 °C for 6

hrs.

Check T.L.C. if ok than add 250 Lit D. M. Water & 30 kg caustic Lye. Settle and

separate the aqueous layer in other distillation reactor.

Start distillation up to 110-125 °C for toluene recovery. Also start vacuum

distillation to recover solvent traces.

Cool it and transfer vacuum distillation reactor. Start vacuum distillation up to

100-125 °C.

Collect 250 kg product NCP (N-CARBETHOXY 4-PIPERIDONE). Also collect

water effluent up to 250 Lit.

Mass Balance Table:

Input per batch Output per batch

Toluene 1700

Carbethoxy

Piperidine 250

ECF 300 Effluent 530

NMP 250 Toluene 1700

D.M. Water 250 Waste residue 50

Caustic Lye 30

TOTAL 2530 2530

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PROCESS FLOW DIAGRAM OF D-3 (NCP)

S. S. Reactor

1700 Lit Toluene

300 Kg Ethyl chloroformate

250 Kg NMP

250 Lit D. M. Water

30 Kg Caustic Lye

Extraction /

Separation

Distillation

250 Kg N-CARBETHOXY

PIPEDINE

250 Lit 7.0 pH water effluent

(530 Kgs)

1650 Lit Toluene Reuse

10 Kgs residue Solid

waste

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Stage -2 - D-4, 4 –AMINO-NCP

Charge NCP 750 Kg at 25-30 °C in hydrogenator. Also charge 900 Lit Methanol

under vacuum.

Charge 15 kg of Ranny nickel catalyst at 25-30°C. Remove nitrogen with vacuum

and cool to 10-15°C.

Charge 900 L Ammonical nitrogen at 15-20°C. Pass hydrogen gas until the

pressure 0.8 to 1 Kg/Cm2 at 20-25°C.

Maintain H2 pressure 0.8 to 1.0 Kg at 25-30 °C for 12 hrs or up to H2 gas

consumption should be nil.

Send the sample for G.C. & T.L.C. If it is ok than release the H2 by passing N2 gas.

Filter the batch & collect used catalyst. Collect mother liquor in distillation reactor.

Start distillation up to 110-115°C. Also apply vacuum for 1-2 hrs at 110-115°C.

Cool it up to 25-30 °C and collect in drum.

Final product of 750 Kg D-4, 4 – Amino – N – Carbethoxy Piperidine (NCP) will be

obtained.

Mass Balance Table:

Input Kg per batch Output Kg per batch

NCP 750 4-Amino NCP 750

Ammonical

Methanol 15% 900 Spent Nickle 15

R. Nickle 15

Ammonical

Methanol 15% 850

Residue 50

TOTAL 1665 1665

PROCESS FLOW DIAGRAM OF D-4 – 4 – AMINO NCP

HYDROGENATOR 750 Kg NCP

900 Lit Ammonical

Methanol 16%

15 Kg R. Nickle catalyst

H2 Gas

Distillation

250 Lit 7.0 pH water

effluent

850 Liters

Ammonical Methanol

16% for reuse

50 Kg Residue

Spent Nickle catalyst 15

Kg for resale

750 Kg 4- AMINO NCP

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REACTION FLOW

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Step -3 D-5, DINITRO (4-(2-NITRO – 5- CHLORO ANILINE) NCP)

Charge 375 Kg 4-Amino-NCP at 25-30 °C

Charge 450 Kg 2.5 DCNB, 150 Kg Soda Ash and 150 Kg Potassium Iodide with

stirring at 25 – 30 °C.

Slowly raise temperature up to 100-105 °C in 1 hr and maintain it for 1 hr.

Now again slowly raise temperature up to 135-140°C in 1 hr and maintain it for

10 hrs.

Check sample for T.L.C., if ok then cool it to 70°C.

Charge 1200 Lit D. M. Water. Stir for 1 hr and cool to 40°C.

Centrifuge the mass and collect the effluent.

Pack the product of nitro compound of 675 kgs in bags.

Mass Balance Table:

Input Kg per batch Output Kg per batch

4-Amino NCP 375 D5 DINITRO 675

2.5 DCNB 450 Effluent 1650

Soda Ash 150

Potassium Iodide 150

D.M. Water 1200

TOTAL 2325 2325

PROCESS FLOW DIAGRAM OF D-5 DINITRO

`

Water 1200 Lit

S. S. Reactor 375 Kg 4-Amino NCP

450 Kg 2.5 DCNB

150 Kg Soda Ash

150 Kg Potassium Iodide

Wash with D. M. Water

Centrifuge Filtrate

1200 Lit pH 8.0 water

effluent

(1650 KGs)

675 Kg 4- AMINO NCP

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Stage – 4- D-6 – DIAMINE (4-(2-AMINO-5- CHLOROANILINE)-N- CARBETHOXY

PIPERIDINE)

Take 810 Lit Methanol and 810 Lit Toluene in Hydrogenator at 25-30°C. Also

charge 675 Kg D-5, DINITRO compounds.

Charge 15 Kg Ranny Nickel catalyst at 25-30°C. Close main hole of hydrogenator

and passing N2 gas for removal of O2 gas.

Passed H2 gas for removal of oxygen and Nitrogen.

Passing H2 gas upto 6 kg pressure, 105 °C temperature.

Maintain H2 Pressure 6 kg up to consumption NIL. Approximately 190 M3 H2 gas

will be consumed.

Check T.L.C., if ok than filter the batch and collect catalyst and mother liquor.

Collect mother liquor in distillation reactor.

Distil out solvent up to 100-110°C for reuse. Cool the batch up to R.T.

Filter in vacuum nutch and centrifuge the mass.

500 Kg of Diamine product is ready for pack.

Mass Balance Table:

Input Kg per batch Output Kg per batch

Methanol 810 D6 Diamine 500

Toluene 810 Spent Nickle 15

D5 Di Nitro W/C 675 Mix Solvent 1570

R. Nickle 15 Effluent 225

TOTAL 2310 2310

PROCESS FLOW DIAGRAM OF D-6 –DIAMINE (4-(2-AMINO-5 CHLOROANILINE)-NCP)

HYDROGENATOR

810 Lit Methanol

810 Lit Toluene

675 Kg D5

15 Kg R. Nickle catalyst

190 m3 H2 Gas

N2 Gas

Distillation/ Chilling 10 Kg Residue

1500 L mix Solvent

Spent Nickle catalyst 20

kgs for resale

N2 & O2 gas

500 Kg DIAMINE

Solvent Recovery 70 L mix Solvent

200 L (225 Kg) Effluent

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REACTION FLOW

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Stage – 5 – D-7 (5-CHLORO -1 (4-PIPERIDYL)-2-BENZ-IMIDAZOLONONE)

Charge 500 Kg of D6-DIAMINE in reactor with 250 Kg Urea at 25-30 °C.

Slowly raise the temperature up to 180-185°C for 2 hrs and maintain same

temperature for 6 hrs.

Check sample for T.L.C., if O.K than cool the material at 100-110°C.

Now charge 1000 Lit D.M. Water and 60 Kg Caustic lye at below 110°C.

Transfer the batch into other reactor and charge 2000 Lit D.M. Water & 1000 Kg

48% caustic lye at below 80-85°C.

Raise the temperature up to 99-101°C and maintain for 10 hrs.

Check the sample for T.L.C, if ok than cool the material up to 80-85°C and charge

15 Kg Carbon. Stir it for 1 hr and filter the batch. Collect mother liquor in other

reactor and cool to 25-30°C.

Now charge Ammonium Chloride (400 kg in 1000 Lit Water) solution at 25-30°C.

Centrifuge the materials & spin dry for 45 min.

Unload the cake

In glass line reactor, charge 2500 Lit D.M. Water and charge material cake at R.T.

Adjust pH 2.0 by adding 200 Lit HCl at 20-25 °C.

Cool to 10°C and stir for 1 hr. Centrifuge the material. Unload the material cake.

Charge 2500 Lit D. M. Water and 1000 Lit 25% Ammonia Solution in reactor.

Charge materials cake at R.T. Slowly apply heat up to 50-55°C and maintain for 6

hrs.

Centrifuge the materials at same temperature. Unload the material and dry at 80-

90°C till moisture content below 1.0 %.

Pack the 450 Kg quantity of D-7 (5-CHLORO -1 (4-PIPERIDYL)-2-BENZ-

IMIDAZOLONONE)

Collected Effluent quantity is also 10000 Lit.

Mass Balance Table:

Input Kg per batch Output Kg per batch

D6 diamine 500 D-7 500

Urea 250 Spent carbon 15

Caustic lye 1060 Effluent 11525

D.M. water 8000

carbon 15

Ammonium

Chloride 1000

HCL 200

Ammonia

Solution 1000

TOTAL 12025 12025

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PROCESS FLOW DIAGRAM OF D-7 (5-CHLORO -1 (4-PIPERIDYL)-2-BENZ-

IMIDAZOLONONE)

S. S. Reactor /

Hydrolysis

500 kg Diamine

250 Kg Urea

60 Kg Caustic Lye

1000 Lit D. M. Water

S. S. reactor

Reactor

500 Kg D-7

1000 Kg Caustic Lye

2000 Lit D. M. Water

15 Kg Carbon

Ammonium Chloride

Solution 25 % (1000kg)

Centrifuge and Spin

Dry

4000 Lit 10-12 pH

alkaline effluent

(4500 KG)

Glass line Reactor 2500 Lit D. M. Water

200 Lit HCl

After filtration

2500 Lit 2-3 pH acidic

effluent (2700 KG)

S. S. Reactor 2500 Lit D. M. Water

1000 Lit 25% NH3

Solution

After filtration

3500 Lit alkaline effluent

(4310 KG)

15 Kg Carbon

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REACTION FLOW

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4. D-2 [1 – (3- CHLOROPROPYL)-1- DIHYDRO-2-H-BENZIMIDA-

ZOLONE ]

Stage – 1 – D-1 Charge 2000 Lit of O – Xylene in reactor at 25-30° C.

Raise the temperature up to 140 °C and reflux for removal of moisture for 2 hrs at

140°C.

Now charge weight wise 300 Kg Ortho Phynylene Diamine (OPD) and 360 Kg

Methyl Aceto Acetate (MAA) at 140°C every two hrs and collect water.

Maintain 140C° temperature for 10 hrs and check the sample for T.L.C. If T.L.C. is

ok then distil out 2000 lit O-Xylene for reused.

Cool to R. T. than chill up to 10°C. Centrifuge the materials and wash with 1:3

volume as O-xylene : Hexane (30 Lit + 90 Lit).

Spin dry the cake for 45 min and unload the materials. Dry the materials at 60-

70°C. So we get 360 kg material cake.

Charge 2000 Lit water and 360 Kg dry mass cake in S.S. reactor.

Stir for 15 min and raise temperature up to 45°C.

Adjust pH 12-13 by addition of 300 kg caustic lye at 45°C up to dissolution.

Stir for 1 hr at 45-50°C till solution should be clear. Charge 5 Kg carbon and stir

for 1 hr.

Clarify the materials. Collect filtrate in other reactor. Adjust pH 4.0 by adding 240

Kg HCL at 30-35°C.

Centrifuge the materials and wash with 160 Lit D. M. Water. Spin dry for 45 min.

Unload the mass and dry at 60-70°C. We get 360 Kg D-1.

About 2160 Lit water effluent will be generated.

Mass Balance Table:

Input per batch Output per batch

O-Xylene 2030 D-1 360

OPD 300 carbon 5

MAA 360 O-Xylene 2000

DM water 2376 Effluent 3221

Hexane 90 Residue 15

Caustic Lye 200

carbon 5

HCL 240

TOTAL 5601 5601

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PROCESS FLOW DIAGRAM OF D-1

S. S. Reactor 2000 Lit O-Xylene

300 Kg OPD

360 Kg MAA

216 Lit Distil Water

Reflux 140oC

Centrifuge / Spin Dry

Centrifuge and Spin

Dry

S.S. Reactor 2000 Lit D. M. Water

300 Kg Caustic Lye

5 Kg Carbon

Reactor 240 Kg HCL

160 Lit D. M. Water

360 Kg Finish product

D-1

5 Kg Spent Carbon

15 kg residue

2160 Lit effluent

(3221 KG)

2000 Lit O-Xylene distilled & reuse 30 L O-Xylene

90 L Hexane

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Stage -2 – D-2

Charge 2150 Lit Acetone at 25-30°C in reactor. Also charge 720 Kg D-1 material at

25-30°C.

Stir for 1 hr till solution should be clear. Add 360 Kg caustic lye to reaction mass at

25-30°C in 3-4 hrs than add 5 Kg TEBAC as catalyst.

Maintain temperature up to 15-20°C for 2 hrs.

Add 840 Kg (1-Bromo -3 Chloro-Propane) BCP at 30-35 °C for 3-4 hrs.

Maintain temperature up to 25-30°C for 10 hrs.

Check T.L.C. of sample if ok then settle the batch for 1 hr. separate the aqueous

layer in clean container.

Now collect oily aqueous layer in glass line reactor. Charge dilutes 1500 Lit HCl at

25-30 °C and raises the temp up to 55-60°C for 4 hrs.

Cool the mass to 30-35°C and observe the material formation. Maintain the same

temp for 1 hr.

Centrifuge the mass. Spin dry for 45 min and unload the dry materials at 55-60 °C.

We get 800 Kg D-2.

Mass Balance Table:

Input per batch Output per batch

Acetone 2150 D-2 800

D-1 720 Acetone 2150

TEBAC 5 Effluent 2610

BCP 840 Residue 10

Caustic Lye 360 Catalyst 5

HCL 1500

TOTAL 5575 5575

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PROCESS FLOW DIAGRAM OF D-2

S. S. Reactor 2150 Lit Acetone

720 Kg D-1 mass

5 Kg TEBAC

840 Kg BCP

360 Kg Caustic Lye

Centrifuge / Spin Dry

Glass Line Reactor

1500 Lit HCL

2150 Lit recover Acetone for distil &

reuse

800 Kg Finish product

D-2

10 kg Organic Residue

5 kg catalyst

1750 Lit 7.0 pH water

effluent (2610 KG)

Glass Line Reactor

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REACTION FLOW

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5. DOMPIRIDONE

5- CHLORO-1-(1-L3-L2-OXO-1-BENXIMIDAZOLINYL) PROPYL) -4-

PIPERIDYL)-2-BENZIMIDAZ

Process

Charge 200 kg M.I.B.K at 25-30 °C in reactor. Now charge 176 Kg D-2, 200 Kg D-7

and 2 Kg Potassium Iodide at 25-30°C in same reactor.

Raise the temperature to 88-90 °C. Add the 144 Kg weight wise Soda ash for every

45 min and record the temperature.

Maintain temperature 88-90 °C for 9 to 10 hrs. Cool the mass to 30 - 35 °C and stir

for 30 - 35 °C for 1 hr.

Centrifuge the materials and unload the wet cake.

Now charge 1500 Lit D. M. Water into another reactor. And add wet cake at R. T.

Raise temperature to 65-70°C.

Charge Ammonium Chloride solution (200 Kg in 1000 Lit) at 60-65°C. Raise the

temp to 65-72°C and maintain for the same for 2 hrs.

Cool to R.T. and maintain for 1 hr.

Centrifuge the materials.

Spin dry for 45 min.

Dry the product and get 320 Kg DOMPIRIDONE AT 80-90 °C

Collect 1800 Lit effluent.

Mass Balance Table:

Input per batch Output per batch

M.I.B.K 200 Dompiridone 320

D-2 176 M.I.B.K 202

D-7 200 Effluent 2950

potassium Iodide 2

Soda ash 144

D.M Water 1750

Ammonium

Chloride solution 1000

TOTAL 3472 3472

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PROCESS FLOW DIAGRAM OF DOMPIRIDONE

S. S. Reactor 200 Lit M.I.B.K.

176 Kg D-2

200 Kg D-7

2 Kg Potassium Iodide

144 KG Soda Ash

Centrifuge / Spin Dry

S. S. Reactor 1500 Lit D. M. Water

1000 Lit 20 % soln. of

Ammonium Chloride

200 lit. M.I.B.K. solvent for distil and

reuse (202 KG)

320 Kg Finish product

DOMPIRIDONE

1800 Lit 7.0 pH water

effluent (2950 KG) 250 Lit D. M. Water Wash

Centrifuge

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REACTION FLOW

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6. 4-CAP (4-CHLORO 2 –AMINO PHENOL)

Process

Take 5500 Lit water in Autoclave.

Charge 600 Kg Caustic flakes or 1250 Kg Caustic lye under stirring. Also charge 1000

Kg 2.5 DCNB slowly with stirring. Close the main hole.

Start heating up to 145-148°C and maintain same temperature for 6 hrs. Take sample

and check melting point and T.L.C.

Cool to 100 °C and release pressure.

Transfer the materials in other M.S. open reactor.

Cool to 20-25°C by adding cooling water.

Filter the batch in nutch filter and centrifuge the materials.

Check the purity and moisture.

Collect the effluent 3000 Lit.

Hydrogenation

Take 3000 Lit water in hydrogenator and charge nitro wet cake in hydrogenator.

Adjust pH 12.5 to 13 by adding caustic lye.

Now charge Platinum/ Carbon catalyst.

Close the main hole and start purge of N2 gas for removal of O2 gas up to Nil.

Start purging of H2 gas two times for removal of N2 & O2 gas. Take pressure 5 Kg of H2

gas.

Start stirring and maintain 5 kg pressure up to reduction completed.

Check T.L.C., if it is ok then filter the batch and collect catalyst for recycle and reuse.

Collect mother liquor in HDPE reactor. Adjust pH up to 4-4.5 by adding HCl.

Filter the mass by nutch filter , centrifuge it ,dry and pack it.

Collect the effluent 2500 Lit.

Mass Balance Table:

Input per batch Output per batch

Water 8500 4 CAP 600

2.5 DCNB 1000 catalyst 8.5

Caustic Flakes 600 Effluent 9800

Platinum Catalyst 8.5

HCL 300

TOTAL 10408.5 10408.5

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PROCESS FLOW DIAGRAM OF 4- CHLORO – 2 – AMINO PHENOL

M. S. Autoclave 5500 Lit water

1000 Kg 2.5 DCNB

600 Kg Caustic Flakes

HDPE Reactor

Hydrogenator

3000 Lit water

8.5 Kg Platinum catalyst

H2 gas

(365 m3 H2 gas)

5500 Lit Alkaline effluent with salt

(6100 KG)

600 Kg Finish product 4

CAP

3000 Lit water effluent

(3700 KG)

Filter 8.5 KG Recovered catalyst for reuse

Filter / Centrifuge

HCL 300 KG

Filter

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REACTION FLOW

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7. CHLOROXAZONE (5-CHLORO-3-H BENZOOXA-ZOLONONE) OR

5-CHLORO-2-BENZOXAZOLIONE

Process

Take 1250 Kg HCL in glass line reactor. Charge 800 Kg real 4 –CAP wet cake in

glass line reactor with stirring. Stir for half hour.

Now add 1065 Kg Urea in glass line reactor with stirring. Close the main hole of

reactor.

Start heating slowly up to 100-101°C for reflux. Reflux for 5-6 hrs up to T.L.C. of

sample shows ok.

Check the pH, it should be 6.0-6.5.

Cool the mass to R. T.

Filter the batch and centrifuge it.

Collect effluent water quantity of 2000 Lit.

Purification

Take 1000 Lit Methanol and charge crude wet cake with stirring.

Heat up to 65-70°C for reflux. Add 10 Kg carbon and reflux for 2 hrs.

Filter the batch and collect mother liquor in other reactor.

Cool the mass to 0-5°C.

Now filter the mass & centrifuge for drying.

Dry the materials and pack.

Mass Balance Table:

Input per batch Output per batch

Real 4 CAP wet

cake 800 CHLOROXAZONE 800

Urea 1065 Effluent 2315

HCL 1250 Carbon 10

Methanol 1000 Methanol 1000

Carbon 10

TOTAL 4125 4125

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PROCESS FLOW DIAGRAM OF CHLORZOXAZONE

Glass Line Reactor 800 Kg Real 4-CAP wet

cake

1065 Kg Urea

1250 Kg HCl

Centrifuge / Chilling

S. S. Reactor 1000 Lit Methanol

10 Kg Carbon

2000 Lit 6.5 to 7.0 pH water effluent

(2315 kg)

800 Kg Finish product

CHLOROXAZONE

1000 Lit Methanol

recovered for reuse

Centrifuge

800 kg

Reflux & Filter

Solid waste 10 Kg carbon

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REACTION FLOW

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8. Peraphenylene Diamine (PPD)

Process :

Take 2500 Lit. Ethyl Acetate in hydrogenation. Charge pera nitro aniline 1600 kg at R. T. Add 11 kgs Ranny Nickle catalyst Purge N2 gas for removing oxygen. Take hydrogen pressure 5 kg. & start stirring. Maintain H2 gas passing upto consumption of H2 Nil Maintain temperature 65 – 70 ºC. H2 gas consumption nil. Then check T.L.C. if ok than filter the batch to collect M.L. in other distillation Reactor & collect spent catalyst for resell Start vaccum distillation for final product packing.

Mass Balance Table:

Input per batch Output per batch

PNA 1600 PPD 1225

Ethyl Acetate 2500 Catalyst 11

R. Nickle 11 Ethyl Acetate 2500

H2 Gas 50 Distilled water 400

waste residue 25

TOTAL 4161 4161

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PROCESS FLOW DIAGRAM OF PERAPHENYLENE DIAMINE (PPD)

Reactor 1600 Kg. PNA

2500 Kg Ethyl Acetate

11 Kg Ranny Nickle

catalyst

480 m3 H2 Gas

Distillation

11 Kg Spent catalyst for resale

Vaccum Distillation

PPD 1225 Kg

Final Product

2500 Kg Ethyl Acetate Reused

400 Liter Distilled Water reused

Filter

25 Kg Waste Residue.

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REACTION FLOW

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9. 2-5 Dichloro Pera Phenylene Diamine Process

Take 0.5 times 1500 Lit mix solvent in Hydrogenator.

Charge 300 Kg 2.5 DCPNA & stirring at R. T.

Charge palladium / carbon catalyst 2.1 kg.

Close the main hole & start N2 gas purge for removing Oxygen.

Purge H2 gas upto 5 kg Pressure

Start hydrogenation

Heat upto 80 – 82 ºC.

Hydrogenation continuous upto H2 gas consumption nil

Take sample & check T.L.C.

If T.L.C. ok than filter the batch

Collect filtrate in other reactor

Chill upto 5 – 10 ºC.

Nutch to C/F the materials. Solvent for distillation & reuse.

Dry the materials 250 kg. & packed

Mass Balance Table:

Input per batch Output per batch

Mix solvent 1500 2.5 DCPPD 250

2.5 DCPNA 300 catalyst 2.75

Pd/Co catalyst 2.1 Mix Solvent 1500

Residue 50

TOTAL 1802.1 1802.1

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PROCESS FLOW DIAGRAM OF 2-5 DICHLORO PERA PHENYLENE DIAMINE

Reactor 1500 lit mix solvent

300 kg 2.5 DCPNA

2.1 kg Pd/C catalyst

90 m3 H2 gas

Chilling/ Nutch Filter 10 Kg Residue

1500 Lit Mix Solvent For reuse

2.1 Kg. catalyst recycled or reuse

2.5 DCPPD

250 Kg

Filter / Centrifuge

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REACTION FLOW

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ANNEXURE – 4

List of Raw Materials

No. Product Raw Materials Qty

Per Month

1 N-METHYL – 4- PIPERIDONE

Methyl Acryalate 17500 Kgs

Mono Methyl Amine

(30% Solution in Methanol)

4900 Kgs

Sodium Methoxide Powder 5600 Kgs

Chloroform 12000 Kgs

D. M. Water 40000 Lit

2 N-METHYL – 4- CHLORO –

PIPERIDINE

(NMCP)

N-Methyl – 4 – Piperdone 2200 Kgs

Nickle Catalyst 80 Kgs

D. M. Water 4700 Lits

Hydrogen Gas 125 m3

Thionyl Chloride 3200 Kgs

Toluene 3000 Kgs

Caustic Lye 800 Kgs

Soda Ash 600 Kgs

Chloroform 2500 Kgs

3

D-7

5-CHLORO-1-(4-PIPERIDYL)- 2 –

BENZIMIDAZOLONONE

N-Methyl – 4- Piperidone 5000 Kgs

Ethyl Chloro Formate 5760 Kgs

Toluene 7000 Kgs

D. M. Water 140000 Lits

Ammonical Methanol

(15 To 17 % Solution)

3000 Kgs

Ranny Nickle Catalyst 300 Kgs

Hydrogen Gas 3000 m3

2,5,Dichloro Nitro Benzene 6000 Kgs

Soda Ash 2000 Kg

Urea 3600 Kg

Methanol 2000 Kgs

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Caustic Lye 12000 Kgs

Ammonium Chloride 5000 Kgs

HCl 2000 Kg

NH3 Liq. 25 % Soln 12000 Kg

Carbon 300 Kg

Nitrogen Gas 300 m3

4

D-2

1 – (3- CHLOROPROPYL)-1-

DIHYDRO-2-1-1-

BENZIMIDA-ZOLONE

Ortho Phenylene Diamine (OPD) 3200 Kg

O-Xylene 4500 Kg

Methyl Aceto Acetate (MAA) 3600 Kg

Caustic Lye 3500 Kg

HCl 10500 Kg

N-Hexane 1000 Kg

Caustic Flakes 1500 Kg

1-Brumo-3-Chloro Propane (BCP) 4000 Kg

Tebac (Catalyst) 350 Kg

Acetone 2500 Kg

Benzene 2500 Kg

D. M. Water 35000 Lit

5

DOMPIRIDONE

5- CHLORO -1-(1-L3-L2-OXO-1-

BENXIMIDAZOLINYL)

PROPYL) -4-PIPERIDYL)-2-

BENZIMIDAZ

D-2 4000 Kg

D-9 4500 Kg

M.I.B.K. (Methyl Iso Butyl Ketone) 5000 Kg

Soda Ash 3200 Kg

Ammonium Chloride 4500 Kg

D. M. Water 50000 Lit

Methanol 7000 Kg

6

CHLORZOXAZONE

(5-CHLORO-3-H BENZOOXA-

ZOLONONE)

OR 5-CHLORO-2-

BENZOXAZOLIONE

4-CAP 10000 Kg

HCl 15500 Kg

Urea 13500 Kg

D. M. Water 30000 Lit

Methanol 5000 Kg

Carbon 300 Kg

Acetic Acid 3500 Kg

7 4-CAP

(4-CHLORO 2 –AMINO PHENOL)

2,5 Dichloro Nitro Benzene (2,5 DCNB) 40000 Kg

Caustic Flakes 22500 Kg

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D. M. Water 325000 Lit

Platinum / Carbon Catalyst 200 Kg

Hydrogen Gas 9360 m3

Nitrogen Gas 500 m3

8 PARAPHENYLENE DIAMINE

Para Nitro Aniline 65500 Kg

Ethyl Acetate 2500 Kg

Ranny Nickle Catalyst 450 Kg

Hydrogen Gas 2850 m3

9 2.5DICHLORO

PARAPHENYLENE DIAMINE

Mix Solvent 1250 Kg

2.5 Dichloroparanitroaniline 11500 Kg

Pd/Co catalyst 85 Kg

Hydrogen Gas 300 m3

1. Resource optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

Our main raw materials are easily available from developmental city like Baroda, Surat,

etc.

2. Availability of water its source, Energy/ power requirement and source should

be given.

Water source: Bore well

Energy/power requirement: 105 HP from UGVCL

3. Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal.

Solid waste generation and disposal

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Sr.

no.

Description Category Total Quantity

per Month

Mode of Disposal

1 Used oil/Spent

Oil

5.1 0.1 MT Collection, storage and Use

within premises as a

lubricant/ sell to registered

recycler

2 Discarded

Plastic Bags/

Drums

33.3 0.8 MT Collection, storage and reuse

within premises / sell to

approved scrap vendor.

3 Waste Residue 28.1 4.5 MT Collection, storage and

incinerated at authorized

CHWIF site.

4 Spent Carbon 28.2 0.3 MT Collection, storage and

incinerated at authorized

CHWIF site.

5 Spent Catalyst 28.2 0.3 MT Collected, Stored and sold to

registered Recycler.

6 ETP Sludge 34.3 22.5 MT Collection, storage and

disposal at authorized TSDF

site.

Waste water generation and Disposal facility

21500 liters waste water will be generated from the Industrial activity.

Effluent treatment plant:

(1) 2 KL/day : Boiler Blow down

(2) 4 KL/day : Washing

(3) 0.5 KL/day : Cooling tower blow down

(4) 15 KL/day : Process Wastewater

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Description of ETP Process

The Waste water from the process will be divided into three streams:

1) High COD stream 2) Stream with high Ammonical Nitrogen 3) Other Effluents

The stream with high COD will be treated in Multi Effect Evaporator.

The Stream with high Ammonical Nitrogen will be passed through Ammonia stripper. Then it will be added with the other effluent stream.

The other effluent Stream will be given complete treatment as follows: First of all, the effluent is given Primary treatment. The effluent will be collected in a collection tank. Then it will be passed through Oil & Grease removal Tank from where Oil will

be collected in Drums. Then the effluent will be given Lime- Alum treatment in Neutralization cum

Equalization Tank which will be followed by Primary Settling Tank for chemical sludge removal.

After this, Biological treatment will be given by means of Aeration Tank where microbes will consume the COD.

This will be followed by secondary settling tank where biological sludge will be removed.

Now this treated effluent will be collected in Treated effluent sump from it will be given tertiary treatment.

The treated effluent will be passed through Pressure Sand Filter and Activated Carbon Filter and collected in Treated Water Sump.

From there, the water will be given pretreatment for Reverse Osmosis in form of Ultra filtration.

Finally this water will be treated by and reused in Gardening, Boiler and Cooling Tower.

The Reject from Ultra filtration & Reverse Osmosis will be sent to Multi Effect Evaporator.

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ETP DIAGRAM:

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4. Schematic representations of the feasibility drawing which give

information of EIA purpose.

The acceptability of the S.O.1533 for the expansion project was explored by

considering different possibilities & provision made in the said notification.

Considering the products & project’s location of the proposed Expansion project,

It is notified that the proposed project falls under Category 5(f)”B” of the

schedule of EIA notification and its amendments.

As per the provisions of the notification, it is necessary to get Environmental

Clearance by applying to MoEF or SPCB, along with the Environmental Impact

Assessment report for the expansion project prior to commissioning of the

expansion activities. Therefore the EIA is required to conduct.

4. Site Analysis

(i) Connectivity.

Nearest Railway

station Jagudan 0.68 Km

Nearest National

highway NH 8 43 Km

Nearest Airport Ahmedabad 53.5 Km

Nearest State highway SH 41 0.75 Km

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(ii) Land Form, Land use and Land ownership.

Fig: 1 Land use pattern

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(iii) Topography (along with map).

Fig: 2 Legendry map of Surendranagar district

Project site

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(iv) Existing land use pattern.

Existing land use pattern shown in fig no: 1

(v) Existing Infrastructure.

(1) Nearest railway station: Jagudan Railway station is 0.68 Km in NW direction

from the project site

(2) Nearest Highway: state highway 41 is 0.75 km in W direction from the

project site.

(3) Nearest Airport: Ahmedabad is 53.5 km in SSE direction from the project site.

(4) Power: 105 HP from Uttar Gujarat Vij Company limited.

(5) Water : Source of the water is Ground water

(6) Basic amenities:

Educational facility: - Gujarat Polytechnic is 0.42 km in west direction from the project site.

Hotel: The Holiday Inn is 4.0 km away in South direction from the project site.

Post Office: - Post office, Sayla is 1.2 km away from the project site.

Hospital: - Sayla is 1.5 km away from the project site.

(vi) Soil classification of district Mahesana

Dominantly the Soils are very deep, well drained and fine and medium textured. They

are slightly alkaline, slight to strong saline. Soil depth in Uttar Gujarat is well distributed

in two parts. The Soils in western side are dominantly very deep followed by

moderately deep and in eastern part soils are dominantly shallow followed by

moderately shallow. The Soils in Mehsana District is dominantly distributed to very

deep soil depth class followed by shallow depth moderately deep soil are also observed,

Soil salinity in Uttar Gujarat varies from slight to strong salinity class. In Mehsana

District soil salinity belongs to slight to moderate.

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(vii) Climatic data from secondary sources.

Month

Air Temperature, °C Humidity, % Mean Wind

Speed,

Km/hr.

Predominating

Wind

Direction Max. Min. Max. Min.

July 2013 37 22.2 98 48 7 SW

August 2013 34.2 23.5 98 56 8 SW

September 2013 38.4 23.3 100 40 7 NW

October 2013 36 17.4 98 26 4 N

November 2013 35.8 12.8 91 24 5 NE

December 2013 32 8.3 97 23 5 N

January 2014 30.7 7 96 20 7 NE

February 2014 33.6 7.8 91 17 5 NE/NW

March 2014 38.7 12.4 87 14 5 WNW

April 2014 43.2 19.4 83 16 5 WNW

May 2014 44.5 24.4 82 12 7 SW

June 2014 45 27.5 81 22 11 SW

5. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town

and Country Planning/Development authority Classification.

Total available area is 6779 sq. meter out of it 2873 sq. meter area will be

provided as a greenbelt area.

(ii) Population Projection

In 2011, Mahesana had population of 2,035,064 of which male and female

were 1,056,520 and 978,544 respectively. In 2001 census, Mahesana had a

population of 1,837,892 of which males were 953,842 and remaining

884,050 were females. SThere was change of 10.73 percent in the population

compared to population as per 2001. Average literacy rate of Mahesana in

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2011 were 83.61 compared to 75.22 of 2001. If things are looked out at

gender wise, male and female literacy were 91.39 and 75.32 respectively.

With regards to Sex Ratio in Mahesana, it stood at 926 per 1000 male

compared to 2001 census figure of 927.

(iii) Land use planning (breakup along with green belt etc).

1 Built Up Area 1960 Sq. mt

2 Green belt area 2873 Sq. mt

3 Open/ Road area 1946 Sq. mt

Total Area 6779 Sq. mt

(iv) Assessment of Infrastructure Demand (Physical & Social).

Super Specialty and modern health facilities and medical stores are needed

around.

(v) Amenities/Facilities.

Industry will provide 2.5 % of total profit for CSR activity.

6. Proposed Infrastructure

(i) Industrial Area

Industry will provide 1960 square meters built up area for industrial process

activity. Which provide all needed facility including proper ventilation, safe

handling system, etc.

(ii) Residential Area

Industry will not provide labor quarter for their labors but will provide all

basic facilities to them.

(iii) Green Belt.

2873 sq. meter area will be proposed for greenbelt development. Approx

1430 sq. mt area will be proposed for tree cover area (approx 216 trees).

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(iv) Social Infrastructure.

The PP proposes the following social infrastructure facilities within 10.0 km periphery of the proposed project.

Education Facilities:-Many Facilities for village schools like game kits, drawing kits, table-chairs; school construction (classroom/toilet/school boundary), ceiling fans/ coolers or books for school library are proposed.

Health Facilities:-The PP proposes to provide assistance to existing

health facilities in Nearest Hospital, for improvement in health facilities or services.

(v) Connectivity

The nearest Town is Mehsana in N-direction. Approaching road state highway

no 41 is 0.75 km away from the project site.

(vi) Drinking Water Management

Out of 22 KL/day water approx 0.5 KL water will be consume for domestic

purpose; 5 KL/day (Reused: 5 KL/day) water will be consume for green belt

development and 21.5 KL/ day fresh water will be used for industrial purpose.

(vii) Sewerage System.

Domestic waste water 0.4 KL/day will be treated disposed in soak pit via septic

Tank.

(viii) Industrial Waste Management.

21.5 KL/day waste water will be generated from the process activity. It will

be treated in effluent treatment plant and evaporate after treatment.

(ix) Solid Waste Management

Used oil, ETP waste, discarded bags are the main solid hazardous waste

generated from the proposed unit. Used oil will be send to register recycler,

ETP sludge will collected from sludge drying bed, stored into solid waste

storage area and disposed to authorized TSDF site. Discarded bags will be

sold to approved vendor. Spent carbon and Waste residue will be sent to

authorized CHWIF for Incineration.

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(x) Power Requirement & Supply / source

105 HP from UGVCL.

7. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion

Start construction work: 1st week of December, 2015

Completion of construction work: March, 2016

(ii) Estimated project cost along with analysis in terms of economic viability of the

project.

Total project cost of Project is around 9 crores.