S ECTI O N C: PRE-F EAS I BI LI TY REPO RT

Expansion of Synthetic Organic Chemical Manufacturing Unit at MIDC Tarapur, Palghar,Maharashtra By M/s Prolific Chemicals Pvt. Ltd.

SECTION C: PRE-FEASIBILITYREPORT

Environmental Consultant- M/s Perfact EnviroSolutions Pvt. Ltd. C-1


TABLE OF CONTENT1. Executive Summary 5

2. Introduction Of The Project 7

3. Project Description 10

4. Site Analysis 62

5. Planning Brief 68

6. Proposed Infrastructure 69

7. Rehabilitation And Resettlement (R & R) Plan 71

8. Project Schedule and Cost Estimates 71

9. Analysis Of Proposal (Final Recommendations) 72

List Of Images1. Figure 1. Close view of the project site with 1 km radius2. Figure 2. Four coordinates of the project site3. Figure 3. Plant layout4. Figure 4. Layout Plan showing additional Green area at Plot E-745. Figure 5. Chemical reaction 2,6 Dichloro Para NitroAniline6. Figure 6. Process Flow Diagram-2,6 Dichloro Para NitroAniline7. Figure 7. Process Flow Diagram- 6 Chloro 2,4 Dinitroaniline8. Figure 8. Chemical Reaction- Ortho Nitro Aniline Para Sulphonic

Acid9. Figure 9. Process Flow Diagram- Ortho Nitro Aniline Para

Sulphonic Acid10. Figure 10. Chemical reaction-2,4 Dinitroaniline11. Figure 11. Process Flow Diagram- 2,4 Dinitroaniline12. Figure 12. Chemical Reaction-DinitroPhenol13. Figure 13. Process Flow Diagram- DinitroPhenol14. Figure 14. Chemical Reaction-Para Nitro Phenol15. Figure 15. Chemical reaction-4 Nitro Amino Phenol16. Figure 16. Process Flow Diagram-4 Nitro Amino Phenol17. Figure 17. Chemical Reaction-6 Bromo 2,4 Dinitroaniline18. Figure 18. Process Flow Diagram-6 Bromo 2,4 Dinitroaniline19. Figure 19. Chemical Reaction- Ortho Chloro Para Nitro Aniline20. Figure 20. Process Flow Diagram- Ortho Chloro Para Nitro Aniline21. Figure 21. Chemical Reaction -Para Nitro Aniline22. Figure 22. Process Flow Diagram- Para Nitro Aniline



23. Figure 23. Chemical Reaction-Ortho Nitro Aniline24. Figure 24. Process Flow Diagram--Ortho Nitro Aniline25. Figure 25. Chemical Reaction- Para Chloro Ortho Nitro Aniline26. Figure 26. Process Flow Diagram- Para Chloro Ortho Nitro Aniline27. Figure 27. Chemical Reaction-Pigment Red -228. Figure 28. Process Flow Diagram-Pigment Red -229. Figure 29. Chemical Reaction-Pigment Yellow30. Figure 30. Process Flow Diagram -Pigment Yellow31. Figure 31. Chemical Reaction-Pigment Orange 532. Figure 32. Process Flow Diagram-Pigment Orange 533. Figure 33. Chemical Reaction-4 Chloro 2 NitroPhenol34. Figure 34. Process Flow Diagram-4 Chloro 2 NitroPhenol35. Figure 35. Chemical Reaction-4 Chloro 2 Amino Phenol36. Figure 36. Process Flow Diagram-4 Chloro 2 Amino Phenol37. Figure 37. Process Flow Diagram-Recovery of Ammonia38. Figure 38. Process Flow Diagram- Calcium Chloride39. Figure 39. MEE Scheme40. Figure 40. Location of project on Industrial Map of Tarapur41. Figure 41. Topographical map

List Of Tables■ Table 1. Project Details■ Table 2. Employment generation details■ Table 3. Latitude and Longitude of the project■ Table 6. Material Balance- 2,6 Dichloro Para NitroAniline■ Table 7. Material Balance- 6 Chloro 2,4 Dinitroaniline■ Table 8. Material Balance-- Ortho Nitro Aniline Para Sulphonic

Acid■ Table 9. Material Balance- 2,4 Dinitroaniline■ Table 10. Material Balance- DinitroPhenol■ Table 11. Material Balance--Para Nitro Phenol■ Table 12. Material Balance-4 Nitro Amino Phenol■ Table 13. Material Balance-6 Bromo 2,4 Dinitroaniline■ Table 14. Material Balance-Ortho Chloro Para Nitro Aniline■ Table 15. Material Balance-Para Nitro Aniline■ Table 16. Material Balance--Ortho Nitro Aniline■ Table 17. Material Balance- Para Chloro Ortho Nitro Aniline■ Table 18. Material Balance-Pigment Red -2■ Table 19. Material Balance-Pigment Yellow■ Table 20. Material Balance-Pigment Orange 5



■ Table 21. Material Balance-4 Chloro 2 NitroPhenol■ Table 22. MAterial Balance-4 Chloro 2 Amino Phenol■ Table 23. Material Balance- Recovery of Ammonia■ Table 24. Material Balance- Calcium Chloride■ Table 26. List of machinery and equipment■ Table 27. Water Management■ Table 28. Wastewater Characteristics■ Table 29. Details of power and its back up■ Table 30. Details of emissions from utilities■ Table 31. Solid waste Management■ Table 32. Process waste Management■ Table 33. Hazardous waste management■ Table 34. Infrastructure nearby to the project site■ Table 35. List of industries within 5 km■ Table 36. Infrastructure near to the project■ Table 37. Land Use-Core Zone■ Table 38. Green area details■ Table 39. Environment Management Plan with Budget



1. Executive SummaryM/s Prolific Chemicals Pvt Ltd is proposing an “Expansion of SyntheticOrganic Chemicals Manufacturing Unit” located at Plot No. E-69, TarapurMIDC, Palghar, Maharashtra. The unit is located on land measuring 0.2040ha in Maharashtra Industrial Development Corporation (MIDC) Tarapur.Land is owned by Maharashtra Industrial Development Corporation (MIDC)and leased to M/s Prolific Chemicals Pvt Ltd for 99 years on 24.02.2010.The project has already been granted Environmental Clearance (EC) byMoEFCC on 31st December 2015 (File No. SEAC-2012/CR-265/TC-2) formanufacture of products for 269 TPM (Including by products).

The project is an operational chemical manufacturing facility with a totalproduction capacity of 3228 TPA (269 TPM) manufacturing SyntheticOrganic Chemicals according to CTO vide letter No. Format 1.0/BO/AST/UAN No. 0000001936/O/CC/170900792 dated 20/09/2017 valid upto31/08/2022 granted by Maharashtra Pollution Control Board. M/s. ProlificChemicals Pvt. Ltd. was incorporated in the year 1995 by Mr. NarendraMamania, the current proprietor and Director. The company commencedoperations in 1998 with the production of Potassium Fluoride and a host ofother inorganic chemicals. For almost a decade, Prolific manufacturedinorganic chemicals with a constant capacity of 200 tons annual.

Due to increase in market demand and change in planning, the productioncapacity has been proposed to increase from 3228 TPA (269 TPM) to8508 TPA (709 TPM).

Since the project lies in Tarapur (Maharashtra) which is a declared CriticallyPolluted Area (CPA) vide CEPI Notification No. 1038/2018 dated10/07/2019, hence attracts the general condition of the EIA Notification2006 and its subsequent amendment.

As the project is involved in the manufacturing of Synthetic organicchemicals the project falls under Schedule 5(f) under Category B of theEIA Notification 2006 and its subsequent amendment but due to theapplicability of the General Conditions (Critically Polluted Area-Tarapur)the project is required to be appraised by Industry 3- EAC at MOEF&CC.

Since the unit lies in the notified industrial area of Maharashtra IndustrialDevelopment Corporation (MIDC), Tarapur established prior 2006,therefore the proposal is exempted from Public Consultation as per



clause 7 (i) (iii) stage (3)(i)(b) of EIA notification 2006 (as per OMJ-11011/321/2016-IA. II(I) dated 27th April 2018).

Project Description

Table 1. Project Details

S. No. Particulars UnitDetails

Existing Proposed Total afterExpansion

1 Location -

Plot No. E-69, Tarapur MIDC, Palghar,Maharashtra.Latitude: 19°48'17.72"NLongitude: 72°43'52.14"E.

Elevation: 14.6 m

2 Plot area ha 0.2040

3 Green Area* m2 350 323.2 673.2 (33% ofPlot Area)

4 Plant Capacity TPA 3228 5280 8508

5 Estimated Project Cost Crores INR 3.705 2.4413 6.1463

6 Manpower Nos. 25 20 45

7 Source of Electricity Supply Maharashtra State Electricity Distribution Co.Ltd. (MSEDCL)

8 Total Power Requirement KW79.8-Installed63.4-Operational

186.4-Installed149.1-Operational

266.2-Installed212.5-Operational

9 DG Sets (Backup) kVA 1 x125 1 x125 2 x125

10 Capacity of Boiler TPH 1 No.x0.8 1 No. x2 1 No. x0.8 & 1No. x2

11 Fuel Requirement -

For DG Set-125 kVAAtPresent-HSD-10 Lit/hrAfterexpansion(Existing DGwill beutilized at fullload)- 33.78Lit/hr,

HSD-33.78Lit/hr(DG-125kVA),Briquette –3000 Kg/Day(Boiler-2 TPHTPH)

HSD-67.56Lit/hr (DG-2x125 kVA),Briquette –5340 Kg/Day(Boiler-0.8TPH & 2 TPH)



For Boiler-0.8 TPHAt Present:Light DieselOil (LDO) -0.3KL/Day orBriquette –300 Kg/DayAfterexpansion(Existingboiler will beutilized at fullload):Light DieselOil (LDO)-986.7KL/Day orBriquette –2340 Kg/Day

12 Source of Water Supply Maharashtra Industrial DevelopmentCorporation (MIDC)

13 Water Requirement KLD 6.9 170.60 177.514 Wastewater Generation KLD 3.3 65.2 68.5

*Green Belt & Plantation Area within plot premise (17.16 % of Plot Area)-350 sqm & Green Belt & Plantation Area outside plot premises i.e. at plot E74, MIDC Tarapur which owned by PP & MoU shall be done for the same(15.84% of Plot Area)- 323.2 sqm

2. Introduction Of The Project(i) Identification of Project and Project ProponentThe proposed project is for “Expansion of Synthetic Organic ChemicalManufacturing Unit” located at Plot No. E-69, Tarapur MIDC, District -Palghar, Maharashtra. It is located at Latitude: 19°48'17.72"N andLongitude: 72°43'52.14"E. The elevation of the site is about 14.6 m withrespect to mean sea level.

Total Capacity: 8508 TPA (After Expansion)

Name of the Applicant: Mr. Narendar Mamania, Partner

Address: Plot No. 207 E, Flat 1501, Ram Kutir CHS, Dr.BabasahebAmbedkar Road, Matunga (E), Maharashtra



Mobile: 9122-24134374

E-Mail: [email protected]

M/s. Prolific Chemicals Pvt. Ltd. was incorporated in the year 1995 by Mr.Narendra Mamania, the current proprietor and Director. The companycommenced operations in 1998 with the production of Potassium Fluorideand a host of other inorganic chemicals. For almost a decade, Prolificmanufactured inorganic chemicals with a constant capacity of 200 tonsannual. Prolific purchased a new plot at E-69 MIDC, Tarapur industrial areato establish a manufacturing facility of Synthetic Organic Chemicals. Landis owned by Maharashtra Industrial Development Corporation (MIDC) andleased to the Company for 99 years.

(ii) Brief description & nature of the project

Location: Plot No. E-69, Tarapur MIDC, Dist: Palghar, State: Maharashtra.Plot size: 0.2040 haLocational advantages: The site can be accessed from the StateHighway-74 Boisar-Tarapur Road located at 1.23 Km NE. The site is wellconnected to MIDC Road ( 2.19 km SSW) and Boisar-Palghar road (3.50km SE).The nearest Railway station is Boisar Railway Station which isapproximately 3.23 Km ESE (aerial distance). The nearest Airport isChhatrapati Shivaji Maharaj International Airport which is approximately80.41 km SSE (aerial distance).

The project is an operational chemical manufacturing facility with a totalproduction capacity of 3228 TPA. Due to increase in market demand andchange in planning, the production capacity has been proposed to increasefrom 3228 TPA to 8508 TPA. As per EIA Notification 2006 and itssubsequent amendment the project falls under Schedule 5(f), Category Bof the but due to the applicability of the General Conditions (CriticallyPolluted Area-Tarapur) the project is required to be appraised by Industry3- EAC at MOEF&CC.

(iii) Need for the project and its importance to the country and orregionThe Indian chemicals industry, which includes basic chemicals & itsproducts, petrochemicals, fertilisers, paints, gases and pharmaceuticals, isone of the oldest industries in the country and plays an important role in itsoverall economic development. Other features that set it apart are therequirement for large capital for set-up, high power consumption forproduction and a highly diversified product range, covering more than70,000 commercial products. The chemical industry forms the backbone of


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the industrial and agricultural development of India, by providing buildingblocks for downstream industries. The chemical industry accounts forabout 17.6 percent of the output of India’s manufacturing sector and about3 percent of the GDP. The industry output is estimated at US$ 35 billion,with a total investment of approximately US$ 60 billion.The global organic pigments market is expected to witness growth onaccount of its use in various end-use industries including printing inks,paints and coatings, plastics, rubber and textiles. Urbanization coupledwith rise in infrastructure spending is likely to boost the paint market whichin turn is anticipated to fuel the organic pigments market over the forecastperiod. Furthermore, use of organic pigments as colorants in textile andplastic industries is expected to contribute to its market growth. Moreover,rising demand for value-added high-quality organic pigments in thecosmetic industry is likely to result in market growth over the next sixyears. Although the organic pigment market has reached maturity in NorthAmerica and Europe, the market is anticipated to receive a boost as majorcompanies are aiming at designing and developing products in sync withcontinuously changing requirements for evolving technologies. However,volatility in raw material prices is likely to be a major restraint for organicpigments market growth.The proposed project will provide a potential growth opportunity for theon-going business of the company and increase the export, which will helpto increase the foreign revenue to the company.(iv) Demand – Supply GapWith increase in the demand of the Synthetic Organic Chemicals will alsoincrease the requirement of its key material imports. Hence, Manufacturingthese chemicals will serve and supply to the local/regional market, therebybridging the existing demand-supply gap(v) Import vs. Indigenous ProductionManufacturing locally at the proposed site will reduce the importingcapacity of the Synthetic Organic Chemicals and will save valuable foriegnexchange.(vi) Export PossibilityExport possibilities will be there as per market demand and order.(vii) Domestic/ Export MarketsMarket for these products not only include the domestic market but there isconsiderable scope in the international market(viii) Employment Generation (Direct and Indirect) due to the projectIndirect employment will be generated due to the project. Totalemployment in the Chemical plant after expansion will be around 57 Nos.At present, the unit has a manpower of 25 people. The local villagers willbe given employment. The details of manpower is given below:-



Table 2. Employment generation details

Particulars Unit Existing Proposed Total after Expansion

Skilled employees No. 17 13 30

Unskilledemployees No. 8 7 15

Total No. 25 20 45

3. Project Description(i) Type of Project including interlinked and independent projects, if any.The proposed project is titled as “Expansion of Synthetic OrganicChemicals Manufacturing Unit” located at Plot No. E-69, Tarapur MIDC,Dist: Palghar, State: Maharashtra developed by M/s Prolific Chemicals Pvt.Ltd. The project is an operational chemical manufacturing facility with atotal production capacity of 3228 TPA. Due to increase in market demandand change in planning, the production capacity has been proposed toincrease from 3228 TPA to 8508 TPA. As per EIA Notification 2006 and itssubsequent amendments, the proposed project requires environmentalclearance as are classified as Category B under item 5(f) but due to theapplicability of the General Conditions (Critically Polluted Area-Tarapur)the project is required to be appraised at MOEF&CC.

Interlinked Projects: There is no interlinked project.Interdependent Projects: There is no interdependent project.(ii) Location of the site is given below:

Location: Plot No. E-69, Tarapur MIDC, Palghar, Maharashtra

Latitude: 19°48'17.72"N

Longitude: 72°43'52.14"E

Elevation: 14.6 m



Figure 1. Close view of the project site with 1 km radius

Latitude & Longitude of the proposed project site is given below :

Table 3. Latitude and Longitude of the project

Direction Latitude Longitude

A, SE 19°48'17.13"N 72°43'53.11"E

B, WSW 19°48'17.14"N 72°43'51.15"E

C, WNW 19°48'18.25"N 72°43'51.13"E

D, ENE 19°48'18.29"N 72°43'53.15"E



Figure 2. Four coordinates of the project site

Plant Layout

Figure 3. Plant layout



Figure 4. Layout Plan showing additional Green area at Plot E-74

(iii) Details of alternative sites considered and basis of selecting theproposed site, particularly the environmental considerations gone intoshould be highlighted.

The proposed project is a brownfield site with the existing chemicalmanufacturing unit. The assessment for the site is presented below:

● Land: The land is available for expansion within the existingindustrial plant, no additional land is required for the proposedexpansion. The unit is located in a notified Industrial area MIDCTarapur.

● Facilities & Utilities: The existing plant has water supply pipelines,access to road, electricity supply, drainage system. All thementioned facilities are able to cater the proposed expansion.

● The ambient air quality at and around the project site is well withinthe limits.

● Lower Capital cost in comparison to the greenfield project, thereforeminimizing the cost of production.



● The site is well connected with roads and railway networks.● No Rehabilitation and resettlement requirements.

Considering the above mentioned advantages of the current projectlocation and limited footprints and incremental impacts, the existing sitehas been considered for the following expansion. This would also givebenefits in utilizing the existing utilities and infrastructure within theproject site to have minimal environmental and social footprints.

(iv) Size or magnitude of operationThe proposal is for expanding the Plant Capacity from 3228 TPA to 8508TPA.

Table 4. Plant Capacity Details

Table 4.

S.No Particulars Existing(TPA)

Proposed(TPA)

Total after Expansion(TPA)

1 Synthetic OrganicChemicals

2532 2568 5100

2 ByProducts 696 2712 3408

Total Production capacity 3228 5280 8508


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Expansion of Synthetic Organic Chemical Manufacturing Unit at MIDC Tarapur, Palghar, Maharashtra By M/s Prolific Chemicals Pvt. Ltd.

Table 5. Details of Products & Production

Table 5.

Sr. No. Products/By-Product Name

Hazardous/NonHazardous &CAS No.

Existing(TPM)

Proposed (TPM)

AfterExpansion(TPM)

ProcessType

End Useof theProduct

State MeansofStorage

No. of Daysof storage

Transportation(byRoad/Air/ Sea)

ProductSale(Local/Export)

A. PRODUCT1 2,6 Dichloro

ParaNitroAniline

HazardousCAS No.-99-30-9

15 70 100 Chlorination dyeintermediate

Solid drum,jumbobag,HDPEbag

7 Road local /export

2 6 Chloro 2,4Dinitro Aniline

Non-HazardousCAS No.-3531-19-9

15 dyeintermediate



3 Ortho NitroAniline ParaSulphonic Acid


20 130 200 Ammonolysis1

dyeintermediate



4 2,4 DinitroAniline

"HazardousCAS No.-97-02-9" 50

dyeintermediate

Solid drum,jumbo bag,HDPE bag

Road local /export



5 DinitroPhenol HazardousCAS No.-51-28-5

25 -35 15 Hydrolysis dyeintermediate



6 Para NitroPhenol

Hazardous CASNo.-100-02-7

25 KSM forpharma/ DyeIntermediate /AgroIntermediate



7 4 Nitro AminoPhenol

HazardousCAS No.-99-57-0

25 -15 10 Misc. dyeintermediate



8 SodiumPicramate

HazardousCAS No:831-52-7

18 -18 0 To be discontinued

9 Picric Acid HazardousCAS No-88-89-1

18 -18 0.00



10 6 Bromo 2,4Dinitro Aniline

HazardousCAS No:1817-73-8

- 50 50 Bromination dyeintermediate



11 a) OrthoChloro ParaNitro Anilineorb) Para NitroAnilineorc) Ortho NitroAnilineord) Para ChloroOrtho NitroAniline

Hazardous121-87-9or100-01-6or88-74-4or89-63-4

- 20 20 Ammonolysis 2

dyeintermediate



12 a) PigmentRedorb) PigmentYelloworc) PigmentOrange -5

Hazardous

- 10 10 Pigments pigment Solid drum,jumbobag,HDPEbag




13 a) 4 Chloro 2NitroPhenolorb) 4 Chloro 2Amino Phenol

Hazardousa)89-64-5

b)95-85-2

- 20 20 Reduction KSM forpharma /DyeIntermediate /AgroIntermediate



A. Total Product capacity 211 214 425B. BY-PRODUCT14 Ammonium

ChlorideNon-HazardousCAS No.-12125-02-9

20 - 20 (GeneratedfromONAPSAand2,4DNA)100%CaptiveConsumption

AllAmmoniumchloridewill beconverted toCalciumChlorideafterammoniumrecovery

Solid StorageTank

7 Road local

15 SodiumSulphate


8 - 8 (GeneratedfromDinitroPhenol)

Solid HDPEBags

7 Road local



16 Spent Acid -HCl

- 96 96 (real basis) Tanker 10 Road local

17 CalciumChloride


30 130 160 (AmmoniumChloride isreactedwithCalciumOxide toformCalciumChloride)

Solid/Slurry

HDPEBags

10 Road local

B. Total ByProduct 58 226 284Total Production Capacity (A+B) 269

(3228TPA)

440(5280TPA)

709(8508TPA)

* All the products will be stored as per the Threshold limit as per MSIHC Rules, 1989



(v) Project description with process details (a schematic diagram/flow chart showing the project layout, components of the project etc.should be given)

A. Chlorination:-

1. 2,6 Dichloro Para NitroAnilineManufacturing Process:Para nitro aniline reacted with HCl at a particular temperature and thenpassed chlorine into the reactor for the preparation of DCPNA.Reaction mass is heated at a particular temperature. On completion ofreaction mass is filtered, and dried to the final product. And filtrate recycledfor the next batch.

Figure 5. Chemical reaction 2,6 Dichloro Para NitroAniline

Figure 6. Process Flow Diagram-2,6 Dichloro Para NitroAniline



Table 6. Material Balance- 2,6 Dichloro Para NitroAnilineInput Qty Unit Output Qty Unit RemarkHydrochloric Acid 1.1 kg 2,6 Dichloro

ParaNitroAniline

1 kg Product

Chlorine gas 0.34 kg ExcessChlorine

0.05 kg Alkali Scrubber

Para nitro Aniline 1.25 kg Spent HCl 3.14 kg Spent Acid HCl(By Product)

Water 1 kg WashingWater

1.5 kg To ETP

Water for washing 2 kgTotal 5.69 kg Total 5.69 kg

2. 6 Chloro 2,4 Dinitroaniline

Manufacturing Process:In a p. p. reactor Hydrochloric Acid & 2, 4 Dinitro Aniline is added. Slowlythe chlorine gas is passed through this mixture. The process is carried outat room temperature & pressure. After 18 hrs.to 20 hrs the process mixtureis passed through a notch filter & sent for centrifugation. The centrifugedproduct is then dried & finished product will be packed.



Figure 7. Process Flow Diagram- 6 Chloro 2,4 Dinitroaniline

Table 7. Material Balance- 6 Chloro 2,4 DinitroanilineInput Qty Unit Output Qty Unit RemarkHydrochloricAcid(30%)

1.08 kg 6 Chloro 2,4Dinitroaniline

1 kg Product

Chlorine gas 0.26 kg Mother liquorreuse in nextbatch

1 kg Reuse inProcess

2,4 DinitroAniline

1.2 kg Spent HCl 3.43 kg Spent HCl

Water ( Fresh- 1.8 , ML - 1)

2.8 kg Excess Chlorine 0.01 kg Alkali Scrubber

Water forwashing

3 kg Washing Water 2 To ETP

Drying Loss 0.9Total 8.34 kg Total 8.34 kg

B. Ammonolysis1:-

3. Ortho Nitro Aniline Para Sulphonic Acid

Manufacturing Process:



Water & Ortho Nitro Chloro Benzene Para Sulphonic Acid is charged in S.S.Reactor. The liquor ammonia is added to this mixture. Then mass is thenheated. The mixture is then filtered through a notch filter. The filtermaterial is then centrifuged, dried & packed.

Figure 8. Chemical Reaction- Ortho Nitro Aniline Para Sulphonic Acid

Figure 9. Process Flow Diagram- Ortho Nitro Aniline Para Sulphonic AcidTable 8. Material Balance-- Ortho Nitro Aniline Para Sulphonic Acid

Input Qty Unit Output Qty Unit RemarkOrtho Nitro ChloroBenzene ParaSulphonic Acid

1.12 kg Ortho NitroAniline ParaSulphonic

1 kg Product

Liquor Ammonia 1 kg Washing Water 1.1 kg to ETPAmmoniumChloride(containing

1.950 kg by product



ammonia +water)

Water 2.5 kg UR NH3 0.066 kg AmmoniaRecovery

Drying Loss 0.5 12

Total 4.62 kg Total 4.62 kg

4. 2,4 Dinitroaniline


The DinitroChloro Benzene & liquor ammonia is charged in the reactor. Themass is heated at the temperature of 70oC as the mass reacts thetemperature increases to 90oC. The mass is then kept for 5 hrs at thepressure of 3 Kgs cm2. Then the mass is taken out & cooled at roomtemperature. The mass is then sent to the filter notch where it is washedwith water & then the water is recycled.

Figure 10. Chemical reaction-2,4 Dinitroaniline



Figure 11. Process Flow Diagram- 2,4 Dinitroaniline

Table 9. Material Balance- 2,4 DinitroanilineInput Qty Unit Output Qty Unit Remark2,4 DinitroChloroBenzene

1.242 kg 2,4 Dinitroaniline 1 Kg Product

Liquor Ammonia(fresh + recycle)

0.9 kg AmmoniumChloride(containingammonia + water)

2.48 kg By-product

Water 3.936 kg Washing Water 1.16 kg To ETPkg Un-reacted

ammonia0.44 kg To

AmmoniaRecovery

Drying Loss 1Total 6.08 kg Total 6.08 kg

C. Hydrolysis:-

5. DinitroPhenol

Manufacturing Process:The raw material i.e. Water, Dinitrochloro benzene & Caustic lye arecharged in the SS reactor in acidic medium. After heating the mass is thenfed to the PP reactor, where it is neutralized with the help of Sulphuric



Acid. Then the mass is filtered through a notch filter. Then it is centrifuged& dried.

Figure 12. Chemical Reaction-DinitroPhenol



Figure 13. Process Flow Diagram- DinitroPhenol

Table 10. Material Balance- DinitroPhenol

Stage -IInput Qty Unit Output Qty Unit Remark2,4 Di nitro chloroBenzene

1.2 kg DinitroPhenol 1 kg To nextstage

Caustic Soda (NaOH) 0.55 kg Mother liquorreuse in nextbatch

1.75 kg To recycle

Water 1.8 kg Water 0.93 kg To ETPkg Excess caustic 0.07 kg To ETP

Total 3.75 kg Total 3.75Stage –IIInput Qty Unit Output Qty Unit RemarkProduct Stage I 1.1 kg DinitroPhenol 1 kg Product



Sulphuric Acid 0.87 kg Sodium Sulphate 0.32 kg By-productWater 2 kg Water 3.93 kg To ETPWater (washing) 2 kg Inorganic 0.71 kg To ETP

kg Organic impurity 0.01 kg To ETPTotal 5.97 kg Total 5.97 kg

6. Para Nitro PhenolManufacturing Process:The raw material i.e. Water, Para nitro chloro benzene & Caustic lye arecharged in the SS reactor. After heating the mass is then fed to the PPreactor, where it is neutralized with the help of Sulphuric Acid. Then themass is filtered through a notch filter. It is then centrifuged & dried.

Figure 14. Chemical Reaction-Para Nitro Phenol



Figure 15.

Figure 15. Process Flow Diagram-Para Nitro Phenol

Table 11. Material Balance--Para Nitro PhenolInput Qty Unit Output Qty Unit RemarkPara Nitro Chlorobenzene

1.35 kg Para Nitro Phenol 1 kg Product

Caustic Soda 0.71 kg Water 5.11 Kg To ETPSulphuric Acid 0.31 kg NaCl+ Na2So4 1.06 Kg MEE SALTWater 3 kgWater for washing 1.8Total 7.17 kg 7.17 kg

D. Miscellaneous:-

7. 4 Nitro Amino Phenol




Dinitro Phenol & Sodium Sulphide is charged into the reactor in HClmedium. After the reaction the mass is filtered through a notch filter,centrifuged & dried.

Figure 16. Chemical reaction-4 Nitro Amino Phenol

Figure 17. Process Flow Diagram-4 Nitro Amino Phenol

Table 12. Material Balance-4 Nitro Amino PhenolInput Qty Unit Output Qty Unit RemarkSodium sulphide 0.21 kg 4 Nitro Amino

Phenol1 kg Product

DinitroPhenol 0.56 kg HCl recovery 0.7 kg To recycle



Aq. HCl 1 kg Effluent 2.0665

kg To ETP

Water for washing 2 kg Excess HCl 0.0025

kg To ETP

kg Organicimpurity

0.001 kg To ETP


8. Sodium Picramate & Picric Acid (to be Discontinued)


Stage-I: Water &DinitroChloro Benzene is charged to the reactor formanufacturing Sodium Picramate and Picric Acid in acidic medium (HCl).Then the caustic lye is slowly added to it. The temperature is maintained &if the batch is ok then it is cooled, acidified and filtered.

Stage II: Sulphuric acid is charged into a reactor & stirred continuously.Then the dried Dinitro Phenol is added to it. After that the Nitric Acidslowly added to it, this process takes place for 3-4 hrs. the mass is thenremoved & kept on ice & water

Stage –III: Dried PicricAcid & water is charged to thereactor.TheSodiumSulphatehydrateisaddedto it. Then the mass is filtered &sent for vacuum drying.

E. Bromination:-

9. 6 Bromo 2,4 Dinitroaniline


In the glass lined reaction vessel first hydrochloric acid is charged. Dinitroaniline is then added .The mass is stirred for 2 hours.Bromine is thenslowly charged for 2 to 3 hours. The reaction mass is maintained for 2hours.Chlorination is then carried out under cooling conditions with thehelp of chlorine gas. Reacted material is checked and if found as perdesired quality it is filtered in filter nutch. Filtrate is reused in the nextbatch. Chlorine, HCL and Bromine gases generated during reaction are sentto caustic scrubber.The process involves acidification,chlorination andbromination.



Figure 18. Chemical Reaction-6 Bromo 2,4 DinitroanilineProcess Flow Diagram

Figure 19. Process Flow Diagram-6 Bromo 2,4 Dinitroaniline

Table 13. Material Balance-6 Bromo 2,4 DinitroanilineInput Qty Unit Output Qty Unit RemarkHydrochloric Acid(30%)

1 kg 6 Bromo 2,4Dinitroaniline

1 kg Product

Chlorine gas 0.115 kg Mother liquorreuse in next batch

1 kg Reuse inProcess



2,4 Dinitro Aniline 0.57 kg Waste Water 2 kg TO ETPLiq Bromine 0.255 Excess Bromine 0.01 Alkali

ScrubberWater ( Fresh - 2.3, ML - 0.7)

2.3 kg Excess Chlorine 0.01 kg AlkaliScrubber

Water Recycled 1 kg Evaporation Loss 1.12Total 5.24 kg Total 5.24 kg

F. Ammonolysis 2 :-

10. Ortho Chloro Para Nitro Aniline

Manufacturing Process: 3,4 DCNB, recycled and fresh liquor Ammonia aretaken together in an autoclave for manufacturing of Ortho Chloro ParaNitro Aniline. Desired temperature and pressure are 15 to 16 hours tocomplete the reaction. Amination is carried out in an autoclave andproducts are isolated by layer separation. When reaction is over & excessof Ammonia is blown off through the vent valve and scrubber in water toform 32% w/w Ammonia solution.

Figure 20. Chemical Reaction- Ortho Chloro Para Nitro Aniline



Figure 21. Process Flow Diagram- Ortho Chloro Para Nitro Aniline

Table 14. Material Balance-Ortho Chloro Para Nitro AnilineInput Qty Unit Output Qty Unit Remark3,4 DCNB 3 kg Ortho Chloro Para

Nitro Aniline2.675 kg Product


2.125 kg Ammonium Chloride(containingammonia + water)

4.15 kg By-product(AmmoniumChlorideSolution)

Water 5.2 kg Washing Water 2.7 TO ETPkg Un-reacted ammonia 0.8 kg To Ammonia

RecoveryTotal 10.325 kg Total 10.325 kg

11. Para Nitro AnilineProcess Description:Para Nitro Chloro Benzene, recycled liquor Ammonia & anhydrousAmmonia are taken together in an autoclave for manufacturing of ParaNitro Aniline. Desired temperature and pressure are 15 to 16 hours tocomplete the reaction. Amination is carried out in an autoclave andproducts are isolated by layer separation. When reaction is over & excessof Ammonia is blown off through the vent valve and scrubber in water toform 32% w/w Ammonia solution.



Chemical Reaction:

Figure 22. Chemical Reaction -Para Nitro Aniline

Process Flow Diagram:

Figure 23. Process Flow Diagram- Para Nitro Aniline

Table 15. Material Balance-Para Nitro AnilineInput Qty Unit Output Qty Unit RemarkPara Nitro ChloroBenzene

2.5 kg Para NitroAniline

2.175 Kg Product


2.125 kg AmmoniumChloride(containingammonia +water)

4.299 kg By-product(AmmoniumChlorideSolution)



Water 4.536 kg Washing Water 2 kg TO ETPkg Un-reacted

ammonia0.687 kg To

AmmoniaRecovery


12. Ortho Nitro AnilineProcess Description:Ortho Nitro Chloro Benzene, recycled liquor Ammonia & anhydrousAmmonia are taken together in an autoclave for manufacturing of OrthoNitro Aniline. Desired temperature and pressure are 15 to 16 hours tocomplete the reaction. Amination is carried out in an autoclave andproducts are isolated by layer separation. When reaction is over & excessof Ammonia is blown off through the vent valve and scrubber in water toform 32% w/w Ammonia solution.

Figure 24. Chemical Reaction-Ortho Nitro AnilineProcess Flow Diagram:



Figure 25. Process Flow Diagram--Ortho Nitro Aniline

Table 16. Material Balance--Ortho Nitro AnilineInput Qty Unit Output Qty Unit RemarkOrtho Nitro ChloroBenzene

2.5 kg Ortho NitroAniline

2.175 Kg Product


2.125 kg AmmoniumChloride(containingammonia +water)

4.299 kg By-product(Ammonium ChlorideSolution)

Water 4.536 kg Washing Water 2 kgkg Un-reacted

ammonia0.687 kg To

AmmoniaRecovery


13. Para Chloro Ortho Nitro AnilineManufacturing Process:2, 5 DCNB, recycled and fresh liquor Ammonia are taken together in anautoclave for manufacturing of Para Chloro Ortho Nitro Aniline. Desiredtemperature and pressure are 15 to 16 hours to complete the reaction.Amination is carried out in an autoclave and products are isolated by layerseparation. When reaction is over & excess of Ammonia is blown off



through the vent valve and scrubber in water to form 32% w/w Ammoniasolution.

Figure 26. Chemical Reaction- Para Chloro Ortho Nitro Aniline


Figure 27. Process Flow Diagram- Para Chloro Ortho Nitro Aniline

Table 17. Material Balance- Para Chloro Ortho Nitro AnilineInput Qty Unit Output Qty Unit Remark2,5 DCNB 3 kg Para Chloro Ortho

Nitro Aniline2.675 Kg Product

LiquorAmmonia(fresh +recycle)

2.125 kg AmmoniumChloride(containingammonia + water)

4.15 kg By-product(AmmoniumChloride Solution)

Water 5.2 kg Washing Water 2.7 kgkg Un-reacted

ammonia0.8 kg To Ammonia

Recovery




G. Pigments:-

14. Pigment Red -2Manufacturing Process :

1. Water, HCL, Ice, NaNO2 and 2,5 DCA are added into the Azo Vessel;and Water, Caustic Lye, Ice and 3-hydroxy Neptelinamide are addedinto the Coupler Vessel.

2. Once the mass in the coupler vessel is ready, the output from theAzo Vessel is added to the Coupler Vessel along with Water, Ice andat the end of coupling, steam is passed to get the requiredtemperature.

3. The final mass obtained is then passed through a filter press, wherethe material is separated in the form of wet cake.

4. This wet cake is washed with water and remaining material is sentinto the dryer. Water gets evaporated into the dryer and the dryproduct is packed after blending.

Figure 28. Chemical Reaction-Pigment Red -2




Figure 29. Process Flow Diagram-Pigment Red -2

Table 18. Material Balance-Pigment Red -2Input Qty Unit Output Qty Unit RemarkHydrochloric Acid 0.375 kg Product 0.44 kg ProductSodium Nitrite 0.07 kg Evaporation

Loss1.005 kg

2,5 Dichloro Aniline 0.162 kg WastewaterStream

5.872 kg

3 HydroxyNeptelinamide

0.26

Water 4.2 kg kgNaOH 0.15 kgIce 2.1Total 7.317 kg Total 7.317 kg



15. Pigment YellowManufacturing Process :

1. Water, HCL, Ice, NaNO2 and 3,3 DCB are added into the Azo Vessel;and Water, Caustic Lye, Ice and Aceto Xylidine are added into theCoupler Vessel.




Chemical Reaction

Figure 30. Chemical Reaction-Pigment Yellow




Figure 31. Process Flow Diagram -Pigment Yellow

Table 19. Material Balance-Pigment YellowInput Qty Unit Output Qty Unit RemarkHydrochloric Acid 0.375 kg Product 0.63 kg ProductSodium Nitrite 0.14 kg Evaporation

Loss1.005 kg

3,3Dichlorobenzidine

0.249 kg WastewaterStream

5.984 kg

Aceto Xylidine 0.355Water 4.2 kg kgNaOH 0.2 kgIce 2.1Total 7.619 kg Total 7.619 kg



16. Pigment Orange 5Manufacturing Process :

1. Water, HCL, Ice, NaNO2 and 2,4 DNA are added into the AzoVessel; and Water, Caustic Lye, Ice and B Naphthol are added intothe Coupler Vessel.




Chemical Reaction:

Figure 32. Chemical Reaction-Pigment Orange 5

Process Flow Diagram



Figure 33. Process Flow Diagram-Pigment Orange 5

Table 20. Material Balance-Pigment Orange 5Input Qty Unit Output Qty Unit RemarkHydrochloric Acid 0.575 kg Pigment

Orange 50.34 kg Product

Sodium Nitrite 0.07 kg EvaporationLoss

1.405 kg Reuse inProcess

2,4 Dinitro Aniline 0.183 kg WastewaterStream

2.927 kg Spent HCl

B Naphthol 0.144Water 3.2 kg kgNaOH 0.1 kgIce 0.4Total 4.672 kg Total 4.672 kg



H. Reduction:-

17. 4 Chloro 2 NitroPhenolManufacturing Process:2,5 Dichloronitrobenzene [2,5 DCNB] is hydrolysed with Sodium Hydroxideat a controlled reaction parameter. After the hydrolysis is completed, MLfrom the reaction mass is decanted and the residual mass is acidified. TheAcidification results in falling out of 4-Chloro-2-Nitro Phenol [4-CNP],which is filtered, washed and dried.Chemical reaction:

Figure 34. Chemical Reaction-4 Chloro 2 NitroPhenol


Figure 35. Process Flow Diagram-4 Chloro 2 NitroPhenol



Mass Balance:Table 21. Material Balance-4 Chloro 2 NitroPhenol

Input Qty Unit Output Qty Unit Remark2,5 DCNB 1.25 kg 4 CNP 1 kg ProductCaustic Lye 1.328 kg Mother Liquor 6.25 kg to ETPHydrochloricAcid

1.563 kg Effluent 9.141 kg to ETP

Water 12.5 Drying Loss 0.25Total 16.641 kg Total 16.641 kg

18. 4 Chloro 2 Amino PhenolManufacturing Process:2,5 Dichloronitrobenzene [2,5 DCNB] is hydrolysed with Sodium Hydroxideat a controlled reaction parameter. After the hydrolysis is completed, MLfrom the reaction mass is decanted and the residual mass is acidified. TheAcidified mass is then subjected to conventional reduction using IronPowder. After completion of reduction Iron Sludge separated out. Theresidual filtrate is treated with activated charcoal, followed by Charcoalremoval and adding other additives along with pH adjustment is thenfiltered, washed and dried.Chemical reaction:

Figure 36. Chemical Reaction-4 Chloro 2 Amino Phenol




Figure 37. Process Flow Diagram-4 Chloro 2 Amino Phenol

Mass Balance:Table 22. MAterial Balance-4 Chloro 2 Amino Phenol

Input Qty Unit Output Qty Unit Remarks2,5 DCNB 1.92 kg 4 CAP 1 kg ProductCaustic Lye 4.447 kg Mother Liquor 18.086 kg to ETPHydrochloricAcid

3.25 kg Iron Sludge 4.808 kg to cement coprocessing

Water 13.22 Drying Loss 0.92Iron Powder 2.04 Carbon

Residue0.144 tswdf

ActivatedCharcoal

0.072

Additives 0.014Total 24.96 kg Total 24.96 kg



I. By Products:-

19. Recovery of AmmoniaScrubber system for Autoclave ReactorAmmonia gas is generated from the autoclave reactor & ONA day tank andrector through a common line and sent to the Primary scrubber andSecondary scrubber are shown in the below diagram/figure.Primary water scrubber: Un- Ammonia gas coming from the Autoclavereactor is scrubbed in primary water scrubber. Here 80-90% gas isscrubbed through re-circulation of water and un-reacted gas goes tosecondary water scrubbers.Secondary water scrubber: Ammonia gas from plant intermediate vesselsvent and unreacted gas is scrubbed though again re-circulation of waterand un reacted gas goes to acid scrubber.Acid scrubber: In acid scrubbing system, all unreacted gas from waterscrubbing system and gas is scrubbed through re-circulation of spent acidsolution and remaining fresh air goes to the environment. The schematicdiagram of the scrubbing system is shown

Figure 38. Process Flow Diagram-Recovery of Ammonia

Table 23. Material Balance- Recovery of AmmoniaInput Qty Unit Output Qty Unit RemarkUnreactedAmmonia

0.41 kg Ammonia(recycled)

1.65 kg Product

AmmoniumChloride Raw

3.11 kg AmmoniumChloride

1.87 kg to calciumchlorideconversion



Solution(byproduct)Total 3.52 kg Total 3.52 kg

20. Calcium ChlorideProcess: Ammonium Chloride is reacted with Calcium Oxide to formCalcium Chloride

Figure 39. Process Flow Diagram- Calcium Chloride

Table 24. Material Balance- Calcium ChlorideInput Qty Unit Output Qty Unit RemarkCarbon 0.003 kg Ammonia 0.39 Earlier Calcium

Chloride

kg CalciumChloride

0.3 kg by product

AmmoniumChloride

0.820 kg WaterLoss

0.2 kg evaporation

Lime 0.1 kg SolidWaste

0.03 kg SWDF




vi) Raw material required along with estimated quantity, likely source,marketing area of final product, mode of transport of raw materials andfinished product.

(a) Raw material Quantity & Transportation of raw materialsThe linkage for raw materials will be open market and will be sourced mainlythrough indigenous industries/ manufacturers by the existing road network. Thestorage time period of the raw material and finished products will be 10-15 daysmaximum and the same is being followed for the existing operational unit. Thevarious raw materials used in the proposed activity of the manufacturing processare given below:

Table 22. Details of Raw materials

Table 25.

Sr. No. Products/By-Product Name

AfterExpansionQuantity(TPM)

Means ofStorage

No. of Days ofstorage

Transportation(by Road/Air/Sea)

Product wise raw materials1 6 Chloro

2,4 DinitroAniline

100.00 HDPE bagsDrums Jumbobags

15 Road

2,4 DNA 120.00 HDPE bagsDrums Jumbobags

5 Road

Chlorine 26.00 Tonner 10 Road

HCl 30% 108.00 Storage Tank Road

2 2,6DichloroParaNitroAniline


5 Road

Hydrochloric Acid

110.00 Storage Tank 5 Road

Chlorinegas

34.00 Tonner 5 Road

Para nitroAniline


5 Road

3 OrthoNitroAnilinePara


10 Road



SulphonicAcidOrthoNitroChloroBenzeneParaSulphonicAcid


5 Road

LiquorAmmonia(24%)


4 DinitroPhenol


15 Road

2,4 DinitrochloroBenzene

6.00 Storage Tank +HDPE Bag

5 Road

CausticSoda(NaOH)


5 Road

SulphuricAcid


5 4 NitroAminoPhenol


10 Road

Sodiumsulphide


5 Road

DinitroPhenol


10 Road

Aq. HCl 10.00 Storage Tank 10 Road

6 2,4 DinitroAniline


5 Road

2,4DinitroChloroBenzene


5 Road

LiquorAmmonia




7 6 Bromo2,4 DinitroAniline


10 Road

HydroChloric Acid(30%)


Chlorinegas

5.75 Tonner 5 Road

Liq.Bromine

12.75 Tonner 5 Road

2,4 DinitroAniline


10 Road

8 Para NitroPhenol


15 Road

PNCB 13.50 HDPE bagsDrums Jumbobags

10 Road

CausticLye


10 Road

Sulphuric 3.00 Storage Tank 5 Road

9 PigmentOrange -5


15 Road

HydroChloric Acid


SodiumNitrite


5 Road

2,4 DinitroAniline


5 Road

BNaphthol


5 Road

NaOH 2.94 Storage Tank +HDPE Bag

5 Road

10 OrthoChloroPara NitroAniline


10 Road



3,4 DCNB 22.43 HDPE bagsDrums Jumbobags

5 Road

LiquorAmmonia


11 Para NitroAniline


5 Road

PNCB 22.99 HDPE bagsDrums Jumbobags

5 Road

LiqAmmonia


12 OrthoNitroAniline


10 Road

ONCB 22.98 HDPE bagsDrums Jumbobags

10 Road

LiqAmmonia


13 ParaChloroOrthoNitroAniline


5 Road


5 Road

LiquorAmmonia


14 PigmentRed


10 Road

HydroChloric Acid


SodiumNitrite


10 Road

2,5DichloroAniline


5 Road



3 HydroxyNeptelinamide


10 Road


5 Road

15 PigmentYellow


15 Road

SodiumNitrite


5 Road

3,3Dichlorobenzidine


5 Road

AcetoXylidine


5 Road


10 Road

16 4 ChloroNitroPhenol

20.00 Storage tanks 10 Road


10 Road

CausticLye


5 Road

Hydrochloric Acid


17 4 ChloroAminoPhenol

20.00 Storage tanks 15 Road

2,5 DCNB 38.40 Storage Tank +HDPE Bag

15 Road

CausticLye


15 Road

Hydrochloric Acid


IronPowder


10 Road



ActivatedCharcoal


5 Road

Additives 0.28 HDPE bagsDrums Jumbobags

5 Road

By Products18 Ammoniu

mChloride100%CaptiveConsumption


19 SodiumSulphate(Generated fromDinitroPhenol)


10 Road

20 SpentAcid - HCl(realbasis)


21 CalciumChloride

160.00 Storage Tank +HDPE bags

15 Road

Lime 5 Road

Carbon 5 Road

AmmoniumChloride

5 Road



(c) Plant & Machineries

Table 26. List of machinery and equipment

Sr. No. List Major Equipments Existing Proposed After Expansion1 Pumps 10 15.00 25

2 Reactor - MS 3 5.00 8

3 Notch Filter 1 -1.00 0

4 Compressor 3 3.00 6

5 MEE 1 1.00 1

6 Filter press 1 3.00 4

7 Cooling tower 75 TR 450 TR 450 TR

8 Vacuum pumps

9 Boiler 1x 0.8 TPH 2 TPH 2 TPH + 0.8 TPH

10 DG sets 1 x 125 kVA 1 x 125 kVA 2 x 125 kVA

11 Scrubber 1 4.00 5

12 RO 0 1.00 1

13 Ammonia RecoveryTank

0 2.00 2

14 Agitated Nutsche Filter 0 4.00 6

15 HDPE Vessel 0 6.00 6

16 Autoclave 0 2.00 2

17 DNCB Storage - 60 KL 60 KL

18 Ammonia Storage - 30 KL 30 KL

(vii) Resources optimization/ recycling and reuse envisaged in theproject, if any, should be briefly outlined.

● Water used for cooling is being partially subjected to evaporationand bleed-off and partially recirculated.

● Boiler ash is given to the cement and brick manufacturing Unit.● Non-Biodegradable waste and E-waste will be given to approved

authorised recyclers.● The discarded raw material containers & bags will be given to

approved authorised recyclers● The existing unit is Zero Liquid discharge (ZLD) and for the

proposed expansion, ETP treated water will be discharged to CETP.



(viii) Availability of water it’s source, Energy/power requirement andsource should be given.

(a) Water Requirement and Source

Source of water: MIDC Supply

Existing Operational Phase: The total water requirement for the existingunit is 6.9 KLD out of which 5 KLD is freshwater which is being sourced byMIDC Supply. 3.3 KLD of wastewater is being generated out of which 1.2KLD is domestic wastewater which is being sent to septic tanks followedby soak pits and 2.1 KLD of wastewater generated from processes is beinggiven primary treatment in ETP of capacity 5 KLD and ETP treated water issent to the MEE of 7 KLD. 1.9 KLD of MEE Condensate is being reused inCooling tower & washing purposes. MEE concentrate is being solarevaporated and salt generated is being sent to the TSDF site. No,wastewater is being discharged outside the unit. Thus, the existing unit isZero Liquid Discharge (ZLD).Total After Expansion:- The total water requirement after expansion willbe 177.50 KLD out of which 175.6 KLD will be freshwater & sourced byMIDC Supply and the remaining 1.90 KLD will be inhouse treated water.68.5 KLD of wastewater will be generated out of which 2.5 KLD isdomestic wastewater which is being sent to septic tanks followed by soakpits and 66 KLD of industrial effluent out of which 63.9 KLD is proposedeffluent and 2.1 KLD is existing effluent. The industrial effluent (38.3 KLDhigh COD and 27.70 KLD low COD) will be separated and sent to ETP ofcapacity 70 KLD followed by RO of capacity 60 KLD and discharged toCETP. CETP inlet norms shall be maintained before disposal.The existing effluent of 2.1 KLD will be given primary treatment in ETP andthe treated ETP water is sent to the MEE. 1.9 KLD of MEE Condensate isbeing reused in Cooling tower & washing purposes. MEE concentrate isbeing solar evaporated and salt generated is being sent to the TSDF site.Hence the existing effluent will be a Zero Liquid Discharge (ZLD) unit.

Table 27. Water Management

ParticularsWater Requirement (KLD) Wastewater Generation (KLD)Existing Proposed Total Existing Proposed Total

Domestic 1.50 3.00 4.50 1.20 1.30 2.50

Industrial process +Scrubber

1.40 68.10 69.50 1.50 36.80 38.30

Drum Washing,Floor Washing

0.70 3.30 4.00 0.10 3.10 3.20

Vessel Washing 0.00 11.00 11.00 0.00 10.00 10.00



Boiler Make-up 1.50 42.50 44.00 0.20 7.00 7.20

Cooling Tower 1.50 38.50 40.00 0.30 7.00 7.30

Gardening 0.30 4.20 4.50 0.00 0.00 0.00

Total 6.90 170.60 177.50 3.30 65.20 68.50

Water Balance Existing:

Figure 40.

Figure 40. Water balance existing

Water Balance Total after Expansion:


https://app.diagrams.net/?page-id=OAogi-ajlpAHDHaQpDb9&scale=auto#G1MmUVEp8cYEaO08sDPB2aidYWkhZDBPvN


Figure 41.

Figure 41. Water balance after expansion

Scheme Of Water Treatment

Raw Effluent Collection/Equalisation

The raw effluent from the processing sections will be collected in twobatch effluent Collection cum Equalisation tanks. The equalisation tankswill be provided with a diffused air agitation system to attenuate thevariations in effluent flow and characteristics.

Electro Coagulation Treatment & Primary Clarification

The equalized raw effluent from the collection tank will be pumped to theproposed ElectroCoagulation plant capable of handling effluent flow.

The electro coagulation process encompasses the addition of an electricalcurrent to sacrificial electrodes. This is done within a highly turbulentelectrochemical cell with a positive anode and negative cathode. Manyprocesses like oxidation, reduction, and neutralisation occur simultaneouslyin any electrochemical cell.



The electro coagulated flock differs significantly from the flocs formedduring the chemical coagulation process, containing less bound water,more resistant to shear and hence better dewatering characteristics.

Two-Stage Aerobic Biological Treatment and Secondary Clarification

The effluent overflowing from the Parallel Plate Separator will be providedwith pre-biological Advanced Oxidation treatment (i.e. UV/H2O2) forpolishing and improving the biodegradability followed by two-stageaerobic biological treatment designed on the basis of activated sludgeprocess working on extended aeration principle.

The stage-I aeration tank will be provided with an air blower of 420 m3/hrcapacity with diffused aeration piping system for supplying necessaryDissolved Oxygen and Mixing in the aeration tank. The overflow fromaeration tank-I will be taken to Aeration tank –II provided with an airblower of 120 m3/hr capacity with diffused aeration piping system forsupplying necessary Dissolved Oxygen and Mixing in the aeration tank.The overflow from the aeration tank-II will be taken to a secondary settlingtank, where solid- liquid separation takes place and the clarified water istaken to the interim collection tank. The bio-sludge from the secondaryclarifier will be recycled back to the aeration tank I & II to maintain thedesired bacterial concentration and the excess bio-sludge will be drainedto a bio-sludge collection tank for further treatment.

Interim Collection tank

The overflow from the Secondary Settling tank will be collected in aninterim collection tank from where it will be pumped to a Pressure sandfilter followed by an Activated Carbon filter.

Pressure Sand Filtration & Activated Carbon Adsorption

The treated water from the interim collection tank will be pumped to apressure sand filter to filter the fine suspended solids present in the treatedeffluent. The filtered water will be passed through a tank filled withcoconut shell based granular activated carbon to polish the treated effluentand remove the trace organic content (COD) in the treated water to lessthan 50 mg/l.

Sludge Dewatering & Disposal

The chemical sludge from the parallel plate separator and excessbio-sludge from the Secondary Settling tank will be collected into separateHDPE collection tanks from where it will be pumped to a recessed type



plate filter press. The filtrate from the filter press can be collected andtaken to a raw effluent collection tank for further treatment. The driedsludge will be packed in polythene bags and stored for disposal.

Reverse Osmosis

The Treated water from the Activated Carbon Filter will be taken to the 1st

Stage of the Two -stage Reverse Osmosis plant for recovering 60%(permeate) as product water with TDS content less than 200 mg/l. TheReject from the 1st Stage will be taken to the 2nd Stage RO for recoveringfurther 50% (permeate) Product water.

The Reject water from the RO will be taken to the Multiple EffectEvaporator for concentration of dissolved salts and further water recovery.The solids slurry from the evaporator will be filtered in a basket filter andthe mother liquor is taken back to the evaporator for further evaporation.The Condensate water from the Multiple effect evaporator is Product waterand is used back in the Process.

Scheme of Evaporator (MEE)

Multi stage evaporator (3 - stages) is a long tube forced circulation typeevaporators where in the first effect high pressure steam of 7.0 kg/cm2 isused to evaporate wastewater. The evaporated water in the form of steamat 2.0 kg/cm2 g pressure is used for evaporating the effluent in the secondstage at atmospheric pressure. Evaporated water from the second stage isused for evaporating wastewater in the third stage under a vacuum of 650-720 mm Hg. Finally, evaporated water from the third stage is condensed inthe steam condenser using cooling water on the other side. Condensatefrom all the three stages is collected in condensate receiving tanks, whichis pure water and hence reused in the process. Concentrated mass fromeach effect is collected in the crystallizer where, on cooling, inorganic saltsare precipitated along with organic contaminants.



Figure 42. MEE Scheme

iii) Wastewater Characteristics:Table 28. Wastewater Characteristics

Parameter(Unit)

Low CODwater

High CODwater

MEEOutlet

RO Outlet Standards forOrganic ChemicalManufacturingIndustry (GSR 608(E)

pH value 9 - 10 9 - 10 7.0-7.5 6.0 – 8.5 6.5-8.5

COD, mg/l 1700-1800 15500-20000 200-250 15 <250

BOD, mg/l 800-900 10-20 175 100

TDS, mg/l 800-900 150000-200000

5-10 5 -

TSS, mg/l 200-300 6975-9000 -- 5 -

(b) Power Requirement and SourceSource of Power: Maharashtra State Electricity Distribution CompanyLimited (MSEDCL)

Table 29. Details of power and its back up

S.No Particular Existing Proposed Total1 Installed Power load

(Source: MSEDCL)107 HP i.e. 79.8KW, 0.0798 MW

250 HP i.e.186.4 KW,0.1864 MW

357 HP i.e.266.2 KW, i.e0.2662 MW

2 Operating Power load(Source: MSEDCL)

85 HP i.e. 63.4KW

200 HP i.e.149.1 KW

162 HP i.e.212.5 KW

3 Capacity of D.G. Sets(For Backup)

125 KVA 125 KVA 2 x 125 KVA



4 Capacity of Boiler 0.8 TPH 2 TPH 2TPH, 0.8 TPH(Existing 1 No ofBoiler & 1 No. ofadditionalproposed boilerwill be utilizedat full load tomeet theproposedrequirement.)

(c) Air Emissions from UtilitiesAfter expansion, 2 boilers of 0.8 TPH (existing) and 2 TPH (proposed) willbe there based on Briquette. The existing Boiler dust collector is alreadyinstalled and after expansion Multi Cyclone Separator as Dust Collectorwith Bag Filter will be installed with appropriate stack height of 15 m. DGsets will be kept in an acoustic enclosure with a stack of maximum height 4m (each) as per CPCB norms.Details of emissions from utilities are as follows:

Table 30. Details of emissions from utilitiesParticulars Capacity Stack No. Stack Height APCM

Boiler -1 0.8 TPH (existing) 1 15.4 m Dust Collector

Boiler -2 2 TPH (proposed) 2 15.4 m

Multi CycloneSeparator as DustCollector with Bag

Filter

DG-11 x 125

kVA(existing)3 4 m

Adequate StackHeight

DG-21 x 125

kVA(Proposed)4 4 m

Adequate Stackheight

(ix) Quantity of wastes to be generated (liquid and solid) and schemefor their Management/disposal

a) Domestic Solid Waste:-Table 31. Solid waste Management

Category Type of Waste Treatment Method Existing(Kg/day)

Proposed(Kg/day)

Total afterExpansion(Kg/day)

Biodegradab Organic Waste Currently it is given to theApproved Vendor For

1.2 0.9 2.1



Disposal At Municipal SolidWaste Disposal Site.

Non-Biodegradable

Recyclable Waste(Plastic,wood,glass etc)

Currently it is given toApproved Recycler and samewill be followed afterexpansion

2.6 2.1 4.7

Total 3.8 3.0 6.8b) Process Waste (Non-Hazardous) :-

Table 32. Process waste Management

ProcessWaste

Unit Existing Quantityof generation

Total after expansionQuantity ofgeneration

Treatment/Disposal

Boiler Ash TPA 0 72.00 will be sold brickManufacturing unit

c) Hazardous Waste Management:Table 33. Hazardous waste management

S.No. Type ofwaste

Category(as perHWMRules,2016)

Unit ExistingQuantity

ProposedQuantity

Total afterexpansionQuantity

Disposal

1 ETP Sludge 35.3 TPA 1.8 30 31.8 CHWTSDF

2 MEE Salt 35.3 TPA 1 0 1

3 SpentCarbon fromETP

36.2 TPA 0 24 24

4 ProcessResidue

28.1 TPA 7.2 100 107.2 CHWTSDF

5 DiscardedemptyContainer

33.1 TPA 45 15 60 CHWTSDF

6 Used Oil 5.1 TPA 0 1 1 CHWTSDF

7 CalciumSludge

5.1 TPA 0 240 240 CHWTSDF

8 Used Filters/FilterClothes

36.2 TPA 0 Whatever isgenerated

CHWTSDF



9 Iron Sludge 26.1 TPA 0 720 720 CementManufacturer

*Any byproduct/process waste if consumed internally in the unit rule-9 ofHazardous and other wastes (Management & Transboundary Movement)Rules, 2016 shall be followed and necessary permission will be taken.record will be maintained for all the hazardous waste including thequantity of its generation and disposal to designated sites.E-Waste whenever generated will be managed as per E-WasteManagement Rules, 2016.Insulation waste whenever generated shall be disposed to TSDF site.

4. Site Analysis(i) Connectivity

a) Existing Infrastructure around the Site:-

The site can be accessed from the State Highway-74 Boisar-Tarapur Roadlocated at 1.23 Km NE. The site is well connected to MIDC Road ( 2.19 kmSSW) and Boisar-Palghar road (3.50 km SE).The nearest Railway station isBoisar Railway Station which is approximately 3.23 Km ESE (aerialdistance). The nearest Airport is Chhatrapati Shivaji Maharaj InternationalAirport which is approximately 80.41 km SSE (aerial distance).

b) Social Infrastructure around the Project Site:-Table 34. Infrastructure nearby to the project site

Particulars Distance (10 KMradius)

Hospital

Parag Hospital, Sneha Nagar, Boisar, MaharashtraVikas Hospital, Navapur Road, Tarapur MIDC, Boisar,MaharashtraHarsh Hospital,Swarup Nagar,Tarapur Road,Boisar,MaharashtraThunga Hospital, AM-32, Tarapur MIDC, Boisar,Maharashtra

1.42 Km ENE1.45 Km SSW

1.62 Km ESE

1.89 Km SE

Post OfficeIndia Post Office, Post T.A.P.P., Boisar, MaharashtraPost Office Boisar, CFC,Taki Naka, Tarapur MIDC, AwadhNagar, Boisar,Maharashtra

1.44 Km NE1.54 Km ESE

3.24 Km ESE



India Post Office, Boisar-Palghar Road, Navapur Naka,Boisar, MaharashtraPost Office, Kumbhavali, Maharashtra

3.90 Km SSW

Place of WorshipHanuman Mandir, Shivaji Nagar,Hanuman Road, TarapurMIDC, Shvajinagar, Salwad, MaharashtraSt. Mary’s Church,Boisar- Tarapur Road,Ind-Area, Boisar,MaharashtraShiv Temple, Tarapur Road, Katkar, Maharashtra

1.28 Km SS0.92 KmWSW1.20 Km ENE

1.41 Km ESEEc) List of Industries within 5 Km of the project site

Table 35. List of industries within 5 km

S.No Name And Type Of Industries1 Aarti Industries Limited Unit-3 - Pharmaceutical Company2 Aarti Industries Ltd Spack Div - Chemical Manufacturer3 Chemate Industry - Manufacturer4 Nikita Chemical Industries - Chemical Manufacturer5 Vap Industries - Chemical Manufacturer6 Pennar Industries Limited - Metal Fabricator7 Comfort Rubber Industries - Manufacturer8 Kubadia Chemicals Ind Pvt Ltd - Chemical Plant9 Angadpal Industries Pvt Ltd - Fabric Product Manufacturer10 Dimetrics Chemicals - Chemical Manufacturer11 S.K. Chemical Industries (Mumbai) Pvt Ltd - Chemical Plant12 Mandhana Industries Ltd ( Dyeing Unit 2) - Textile Mill13 Ivp Industries Tarapur - Chemical Manufacturer14 Vivid Global Industries Ltd. - Chemical Manufacturer15 Arochem Industry Ltd - Chemical Manufacturer16 Mandhana Industries Garment - Manufacturer17 Otex Industries - Pipe Manufacturer18 Aadinath Chemical Industries - Chemical Manufacturer19 Adarsh Knitting Industries - Fabric Product Manufacturer20 Sirmaxo Chemicals Pvt. Ltd. - Pharmaceutical Company21 Om Pharmaceutical Industries - Pharmaceutical Company22 Ally Pharma Options Pvt. Ltd. - Pharmaceutical Company

(ii) Landform, Land use and Land ownership


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The project is located on the land measuring 0.2040 ha in MaharashtraIndustrial Development Corporation (MIDC) Tarapur and Land is owned byMaharashtra Industrial Development Corporation (MIDC) and leased to theCompany for 99 years. The land use of the project site is industrial land.The proposed expansion unit will be constructed within the allotted area of0.2040 ha. The land papers and MIDC leased papers are enclosed inAnnexures.

Figure 43. Location of project on Industrial Map of Tarapur(iii) Topography (along with map)The topography of the area forms part of western slope of Sahayadri hillrange. This hill range passes through the eastern part of the district. Majorpart of the region constitutes rugged and uneven topography, characterizedby high hills and steep valleys. Physiographically, region can be dividedinto two broad divisions-Undulating Hilly Tract and Coastal Plain inwestern part The maximum elevation of the buffer area is 211 m AMSLnear the Dhodhadi Waterfall which is located approx 9.77 Km in the northeast direction from project site and minimum elevation is -13 m AMSL (Itfalls under sea water surface).The proposed site or core zone is situated on land having elevation rangesfrom 14 m AMSL to 15m AMSL.



Figure 44. Topographical map(iv) Existing land use pattern (agriculture, non-agriculture, forest,water bodies (including area under CRZ)), shortest distances from theperiphery of the project to periphery of the forests, national park,wildlife sanctuary, eco sensitive areas, water bodies (distance from theHFL of the river), CRZ. In case of notified industrial area, a copy of theGazette notification should be given

Table 36. Infrastructure near to the project

S. No. Particulars Details1. Nearest Town / City2. Nearest National

Highway / State HighwayState Highway-74 Boisar-Tarapur Road- 1.23 Km NE

3. Nearest Railway station Boisar Railway Station- 3.23 Km ESE



4. Nearest Airport Chhatrapati Shivaji Maharaj International Airport,Mumbai- 80.41 Km SSE

5. National Parks, WildlifeSanctuaries, BiosphereReserves within 10 kmradius

None

6. Reserve Forests (RF) /Protected Forests (PF)within 10 km radius

Reserved Forest near Boisar- 4.04 Km EReserved Forest near Shigaon- 6.01 Km NEReserved Forest near Vakorapadge- 8.52 Km SEReserved Forest near Mahagaon- 8.85 Km EReserved Forest near Sumadapada-9.49 Km ENE

7. River / Water Body(within 10 km radius)

Banganga Nadi-2.06 Km NNEJununa River-3.46 Km SSEAlewadi Lake-5.04 Km SWDudh River- 5.19 Km SSEGundale Talav-5.23 Km SSWArabian Sea-5.46 Km WBandhara Talav-5.73 Km SSWNandgaon Lake-6.25 Km SSWVikas Nagar Talav-8.26 Km SSW

8. Seismic Zone III

Land Use Distribution of project

Table 37. Land Use-Core Zone

Particulars Total area in m2 % AreaGround Coverage 770.0 37.75

Green Belt & Plantation Area* 673.2 33.00

Parking Area 208.0 10.20

Road & Open area 388.8 19.06

Total Plot area 2040 100.00

Table 38. Green area details

*Required Green Belt & Plantation Area (33% of Plot Area) 673.2 sqm

*Green Belt & Plantation Area within plot premise (17.16% of Plot Area) 350 sqm

*Green Belt & Plantation Area outside plot premises i.e. atplot E 74, MIDC Tarapur which owned by PP & MoU shallbe done for the same (15.84% of Plot Area) 323.2 sqm

*Total Green Belt & Plantation Area provided 673.2 sqm



Figure 45. Land use(v) Existing Infrastructure

The unit is located on land measuring 0.2040 ha in Maharashtra IndustrialDevelopment Corporation (MIDC) Tarapur. Land is owned by MaharashtraIndustrial Development Corporation (MIDC) and leased to M/s ProlificChemicals Pvt Ltd for 99 years on 24.02.2010. The project is anoperational chemical manufacturing facility with a total production capacityof 3228 TPA manufacturing Synthetic Organic Chemicals according to CTOvide letter No. Format 1.0/BO/AST/ UAN No.0000001936/O/CC/170900792 dated 20/09/2017 valid upto 31/08/2022granted by Maharashtra Pollution Control Board.The site can be accessed from the State Highway-74 Boisar-Tarapur Roadlocated at 1.23 Km NE. The site is well connected to MIDC Road ( 2.19 kmSSW) and Boisar-Palghar road (3.50 km SE).(vi) Soil classificationMost of the soils in the region can be considered as being derived from trap(Basaltic) rocks. The soil has been classified into three broad categoriesbased on the characteristics and relationship with topographic set up.

● Soil of Coastal Lands with Residual Hills - These soils are slightlydeep, poorly drained, fine soils on gentle sloping land and very finesoil on sloping land. These soils are calcareous and occur along thecoast of Vasai, Palgarh and Dahanu.,

● Lighter Colored soils - These are medium to deep grayish in color,poor in fertility, clayey to loamy in nature, shallow in depth andcoarse in texture. These soils are known as Varkas and are suitablefor rice. These soils occur in the eastern part of the region.



● Black Colored Soil- These soils occur on plains in the middle andeastern part of the district along the valleys.

(vii) Climatic data from secondary sourcesThe climate of the region is characterized by high humidity throughout theyear, an oppressive summer followed by well distributed and heavy rainfallduring the southwest monsoon season. The cold season starts fromDecember to February followed by summer from March to May. Thesouthwest monsoon season is from June to September while October andNovember constitute the post monsoon season. The mean daily maximumtemperature is 32.9°C and mean daily minimum temperature at 26.8°C.Thenormal annual rainfall over the district ranges from 1900 mm to 2600 mm.The maximum rainfall was recorded in July (upto 1356.9 mm) in 2014.From data, it is clear that the maximum time of year remains moist, the wetmonths exceed dry months. July, August & September are the wettestmonths and are considered the monsoon season. Average Annual rainfallis 2182.9 mm.(viii) Social Infrastructure availableAll Necessary infrastructure such as transport facilities, electricity, watersupply exists near to the project site as it is located in an industrial area.

5. Planning Brief(i) Planning Concept (type of industries, facilities, transportationetc.) Town and country Planning/ Development authority Classification.Existing industry is a synthetic chemical manufacturing industry.Transportation of raw material and final product is being done via existingroad and rail networks. Same shall be followed after expansion.(ii) Population ProjectionAfter Expansion influx of 57 No. of people will be there as skilled,administration staff and unskilled staff. However, a temporary influx of 15No. of labourers will occur during the construction phase.(iii) Land use planning (breakup along with green belt etc)Since, the proposed expansion will be done within the existing land area.Out of the total plant area; 673.2 sqm (total 33% of Green area - 22.9 %within plot area and 10.1 % outside plot premises i.e. at plot E 74, MIDCTarapur which is owned by PP) on the ground shall be developed. Theplantation work for green belt development shall be carried out as perCPCB guidelines.(iv) Assessment of Infrastructure Demand (Physical & Social)M/s Prolific Chemicals Pvt. Ltd, has assessed the demand of infrastructure(Physical & Social) in the nearby area of the plant site and development



activities are being undertaken under corporate social responsibilitiesprogram for rural development initiatives for the upliftment of the nearbycommunities from time to time.(v) Amenities/FacilitiesThe developments of the amenities / facilities are being maintained in thearea of the plant site as per requirement of local people under corporatesocial responsibilities programme.

6. Proposed Infrastructure(i) Industrial Area (Processing Area)Following infrastructure is provided as following:

● Storage: Space is provided in the storage yard for the storage of rawmaterials and the same will be used for expansion.

● Parking: Adequate parking space has been provided in the plantpremises for the parking of vehicles.

(ii) Residential Area (Non-processing area) Indirect employment will be generated due to this project.

(iii) Green Belt

Out of the total plant area; 673.2 sqm (total 33% of Green area - 17.16 %within plot area and 15.84 % outside plot premises i.e. at plot E 74, MIDCTarapur which is owned by PP) on the ground shall be developed. Theplantation work for green belt development shall be carried out as perCPCB guidelines.(iv) Social InfrastructureProposed expansion project will result in growth of the surrounding areasby increased indirect employment opportunities in the region includingancillary development and supporting infrastructure.(v) Connectivity (Traffic and Transportation Road/Rail/Metro/Waterwaysetc)The site can be accessed from the State Highway-74 Boisar-Tarapur Roadlocated at 1.23 Km NE. The site is well connected to MIDC Road ( 2.19 kmSSW) and Boisar-Palghar road (3.50 km SE). The nearest Railway stationis Boisar Railway Station which is approximately 3.23 Km ESE (aerialdistance). The nearest Airport is Chhatrapati Shivaji Maharaj InternationalAirport which is approximately 80.41 km SSE (aerial distance).(vi) Drinking Water Management (Source & Supply of water)Domestic water requirement after expansion will be 3 KLD which will besourced from MIDC supply.(vii) Sewerage System



After expansion 2.5 KLD of domestic wastewater will be generated fromthe workers and will be disposed of to septic tanks followed by soak pits.(viii) Industrial Waste managementThe total water requirement after expansion will be 177.50 KLD out ofwhich 175.6 KLD will be freshwater & sourced by MIDC Supply and theremaining 1.90 KLD will be inhouse treated water. 68.5 KLD of wastewaterwill be generated out of which 2.5 KLD is domestic wastewater which isbeing sent to septic tanks followed by soak pits and 66 KLD of industrialeffluent out of which 63.9 KLD is proposed effluent and 2.1 KLD is existingeffluent. The industrial effluent (38.3 KLD high COD and 27.70 KLD lowCOD) will be separated and sent to ETP of capacity 70 KLD followed byRO of capacity 60 KLD and discharged to CETP. CETP inlet norms shall bemaintained before disposal.The existing effluent of 2.1 KLD will be given primary treatment in ETP andthe treated ETP water is sent to the MEE. 1.9 KLD of MEE Condensate isbeing reused in Cooling tower & washing purposes. MEE concentrate isbeing solar evaporated and salt generated is being sent to the TSDF site.Hence the existing effluent will be a Zero Liquid Discharge (ZLD) unit.

(ix) Solid Waste ManagementAfter expansion 6.8 kg/day of solid waste will be generated from the plantout of which 2.10 kg/day is biodegradable waste (will be sent to solidwaste disposal site) and 4.70 kg/day is non biodegradable waste ( given toAuthorised Recycler).Boiler ash of 72 TPA is generated (sent to Cement and brick Manufacturingunit), 31.8 TPA ETP Chemical sludge from wastewater treatment, 1 TPAMEE salt, 24 TPA spent carbon from ETP, 107.2 TPA Process residue, 240TPA of Calcium sludge will be disposed off to Mumbai Waste ManagementTSDF Site, Taloja. 60 TPA of discarded empty containers will be sold toauthorised recyclers after decontamination and 1 TPA of Used oil from DGset generated will be sold to approved recyclers & Iron Sludge of 720 TPAwill be sold to cement manufacturers.

(x) Power Requirement & Supply/sourcePower installed after expansion will be 357 HP i.e. 266.2 KW, howeveroperating load will be 162 HP i.e. 212.5 KW. The Power is being sourcedthrough Maharashtra State Electricity Distribution Company Limited.



7. Rehabilitation AndResettlement (R & R) Plan(i) Policy to be adopted (Central/State) in respect of the project affectedpersons including home oustees, land oustees and landless labourers (abrief outline to be given).Proposed expansion is of the existing synthetic chemical manufacturingindustry located in notified industrial area MIDC-Tarapur, hence R & R isnot applicable.

8. Project Schedule and CostEstimates(i) Likely date of start of construction and likely date of completion(Time schedule for the project to be given).The expansion of the project will be done only after obtainingEnvironmental Clearance and other clearances from statutory stateauthority. Project will be completed within 12 months after obtaining allthe regulatory approvals.(ii) Estimated project cost along with analysis in terms of economicviability of the project.Total cost of the Project: Rs.6.1463 Crore (Existing- Rs 3.705 crores,

Proposed for expansion- 2.4413 crores)Table 39. Environment Management Plan with Budget

Capital Expenditure in Lakhs

Sr.No.

ParticularsExisting Unit(Lacs)

ProposedUnit (Lacs)

Total AfterExpansion (Lacs)

1 Air Pollution Control 8 8 16

2 Water Pollution Control 12 59 71

3 Noise Pollution Control 5 1 6

5 Landscaping/Green Belt 1.5 0.62 2.12

6 Rain Water Harvesting 12 0.5 12.5

7 Solid Waste Management 1 3 4



8 Environment monitoring 0 1.5 1.5

8 Social Activities 0 5.81 5.81

Total 39.5 79.43 118.93

Recurring Expenditure in lakhs per annum

Sr.No.

ParticularsExisting Unit(Lacs)

ProposedUnit (Lacs)

After Expansion(Lacs)

1 Air Pollution Control 4 4 8

2 Water Pollution Control 5 1.5 6.5

3 Noise Pollution Control 1 1 2

4 Occupational Health 2 3 5

5 Landscaping/Green Belt 0.5 0.43 0.93

6 Rain Water Harvesting 0.5 0.5 1

7 Solid Waste Management 0.5 228.85 229.35

8 Environment monitoring 2 2 4

Total 15.5 241.28 256.78

9. Analysis Of Proposal (FinalRecommendations)(i) Financial and social benefits with special emphasis on the benefitto the local people including tribal population, if any, in the area.

● Establishment of the proposed expansion of industry will contributeto the increase in the market size of the Organic Chemicals in India.The synthetic organic chemicals will be given to manufacturerswhich will replace the imports of the chemicals. The expansion willhelp to reduce dependence on imports of many pharmaintermediates and save foreign exchange. Addition of revenue to thestate government by taxes.

● Synthetic Organic Chemicals manufacturing Industry is a large andgrowing market. There will be economic benefits due to the sellingof products all over India. The project will create extra opportunitiesof direct and indirect employment for which skilled and unskilledmanpower will be needed.

● In the operation phase, the proposed plant would require asignificant workforce of nontechnical and technical persons. About50 people will be deployed temporarily during construction of the



project and about 57 people will be employed during theoperational stage of the project (direct or in direct). The project willbe beneficial in the government's target of increasing the productionof foodgrains and yield in the field due to use of pesticides for cropprotection.

● The Industries will require raw materials, skilled and unskilledlaborers. It will be available from the local area. Due to increasingindustrial activities, it will boost the commercial and economicalstatus of the locality, to some positive extent.


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