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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
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
REACTION FLOW
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
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
REACTION FLOW
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
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
REACTION FLOW
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
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.
REACTION FLOW
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
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
REACTION FLOW
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
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
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
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
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.
ETP DIAGRAM:
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
(ii) Land Form, Land use and Land ownership.
Fig: 1 Land use pattern
(iii) Topography (along with map).
Fig: 2 Legendry map of Surendranagar district
Project site
(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.
(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
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).
(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.
(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