PROPOSED BULK DRUGS & BULK DRUG ...environmentclearance.nic.in/writereaddata/Online/TOR/07...M/s. SHREE RAMDEV PHARMA CHEM PLOT NO. 2314-2315, PHASE – III, GIDC PANOLI, DIST: BHARUCH

1

FORM-1

for

PROPOSED BULK DRUGS & BULK DRUG

INTERMEDIATES IN EXISTING INORGANIC

PRODUCTS UNIT

of

M/s. SHREE RAMDEV PHARMA CHEM

PLOT NO. 2314-2315, PHASE – III, GIDC PANOLI,

DIST: BHARUCH (GUJ.)

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

2

APPENDIX I

(See paragraph - 6)

FORM 1

Sr.

No.

Item Details

1. Name of the project/s M/s. Shree Ramdev Pharma Chem

2. S. No. in the schedule 5(f)

3. Proposed capacity/ area/ length/ tonnage

to be handled/ command area/ lease area/

number of wells to be drilled

Please refer Annexure – I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. Proposed Capacity: 75 MT/Month

6. Category of Project i.e. ‘A’ or ‘B’ A

7. Does it attract the general condition? If yes,

please specify.

Yes. Located within 5 km of critically

polluted area (Ankleshwar).

8. Does it attract the specific condition? If yes,

please specify.

No

Location

Plot/Survey/Khasra No. Plot No. 2314-2315

Village GIDC Panoli

Tehsil Ankleshwar – 394 116

District Bharuch

9.

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Railway Station: Ankleshwar (5 km)

Airport: Surat (60 km)

11. Nearest Town, city, District Headquarters

along with distance in kms.

Panoli Village (2 km),

Bharuch (15 km)

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Panoli Village, Taluka: Ankleshwar – 394 116,

Dist: Bharuch (Gujarat)

13. Name of the applicant M/s. Shree Ramdev Pharma Chem

14. Registered Address Plot No. 2314-2315, GIDC Panoli, Tal:

Ankleshwar – 394 116, Dist: Bharuch (Guj)

Address for correspondence:

Name Mr. Pragnesh R. Patel

Designation (Owner/Partner/CEO) Partner

Address M/s. Shree Ramdev Pharma Chem

Plot No. 2314-2315, GIDC Panoli,

Ta. Ankleshwar – 394 116,

Dist: Bharuch (Guj)

15.

Pin Code 394 116

3

E-mail [email protected],

[email protected]

Telephone No. Phone : 02646 –650947, 272756

Mob. : +919227607734 & +919824407734

Fax No. NA

16. Details of Alternative Sites examined, if any.

Location of these sites should be shown on

a top of sheet.

NA

17. Interlinked Projects NA

18. Whether separate application of interlinked

project has been submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

21. Whether the proposal involves

approval/clearance under: if yes, details of

the same and their status to be given.

(a) The Forest (Conservation) Act, 1980?

(b) The Wildlife (Protection) Act, 1972?

(c) The C.R.Z. Notification, 1991?

No

22. Whether there is any Government

Order/Policy relevant/relating to the site?

No

23. Forest land involved (hectares) NA

24. Whether there is any litigation pending

against the project and/or land in which the

project is propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if any

and its relevance with the proposed

project.

NA

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,

mining lease area and production capacity for mineral production, area for mineral

exploration, length for linear transport infrastructure, generation capacity for power

generation etc.,)

4

(II) Activity 1. Construction, operation or decommissioning of the Project involving

actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes/No Details there of with approximate quantities

frates, wherever possible) with source of

information data

1.1 Permanent or temporary change in land

use, land cover or topography including

increase intensity of land use (with

respect to local land use plan)

No Proposed expansion is within the existing

premises of GIDC Panoli. Expected cost of the

expansion project is Rs. 325 Lakhs.

Total Plot Area = 3,766 m2

Green Belt = 400 m2

1.2 Clearance of existing land, vegetation

and Buildings?

No Proposed expansion is within the existing

premises of GIDC Panoli.

1.3 Creation of new land uses? No

1.4 Pre-construction investigations e.g.

bore Houses, soil testing?

No

1.5 Construction works? Yes Plant Layout attached as Annexure - II

1.6 Demolition works? No

1.7 Temporary sites used for construction

works or housing of construction

workers?

No

1.8 Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

No Plant Layout attached as Annexure - II

1.9 Underground works mining or

tunneling?

No

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Off shore structures? No

1.13 Production and manufacturing

processes?

Yes For detail Please refer Annexure –III

1.14 Facilities for storage of goods or

materials?

Yes Specified storage area shall be provided for

storage of goods, Raw materials & Finished

products.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes For detail please refer Annexure – IV & V

1.16 Facilities for long term housing of

operational workers?

No

1.17 New road, rail or sea traffic during

Construction or operation?

No

1.18 New road, rail, air waterborne or other

transport infrastructure including new

or altered routes and stations, ports,

airports etc?

No

1.19 Closure or diversion of existing

transport routes or infrastructure

No

5

leading to changes in Traffic

movements?

1.20 New or diverted transmission lines or

Pipelines?

No

1.21 Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No

1.22 Stream crossings? No

1.23 Abstraction or transfers of water form

ground or surface waters?

No No ground water shall be used. The raw water

shall be supplied by GIDC Authority.

1.24 Changes in water bodies or the land

surface Affecting drainage or run-off?

No

1.25 Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel, raw material and

products will be primarily by road only

1.26 Long-term dismantling or

decommissioning or restoration works?

No

1.27 Ongoing activity during

decommissioning which could have an

impact on the environment?

No

1.28 Influx of people to an area either

temporarily or permanently?

No This is a well developed GIDC Estate and due to

the expansion of this project, M/s. Shree

Ramdev Pharma Chem will give direct

employment to local people based on

qualification and requirement. In addition to

direct employment, indirect employment shall

generate ancillary business to some extent for

the local population.

1.29 Introduction of alien species? No

1.30 Loss of native species or genetic

diversity?

No

1.31 Any other actions? No

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

Sr.

No.

Information/checklist confirmation Yes/No Details there of (with approximate quantities

frates, wherever possible) with source of

information data

2.1 Land especially undeveloped or

agricultural land (ha)

No GIDC land of 3,766 m2.

2.2 Water (expected source & competing

users) unit: KLD

Yes The entire water requirement will be met

through GIDC. Water available from GIDC. For

detail please refer Annexure – VI

2.3 Minerals (MT) No

6

2.4 Construction material: stone, aggregates,

and / soil (expected source – MT)

Yes Construction materials like crushed stones, sand,

rubble, cement, steel, etc. required for the

project shall be procured from the local market of

the region.

2.5 Forests and timber (source – MT) No

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes For detail please refer Annexure – VI

2.7 Any other natural resources (use

appropriate standard units)

No

3. Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.

Sr.

No.

Information/Checklist confirmation Yes/No Details there of (with approximate

quantities/rates, wherever possible)

with source of information data

3.1 Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes For detail please refer Annexure –VII.

3.2 Changes in occurrence of disease or affect

disease vectors (e.g. insect or water borne

diseases)

No

3.3 Affect the welfare of people e.g. by

changing living conditions?

No

3.4 Vulnerable groups of people who could

be affected by the project e.g. hospital

patients, children, the elderly etc.

No

3.5 Any other causes No

(II) Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr.

No.




4.1 Spoil, overburden or mine wastes No

4.2 Municipal waste (domestic and or

commercial wastes)

No

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Please refer Annexure – V

4.4 Other industrial process wastes No

4.5 Surplus product No

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Please refer Annexure – V

7

4.7 Construction or demolition wastes No

4.8 Redundant machinery or equipment No

4.9 Contaminated soils or other materials No

4.10 Agricultural wastes No

4.11 Other solid wastes Yes

Please refer Annexure – V

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr.)

Sr.

No.

Information/Checklist

confirmation

Yes/No Details there of (with approximate quantities/rates,

wherever possible) with source of information data

5.1 Emissions from combustion of

fossil fuels from stationary or

mobile sources

Yes For details Please refer Annexure – VIII

5.2 Emissions from production

processes

Yes For details Please refer Annexure – VIII

5.3 Emissions from materials handling

storage or transport

Yes All liquid raw materials shall be procured

in tankers and shall be transferred through a closed

circuit pipe lines.

Solid raw materials shall be charged through close

pipeline into reactors and the dust collection hopper

shall be connected to a bag filter and ID fan.

Also all hazardous chemicals storage tanks will be

provided with flame arrestors & breather valves for

safety.

5.4 Emissions from construction

activities including plant and

equipment

Yes During construction work, only dust contamination will

be there & water sprinklers shall be utilized whenever

necessary.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Solvent vapors shall be cooled in appropriate

condensers and shall be passed through trap vessel

fitted with condensers. All the waste shall be stored in

designated place and shall be transported to TSDF site

in approved closed vehicles owned by the TSDF

authority.

Dust from drying will be collected in to dust collector

through cyclone separator & recovered powder will be

recycled back to process. Air Handling Unit will be

provided where ever applicable.

5.6 Emissions from incineration of No 5.7 Emissions from burning of waste

in open air e.g. slash materials,

construction debris)

No

5.8 Emissions from any other sources No

8

(III) Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.


quantities/rates, wherever possible) with

source of information data with source of

information data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes All machinery / equipment shall be well

maintained, shall be proper foundation with

anti vibrating pads wherever applicable and at

noise levels within permissible limits. DG set

shall have acoustic enclosure. Expected Noise

level at different locations in the plant is

enclosed as Annexure – IX

6.2 From industrial or similar processes Yes Please refer Annexure – IX

6.3 From construction or demolition No

6.4 From blasting or piling No

6.5 From construction or operational traffic No

6.6 From lighting or cooling systems Yes Please refer Annexure – IX

6.7 From any other sources No

7. Risks of contamination of land or water from releases of pollutants into the ground or

into sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No.


quantities/rates, wherever possible) with

source of information data

7.1 From handling, storage, use or spillage

of hazardous materials

Yes Hazardous material shall be stored in designated

storage area with bund walls for tanks. Other

material will be stored in bags/drums on pallets

with concrete flooring and no spillage is likely to

occur. All liquid raw materials shall be

transported through pumps and closed pipelines

and no manual handling shall be involved. Spill

Container will be kept at appropriate places to

collect spillage. SOP for collection,

decontamination & disposal of spilled material

will be displaced at necessary locations. For

details please refer Annexure – VII

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes The neutralized low COD effluent after primary

treatment will be sent to the CETP of M/s PETL,

Panoli for the further treatment and final

disposal. The neutralize high COD effluent after

primary treatment will be sent to the Common

Spray Dryer of M/s PETL, Panoli for the further

9

treatment and final disposal.

7.3 By deposition of pollutants emitted to

air into the and or into water

No

7.4 From any other sources No

7.5 Is there a risk of long term build up of

pollutants in the environment from

these sources?

No

8. Risk of accidents during construction or operation of the Project, which could affect

human health or the environment

Sr.

No.


quantities/rates, wherever possible) with source

of information data

8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes For detail please refer Annexure – VII

8.2 From any other causes No

8.3 Could the project be affected by

natural disasters causing

environmental damage (e.g. floods,

earthquakes, landslides, cloudburst

etc)?

No

9. Factors which should be considered (such as consequential development) which could

lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr.

No.

Information/Checklist confirmation

Yes/

No

Details there of (with approximate



9.1 Lead to development of supporting. utilities,

ancillary development or development stimulated

by the project which could have impact on the

environment e.g.

• Supporting infrastructure (roads, power supply,

waste or waste water treatment, etc.)

• housing development

• extractive industry

• supply industry

• other

Yes For detail please refer Annexure – X

9.2 Lead to after-use of the site, which could have an

impact on the environment

No

9.3 Set a precedent for later developments No

9.4 Have cumulative effects due to proximity to other

existing or planned projects with similar effects

No

10

(IV) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance (within 15km.) Proposed

project location boundary

1 Areas protected under international

conventions, national or local legislation

for their ecological, landscape, cultural

or other related value

No Proposed Expansion project site is within the

GIDC Estate of Panoli

2 Areas which important for are or

sensitive Ecol logical reasons –

Wetlands, watercourses or other water

bodies, coastal zone, biospheres,

mountains, forests

No

3 Area used by protected, important or

sensitive Species of flora or fauna for

breeding, nesting, foraging, resting,

over wintering, migration

No

4 Inland, coastal, marine or underground

waters

No No inland, costal or marine within 5 km from

the proposed project

5 State, National boundaries No 6 Routes or facilities used by the public

for access to recreation or other tourist,

pilgrim areas

No

7 Defense installations No

8 Densely populated or built-up area Ankleshwa

r

5 km

9 Area occupied by sensitive man-made

land uses Hospitals, schools, places of

worship, community facilities)

No

10 Areas containing important, high quality

or scarce resources (ground water

resources, surface resources, forestry,

agriculture, fisheries, tourism, minerals)

No

11 Areas already subjected to pollution

environmental damage. (those where

existing legal environmental standards

No

12 Areas susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquakes, subsidence, landslides,

flooding, erosion, or extreme or adverse

climatic conditions)

No

IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – XI

11

12

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products with their Production Capacity

II Layout Map of the Plant

III Brief Manufacturing Process Description

IV Description of Effluent Treatment Plant with flow diagram

V Details of Hazardous Waste

VI Water, Fuel & Energy Requirements

VII Details of Hazardous Chemicals Storage & Handling

VIII Details of Stacks and Vents

IX Expected Noise level at Different source within the premises

X Socio-economic Impacts

XI Proposed Terms of Reference for EIA studies

XII GIDC Letter for Water Consumption

XIII NCTL Membership Letter for Wastewater Disposal

13

ANNEXURE-I

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

Production Capacity (MT/Month) Sr.

No.

Name of Product

Existing Total After Proposed

Expansion

Inorganic Products (Existing)

1 Potassium Sulphate

2 Potassium Chloride

3 Potassium Bromide

4 Potassium Nitrate

5 Zinc Chloride

6 Zinc Sulphate

7 Copper Sulphate

8 Magnesium Sulphate

9 Sodium Nitrate

10 Sodium Bromide

11 Sodium Hypo Bromite

12 Di Calcium Phosphate

500

500

Additional Proposed

13 Diphenyl Acetonitrile -

14 Diphenyl Acetic Acid -

15 2-(Diphenylmethoxy)-N,N-

Dimethylethanamine Hydrobromide

-

16 Diphenyl Methane -

17 P-Chloro Benzophenone -

18 P-Chlorobenzhydryl Chloride -

19 p-Chlorobenzhydryl Piperazine -

20 2-[4-(4-Chlorobenzhydryl)-1-

Piperazinyl] Ethanol

-

21 1-(3-Chloropropyl)-2-

Benzimidazolidinone

-

22 5-Chloro-1-(4-Piperidinyl)-2-

Benzimidazolidinone

-

23 Nosyl Chloride -

75

Total - 75

Grand Total 500 575

14

LIST OF RAW MATERIAL (EXISTING)

SR.

NO.

PRODUCT WISE RAW MATERIALS QUANTITY

(MT/MT)

1. Potassium Sulphate

Potassium Hydroxide (85%) 0.72

Sulfuric Acid 0.56

2. Potassium Chloride


Hydrochloric Acid (30%) 1.66

3. Potassium Bromide


Hydrobromic Acid (30%) 2.40

4. Potassium Nitrate

Potassium Carbonate 0.70

Nitric Acid (45%) 1.40

5. Zinc Sulphate

Zinc Metal 0.23

Sulfuric Acid 0.35

6. Zinc Chloride

Zinc Metal 0.48

Hydrochloric Acid (30%) 1.80

7. Copper Sulphate

Copper Oxide 0.50

Sulfuric Acid 0.61

8. Magnesium Sulphate

Magnesium Oxide 0.34

Sulfuric Acid 0.83

9. Sodium Nitrate

Sodium Hydroxide 0.48

Nitric Acid (45%) 1.69

10. Sodium Bromide


Hydrobromic Acid (30%) 2.70

11. Sodium Hypo Bromite


Liq. Bromine 0.14

12. Di Calcium Phosphate

Calcium Hydroxide 0.44

Phosphoric Acid (85%) 0.68

15

LIST OF RAW MATERIAL (ADDITIONAL PROPOSED)

SR.

NO.

PRODUCT WISE RAW MATERIALS QUANTITY

(MT/MT)

1. Diphenyl Acetonitrile

Phenyl Acetonitrile 0.80

Liquid Bromine 1.11

Aluminium Chloride 1.05

Benzene 4.00

Soda Ash 0.004

Methanol 2.00

Hydro 0.004

2 Diphenyl Acetic acid

Diphenyl Acetonitrile 1.00

Sulfuric Acid 0.30

3 Diphenyl methane

Dibenzyl Ether 0.84

Benzene 4.00

Phosphoric Acid 0.10

Soda Ash 0.004

4 2-(Diphenylmethoxy)-N,N-Dimethylethanamine Hydrobromide

Diphenyl Methane 0.56

Liq. Bromine 0.53

N,N-Dimethyl Amino Ethanol 0.31

Mono Chloro Benzene 0.60

5 p-Chloro Benzophenone

Benzoyl Chloride 0.83

Mono Chlorobenzene 0.67

Aluminum Chloride 0.80

Methanol 3.00


6 p-Chlorobenzhydryl Chloride

P-Chloro Benzophenone 1.00

Methanol 1.00

Sodium Borohydride 0.07

Hydrochloric acid 2.00


7 p-Chlorobenzhydryl Piperazine

P-Chloro Benzhydryl Chloride 1.00

Piperazine 1.24

16

Toluene 3.00

Hydrochloric Acid 1.00


8 2-[4-(4-Chlorobenzhydryl)-1-Piperazinyl] Ethanol

P-Chloro Benzhydryl Piperazine 0.87

2-Chloro Ethanol 0.52

Toluene 3.20

Tri Ethyl Amine 0.80


9 1-(3-Chloropropyl)-1,3-Dihydro-2h- Benzimidazol-2-One

o-Phenylene Diamine 0.88

Methyl Aceto Acetate 0.96

o-Xylene 4.00

1-Bromo-3-Chloro Propane 1.28

Methanol 3.00

KOH 0.68

HCl 1.00

10 Nosyl Chloride

P-Nitro Aniline 1.00

Sodium Nitrite 0.56

Sodium Bisulfite 1.43

Copper Sulphate 0.27

o-Xylene 3.00

Acetic Acid 1.00

HCl 9.50

NaOH Lye 1.00

11 5-Chloro-1-(4-Piperidinyl)-2-Benzimidazolidinone

N-Carbethoxy-4-piperidone 1.80

Ammonia gas 0.63

Methanol 26.25

Raney Nickel 0.68

Hydrogen 0.23

2,5-Dichloro Nitrobenzene 1.78

Sodium Carbonate 0.70

Toluene 8.00

Urea 0.45


Activated carbon 0.15

17

ANNEXURE-II

LAYOUT MAP OF THE PLANT

Z

SITE PLAN

18

LAYOUT PLAN

5. 00 MT G.S.

20 MT ROAD No. 23

5. 00 MT G.S.

5.

MT

G.

S.

5.

MT

G.

S.

20.

MT

R

O

A

D

No.

352315 2314

52. 5530. 00

54. 85 30. 00

4

5.

0

0

4

5.

0

0

4

5.

05

N

PLOT NO. AREA

2314 45.00 × 30.00 = 1350.00

2315 54.85 + 52.55 ×45 = 2416.00

2

TOTAL = 3766.00

19

ANNEXURE-III

BRIEF PROCESS DESCRIPTION

EXISTING

BLOCK DIAGRAM FOR MANUFACTURING PROCESS

R.M.-1 R.M.-2

REACTION VESSLE

EVAPORATION

CENTRIFUGE

DRYING

PACKING

Mother Liquor

20

POTASSIUM SULPHATE

Manufacturing Process

Potassium Sulphate Aqueous solution of 8-10% is being evaporated in reactor to remove

Water Contain. After giving adequate temperature (90-120°C) for 6 to 8 hrs. Material is

being shifted to crystallizer for cooling. The mass taking centrifuge to separate crystal of the

product and mother liquor. The Mother liquor is collected and once again charge is reactor

for evaporation. Crystal of the product is collected and dried for the in the dryer if

necessary required to remove surface moisture contain or it is being packed in HDPE Bag

for selling.

Chemical Reaction

2KOH + H2SO4 K2SO4 + 2H2O

Mass Balance

INPUTS for 500.0 Kgs Out Puts

RM QTY Product & By Product & Waste QTY

Potassium Hydroxide (85%) 360 Kgs Potassium sulfate 500 Kgs

Sulfuric acid 282 Kgs Water evaporate approx. 1100 Kgs

water 1500 Kgs CF ML add in next batch 542 Kgs

Total 2142 Kgs Total 2142 Kgs

21

POTASSIUM CHLORIDE


Potassium Chloride Aqueous solution of 25-28% is being evaporated in reactor to remove

Water Contain. After giving adequate temperature (90-120oC) for 6 to 8 hrs. Material is

being shifted to crystallizer for cooling. The mass is taking centrifuge to separate crystal of

the product and mother liquor. The Mother liquor is collected and once again charge is

reactor for evaporation. Crystal of the product is collected and dried for the in the dryer if

necessary required to remove surf ace moisture contain or it is being packed in HOPE Bag

for selling.

Chemical Reaction

KOH + HCl KCl + H2O

Mass Balance


RM QTY Product & By Product &

waste

QTY

Potassium Hydroxide (85%) 425 Kgs Potassium Chloride 500 Kgs

Hydrochloric acid (30%) 830 Kgs Water evaporate approx. 1200 Kgs



22

KOH + HBr KBr H2O+

M.WT.: 56.12 M.WT.: 80.91 M.WT.: 119.00 M.WT.: 18.01

POTASSIUM BROMIDE


Potassium Hydroxide solution reacts with Hydrobromic Acid to give Potassium Bromide.

Chemical Reaction

Mass Balance



waste

QTY

Potassium Hydroxide (85%) 300 Kgs Potassium Chloride 500 Kgs

Hydrobromic acid (30%) 1200 Kgs Water evaporate approx. 800 Kgs



23

POTASSIUM NITRATE


Potassium Nitrate Aqueous solution of 8-10% is being evaporated in reactor to remove

Water Contain. After giving adequate temperature for 6 to 8 hrs. Material is being shifted

to crystallizer for cooling. The mass will take into centrifuge to separate crystal of the

product and mother liquor. The Mother liquor is collected and once again charge is react or

for evaporation. Crystal of the product is collected and dried for the in the dryer if

necessary required to remove surface moisture contain or it is being packed in HOPE Bag

for selling.

Chemical Reaction

K2CO3 + 2HNO3 2KNO3 + H2O + CO2

Mass Balance



waste

QTY

Potassium Carbonate 350 Kgs Potassium Nitrate 500 Kgs

Nitric acid (45%) 700 Kgs CO2 Gas 109 Kgs

water 800 Kgs Water evaporate approx. 800 Kgs

CF ML add in next batch 441 Kgs


24

ZINC SULPHATE


Toke Fresh 585 Kgs 98% Sulphuric Acid & Add 1.5 KL Fresh Water (up to 70%) in a brick line

d vessel. Add slowly 400 Kg Zinc metal into brick Lined vessel. Agitated the vessel for six

hours and maintain temp. Up to 6000C. After that pumped the liquid for Filtration. Filtered

liquid transferred into settling tank in which crystallization will take place in 12 hours to 16

hours. From settling tank Zinc Sulphate separated by centrifuge and Mother liquid from

centrifuge and Filter press and come out from Filter press is unreacted Zinc or pump wash is

recycle back for next batch. Then Zinc Sulphate is packed in bags

Chemical Reaction

Zn + H2SO4 ZnSO4 + 7H2 + H2

Mass Balance



waste

QTY

Zinc Metal 115 Kgs Zinc sulfate hepta hydrate 500 Kgs




25

M.WT.: 65.41

+ 2HCl

M.WT.: 72.92

ZnCl2

M.WT.: 136.32

+ H2

M.WT.: 2.01

Zn2+

Process Flow Diagram

ZINC CHLORIDE


Zinc Chloride is manufactured by using hydrochloric acid instead of Sulphuric acid in above

process

Chemical Reaction

Mass Balance



waste

QTY

Zinc Metal 240 Kgs Zinc Chloride 500 Kgs

Hydrochloric acid (30%) 900 Kgs Water evaporate approx. 1190 Kgs



REACTION

FILTRATION

CRYSTALLIZATION

NUTCH FILTRATION

Zinc (Metal) Fresh H2 SO4 (98 %)

PACKING

DISPATCH

Un- reacted metal (Zinc) for

re-use in next batch

M. L. For re-use

in next batch

M.L. re –use

in next batch

26

COPPER SULPHATE


Required quantity of water is taken in reaction vessel and conc. Sulphuric acid is charged

gradually. Next Copper oxide powder is added slowly. The reaction takes place and CuO

dissolves in the solution forming Copper Sulphate. After complete reaction, the reaction

mass is heated to Crystallize the product which is centrifuged, dried and packed. The

mother liquor is recycled in next batch.

Chemical Reaction

CuO + H2SO4 CuSO4 + H2O

Mass Balance



waste

QTY

Copper oxide 250 Kgs Copper sulfate 500 Kgs




27

MAGNESIUM SULPHATE


Required quantity of water is taken in reaction vessel and cone. Sulphuric acid is charged

gradually. Next magnesium oxide powder is added slowly. The reaction takes place and

MgO dissolves in the solution forming Magnesium Sulphate. After complete reaction, the

reaction mass is heated to Crystallize the product which is centrifuged, dried and packed.

The mother liquor is recycled in next batch.

Chemical Reaction

MgO + H2SO4 MgSO4 + H2O

Mass Balance



waste

QTY

Magnesium oxide 170 Kgs Magnesium sulfate 500 Kgs

Sulfuric acid 415 Kgs Water evaporate approx. 1305 kgs



28

SODIUM NITRATE


Sodium Nitrate Aqueous solution of 8-10% is being evaporated in reactor to remove Water

Contain. After giving adequate temperature for 6 to 8 hrs. Material is being shifted to

crystallizer for cooling. The mass will take into centrifuge to separate crystal of the product

and mother liquor. The Mother liquor is collected and once again charge is reactor for

evaporation. Crystal of the product is collected and dried for the in the dryer if necessary

required to remove surface moisture contain or it is being packed in HDPE Bag for selling.

Chemical Reaction

NaOH + HNO3 NaNO3 + H2O

Mass Balance



waste

QTY

Sodium Hydroxide 240 Kgs Sodium Nitrate 500 Kgs

Nitric acid (45%) 845 Kgs Water evaporate approx. 1295 Kgs



29

NaOH + HBr NaBr H2O

M.WT.: 40.00 M.WT.: 80.91 M.WT.: 102.89 M.WT.: 18.01

+

NaOH + 1/2Br2NaOBr

M.WT.: 40.00 M.WT.: 79.9 M.WT.: 118.89

+ 1/2H2

M.WT.: 1.0

SODIUM BROMIDE & SODIUM HYPO BROMITE


Sodium Hydroxide reacts with Hydrobromic Acid to give Sodium Bromide.

Sodium Hydroxide reacts with Liq. Bromine to give Sodium Hypo Bromite.

Chemical Reaction

Mass Balance



waste

QTY

Sodium Hydroxide 200 Kgs Sodium Bromide 500 Kgs

Hydrobromic acid (30%) 1350 Kgs Water evaporate approx. 1250 Kgs



Chemical Reaction

Mass Balance


RM QTY Product & By Product & waste QTY

Sodium Hydroxide 34 Kgs Sodium hypo bromite (20%) Sol. 502 Kgs

Liq. Bromine 68 Kgs

water 400 Kgs


30

Ca(OH) 2H3PO4

M.WT.: 74.08

+

M.WT.: 98.0

CaHPO 4.2H2O

M.WT.: 172.08

DI CALCIUM PHOSPHATE


Calcium Hydroxide reacts with Phosphoric Acid in presence of water to give Di calcium

Phosphate.

Chemical Reaction

Mass Balance



Calcium Hydroxide 220 Kgs Di calcium phosphate 500 Kgs

Phosphoric acid

(85%)

340 Kgs Water evaporate approx. 960 Kgs



31

PROPOSED

DIPHENYL ACETONITRILE

Process Description

Liq. Bromine is reacting with Phenyl Acetonitrile at 80°C gives α-Bromo Phenyl Acetonitrile.

α-Bromo Phenyl Acetonitrile is react with Benzene in presence of Aluminium Chloride is

gives Diphenyl Acetonitrile

Chemical Reaction

N

+ Br Br

N

Br

+

N

M.WT.: 117.15M.WT.: 159.81

M.WT.: 196.04

+

M.WT.: 80.91

M.WT.: 78.11

M.WT.: 133.34

M.WT.: 193.24

+ BrH

M.WT.: 80.91

BrH + AlCl3

M.WT.: 133.34

AlCl3

Mass Balance



waste

QTY

Phenyl Acetonitrile 400.0 Kgs Diphenyl Acetonitrile 500.0 Kgs

Liquid Bromine 554.0 Kgs Benzene 1590.0 Lts

Aluminium Chloride 525.0 Kgs Methanol 950.0 Lts

Benzene 2000.0 Lts Hydrobromic acid 35% 800.0 Kgs

Water 3000.0 Lts Hydrobromic acid + AlCl3

Solution

3103.0 Kgs

Soda Ash 2.0 Kgs Residue 40.0 Kgs

Methanol 1000.0 Lts Water 500.0 Kgs

Hydro 2.0 Kgs

Total 7483.0 Kgs Total 7483.0 Kgs

32

DIPHENYL ACETIC ACID

Process Description

In GLR -hydrolysis of Diphenyl Acetonitrile in Dilute Sulfuric Acid gives Diphenyl Acetic Acid.

Chemical Reaction

N

M.WT.: 193.24

+

M.WT.: 49.04

H2SO4H2O

MWt: 54.06

+

O

OH

(NH4)2SO4

M.Wt.:66.06

+ +1/2 H2O

MWt: 18.02

3

M.WT.: 212.24

1/2

Mass Balance



waste

QTY

Diphenyl Acetonitrile 500.0 Kgs Diphenyl Acetic Acid 500.0 Kgs

Sulfuric Acid 150.0 Kgs Water 550.0 Kgs

Water 400.0 Kgs


33

DIPHENYL METHANE

Process Description

In presence of Phosphoric Acid, Dibenzyl Ether is reacted with Benzene gives Diphenyl

Methane.

Chemical Reaction

O +

M.WT.: 156.22M.WT.: 198.26

M.WT.: 336.46

22 Phosphoric acid as Catalyst

+ H2O

MWt: 18.02

Mass Balance



waste

QTY

Dibenzyl ether 420.0 Kgs Diphenyl Methane 500.0 Kgs

Benzene 2000.0 Lts Benzene 1600.0 Lts

Phosphoric Acid 50.0 Kgs Phosphoric Acid 48.0 Kgs

Soda Ash 2.0 Kgs Residue 40.0 Kgs

Water 800.0 Kgs Water 1084.0 Kgs


34

2-(DIPHENYLMETHOXY)-N,N-DIMETHYLETHANAMINE HYDROBROMIDE

Process Description

In a Glass Reactor, Bromine Liquid is added to Diphenyl Methane at appropriate temp, to

give Benzydryl Bromide, which is condensed with Dimethyl Amino Ethanol gives 2-

(Diphenylmethoxy)-N,N-Dimethylethanamine Hydrobromide

Chemical Reaction

Br Br

M.WT.: 159.81

+

M.WT.: 168.23

Br

M.WT.: 80.91

BrH+ OH N

M.WT.: 89.14

ON

CH3

CH3BrH

M.Wt.: 336.27

+MCB

M.WT.: 247.13

Mass Balance



Diphenyl methane 280.0 Kgs 2-(Diphenylmethoxy)-N,N-

Dimethylethanamine

Hydrobromide

500.0 Kgs

Liq. Bromine 266.0 Kgs Monochlorobenzene 285.0 Lts

N,N-Dimethyl Amino Ethanol 154.0 Kgs Hydrobromic Acid 385.0 Kgs

Mono Chloro Benzene 300.0 Lts Water 100.0 Kgs

Water (Scrubber) 250.0 Lts Residue 30.0 Kgs

Water 50.0 Lts


35

p-CHLORO BENZOPHENONE

Process Description

In Glass line reactor charge Monochloro Benzene & Aluminium Chloride at RT then slowly

adds Benzoyl Chloride into reaction mass at 48ºC & Stir for 3 hrs. Then heat to 100ºC and

maintained for 2 hrs. Then add slowly water into reaction mass (during addition of water

generate HCl gas – scrub with NaOH soln. using scrubber) separate p-Chloro Benzophenone

Chemical Reaction

ClO

+

Cl

M.WT.: 133.34

AlCl3

O

Cl

+

M.WT.: 140.57 M.WT.: 112.66M.WT.: 216.66

ClH

M.Wt.: 36.46

Mass Balance



waste

QTY

Benzoyl Chloride 415.0 Kgs p-Chloro Benzophenone 500.0 Kgs

Mono Chlorobenzene 333.0 Kgs Methanol 1430.0 Lts

Aluminum Chloride 400.0 Kgs AlCl3 Solution (25%) 1600.0 Kgs

Methanol 1500.0 Lts Water 1308.0 Kgs

Water (Scrubber) 600.0 Lts Residue 30.0 Kgs

Sodium Hydroxide (Scrubber) 120.0 Kgs

Water 1500.0 Lts


36

p-CHLOROBENZHYDRYL CHLORIDE

Process Description

In Reactor charge MeOH and P-Chlorobenzophenone and cool to 25˚C, then slowly add

Sodium Borohydride and maintain for 4 hr, there after distilled out MeOH and charge

hydrochloric acid and stir the mass for 6 hr. discard acidic layer and collect p-

Chlorobenzhydryl Chloride

Chemical Reaction

O

Cl

M.WT.: 216.66

+ NaBH4

M.WT.: 37.81

OH

Cl

M.WT.: 218.68

NaBH2+

M.WT.: 35.81

MeOH

ClH

M.Wt.: 36.46Toluene

Cl

Cl

M.WT.: 237.12

Mass Balance



waste

QTY

p-Chloro Benzophenone 500.0 Kgs p-Chloro Benzhydryl Chloride 500.0 Kgs

Methanol 500.0 Lts Methanol 470.0 Lts

Sodium Borohydride 35.0 Kgs Water 1735.0 Kgs

Hydrochloric Acid 1000.0 Kgs Residue 30.0 Kgs

Sodium Hydroxide 200.0 Kgs

Water 500.0 Lts


37

p-CHLOROBENZHYDRYL PIPERAZINE

Process Description

In reactor charge Toluene, P-Chlorobenzhydryl Chloride and Piperazine into heat to 70ºC &

maintain for 3 hrs. Then add HCl at RT & product extract with HCl & side up Toluene layer

and recover for next batch. Product contains HCl charge into reactor & adjusts 9 pH by

NaOH soln. & centrifuge the product and dry at 50ºC.

Chemical Reaction

Cl

Cl

M.WT.: 237.12

NH

NH

+

M.WT.: 86.14

TolueneNaOH

M.Wt: 40.00

Na Cl OH2

M.Wt.:58.44 MWt: 18.02

+

N

Cl

NH

++

M.WT.: 286.80

Mass Balance



waste

QTY

P-Chloro Benzhydryl chloride 500.0 Kgs P-Chloro Benzhydryl

Piperazine

500.0 Kgs

Piperazine 620.0 Kgs Toluene 1420.0 Lts

Toluene 1500.0 Lts Piperazine 400.0 Kgs

Hydrochloric Acid 500.0 Kgs NaOH Soln. 900.0 Kgs

Sodium Hydroxide 500.0 Kgs Water 3380.0 Kgs

Water 3000.0 Lts Residue 20.0 Kgs


38

2-[4-(4-CHLOROBENZHYDRYL)-1-PIPERAZINYL] ETHANOL

Process Description

S.S.R. to be clean and dry. Charge toluene, p-Chloro Benzhydryl Piperazine, Triethyl Amine

and 2-Chloro Ethanol at RT. Then heat up to reflux and maintain reflux for 8 hr. then distilled

out toluene completely & collect product

Chemical Reaction

N

Cl

NH

+

M.WT.: 286.80

NaOH

M.Wt: 40.00

OH Cl +

M.WT.: 80.51

Toluene

Tri Ethyl AmineN

Cl

N

OH

OH2

M.Wt.:58.44

MWt: 18.02

+ Na Cl

M.WT.: 330.85

+

Mass Balance



waste

QTY

p-Chloro Benzhydryl

Piperazine

435.00 Kgs P-Chloro Benzhydryl

Piperazine

500.0 Kgs

2-Chloro Ethanol 260.0 Kgs Toluene 1520.0 Lts

Toluene 1600.0 Lts TEA reuse in Next Batch 380.0 Kgs

Tri Ethyl Amine 400.0 Lts Water 1345.0 Kgs

Sodium Hydroxide 50.0 Kgs

Water 1000.0 Lts


39

1-(3-CHLOROPROPYL)-1,3-DIHYDRO-2H- BENZIMIDAZOL-2-ONE

Process Description

In SSR charge o-Xylene and OPDA at RT. Then heat the mass up to 120º. Slowly add Methyl

Aceto Acetate in to the reactor then stir the mass for 6 hrs. and cool up to RT and Centrifuge

the mass spine dry and unload it .

In other SSR charge water, KOH, Bromo Chloro Propane and wet cake from previous stage at

RT. Then heat the mass up to 45ºc and stir for 6hrs there after charge HCl in to the mass and

heat up to 60º and stir for 2hr. then cool the mass up to RT and centrifuge the mass .

Chemical Reaction

Stage-1

N

NH

O

CH3

CH2

O-Xylene + CH3 OH OH2+NH2

NH2

+

CH3 O

CH3

O O

M.Wt.: 108.14 M.Wt.: 116.12 M.Wt.: 174.2 M.Wt.: 32.04 M.Wt.: 18.02

Stage-2

BrCl

N

NH

O

CH3

CH2

+ + KOH

N

N

O

CH3

CH2

Cl

+ K Br + OH2

N

N

O

CH3

CH2

Cl

+ ClHMeOH

NH

N

OCl

+Cl

CH3

CH2

M.Wt.: 157.44 M.Wt.: 56.12 M.Wt.: 250.72 M.Wt.: 119.00

M.Wt.: 36.46M.Wt.: 210.66 M.Wt.: 76.52

M.Wt.: 174.2 M.Wt.: 18.02

M.Wt.: 250.72

40

Mass Balance



Stage-1 Stage-1 110.0 Kgs

O-Phenylene Diamine 88.0 Kgs O-Xylene 380.0 Lts

Methyl Aceto Acetate 96.0 Lts Water + Methanol From

Reaction

41.0 Lts

O-Xylene 400.0 Lts Water 138.0 Kgs

Water 100.0 Lts Residue 15.0 Kgs


Stage-2

Stage-1 110.0 Kgs Stage-2 1-(3-Chloropropyl)-1,3-

Dihydro-2H- Benzimidazol-2-

One

100.0 Kgs

1-Bromo-3-Chloro Propane 128.0 Kgs Methanol 270.0 Kgs

Methanol 300.0 Lts KBr Sol 275.0 Kgs

KOH 68.0 Kgs Water 556.0 Kgs

HCL 100.0 Kgs Residue 5.0 Kgs

Water 500.0 Lts


41

N

OO

NH

CH3

Cl

O2N

M.Wt.: 327.76

+ 3H2Toluene

Raney Nickel

N

OO

NH

CH3

Cl

NH2

2H2O+

M.Wt.: 6.04

M.Wt.: 297.78

M.Wt.: 36.03

N

OO

NH2

CH3

M.Wt.: 172.22

+Cl NO2

Cl

M.Wt.: 192.00

1/2Na2CO3 Methanol NaCl

M.Wt.: 58.44

+ 1/2H2O

M.Wt.: 9.0

1/2CO2+

M.Wt.: 22.00

+

M.Wt.: 53.0

N

OO

NH

CH3

NO 2

Cl

M.Wt.: 327.76

+

5-CHLORO-1-(4-PIPERIDINYL)-2-BENZIMIDAZOLIDINONE

Process Description

Stage-1- N-carbethoxy-4-piperidone is reacted with Hydrogen and Ammonia in the presence

of Raney nickel as catalyst and Methanol as solvent media to give stage-1 as product.

Stage-2-Stage-1 reacts with 2, 5-Dichloro nitrobenzene & Sodium Carbonate in presence of

Methanol as a solvent media to give Stage-2 as product.

Stage-3-Stage-2 reacts with Hydrogen in presence of Raney Nickel as catalyst and Toluene as

solvent media to give Stage-3 as product.

Stage-4-Stage-3 reacts with Urea in the presence of Sodium Hydroxide and there after

hydrolysis with Sodium Hydroxide to give 5-Chloro-1-(4-Piperidinyl)-2-Benzimidazolidinone

which is purified in methanol gives pure product

Chemical Reaction

Stage-1

N

OO

O

CH3

+ H2 + NH

3

N

OO

NH2

CH3

+ OH2Raney Nickel

M.Wt.: 171.19

M.Wt.: 2.02

M.Wt.: 17.03

M.Wt.: 172.22

M.Wt.: 18.02

Stage-2

Stage-3

42

NH

N

NH

O

Cl

M.Wt.: 251.77

NH

N

NH

O

Cl

M.Wt.: 251.77

Methanol

N

OO

NH

CH3

Cl

NH2

N

OO

N

CH3

NH

O

Cl

M.Wt.: 297.78

+ NH2NH2

O

+ 2NH3

M.Wt.: 60.03

M.Wt.: 323.77

M.Wt.: 34.06

NaOH

M.Wt.: 40.00+

NH

N

NH

O

Cl

OCH3 Na + CO2

M.Wt.: 251.77

M.Wt.: 68.05M.Wt.: 44.00

Stage-4

Stage-5

Mass Balance



Stage-1

N-Carbethoxy-4-piperidone 180.0 Kgs Stage-1 160.0 Kgs

Ammonia gas 63.0 Kgs Methanol Recovery 640.0 Kgs

Methanol 675.0 Kgs Methanol Loss 35.0 Kgs

Raney Nickel 45.0 Kgs Raney Nickel reuse 45.0 Kgs

Hydrogen 11.25 Kgs Residue 40.0 Kgs

Process Emission( Ammonia +

Hydrogen)

54.25 Kgs


Stage-2

Stage-1 160.0 Kgs Stage-2 215.0 Kgs

2,5-Dichloro Nitrobenzene 178.0 Kgs Methanol Recovery 1100.0 Kgs

Sodium Carbonate 70.0 Kgs Methanol Loss 50.0 Kgs

Methanol 1150.0 Kgs Water 583.0 Kgs

Water 450.0 Kgs Process Emission (CO2) 20.0 Kgs

Residue 40.0 Kgs


43



Stage-3


Hydrogen 11.3 Kgs Toluene Recovery 760.0 Kgs

Raney Nickel 22.6 Kgs Toluene Loss 40.0 Kgs

Toluene 800.0 Kgs Raney Nickel reuse 22.6 Kgs

Water 450.0 Kgs Residue 20.0 Kgs

Process Emission(Hydrogen) 7.5 Kgs

Water 478.8 Kgs


Stage-4


Urea 45.0 Kgs Process Emission (ammonia) 19.0 Kgs

Sodium Hydroxide 80.0 Kgs Water 1371.0 Kgs

Water 1200.0 Kgs


Stage-5

Stage-4 105.0 Kgs 5-Chloro-1-(4-Piperidinyl)-2-

Benzimidazolidinone

100.0 Kgs

Methanol 800.0 Lts Methanol Recovery 760.0 Kgs

Activated carbon 15.0 Kgs Methanol Loss 40.0 Kgs

Spent carbon 15.0 Kgs

Residue 5.0 Kgs


44

NOSYL CHLORIDE

Process Description

Para Nitro aniline reacts with sodium nitrite & Aq. HCl at below 10˚C temp. This gives

diazonium compound, which on reaction with Sodium Bisulfite in Aq. HCl in presence of

Copper Sulfate gives Nosyl Chloride which on purification in Xylene and Acetic Acid gives

Pale yellow Crystalline Powder of Nosyl Chloride

Chemical Reaction

NO2

NH2

+ Na NO2+ ClH

M.Wt.: 72.92M.Wt.: 69.00

NO2

N2+

Cl-

NaHSO 3+ + ClH

M.Wt.: 36.46M.Wt.: 104.06

2 + NaCl H2O+ 2

M.Wt.: 36.02M.Wt.: 58.44

M.Wt.: 138.12 M.Wt.: 185.58

NO2

N2+

Cl-

M.Wt.: 185.58

CuSO4

M.Wt.: 159.60

NO2

SO2Cl

M.Wt.: 221.62

+

M.Wt.: 53.49

NH4Cl H2O+ Na NO2

M.Wt.: 69.00 M.Wt.: 18.02

++ 2

M.Wt.: 36.02

H2O

NO2

SO2Cl

M.Wt.: 221.62

Toluene

Acetic Acid

NO2

SO2Cl

M.Wt.: 221.62

Mass Balance



waste

QTY

P-Nitro Aniline 100.0 Kgs Nosyl Chloride 100.0 Kgs

Sodium Nitrite 56.0 Kgs Xylene 280.0 Lts

Sodium Bisulfite 143.0 Kgs Acetic acid 80.0 Lts

Copper Sulphate 27.0 Kgs Residue 20.0 Kgs

O-Xylene 300.0 Lts Water 2896.0 Lts

Acetic Acid 100.0 Lts

HCL 950.0 Kgs

NaOH Lye 100.0 Kgs

Water 1600.0 Lts


45

ANNEXURE-IV

TREATMENT PROCESS

Details of Effluent Treatment Plant along with flow diagram

Stream I (Low COD & TDS Stream) = 11.83 KL/Day

First all non-toxic and biodegradable streams (low & medium COD & TDS) of wastewater

shall pass through Screen Chamber where floating material shall be removed with help of

Screen. Then effluent shall be passed through Oil & Grease Removal Tank. Automatic

mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and grease

from the wastewater to Oil & Grease Collection Tank. Then effluent shall be collected in

Collection cum Equalization tank-1. Pipe grid is provided at bottom of the CET-01 to keep all

suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1W+1

stand-by) shall supply air through to pipe grid.

Then after, equalized wastewater shall be pumped to Neutralization Tank-1 where the

continuous addition and stirring of Caustic solution is done to maintain neutral pH of

wastewater from Caustic Dosing Tanks as per requirement by gravity. Then after,

neutralized wastewater shall go to Flash Mixer-1 by gravity. Alum and Polyelectrolyte shall

be dosed from Alum Dosing Tank and Polyelectrolyte Dosing Tank respectively by gravity

into FM-1 to carry out coagulation by using a Flash Mixer. Then after, coagulated

wastewater shall be settled in Primary Clarifier. Treated effluent will be sent to CETP of

PETL, Panoli for further treatment.

Stream II (High COD & TDS Stream) = 1.67 KL/Day

High COD effluent shall be passed through collection cum neutralization tank where the

continuous addition and stirring of Caustic solution is done to maintain neutral pH of

wastewater from Caustic Dosing Tanks as per requirement by gravity. Treated neutral

effluent will be sent to Common Spray Dryer facility of PETL, Panoli for further treatment.

46

FLOW DIAGRAM OF ETP:

Screen Chamber Oil & Grease

Trap

Collection cum

Equalization

Tank

Neutralization

Tank

Primary Settling

Tank

CETP of PETL,

Panoli

Common

Spray Dryer

of PETL,

Panoli

Raw Effluent

Low COD

Collection cum

Neutralization

Tank

High COD

47

SIZE OF TANKS

S.N. Name of unit Size (m x m x m) No. MOC/ Remark

Stream I (Low COD & TDS Stream) 11.83 KL/Day

1 Screen Chamber 2.5 x 1.0 x (0.05 +0.3 FB) 1 RCC M25+A/A Bk.

Lining

2 Collection cum Equalization

Tank-1

3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

3 Neutralization Tank 3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

4 Flash Mixer-1 0.8 x 0.8 x (1.5 LD +0.5 FB) 1 RCC M25

5 Primary Clarifier 2.0 x 1.2 x (2.0 LD + 0.75

HB+ 0.5 FB)

1 RCC M25

6 Aeration Tank-1 7.0 x 5.2x (3.5 LD +0.5FB) 1 RCC M25

7 Secondary Clarifier-1 2.0 x 1.2 x (2.0 LD + 0.75

HB+ 0.5 FB)

1 RCC M25

Stream II (High COD & TDS Stream) 1.67 KL/Day

1 Collection cum

Neutralization Tank-1

3.2 x 3.2 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.

Lining

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PCC = PLAIN CEMENT CONCRETE

PP = POLYPROPELENE

MSEP = MILD STEEL EPOXY PAINTED

SS = STAINLESS STEEL

48

EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-I)

Sr.

No.

Category of Wastewater Before Treatment After Treatment

1 pH 3.5-6.5 6.5-8.0

2 COD (mg/L) 5500 1000

3 BOD3 (mg/L) 1700 300

4 TDS (mg/L) 3500 3250

5 Ammonical Nitrogen (mg/L) 30 20

EXPECTED CHARACTERISTIC OF EFFLUENT (STREAM-II)

Sr.

No.

Category of Wastewater Before Treatment

1 pH 2-10

2 COD (mg/L) 55000

3 BOD3 (mg/L) 12000

4 TDS (mg/L) 40000

5 Ammonical Nitrogen (mg/L) 300

49

ANNEXURE-V

HAZARDOUS WASTE GENERATION AND DISPOSAL

Generation Sr.

No

Type of Waste Category

Existing Total

Proposed

Mode of Treatment & Disposal

1. ETP Sludge 35.3 - 0.8

MT/Month

Collection, Storage, Transportation &

Sent to TSDF site of M/s. PSWML,

Panoli or M/s. BEIL, Ankleshwar

2. Used Oil 5.1 0.01

MT/Month

0.5

Lit/Month


Sale to registered re-processor or

used for lubrication within premises

3. Spent Carbon 28.3 - 3.8

MT/Month


co-processing in cement industries or

Send to M/s. BEIL, Ankleshwar for

incineration

4. Discarded Containers

/Barrels/Liners

33.1 0.5

MT/Month

500

Nos/Month

Collection, Storage, Transportation,

Decontamination & sold to

registered vendor

5. Distillation Residue 36.1 - 10

MT/Month


Sent to Common Incineration of M/s.

BEIL, Ankleshwar or for Co-

Processing in Cement Industries

6. Hydrobromic Acid - - 65

MT/Month

7. Aluminium Chloride

Soln.

- - 80

MT/Month

8. Potassium Bromide

Soln.

- - 40

MT/Month

Collection, Storage & Sold to re-

processors or end users

50

ANNEXURE-VI

_______________________________________________________________________

WATER, FUEL & ENERGY REQUIREMENT

WATER CONSUMPTION AND WASTEWATER GENERATION

Water Consumption

(KL/Day)

Waste Water

Generation (KL/Day)

Sr.

No.

Category

EXISTING TOTAL

PROPOSED

EXISTING TOTAL

PROPOSED

1. Domestic 8 10 7.5 9

2. Other (Gardening) NIL 1 NIL NIL

3. Industrial

Process 2 15 NIL 13.5

Boiler NIL 0.7 NIL 0.03

Cooling NIL 0.4 NIL 0.2

Washing NIL 1.4 NIL 1.4

Total Industrial 2 17.5 0 15.13

Grand Total 10 28.5 7.5 24.13

51

WATER BALANCE DIAGRAM (EXISTING)

Domestic

8

Water Consumption

10

Domestic

7.5

Wastewater

7.5

Septic Tank/Soak Pit

Process

2

Process

0

All Figures in KLD

52

WATER BALANCE DIAGRAM (TOTAL PROPOSED)

All Figures in KLD

Domestic

10

Boiler

0.7

Washing

1.4

Water Consumption

28.5

Domestic

9

Cooling

0.4

Wastewater

13.46

Boiler

0.03

Washing

1.4

Cooling

0.2

ETP

Process

15

Sent to PETL, Panoli

Process

13.5

Gardening

1

High COD &

High TDS �

1.67

Common Spray

Dryer of PETL,

Panoli for further

treatment

Septic Tank/Soak Pit

53

TOTAL POWER REQUIREMENT & SOURCE OF POWER

Power requirement will be 75 HP (Existing) + 50 HP (Additional Proposed) = 125 HP which

will be taken from DGVCL. 1 No. of 62 KVA DG Set will be kept for emergency power back

up.

FUEL REQUIREMENT

SR.

NO.

NAME OF FUEL QUANTITY

1 Natural Gas 600 Sm3/day

2 LDO 500 Lit/day

54

ANNEXURE-VII

STORAGE DETAILS OF HAZARDOUS CHEMICALS

Quantity Sr.

No.

Name of Hazardous

Substances Max.

That can be

stored (MT)

State &

Operating

Pressure &

Temp.

Type of

Hazard

Possible

(Fire, Explosion etc.)

Remarks

1 Ethyl Chloro Formate 250.0 kgs NTP Corrosive HDPE DRUM

2 Toluene 1000.0 kgs NTP Flammable MSDRUM

3 Ammonia Anhydrous 200.0 kgs NTP Harmful CYLINDER

4 Hydrogen Gas. 100.0 kgs NTP Highly Flammable CYLINDER

5 2,5,Dichloro Nitrobenzene 200.0 kgs NTP Flammable HDPE DRUM

6 Isopropyl Alcohol 500.0 kgs NTP Flammable MS DRUM

7 HCl 500.0 kgs NTP Corrosive CARBOY

8 Soda Ash 500.0 kgs NTP Corrosive BAGS

9 Dimethyl Formamide 500.0 kgs NTP Harmful MS DRUM

10 Raney Nickel 100.0 kgs NTP Flammable CARBOY

11 Ethyl Acrylate 250.0 kgs NTP Harmful CARBOY

12 Benzene 1000.0 kgs NTP Flammable MS DRUM

13 Sodium Methoxide 200.0 kgs NTP Corrosive CARBOY

14 Thionyl Chloride 300.0 kgs NTP Corrosive, Harmful GAL.DRUM

15 Methylene Dichloride 500.0 kgs NTP Harmful HDPE DRUM

16 Sodium Hydroxide 300.0 kgs NTP Corrosive BAGS

17 Monochlorobenzene 750.0 kgs NTP Irritant MS DRUM

18 Benzoyl Chloride 250.0 kgs NTP Corrosive, Irritant HDPE DRUM

19 Aluminium Chloride 500.0 kgs NTP Corrosive, Harmful BAGS

20 Sodium Borohydride 50.0 kgs NTP Corrosive, Flammable MS CARBOY

21 1-Naphthol 500.0 kgs NTP Harmful BAGS

22 O-Dichloro Benzene 500.0 kgs NTP Flammable MS DRUM

23 Phenol 500.0 kgs NTP Corrosive ,Harmful MS DRUM

24 Carbon Tetrachloride 750.0 kgs NTP Harmful MS DRUM

25 Liq. Bromine 500.0 kgs NTP Corrosive CARRET PACK.

26 Ethylene Dichloride 500.0 kgs NTP Flammable HDPE DRUM

27 Zinc Chloride 200.0 kgs NTP Harmful ,Corrosive FIBER DRUM

55

ANNEXURE-VIII

_______________________________________________________________________

DETAILS OF STACKS & VENTS

Details of Flue Gas Emissions

Sr. No. Source of

Emission

Type of

Emission

Stack Height

(meter)

Stack

Diameter

(meter)

Pollution Control

Equipment

1 Boiler SPM, SO2,

NOx

15 0.5 -

2 DG Sets SPM, SO2,

NOx

8 0.2 -

2 Process Vent-1 SO2,

HCl, HBr

15 0.3 Scrubber

3 Process Vent-1 NH3 15 0.3 Scrubber

56

ANNEXURE-IX

_______________________________________________________________________

EXPECTED NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES

Various sources of noise in industry have been identified as under,

• Pumps

• Boiler

• Reaction vessel

The typical noise levels of equipments, as indicated by the equipments manufacturers are

given below:

Sr. No. Name of Machinery / Units Noise level, dB(A)

1 Pumps 60 – 65

2 Boiler 65 – 75

3 Reaction Vessel 55 – 60

EXPECTED NOISE LEVELS:

SR.

NO.

SOURCE OF NOISE PERMISSIBLE LIMIT

(DAY/NIGHT)

dB (A)

EXPECTED NOISE

LEVEL dB (A)

1. Near Security Gate 75/70 60

2. Near Administration Building 75/70 60

3. Near Boiler & Utility Block 75/70 65

4. Near ETP 75/70 65

5. Near Process Plant 75/70 65

6. Near Canteen 75/70 50

• DG set with acoustic enclosure, housed in a separate room, erected on anti vibrating

pad.

• Ear muffs & ear plugs are provided to operators.

• Regular preventive maintenance of equipments is carried out.

57

ANNEXURE-X

_______________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

During construction phase, skilled and unskilled manpower will be needed. This will

temporarily increase the employment opportunity. Secondary jobs are also bound to be

generated to provide day-to-day needs and services to the work force. This will also

temporarily increase the demand for essential daily utilities in the local market. The

manpower requirement for the proposed diversification is expected to generate some

permanent jobs and secondary jobs for the operation and maintenance of plant. This will

increase direct / indirect employment opportunities and ancillary business development to

some extent for the local population. This phase is expected to create a beneficial impact on

the local socio-economic environment.

2) INDUSTRIES

During construction of the project, the required raw materials and skilled and unskilled

laborers will be utilized maximum from the local area. The increasing industrial activity will

boost the commercial and economic status of the locality, to some extent.

3) PUBLIC HEALTH

During construction period, workers will be provided with basic amenities like safe water

supply, low cost sanitation facilities, first aid, required personal protective equipment, etc.

Otherwise, there could be an increase in diseases related to personal hygiene. Emission, if

uncontrolled from process and utility stacks may cause discomfort, burning of eyes to the

recipients in the down wind direction. This may be caused due to the failure of control

equipment / process. The company regularly examines, inspects and tests its emission from

sources to make sure that the emission is below the permissible limit. Hence, there will not

be any significant change in the status of sanitation and the community health of the area,

as sufficient measures will be taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the new factory will have proper linkage for the transport and communication, the

development of this project will not cause any additional impact. In brief, as a result of the

project there will be no adverse impact on communication, as sufficient measures will be

proposed to be taken under the EMP. The proposed project is not expected to make any

significant change in the existing status of the socio - economic environment of this region.

58

ANNEXURE-XI

_______________________________________________________________________

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

1. Project Description

• Justification of project.

• Promoters and their back ground

• Project site location along with site map of 5 km area and site details providing various

industries, surface water bodies, forests etc.

• Project cost

• Regulatory framework

• Project location and Plant layout.

• Existing infrastructure facilities

• Water source and utilization including proposed water balance.

• Product spectrum (proposed products along with production capacity) and process

• List of hazardous chemicals with their toxicity levels.

• Mass balance of each product along with the batch size

• Storage and Transportation of raw materials and products.

• Existing environmental scenario

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall

in 5 km area.

• Study of Data from secondary sources.

• Other industries in the impact area

• Prevailing environment quality standards

• Existing environmental status vis a vis air, water, noise, soil in 5 km area from the project

site. For SPM, RSPM, SO2, NOx.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

• Existing socio-economic status, land use pattern and infrastructure facilities available in

the study area were surveyed.

4. Impacts Identification and Mitigatory Measures.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

59

6. Risk Assessment

• Objectives, Philosophy and methodology of risk assessment

• Details on storage facilities

• Identification of hazards

• Consequence analysis through occurrence & evaluation of incidents

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

• Safety precautions for the storage of Chemicals and vapour condensation.

7. Information for Control of Fugitive Emissions

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.

9. Occupational Health and Safety Program for the Project.

10. Information on Rain Water Harvesting

11. Green Belt Development Plan

60

ANNEXURE-XII

_______________________________________________________________________

GIDC LETTER FOR WATER CONSUMPTION

61

ANNEXURE-XIII

_______________________________________________________________________

PETL MEMBERSHIP LETTER

62

63

ANNEXURE-XIV

_______________________________________________________________________

BEIL MEMBERSHIP LETTER

PROPOSED BULK DRUGS & BULK DRUG ...environmentclearance.nic.in/writereaddata/Online/TOR/07...M/s. SHREE RAMDEV PHARMA CHEM PLOT NO. 2314-2315, PHASE – III, GIDC PANOLI, DIST: BHARUCH

Documents