M/s. ALLCHEM LABORATORIES BLOCK NO. 1088/B/P, 1088/A, … · m/s. allchem laboratories block no....

M/s. ALLCHEM LABORATORIES BLOCK NO. 1088/B/P, 1088/A, LAMDAPURA ROAD, VILLAGE MANJUSAR, TALUKA SAVLI – 391 775, DIST. VADODARA (GUJ)

ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT FOR PROPOSED EXPANSION OF EXISTING ADVANCE PHARMACEUTICAL INTERMEDIATE PRODUCTS MANUFACTURING UNIT

Winter ‐ 2011

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

Applied to QCI dated 08/04/2010 & Applicant No. 55 (Ref.: www.qcin.org/nabet/consapplorg.php#)

ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT

CLIENT

PROJECT TITLE

PROJECT NO.

:

:

:

M/s. ALLCHEM LABORATORIES

BLOCK NO. 1088/B/P, 1088/A,

LAMDAPURA ROAD, VILLAGE MANJUSAR,

TALUKA SAVLI – 391 775, DIST. VADODARA (GUJ)

ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT

FOR PROPOSED EXPANSION OF EXISTING ADVANCE

PHARMACEUTICAL INTERMEDIATE PRODUCTS

MANUFACTURING UNIT

389000

** PREPARED BY **

NABL Accredited Testing Laboratory

An ISO 9001:2008 Certified Company

Aqua‐Air Environmental Engineers P. Ltd.

(Pollution Control Consultants & Engineers)

403, Centre Point, Nr. Kadiwala School, Ring Road, Surat – 395002 (Guj)

Tel: +91 (261) 2460854/2461241/3048586 Fax: +91 (261) 2707273/3987273

e‐mail: [email protected] website: www.aqua‐air.co.in

INDEX

SR. NO. TITLE PAGE NO.

1 CHAPTER 1: INTRODUCTION

1.1 INTRODUCTION 1‐1

1.1.1 PROMOTERS& THEIR BACKGROUND 1‐1

1.1.2 JUSTIFICATION OF PROJECT 1‐6

1.2 PROJECT DETAILS 1‐7

1.2.1 REGULATORY FRAMEWORK 1‐11

1.3 PROJECT SETTING 1‐12

1.3.1 LOCATION 1‐12

1.3.2 KEY INFRASTRUCTURAL FEATURES AND SETTLEMENTS 1‐16

1.3.2.1 METHOD OF DATA PREPARATION 1‐16

1.3.2.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT

SITE

1‐16

1.3.2.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1‐17

1.4 PURPOSE OF EIA 1‐20

1.5 OBJECTIVES OF EIA 1‐20

1.6 METHODOLOGY FOR EIA 1‐20

1.6.1 BASE LINE ENVIRONMENTAL CONDITION 1‐20

1.6.1.1 AMBIENT AIR ENVIRONMENT 1‐20

1.6.1.2 GROUND AND SURFACE WATER ENVIRONMENT 1‐21

1.6.1.3 NOISE ENVIRONMENT 1‐21

1.6.1.4 SOIL ENVIRONMENT 1‐21

1.6.1.5 BIOLOGICAL ENVIRONMENT 1‐22

1.6.1.6 SOCIO‐ECONOMIC ENVIRONMENT 1‐22

1.6.2 IDENTIFICATION OF POLLUTION SOURCE 1‐22

1.6.3 EVALUATION OF POLLUTION CONTROL AND ENVIRONMENTAL

MANAGEMENT SYSTEM

1‐22

1.6.4 EVALUATION OF IMPACT 1‐22

1.6.5 PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN 1‐22

1.7 STRUCTURE OF REPORT 1‐23

2 CHAPTER 2: PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND 2‐1

2.2 PROJECT COST 2‐1

2.3 MAIN PHASES OF THE PROJECT 2‐2

2.3.1 PRE CONSTRUCTION ACTIVITIES 2‐2

2.3.2 CONSTRUCTION ACTIVITIES 2‐2

2.3.3 MANUFACTURING ACTIVITIES 2‐3 to 2‐44

2.4 RAW MATERIAL CONSUMPTION, STORAGE AND HANDLING 2‐45

2.4.1 DETAILS OF SOLVENT RECOVERY PLAN 2‐49

2.5 INFRASTRUCTURE FACILITIES 2‐53

2.5.1 LAND 2‐53

2.5.2 TRANSPORTATION FACILITIES 2‐54

2.5.3 WATER AND WASTEWATER 2‐54

2.5.3.1 TREATMENT PROCESS 2‐58

2.5.3.2 REVERSE OSMOSIS (RO) SYSTEM 2‐64

2.5.4 DETAILS OF UTILITIES 2‐71

2.5.5 ELECTRICITY REQUIREMENT 2‐72

2.6 POLLUTION POTENTIAL AND ITS CONTROL MEASURE 2‐72

2.6.1 AIR POLLUTION AND CONTROL SYSTEM 2‐72

2.6.1.1 BOILER DETAIL 2‐73

2.6.1.2 SCRUBBER SYSTEM 2‐74

2.6.2 NOISE LEVEL AND CONTROL SYSTEM 2‐78

2.6.3 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM 2‐78

2.6.4 DETAILS OF GREENBELT 2‐81

3 CHAPTER 3: BASELINE ENVIRONMENTAL STATUS

3.1 ESTABLISHMENT OF IMPACT ZONE 3‐2

3.2 METEOROLOGY 3‐3

3.3 MICRO‐METEOROLOGY OF THE AREA 3‐3

3.3.1 TEMPERATURE DETAILS 3‐4

3.3.2 RELATIVE HUMIDITY (RH) 3‐5

3.3.3 RAINFALL 3‐6

3.3.4 WIND SPEED 3‐7

3.4 AIR ENVIRONMENT 3‐11

3.4.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY MONITORING

LOCATIONS

3‐11

3.4.2 RECONNAISSANCE 3‐11

3.4.3 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING 3‐12

3.5 NOISE ENVIRONMENT 3‐19

3.5.1 METHODOLOGY FOR NOISE MONITORING 3‐19

3.5.2 NOISE LEVELS DUE TO TRANSPORTATION 3‐22

3.6 WATER ENVIRONMENT 3‐24

3.6.1 RECONNAISSANCE 3‐24

3.6.2 METHODOLOGY FOR WATER QUALITY MONITORING 3‐25

3.7 LAND ENVIRONMENT 3‐31

3.7.1 METHODOLOGY FOR SOIL MONITORING 3‐31

3.7.3 SOIL CLASSIFICATIONS 3‐35

3.7.3.1 METHOD OF PREPARATION 3‐35

3.7.3.2 DESCRIPTION OF SOIL CHARACTERISTICS AND AREA UNDER DIFFERENT

SOIL TYPES

3‐35

3.7.3.3 SOIL CHARACTERISTICS MAP 3‐35

3.8 GEOLOGICAL DATA 3‐38

3.8.1 METHOD OF PREPARATION 3‐38

3.8.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA UNDER

DIFFERENT FORMATIONS

3‐38

3.7.3 GEOLOGICAL MAP 3‐38

4 CHAPTER 4: LAND USE PATTERN, BIOLOGICAL ENVIRONMENT & SOCIO ‐ ECONOMIC

ENVIRONMENT

4.1 LAND USE PATTERN 4‐1

4.1.1 METHOD OF DATA PREPARATION 4‐1

4.1.2 AREA UNDER DIFFERENT LANDUSE 4‐2

4.2 ECOLOGICAL INFORMATION 4‐4

4.2.1 INTRODUCTION 4‐4

4.2.2 VEGETATION COVER AND FOREST BOUNDARIES WITHIN VADODARA

DISTRICT

4‐4

4.2.2.1 AREA UNDER FORESTS AND SANCTUARY 4‐5

4.2.3 FLORA 4‐6

4.2.4 FAUNA 4‐7

4.2.5 GROUND WATER HYDROLOGY 4‐8

4.3 SOCIO‐ECONOMIC ENVIRONMENT 4‐10

4.3.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN 4‐10

4.3.1.1 METHOD OF DATA PREPARATION 4‐10

4.3.1.2 DEMOGRAPHIC DATA WITHIN THE REGION 4‐10

4.3.1.3 LITERACY RATE 4‐14

4.3.2 OCCUPATIONAL STRUCTURE 4‐16

4.3.3 LAND USE AND LAND COVER WITH TOWNS AND VILLAGE LOCATIONS 4‐18

4.3.4 AMENITIES 4‐20

5 CHAPTER 5: IDENTIFICATION AND ASSESSMENT OF IMPACTS

5.1 IDENTIFICATION OF IMPACTS 5‐1

5.2 EVALUATION AND PREDICTION OF IMPACTS 5‐8

5.2.1 WATER ENVIRONMENT 5‐10

5.2.1.1 CONSTRUCTION PHASE IMPACTS 5‐10

5.2.1.2 OPERATION PHASE IMPACTS 5‐11

5.2.1.3 MITIGATION MEASURES 5‐11

5.2.2 AIR ENVIRONMENT 5‐12




5.2.3 NOISE ENVIRONMENT 5‐26



5.2.4 LAND USE AND SOIL QUALITY 5‐27




5.2.4.4 DETAILS OF HAZARDOUS WASTE GENERATION 5‐28

5.2.4.5 TRANSPORTATION OF HAZARDOUS WASTE 5‐28

5.2.4.6 DISPOSAL OF HAZARDOUS WASTE 5‐29

5.2.5 HOUSING 5‐29

5.2.6 INFRASTRUCTURE AND SERVICES 5‐29

5.2.7 ENVIRONMENTAL HAZARDS 5‐30

5.2.8 ECOLOGY 5‐30

5.2.8.1 NATURAL VEGETATON 5‐31

5.2.8.2 CROPS 5‐31

5.2.8.3 FOREST AND SPECIES DIVERSITY 5‐31

5.2.8.4 FISHERIES & AQUATIC LIFE 5‐31

5.2.8.5 AESTHETIC ENVIRONMENT 5‐32

5.2.8.6 DEMOGRAPHY, ECONOMICS, SOCIOLOGY & HUMAN SETTLEMENT 5‐32

5.2.8.7 SOCIO ‐ ECONOMIC IMPACTS 5‐32

5.3 MATRIX REPRESENTATION 5‐34

5.3.1 CUMULATIVE IMPACT CHART 5‐34

6 CHAPTER 6: ENVIRONMENTAL MANAGEMENT PLAN


6.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN 6‐1

6.3 ENVIRONMENTAL MANAGEMENT CELL 6‐2

6.4 ENVIRONMENTAL MANAGEMENT PLAN 6‐4

6.4.1 PROJECT ENVIRONMENT MONITORING PLAN 6‐5

6.4.2 CONSTRUCTION PHASE MANAGEMENT 6‐7

6.4.3 OPERATIONAL PHASE MANAGEMENT 6‐8

6.4.3.1 WATER ENVIRONMENT 6‐8

6.4.3.2 AIR ENVIRONMENT 6‐9

6.4.3.3 NOISE ENVIRONMENT 6‐9

6.4.3.4 LAND ENVIRONMENT 6‐10

6.4.3.5 GREEN BELT DEVELOPMENT 6‐11

6.4.3.6 HEALTH AND SAFETY 6‐13

6.4.3.7 INFORMATION FOR CONTROL OF FUGITIVE EMISSIONS 6‐13

6.4.3.8 INFORMATION FOR RAIN WATER HARVESTING 6‐14

6.4.3.9 MEASURES FOR CONSERVATION OF ENERGY 6‐17

6.4.3.10 ODOR MANAGEMENT PLAN 6‐17

6.5 SOCIO ECONOMIC DEVELOPMENT ACTIVITIES 6‐19

6.6 CAPITALS AND O&M COST FOR ENVIRONMENTAL MANGEMENT 6‐19

7 CHAPTER 7: RISK ANALYSIS & DISASTER MANAGEMENT PLAN


7.2 STORAGE AND HANDLING OF HAZARDOUS CHEMICALS 7‐1

7.2.1 HAZARD AND CONTROL 7‐5 to 7‐38

7.3 HEALTH & SAFETY MEASURES 7‐38

7.3.1 OCCUPATIONAL HEALTH SCHEME FOR THE WORKERS 7‐39

7.3.2 TRAINING AND EDUCATION OF EMPLOYEES AND PERSONAL PROTECTIVE

EQUIPMENTS

7‐40

7.4 FIRE FIGHTING SYSTEM 7‐41

7.5 MAJOR HAZARDS AND DAMAGE CRITERIA 7‐41

7.6 HAZARD IDENTIFICATION 7‐43

7.7 CONSEQUENCE ANALYSIS 7‐44

7.7.1 DAMAGE CRITERIA 7‐45

7.7.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS 7‐50

7.7.3 CONSEQUENCE ANALYSIS CALCULATIONS 7‐51

7.7.4 SCENARIOS 7‐54

7.8 DETAILED SUMMARY OF RESULTS: 7‐55

7.8.1 SCENARIO # 1: RELEASE OF TOLUENE 7‐55

7.8.2 SCENARIO # 2: RELEASE OF IPA 7‐62

7.8.3 SCENARIO # 3: RELEASE OF AMMONIA 7‐67

7.8.4 SCENARIO # 4: RELEASE OF BROMINE 7‐73

7.8.5 SCENARIO # 5: RELEASE OF HCl (30 %) 7‐78

7.8.6 SCENARIO # 5: RELEASE OF DICHLOROMETHANE 7‐83

7.8.7 SCENARIO # 5: RELEASE OF ETHYL ACETATE 7‐89

7.8.8 SCENARIO # 5: RELEASE OF METHANOL 7‐94

7.8.9 SCENARIO # 5: RELEASE OF PHOSPHORUS OXYCHLORIDE 7‐101

7.8.9 SCENARIO # 5: RELEASE OF THIONYL CHLORIDE 7‐107

7.9 DISASTER MANAGEMENT PLAN 7‐113

7.9.1 DEFINING THE NATURE OF EMERGENCY 7‐113

7.9.2 OBSERVER 7‐113

7.9.3 STRUCTURE OF EMERGENCY MANAGEMENT 7‐114

7.9.3.1 CHIEF EMERGENCY CONTROLLER 7‐114

7.9.3.2 INCIDENT CONTROLLER 7‐115

7.9.3.3 SITE MAIN CONTROLLER 7‐117

7.9.3.4 KEY PERSONNELS 7‐118

7.9.3.5 ESSENTIAL WORKERS 7‐119

7.9.3.6 ASSEMABLY POINT 7‐120

7.9.3.7 EMERGENCY CONTROL CENTER 7‐122

7.9.3.8 FIRE CONTROL ARRANGEMENTS 7‐122

7.9.3.9 MEDICAL SERVICES 7‐123

7.10 COMMMUNICATION SYSTEM 7‐123

7.10.1 RAISING THE ALARM 7‐124

7.10.2 DECLARING THE MAJOR EMERGENCY 7‐124

7.10.3 TELEPHONE MESSAGES 7‐124

7.10.4 COMMUNICATION OF EMERGENCY 7‐124

7.11 SAFETY INCHARGE 7‐129

7.11.1 ROLE OF SR. SECURITY OFFICER AND SECURITY SUPERVISORS 7‐129

7.11.2 ROLE OF SECURITY GUARD 7‐130

7.11.3 MAINTENANCE SERVICES 7‐131

7.11.4 ROLE OF ELECTRICAL DEPARTMENT 7‐131

7.11.5 ROLE OF INSTRUMENT DEPARTMENT 7‐132

7.12 OFF – SITE EMERGENCY PLAN 7‐132

7.12.1 NEED OF THE OFF – SITE EMERGENCY PLAN 7‐132

7.12.2 ROLE OF FACTORY MANAGEMENT 7‐134

7.12.3 ROLE OF EMERGENCY CO‐ORDINATION OFFICER (ECO) 7‐134

7.12.4 ROLE OF THE FIRE AUTHORITIES 7‐134

7.12.5 ROLE OF THE HEALTH AUTHORITIES 7‐136

7.12.6 ROLE OF TELEPHONE DEPARTMENT 7‐135

7.13 TRAINING, REHERASAL & RECORDS 7‐135

7.13.1 NEED OF TRAINNING & REHEARASAL 7‐135

7.13.2 SOME CHECK POINTS 7‐136

7.13.3 RECORDS AND UPDATING THE PLAN 7‐137

LIST OF TABLES

TABLE

NO.

TITLE PAGE NO.

1.1 LIST OF PRODUCTS ALONGWITH PRODUCTION CAPACITY (EXISTING &

PROPOSED)

1‐8 TO 1‐11

1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT

SITE

1‐16

2.1 BREAK UP OF PROPOSED INVESTMENT & MEANS OF FINANCE 2‐1 to 2‐2

2.2 RAW MATERIAL REQUIREMENT (EXISTING & PROPOSED ) 2‐45 to 2‐49

2.3 LIST OF SOLVENTS ALONGWITH TOTAL RECOVERY 2‐52

2.4 LAND BREAK‐UP OF THE PLANT 2‐53

2.5 WATER CONSUMPTION & WASTE WATER GENERATION (EXISTING &

PROPOSED SCENARIO)

2‐55

2.6 LIST OF ETP UNITS (EXISTING) 2‐59

2.7 LIST OF ETP UNITS (PROPOSED) 2‐62

2.8 THE DETAILS OF UTILITIES 2‐71

2.9 THE DETAILS OF SOURCE OF EMISSION & CONTROL MEASURES 2‐72

2.10 HAZARDOUS & SOILD WASTE GENERATION QUANTITY, PHYSICAL

CHARACTERISTICS AND MODE OF DISPOSAL

2‐79 to 2‐80

3.1 TEMPERATURE DETAILS 3‐4

3.2 RELATIVE HUMIDITY DETAILS 3‐5

3.3 RAINFALL DETAILS 3‐6

3.4 WIND SPEED DETAILS 3‐7

3.5 SITE SPECIFIC METEOROLOGICAL DATA 3‐8

3.6 DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS 3‐13

3.7 AMBIENT AIR QUALITY STATUS 3‐15 to 3‐18

3.8A DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS 3‐20

3.8B BACKGROUND NOISE LEVELS 3‐22

3.9 NOISE LEVELS DUE TO TRANSPORTATION 3‐24

3.10 SAMPLING LOCATIONS FOR MONITORING SURFACE WATER AND GROUND

WATER QUALITY

3‐25

3.11 WATER QUALITY‐ PHYSICAL PARAMETERS 3‐27 to 3‐30

3.12 SAMPLING LOCATIONS: SOIL QUALITY 3‐31

3.13 PHYSICO‐CHEMICAL CHARACTERISTICS OF SOIL 3‐33 to 3‐34

3.14 SOIL CHARACTERISTICS UNDER PROJECT AREA 3‐36

3.15 GEOLOGICAL FEATURES 3‐38

4.1 AREAS UNDER DIFFERENT LANDUSE 4‐2

4.2 DETAILS OF FOREST COVER OF VADODARA DISTRICT 4‐4

4.3 FLORA 4‐6

4.4 FAUNA 4‐7

4.5 DEMOGRAPHIC DATA (CENSUS‐2001) 4‐11

4.6 POPULATION DENSITY 4‐12

4.7 LITERACY RATE 4‐14

4.8 OCCUPATIONAL STRUCTURE 4‐16 TO 4‐

17

4.9 DETAILS OF AMENITIES AVAILABLE IN THE STUDY AREA 4‐21 to 4‐23

5.1 CHARACTERISTICS OF EFFLUENT (EXISTING) 5‐12

5.2 DETAILS OF EMISSION FROM STACKS (PROPOSED) 5‐16

5.3 SUMMERY OF ISCST3 MODEL OUTPUT FOR SPM, SO2, NOx , HCl, AMMONIA,

Cl2 and HBr

5‐24

5.4 PREDICTED AMBIENT AIR QUALITY FOR SPM, SO2, NOX, HCL & Cl2 5‐25

5.5 NOISE LEVELS AT DIFFERENT LOCATIONS WITHIN INDUSTRY 5‐26

5.6 IMPACT IDENTIFICATION MATRIX 5‐35 & 5‐36

5.7 POTENTIAL IMPACTS & MITIGATIVE MEASURES 5‐37

5.8 ENVIRONMENTAL IMPACT MATRIX 5‐38

5.9 CUMULATIVE IMPACT CHART 5‐39

6.1 ENVIRONMENT MANAGEMENT PLAN 6‐4

6.2 PROJECT ENVIRONMENT MONITORING PLAN 6‐5 to 6‐7

6.3 GREEN BELT DEVELOPMENT PLAN & SPECIES AS GREENBELT 6‐12 to 6‐13

7.1 STORAGE DETAILS OF HAZARDOUS CHEMICALS 7‐2 to 7‐4

7.2 ENVIRONMENT ASPECTS, IMPACT, RATINGS AND CONTROL MEASURES 7‐11 to 7‐37

7.3 DETAILS OF FIRE AND SAFETY EQUIPMENT 7‐41

7.4 POSSIBLE ACCIDENT SCENARIOS AT M/S. ALLCHEM LABORATORIES 7‐54

7.5 EMERGENCY CONTACT TELEPHONE NUMBERS (ON SITE EMERGENCY) 7‐126

7.6 A FORM TO RECORD EMERGENCY TELEPHONE CALL 7‐129

LIST OF FIGURES

FIGURE

NO.

TITLE PAGE NO.

1.1 STUDY AREA 1‐13

1.2 LAYOUT OF THE PLANT 1‐14

1.3 MAP TO DISTANCES OF CRITICALLY/SEVERELY POLLUTED AREA FROM THE

PROJECT SITE (GOOGLE MAP)

1‐15

1.4 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1‐18

1.5 SATELLITE IMAGERY ALONG WITH PRESENT LAND USE PATTERN 1‐19

1.6 EIA PLAN & PROCEDURE 1‐25

2.1 WATER BALANCE DIAGRAM (EXISTING AND TOTAL AFTER PROPOSED

EXPANSION)

2‐56 TO 2‐

57

2.2 FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (EXISTING) 2‐60

2.3 FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (PROPOSED) 2‐63

2.4 FLOW DIAGRAM OF RO PLANT 2‐70

2.5 SCRUBBER SYSTEM‐I, II & III 2‐75 to 2‐77

3.1 WIND ROSE DIAGRAM & STABILITY CLASS DISTRIBUTION 3‐9 to 3‐10

3.2 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS 3‐14

3.3 LOCATION OF NOISE LEVEL MONITORING STATIONS 3‐21

3.4 LOCATION OF NOISE LEVEL MONITORING STATIONS (TRANSPORTATION) 3‐23

3.5 LOCATIONS OF WATER SAMPLING STATIONS 3‐26

3.6 LOCATIONS OF SOIL SAMPLING STATIONS 3‐32

3.7 SOIL CHARACTERISTICS MAP 3‐37

3.8 MAJOR GEOLOGICAL FEATURES 3‐39

4.1 LAND USE/ LAND COVER 4‐3

4.2 GRAPHICAL REPRESENTATION OF FOREST COVER OF VADODARA DISTRICT 4‐5

4.3 HYDROLOGY 4‐9

4.4 DETAILS OF SEX RATIO & POPULATION DENSITY 4‐13

4.5 LITERACY RATE 4‐15

4.6 LANDUSE/ LANDCOVER WITH VILLAGE LOCATIONS 4‐19

5.1 IMPACT NETWORK ON AIR, NOISE, WATER, SOCIO‐ECONOMIC AND

CULTURAL AND LAND ENVIRONMENTS

5‐2 to 5‐7

5.2 EQUAL CONCENTRATION CONTOUR PLOT FOR SPM, SO2, NOx , HCl, 5‐17 to 5‐23

AMMONIA, Cl2 and HBr

6.1 ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 6‐3

6.2 LOCATION OF BORE WELL FOR RAINWATER HARVESTING 6‐16

7.1 LAYOUT & GRAPHS FOR SCENARIO # 1 7‐57 to 7‐61

7.2 LAYOUT & GRAPHS FOR SCENARIO # 2 7‐63 to 66






7.8 LAYOUT & GRAPHS FOR SCENARIO # 8 7‐96 to 7‐

100



7.11 LOCATION OF ASSEMBLY POINT 7‐121

CONSULTANTS ENGAGED M/s. Allchem Laboratories proposes to expand manufacturing activities by introduction of

new products at existing unit. Since this proposed project activity require Environmental

Impact Assessment Studies and Environmental Clearance, the Company has entrusted M/s.

Aqua‐Air Environmental Engineers Pvt. Ltd., Surat for carrying out the EIA Studies as per the

prevailing rules and regulations.

Company has applied for Environmental Clearance to Ministry of Environment & Forests.

TORs Presentation to Expert Appraisal Committee of MoEF was done on December 23, 2011.

TORs has been finalized in the meeting, including certain additional points. M/s. Aqua‐Air

Environmental Engineers Pvt. Ltd. has carried out EIA Studies as per TOR and guidelines of

EAC, MoEF, New Delhi.

COPY OF TORs FROM EAC (NEW DELHI)

COMPLIENCE OF ADDITIONAL TERMS OF REFERENCES (TORs)

SR.

NO.

TERMS OF REFERENCES COMPLIENCE

1 Executive Summery of the Project. Please Refer Annexure‐7. Page No. A‐11.

2 Justification of the Project. Please Refer Chapter‐1, Section‐1.1.2, Page

No. 1‐6 to 1‐7.

3 Promoters and their back ground. Please Refer Chapter‐1, Section‐1.1.1, Page

No. 1‐1 to 1.6.

4 Regulatory framework. Please Refer Chapter‐1, Section‐1.2.1, Page

No. 1‐11.

5 A map indicating location of the project and

distance from severely polluted area.

Please Refer Chapter‐1, Figure‐1.3, Page No.

1‐15.

6 Project location and Plant Layout. Project Location: 22° 26' 45.178656" North

latitude and 73° 11' 5.395236" East

longitude. Please Refer Chapter‐1, Figure‐

1.1 and 1.4, Page No. 1‐13 and 1‐18

respectively.

For Plant Layout, Chapter‐1, Figure‐1.2, Page

No. 1‐14.

7 Infrastructure facilities including power

sources.

Please Refer Chapter‐2, Section‐2.5, Page

No. 2‐53 to 2‐72.

8 Total cost of the project along with total

capital cost and recurring cost/annum for

environmental protection measures.


No. 6‐19.

9 Project site location along with site map of 10

km area and site details providing various

industries, surface water bodies, forests etc.


1‐18.

10 Present land use based on satellite imagery

for the study area of 10 km radius.


1‐19.

11 Location of National Park/Wild life There is no National Park/Wild life

sanctuary/Reserve Forest within 10 km radius

of the project.

sanctuary/Reserve Forest falls within 10 Km

radial distance from the project site.

12 Details of the total land and break‐up of the

land use for green belt and other uses.

Please Refer Chapter‐2, Section‐2.5.1, Table‐

2.4, Page No. 2‐53 to 2‐54.

13 Environment clearance for the existing unit

issued by the Ministry (reasons, if not

obtained). Consent to Operate and

Authorization accorded by the GPCB along

with point‐wise compliance report.

The existing products manufacturing by M/s.

Allchem Laboratories did not fall under Old

EIA Notification, 1994 so that we have

obtained NOC for the same from GPCB in

the year 2004, please refer Annexure‐8.

Page No. A‐17.

For consent to operate and authorization

accorded by GPCB and its point‐wise

compliance report please refer Annexure‐9

and Annexure‐10 respectively. Page No. A‐

29 and A‐35 respectively.

14 List of products alongwith the production

capacities and list of solvents and its recovery

plan.

For products list; Please Refer Chapter‐1,

Table‐1.1, Page No. 1‐8 to 1‐11.

For Solvents list and its recovery plan: Please

Refer Chapter‐2, Section‐2.4.1, Table‐2.3,

Page No. 2‐49 to 2‐52.

15 Detailed list of raw material required and

source, mode of storage and transportation.

For raw material list; Please Refer Chapter‐2,

Section‐2.4, Table‐2.2, Page No. 2‐45 to 2‐

49.

The raw materials are procured from

nearest sources as much as possible from

Indian market.

The raw materials are received in tanks,

HDPE/fibre drums, HMHDPE Carboys and

cylinders as well as through tankers and

stored at ambient temperature. All the

storage tanks of hazardous flammable

substances are located within premises in

separate storage area i.e. solvent farm area

at ambient temperature. Solvent like

Methanol, Toluene, IPA, Xylene, etc. shall be

stored in underground MS/SS tank with all

precautionary process instrumentation and

safety appliances.

Large area shall be covered by well‐designed

warehouse, which is containing store office,

raw material store, finished product store,

etc.

Transportation of all the raw material and

products are primarily by road only.

The above procedures will remain same

after proposed expansion.

16 Details of the existing Sulphonation plant. NA

17 Manufacturing process details alongwith the

chemical reactions and process flow chart.

Please Refer Chapter‐2, Section‐2.3.3, Page

No. 2‐3 to 2‐44.

18 Action plan for the transportation of raw

material and products.

Transportation of all the raw materials and

products are primarily by road only and also

remain by same way after proposed

expansion.

19 Site‐specific micro‐meteorological data using Please Refer Chapter‐3, Section‐3.3.1 to

temperature, relative humidity, hourly wind

speed and direction and rainfall is necessary.

3.3.4, Table‐3.1 to 3.5, Page No. 3‐4 to 3‐8.

20 Ambient air quality monitoring at 6 locations

within the study area of 5 km., aerial

coverage from project site as per NAAQES

notified on 16th September, 2009. Location

of one AAQMS in downwind direction.


No. 3‐11 to 3‐18.

21 One season site‐specific micro‐

meteorological data using temperature,

relative humidity, hourly wind speed and

direction and rainfall and AAQ data (except

monsoon) for PM10, SO2, NOx including HC

and VOCs should be collected. The

monitoring stations should take into account

the pre‐dominant wind direction, population

zone and sensitive receptors including

reserved forests. Data for water and noise

monitoring should also be included.

For sit‐specific micro‐meteorological data:

Please Refer Chapter‐3, Table‐3.5, Page No.

3‐8.

For AAQ data: Please Refer Chapter‐3,

Section‐3.4, Page No. 3‐11 to 3‐18.

For water monitoring data: Please Refer

Chapter‐3, Section‐3.6, Page No. 3‐24 to 3‐

30.

For noise monitoring data: Please Refer


24.

22 Air pollution control measures proposed for

the effective control of gaseous emissions

within permissible limits.

Please Refer Chapter‐2, Section‐2.6.1.2,

Figure‐2.6, Page No. 2‐74 to 2‐77.

23 Name of all the solvents to be used in the

process and details of solvent recovery

system.

Please Refer Chapter‐2, Table‐2.3, Page No.

2‐52.

24 Design details of ETP, incinerator, if any

alongwith control of Dioxin & Furan, boiler,

scrubbers/bag filters etc.

ETP detail: please refer Chapter‐2, Section‐

2.5.3.1, Page No. 2‐58 to 2‐63.

At Site, the incinerable waste is sent to

CHWI for final disposal and after proposed

expansion, additional incinerable waste will

be disposed by same manner as existing.

Boiler Detail: Please Refer Chapter‐2,

Section‐2.6.1.1, Figure‐2.6, Page No. 2‐73 to

2‐74.

Scrubbers system: Please Refer Chapter‐2,

Section‐2.6.1.2, Figure‐2.6, Page No. 2‐74 to

2‐77.

25 Details of water and air pollution and its

mitigation plan.

For water pollution; Please refer Chapter‐2,

Section‐2.5.3, Page No. 2‐54 to 2‐63 &

Chapter‐6, Section‐6.4.3.1, Page No. 6‐8.

For air pollution; Please refer Chapter‐2,

Section‐2.6.1, Page No. 2‐72 to 2‐77 &

Chapter‐6, Section‐6.4.3.2, Page No. 6‐9.

26 Action plan to control ambient air quality as

per NAAQES Standards notified by the

Ministry on 16th September, 2009.

Adequate pollution control system will be

provided for control of emission. Ambient

air quality monitoring will be carried out

through out side competent approved

agency.

Please refer Chapter‐2, Section‐2.6.1, Page

No. 2‐72 to 2‐77 & Chapter‐6, Section‐

6.4.3.2, Page No. 6‐9.

27 An action plan to control and

monitor secondary fugitive emissions from all

the sources as per the latest permissible

limits issued by the Ministry vide G.S.R.

Please refer Chapter‐6, Section‐6.4.3.7, Page

No. 6‐13 to 6‐14.

414(E) dated 30th May, 2008.

28 Determination of atmospheric inversion level

at the project site and assessment of ground

level concentration of pollutants from the

stack emission based on site‐specific

meteorological features. Air quality

modelling for proposed plant.

Please Refer Chapter‐5, Section‐5.2.2, Page

No. 5‐12 to 5‐25.

29 Permission for the drawl of 53

m3/day ground water from the

CGWA/SGWB. Water balance chart including

quantity of effluent generated recycled and

reused and discharged.

We have applied for grant of permission for

abstraction of ground water to Central

Ground Water Authoriy, New Delhi. Please

Refer Annexure‐13. Page No. A‐40

Water balance chart including quantity of

effluent generated recycled and reused and

discharged: Please refer Chapter‐2, Figure‐

2.2, Page No. 2‐56 to 2‐57.

30 Narmada Canal water instead of ground

water should be the preferred source of

water for which efforts should be made with

concerned department and authority.

We will ensure to Sardar Sarovar Narmda

Nigam Ltd. (SSNNL), which is about 1.5 Km

away from project site, as optional water

supply if in case of non‐availability of ground

water. We have forwarded a request letter

to SSNNL regarding the same. Please refer

Annexure‐14. Page No. A‐47

31 Action plan for Zero Discharge of effluent as

proposed should be included.

After proposed expansion, total 24.95

m3/day waste water will be generated. To

treat the additional effluent load, company

is proposing a new ETP facility where

wastewater is treated by physico chemical

treatment. Treated effluent will be sent to

CETP of M/s. EICL, Umaraya for further

treatment & disposal or further passed

through Multiple Effect Evaporator followed

by Thin Film Dryer. After evaporation and

condensation, water is reused as boiler feed

water & in process. The unit maintains "Zero

Effluent Discharge." Company has valid

membership of CETP. Please refer

Annexure‐11. Page No. A‐38

32 Ground water monitoring minimum at 6

locations should be carried out. Geological

features and Geo‐hydrological status of the

study area and ecological status (Terrestrial

and Aquatic).



30.


No. 4‐4 to 4‐9.

33 The details of solid and hazardous wastes

generation, storage, utilization and disposal

particularly related to the hazardous waste

calorific value of hazardous waste and

detailed characteristic of the hazardous

waste. Action plan for the disposal of fly ash

generated from boiler should be included.

Please refer Chapter‐2, Section‐2.6.3, Table‐

2.9, Page No. 2‐78 to 2‐80.

Fly Ash generated from boiler will be sold to

nearest brick manufacturer.

34 Precautions to be taken during storage and

transportation of hazardous chemicals should

be clearly mentioned and incorporated.

Transportation of all the raw material and

products shall be primarily by road only. The

raw materials will be received in tanks,

HDPE/fiber drums, HMHDPE Carboys and

cylinders as well as through tankers. All the

storage tanks of hazardous flammable

substances will be located within premises

in separate storage area i.e. solvent farm

area. Solvent like Methanol, Toluene, IPA,

Xylene, etc. shall be stored in underground

MS/SS tank with all precautionary process

instrumentation and safety appliances.

Large area shall be covered by well‐designed

warehouse, which is containing store office,

raw material store, finished product store,

etc.

35 A copy of the Memorandum of

Understanding signed with cement

manufacturers indicating clearly that they

will utilized all the organic solid waste

generated.

Please refer Annexure‐15. Page No. A‐48

36 Details of land fill along with design details as

per CPCB guidelines. Location of secured land

fill/TSDF.

Secured land fill site operated by M/s

Nandesari Environment Control Ltd. (NECL),

is located in Nandesari about 23 km away

from the project site.

37 Authorization/Membership for the disposal

of liquid effluent in CETP and solid/hazardous

waste in TSDF.

Please refer Annexure‐11 and 12. Page No.

A‐38 and A‐39 respectively..

38 Ground water monitoring around the project

site as well as around land fill site.



30. Please refer Annexure‐18. Page No. A‐

57.

39 Risk assessment for storage for

chemicals/solvents and phosgenes. Action

plan for handling & safety system, whenever

any cyanide is involved in process.

Company is not using phosgene as raw

material or manufacturing the same in

existing scenario or not going to use or

manufacture in proposed scenario.

There is no any process which involved any

cyanide in existing as well as proposed

scenario.

For Risk assessment; please refer Chapter‐7.

40 An action plan to develop green belt in 33 %

area

Please refer Chapter‐6, Section‐6.4.3.5,

Table‐6.3, Page No. 6‐11 to 6‐13.

41 Action plan for rainwater harvesting Please refer Chapter‐6, Section‐6.4.3.8, Page

measures at plant site should be included to

harvest rainwater from the roof tops and

storm water drains to recharge the ground

water.

No. 6‐14 to 6‐16.

42 Occupational health of the workers needs

elaboration including evaluation of noise,

heat, illumination, dust, any other chemicals,

metals being suspected in environment and

going into body of workers either through

inhalation, ingestion or through skin

absorption and steps taken to avoid musculo‐

skeletal disorders (MSD), backache, pain in

minor and major joints, fatigue etc.

Occupational hazards specific pre‐placement

and periodical monitoring should be carried

out.

Please refer Chapter‐7, Section‐7.3.1 and

7.3.2, Page No. 7‐39 to 7‐40.

43 Socio‐economic development activities

should be in place.


No. 6‐19 and Annexure‐17, Page No. 54.

44 Note on compliance to the recommendations

mentioned in the CREP guidelines.

Please refer Annexure‐16, Page No. A‐49.

45 Detailed Environment management Plan

(EMP) with specific reference to details of air

pollution control system, water &

wastewater management, monitoring

frequency, responsibility and time bound

implementation plan for mitigation measure

should be provided.

Please Refer Chapter‐6.

46 EMP should include the concept of waste‐

minimization, recycle / reuse / recover

techniques, Energy conservation, and natural

resource conservation.

Please Refer Chapter‐6.

47 Any litigation pending against the project NA

and/or any direction/order passed by any

Court of Law against the project, if so, details

thereof.

48 Public hearing issues raised and

commitments made by the project

proponent on the same should be included

separately in EIA/EMP Report in the form of

tabular chart with financial budget for

complying with the commitments made.

‐

49 A tabular chart with index for point wise

compliance of above TORs.

‐

CHAPTER ‐ 1

INTRODUCTION

________________________________________________________________________________________________________________ D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐1

CHAPTER – 1

INTRODUCTION

1.1 INTRODUCTION

M/s. Allchem Laboratories, existing advance pharmaceutical intermediates manufacturing

company, is located at Block No. 1088/B/P, 1088/A, Lamdapura Road, Village Manjusar, Taluka

Savli – 391 775, Dist: Vadodara, Gujarat. Allchem Laboratories is an ISO 9001:2008, 14001:2004

& OHSAS 18001:2007 certified company. A very small team of highly qualified scientists,

engineers and technicians is engaged in this process.

1.1.1 PROMOTERS& THEIR BACKGROUND

M/s. Allchem Laboratories is founded and promoted by Mr. Bipin K. Patel, M.Sc. (Organic

chemistry). He is well qualified and experience of pharmaceutical industry, pharmaceutical

chemistry, organic chemistry, etc. & specialized in executing research and development,

manufacturing of advance pharmaceutical intermediates, speciality chemical products. He has

good knowledge of lab/pilot plant production, commercial production, different type of

technologies used in this field and handling of different kind of chemicals at small quantity to

larger quantity. He is looking after all departments & see that project is successful in all the

way. The brief detail is as below;

1.1.1.1 EXPERIENCE

• He worked as R & D chemist in M/s. Rubamin Pharmaceuticals Pvt. Ltd, (ISO 9001 company)

and R & D executive in M/s. Parekh Laboratories Pvt. Ltd at Baroda.

• Total working experience in this filed around 17 years.

• Since, 2003, He has been continuing in M/s. Allchem Laboratories (Manufacturers of

speciality chemicals and advance pharmaceutical intermediates) at Baroda as Proprietor.


1.1.1.2 TYPE OF WORK IN DIFFERENT AREAS

1.1.1.2.1 RESEARCH AND DEVELOPMENT

• Laboratory glassware selection and design as per process

• Laboratory autoclave (pressure reaction)

• Preparing samples for approval

• Isolation of product using distillation (high vacuum) or crystallization

• Procurement of laboratory chemicals for development purpose

• Library work like chemicals abstract, journals, patents, etc.

• To train the people and take out put from them

• Perfect housekeeping of laboratory

• Labeling of all the chemicals and keep in the systematic manner

• Making batch record in systematic manner

1.1.1.2.2 ANALYTICAL WORK (QC DEPARTMENT)

• Testing of all the raw materials, finished products and in process samples by all the possible

method as per GMP.

• Reagent preparation, standardization and calibration

• Familiar with titration like perchloric acid, acid‐base titration, chloride titration and many

more

• Familiar with GC (Shimadzu) with its parts (column) and maintenance etc.

• Familiar with HPLC, IR, Polariment, auto titrator etc.

• Evaluation of NMR spectra

• Making SOP for the instruments & calibration of the instruments.

• Making records of all the testing results

• Making certificate of analysis for dispatch

1.1.1.2.3 SCALE UP WORK (LAB > PILOT PLANT > COMMERCIAL PRODUCTION)

• Selection of pilot plant for multipurpose reactions (mainly utilized for custom synthesis

work and scale of the any products i.e. advance pharmaceutical intermediates)


• Arrangement of glass assemblies, SS reactors, autoclave, vaccum ejector, scrubber and

centrifuges etc.

• Maintenance and operation of pilot plant

• Autoclave reaction using hydrogen pressure up to 15 kg/cm2 and temp up to 100 deg C

• Precious metal catalyst hydrogenation like Pd, Rh, Pt etc.

• During scale up lots of factors keep in mind like handling of hazardous chemicals in safe

manner, high production yield, avoid pollution, clean environment and maximum

production etc.

• High vaccum fractional distillation up to 0.05 mm in 5 lit to 400 lit reactors.

• Different purification techniques like distillation, crystallization etc.

1.1.1.2.4 KNOWLEDGE OF DIFFERENT TYPES OF TECHNOLOGIES

• Acetylation (‐C, ‐N, ‐O, ‐S etc.)

• Alkylation (‐C, ‐N, ‐O, ‐S etc.)

• Acylation (fridel craft reaction using aluminum chloride)

• Hydrolysis of nitriles, esters and amides

• Reductive amination

• Arylation of piperazines

• Bromination (ring as well as side chain) up to 170 deg C

• Chlorination (ring as well as side chain)

• Cyclization

• Decarboxylation

• Dimethyl sulphate reaction (at –N, ‐O, ‐S etc.)

• Hydrogenation using (raney Ni, Rh, Pd, Pt, etc.)

• Phase transfer reaction

• Ring closer reaction

• Acid chloride reaction and amide formation

• Esterification

• Mannich reaction


• 1,4‐ addition

• Mannich reaction

• Griganard reaction

• High vaccum fractional distillation (0.05 mm of Hg)

• Dieckmann cyclization

• Stork enamine reaction

• Chloromethylation reaction

• Vilsmeier haak reaction

• Gabriel synthesis

• Hoffman degradation

• Knoevenagel condensation

• Reduction using sodium borohydride, aluminium hydride, aluminium isopropoxide, Iron

powder, Raney nickel with hydrazine hydrate, etc.

1.1.1.2.5 HANDLING OF DIFFERENT KINDS OF CHEMICALS

• Thionyl chloride up to 1000 kg level

• Aluminum chloride anhydrous during fridel craft acylation

• Sodium cyanide up to 400 kg level at a time

• Phosphorous oxychloride up to 300 kg level

• Sodium azide reaction up to 10 kg level

• Grignard reagents

• Oxalyl chloride handling and reactions

• Bromine and chlorine in halogenations step

• Sodium metal and potassium metal

• Sodium amide and potassium amide formation

• Sodium methoxide and sodium ethoxide generation

• All flammable solvents like toluene, ether, Xylene, methanol, MDC, ethyl acetate, acetone,

IPA, hexane, DMF etc.

• Dry HCl gas generation at plant level


• All types of acids and strong bases

• Acid chlorides and anhydrides

• Raney Nickel in autoclave

• Sodium borohydride for reduction at low as well as high temp.

• Precious metal catalyst (Pd, Pt, Rh, Ru etc.)

• Handling of low temperature reactions using dry Ice (up to ‐70 deg C)

1.1.1.2.6 DIFFERENT TYPES OF DERIVATIVES

• Drug intermediates like, domperidone, cetrizine, astemazole, nimesulide, buflomedil,

quatipine, ebastine, carvedilol, meloxicam, sibutramine, cefuroxime, cefazolin, ceftrixone

Iritocan, Trazodone and many more

• Piperazine derivatives (aryl and aliphatic)

• Piperidone and piperidine derivatives

• Cycloalkane derivaties

• Aldehyde and ketone derivatives

• Carboxylic acid and derivatives

• Amine derivatives (aryl, aliphatic and bezylic )

• Hetrocyclic derivaties (pyrimidine, imidazole, benzimidazole, benzothiozole, etc.)

• Custom synthesis and contract research type of products ranging from 20 gm to 50 kg level

1.1.1.2.7 UTILITIES EQUIPMENTS

• Handling of various utility equipments during process scale up for commercial production

like, boiler, thermic fluid, water ejector, chilling plant, cooling tower, centrifuges, air

compressor, etc.

• Handling of various equipment during commercial production Dryers, high vaccum pumps,

scrubbers, glass line reactors, SS reactors and handling of various hazardous chemicals in

safe manner.

• Transferring solid and liquid from reactor to reactor


1.1.1.2.8 ELECTRICAL KNOWLEDGE

• Calculation of electrical load in the company

• GEB licensing work like application

• Single phase wiring knowledge, three phase wiring

• Knowledge of electric motors, electrical heaters, MCB, Starter, Electrical penal, Checking of

earthings, Voltage checking, distribution of electrical load, etc.

1.1.1.2.9 CHEMICALS SOURCING KNOWLEDGE

• He has visited seven times CPhI which is held in Europe at Germany, Belgium, Spain and

France. From these fairs He came to know there is lot of potential for the supply of advance

pharmaceutical intermediates.

• Knowledge of lots of sourcing database

• These are the very important things for custom synthesis work and making of advance

pharmaceutical intermediates.

1.1.1.2.10 MARKETING WORK RELATED TO PHARMACEUTICALS (FINE CHEMICALS, DRUG

INTERMEDIATES AND ORGANIC CHEMICALS)

• He has visited seven times CPhI which is held in Europe at Germany, Belgium, Spain and

France.

• From these fairs He came to know lots of new customers (Fine chemicals, drug

intermediates and organic chemicals) related to pharma industries, their requirements, etc.

• Selection of the products, decide the pricing and make viable on commercial levels.

• Conveyance to customer and take the orders from them.

1.1.2 JUSTIFICATION OF PROJECT M/s. Allchem Laboratories is located in Savli Taluka has population of around 2,05,478 and

Savli village which is about 15 km away and has all essential facilities such as water, power, fuel,

post, telecommunication, bank, etc. and is well connected by road and rail to rest of India.

Development of Communication systems is good in the region. Sources of water in the region


include river and ground water resources. Nearer village is lamdapura which is about 1.5 Km

away from the project site. Vadodara city, the commercial city of Gujarat, is about 29 km and

airport is about 13 km away from project site. The project site is located about 8 km away from

National Highway No. 8 & 0.5 km, 11.05 km, 11.11 km, 11.8 km away from State Highway No

158, 87, 63 and 150 respectively. The nearest Broad‐gauge railway station is vadodara at 29 Km.

However, the predominant mode of transportation in the area is by network of roads only.

Main source of water in the area surrounding to plant site is ground water. The river Mahi flows

10 km distance from the project site.

Project site, where M/s. Allchem Laboratories, is located, comes under Vadodara District, which

is 29 km away from Nandesari GIDC an important industrial city of Gujarat and India. In

addition, it is a major centre of the pharmaceutical and glass industry in India; the basic

chemical industry is also a growing one. At Koyali nearby is a large oil‐refinery and at Ranoli

petro‐chemical‐based industries; while at Bajwa there is a fertilizer factory.

Towns like Padra, Anand, Bharuch, etc. are quite near to this project site. This makes Vadodara

an ideal location for transportation, communication, residential and manpower availability.

Common effluent treatment plant operated by M/s. Enviro Infrastructure Control Ltd., Umaraya

is located about 35 Km away from the project site. Secured land fill site and Common

Incineration facility operated by M/s Nandesari Environment Control Ltd. is located in

Nandesari about 23 km away from the project site.

1.2 PROJECT DETAILS

M/s. Allchem Laboratories is an existing unit of very small capacity. M/s. Allchem Laboratories is

an ISO 9001:2008, 14001:2004 & OHSAS 18001:2007 certified company. In order to meet

commercial quantities demand, the growing market demand and availability of space for

manufacturing facility at existing premises, M/s. Allchem Laboratories proposes to expand

manufacturing activities by introduction of new products at existing unit. As proposed project

activity comes under category A‐5(f) (Industrial Project) as per EIA notification, 2006 of Ministry


of Environment & Forest under the provisions of Environmental Protection Act, 1986. Since this

proposed project activity require Environmental Impact Assessment Studies and Environmental

Clearance, the Company has entrusted M/s. Aqua‐Air Environmental Engineers Pvt. Ltd., Surat

for carrying out the EIA Studies as per the prevailing rules and regulations. Company has

applied for Environmental Clearance to Ministry of Environment & Forests. TOR Presentation to

Expert Appraisal Committee of MoEF was done on December 23, 2010. TOR has been finalized

in the meeting, including certain additional points. M/s. Aqua‐Air Environmeantal Engineers

Pvt. Ltd., Surat has carried out EIA Studies as per TOR and guidelines of EAC, MoEF, New Delhi.

As the project under consideration is expansion activity, the suitability of the project site has

been assessed in the report. A mitigation plan has been prepared and a detailed environmental

management plan (EMP) is drawn out to effectively mitigate or minimize potentially adverse

environmental impacts and the details are presented in the following chapters. The list of

existing & proposed products along with their productions capacity is given in Table 1.1 as

below;

TABLE 1.1

LIST OF PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY (EXISTING & PROPOSED)

Quantity

(MT/Month)

Sr.

No.

PRODUCTS

Existing Total After Proposed

Expansion

1 1‐Benzylpiperazine, 99% 0.100 0.100

2 Dibutyl oxalate, 98% 0.100 0.100

3 1,4‐Piperazinedicarboxaldehyde, 99% 0.100 0.100

4 1,4‐Dibromobutane, 99% 0.100 0.100

5 1‐(4‐Fluorophenyl)piperazine, 99% ‐ 0.500

6 1‐Benzyldiethanolamine, 98% 0.050 0.050

7 1‐(3‐Chlorophenyl)piperazine, 99 % ‐ 8.000


Other Aryl piperazines

1‐[2‐(2‐Hydroxyethyl)ethoxy]piperazine, 99 % 8

Other aliphatic piperazines

‐ 3.000

1‐(3‐Chloropropyl)‐4‐(3‐chlorophenyl)piperazine

hydrochloride, 98 %

9

Other amines hydrochlorides

‐ 12.000

1‐(2‐Methoxyphenyl)piperazine hydrochloride,

98 %

10

Other Aryl Piperazine hydrochlorides

‐ 2.000

Isovaleryl chloride, 98 % 11

Other Acid chlorides

‐ 1.500

2‐Methoxybenzylamine, 98 % 12

Other benzylamines

‐ 0.500

1‐Benzyl‐4‐piperidone, 98 % 13

Other piperidones

‐ 2.000

Veratraldehyde, 98 % 14

Other aldehydes

‐ 0.500

1‐Indanone, 98 % 15

Other ketones

‐ 2.000

1‐(4‐Fluorophenyl)piperazine, 98 % 16

Other Aryl Piperazines

‐ 0.500

N‐Acetyl‐4‐piperidinecarboxylic acid, 99 % 17

Other piperidines

‐ 1.000

4'‐Chlorobenzhydrol, 98 % 18

Other benzhydrol

‐ 0.500

Heptylamine, 99 % 19

Other aliphatic amines

‐ 5.000

20 4‐Benzyloxyaniline HCl, 98 % ‐ 0.500


Other anilinehydrochlorides

Cyclobutanecarboxylic acid, 98 % 21

Other carboxylic acids

‐ 0.500

22 Diethyl cylopentanceaboxylate, 98 % ‐ 0.500

Other carboxylic esters

1‐Iodonathalene, 98 % 23

Other aromatic halides

‐ 0.500

1‐Allyl imidazole, 98 % 24

Other imidazoles

‐ 0.250

2‐Chlorobenzimidazole, 98 % 25

Other benzimidazoles

‐ 1.500

1‐(4‐Chlorophenyl)cyclobutanecarbonitrile, 98 % 26

Other carbonitriles

‐ 1.000

3,5‐Dimethyl‐4‐cyanophenol, 98 % 27

Other benzonitriles

‐ 0.500

1‐Boc‐3‐piperidone, 97 % 28

Other Boc amides

‐ 0.500

1‐(3‐Chloropropyl)‐2‐benzimidazolidinone, 98 % 29

Other benzimidazoles

‐ 3.000

1‐Pyrrolidinebutanenitrile, 98 % 30

Other pyrrolidines

‐ 1.000

1‐(4‐Chlorophenyl)‐4‐hydroxypiperidine, 98 % 31

Other piperidines

‐ 0.750

32 R & D Project (Less than 25 Kg each) ‐ 1.000

33 Kilo Lab (25 Kg to 500 Kg) ‐ 1.500

34 Advance Pharma Intermediates ‐ 3.500

Total 0.45 55.95


TABLE‐1.1 (CONTD.)

BY‐PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY

Quantity

(MT/Month)

Sr.

No.

PRODUCTS

Existing Total After Proposed

Expansion

1 Sodium Chloride 0.048 16.048

2 Potassium chloride 0.031 2.511

3 Sodium bromide ‐ 7.86

4 Potassium bromide ‐ 1.39

5 Ammonia solution 25% in water ‐ 1.94

6 Hydrochloric acid 30% in water ‐ 4.125

7 Hydrobromic acid 48% in water ‐ 8.22

8 Sodium Sulphite ‐ 2.115

9 Polyaluminium Chloride ‐ 2.286

10 Cuprous bromide ‐ 0.65

Total 0.079 47.145

1.2.1 REGULATORY FRAMEWORK

For proposed project, following assumption has been considered;

• Capacity of Plant 55.95 MT/ Month

• Total working days in a year around 315 days

• Raw material storage facility for 30‐45 days

• Finished product storage in drums for 8 tons

• Solvent storage for 30 days


1.3 PROJECT SETTING

1.3.1 LOCATION

M/s. Allchem Laboratories is located at 22° 26' 45.178656" North latitude and 73° 11'

5.395236" East longitude. Location & study area of the Project Site is shown in Figure‐1.1.

Detailed layout map of the plant is shown in Figure – 1.2. A map indicating location of the

project and distance from severely polluted area is shown in Figure‐1.3. Total area covered by

Vadodara is about 693.43 Sq. Km. Total area covered by Savli taluka is about 792 Sq. Km.

Important places around Plant are:

Savli city ‐To the North

Vadodara City ‐ To the South‐East

The salient features of the site are as under;

1. Minimum distances:

a) From City : Vadodara 29 km (Population 13,41,575)

b) Village : Manjusar 2.5 km (Population – 3,716)

c) Historical Site : None

d) Sanctuaries : None

e) Highway : National Highway No. 8 (8 km South‐West), State Highway SH 158 (0.55 km East)

State Highway SH 87 (11.05 km South‐East)

State Highway SH 63 (11.11 km North‐East)

State Highway SH 150 (11.8 km North‐East)

F) Sea coast : 55 km

g) CETP location : 35 km

h) Secured landfill site : 23 km

2. Use of forest land : None

3. Use of prime agricultural land: None

4. Planned submergence : None

5. Displacement of population : None


FIGURE ‐ 1.1

STUDY AREA


FIGURE ‐ 1.2

LAYOUT OF THE PLANT


FIGURE ‐ 1.3

MAP TO DISTANCES OF CRITICALLY/SEVERELY POLLUTED AREA FROM THE PROJECT SITE (GOOGLE MAP)

74.58 Km

105 Km


1.3.2 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

1.3.2.1 METHOD OF DATA PREPARATION

Key infrastructure features have been extracted from Survey of India (SoI) topographical maps

of 1:50,000 scale. The features have been updated using satellite data and have been verified

with ancillary information derived from TTK maps and guide maps. The locations of the

settlement have been extracted from Census of India (CoI) maps and have been verified by

using SoI topographical maps and satellite data.

1.3.2.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

The distance of railways and National & State highways are presented in Table 1.2 as below.

There is no National Park/Wild life sanctuary/ Reserve Forest falls within 10 Km radial distance

from the project site.

TABLE 1.2

DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

SR.

NO.

NEAREST INFRASTRUCTURE FEATURE DISTANCE FROM PROJECT SITE

1 Village Manjusar 2.5 Km in South‐East Direction

2 NH‐8 8.0 Km in South‐West Direction

3 NE1 (Ahmedabad Vadodara Expressway) 8.0 Km in South‐West Direction

4 SH‐158 0.50 Km in East Direction

5 SH‐87 11.05Km in South‐East Direction

6 SH‐63 11.11 Km in North‐East Direction

7 SH‐150 11.80 Km in North‐East Direction

8 Railway line 4.52 Km in South‐East Direction

9 Mahi River 10.27 Km in West Direction

10 Vadodara Airport 22 Km in South‐East Direction

(Courtesy: Environmental Information Center, New Delhi)


1.3.2.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

A map depicting administrative boundaries up to Taluka level, showing locations of towns and

villages along with National and State highways, major and medium roads and railways is

presented as Figure 1.4. The map also shows the water bodies and forest boundaries for better

understanding of project area. The map marks the area within 10 km with the project site as

the center. Satellite imagery of area around 10 km radial distance from the project site as

center is shown in Figure‐1.5.


FIGURE‐1.4

KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

1. Basemetal Chemicals 2. Anugrah In‐org pvt. Ltd. 3. Universal Esters Pvt. Ltd 4. Gurunanak Industries 5. J.R.Corporation 6. Uma Organics


FIGURE‐1.5

SATELLITE IMAGERY ALONG WITH PRESENT LAND USE PATTERN


1.4 PURPOSE OF EIA

The purpose of EIA study is to critically analyzed the construction and operation phase activity

of proposed project with respect to manufacturing process of different products with reference

to types and quantity of raw material consumption, possible source of water consumption &

wastewater, air emission and hazardous waste generation, control measures to reduce the

pollution and to delineate a comprehensive environment management plan along with

recommendations and suggestions based on the finalized TORs by EAC, New Delhi.

1.5 OBJECTIVES OF EIA

The main objectives of the study are

1) To assess the background environmental status.

2) To identify potential sources of pollution.

3) To predict and evaluate the impact on environment along with pollution control

measures taken.

4) To prepare a comprehensive Environment and Disaster Management Plan.

1.6 METHODOLOGIES FOR EIA

Taking into consideration proposed project activities and guidelines, an area of 10 km radius

from the center of the project has been selected and is designated as the study area for the

purpose of EIA study.

1.6.1 Base Line Environmental Condition

The samples of ambient air, ground & surface water and soil are collected and analyzed as per

the standard methods for establishing the baseline data and to determine the impact of

proposed activity on the same.

1.6.1.1 Ambient Air Environment

The air environment around the plant was studied by setting up eight locations within the study

area of 10 Km radius from the project site and collection & monitoring the site specific


meteorological data, viz. wind speed and direction, humidity, rainfall and ambient temperature.

Design of network for ambient air quality monitoring location is based on guidelines provided

by CPCB. The ambient air samples were collected and analysed for SPM, PM2.5, PM10, SO2, NOx,

O3, Pb, CO, NH3, C6H6, Benzo (a) Pyrene (BaP) particulate phase only, As, as Ni, HC and VOCs for

identification, prediction, evaluation and assessment of potential impact on ambient air

environment.

1.6.1.2 Ground And Surface Water Environment

The water required for domestic and industrial uses is being made available from ground water

only. Hence, to assess the physico‐chemical quality of the water, a number of water samples

were collected and analyzed for pollution parameters viz., pH, TDS, TSS, BOD3, COD, Fluorides,

Chlorides, Sulphates, Nitrates, Ammonical Nitrogen, Alkalinity, Iron, etc. and some trace heavy

metals in order to find out the contamination, if any.

1.6.1.3 Noise Environment

Noise pollution survey was conducted in the study zone for evaluating existing status. The

anticipated noise sources were automobile activities, which are likely to be increased due to

proposed activity. Noise levels were also recorded at the noise generating places and in the

surrounding villages for evaluating general scenario of the study area. Hourly equivalent sound

levels (Leq) were also recorded for calculating Day and Night noise levels in the surrounding

villages.

1.6.1.4 Soil Environment

Soil sampling and analysis was carried out to assess physico‐chemical characteristics of the soils

and delineate existing cropping pattern, existing land use and topography, within the study

area. Identification of potential utilities of effluent in land application and subsequent impacts

are assessed.


1.6.1.5 Biological Environment

Keeping in view, the importance of biological component of total environment due to the

proposed project activity, biological characterization of terrestrial and aquatic environments,

changes in species diversity of flora and fauna in terrestrial as well as aquatic systems were

studied for impact analysis due to proposed project activity.

1.6.1.6 Socio‐economic Environment

Demographic and related socio‐economic data was collected from census handbook and EIC to

assess socio‐economic status of study area. Assessment of impact on significant historical,

cultural, and archeological sites/places in the area and economic and employment benefit

arisen out from the project activity is given special attention.

1.6.2 Identification of Source of Pollution

Detailed studies of manufacturing process are carried out along with input and output of

materials, water, and wastewater as well as infrastructure facilities available.

1.6.3 Evaluation of Pollution Control and Environmental Management System

The qualitative and quantitative analysis of various pollution sources as well as evaluation of

pollution control system is carried out.

Evaluation of Impact

A comprehensive evaluation of environmental impact with reference to proposed expansion

activities is carried out.

1.6.4 Preparation of Environmental Management Plan

A comprehensive Environmental Management Plan has been prepared covering all the aspects

of pollution prevention measures, Air and Water Pollution Control measures, Hazardous Waste

Management, Environmental Surveillance and Environmental Management Plan.


The present report is a rapid EIA conducted during winter season of January to March, 2011.

The baseline environmental conditions have been established through field monitoring and

literature survey. The contents of EIA report, details of data collection and source of secondary

data are presented in Figure 1.6.

1.7 STRUCTURE OF REPORT

The objectives of the EIRA study is preparation of Environment Impact and Risk Assessment

(EIRA) report based on the guidelines of the Ministry of Environment and Forests (MoEF), CPCB

and GPCB, Incorporating;

Chapter‐1: Introduction

This chapter provides an Introduction of Industry, their premises and surrounding areas. It is

also expressing the basic objectives and methodologies for EIA studies and work to be covered

under each Environment component.

Chapter‐2: Project Description and Infrastructural Facilities

This chapter includes Project Description and Infrastructure facilities delineating all industrial

and environmental aspect of M/s. Allchem Laboratories. Construction and operation phase

activities as well as manufacturing process of existing as well as proposed products. This

chapter gives information about raw material storage and handling, water and wastewater

quantitative details, air pollution and control system, sludge storage facility, utilities, greenbelt

and safety measures for proposed project activity.

Chapter‐3: Baseline Environmental Status

This chapter provides Base Line Environmental Status delineating meteorological details and

identification of base line status of Environmental components (primary data) of surrounding

area.


Chapter‐4: Land Use Pattern, Biological Environment and Socio Economic Environment

This chapter presents a study of land use pattern, Biological Environment & Socio‐Economic

Environment giving details about District Vadodara, Taluka Savli and the study area in terms of

land use pattern, biological environment, and socio‐economic environment.

Chapter‐5: Identification, Prediction and Evaluation of Impact with Environment

Management System

This chapter includes Identification and Prediction of Impact, which provides quantification of

significant impacts of the proposed project activities of plant of various environmental

components. Evaluation of the proposed pollution control facilities is also carried out in this

chapter.

Chapter‐6: Environmental Management Plan

This chapter includes Environment Management plan delineating preparation of Environment

Management Plan (EMP) to be adopted for mitigation of anticipated adverse impacts if any,

and to ensure acceptable impacts.

Chapter‐7: Risk Analysis & Disaster Management Plan

This chapter provides details of Risk Analysis and Disaster Management Plan; it provides basis

for what should be type and capacity of its on‐site and off‐site emergency plan also what types

of safety measures are required. Risk and consequence analysis is carried out considering

storage and handling of various hazardous raw materials, intermediates and product as well as

manufacturing process.

D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐ 25

FIGURE – 1.6

E.I.A. PLAN & PROCEDURE

RECONNAISSANCE SURVEY OF EXISTING PLANT

ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO‐ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS

BASELINEENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT. INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMICSTATUS &

INFRASTRUCTURE

EXISTING PLANT

FACILITY DESCRIPTION

IMPACTS METHODOLOGY OF

IMPACT ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E I A STUDIES

ACTIVITIES

ENVIRONMENTAL MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT MONITORING PROGRAM

RISK ANALYSISSTUDIES & DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

CHAPTER ‐ 2

PROJECT DESCRIPTION

AND

INFRASTRUCTURAL FACILITIES


CHAPTER ‐ 2

PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND

M/s. Allchem Laboratories is advance pharmaceutical intermediates manufacturing company

and plans to introduce new products at company premises by using existing as well as

additional manufacturing and infrastructure facilities. Various utilities i.e. boiler, thermic fluid

heater, cooling tower, brine plant, chilling Plant, RO water plant, air compressor, DM water

plant, DG set, etc. are the utilities will be proposed to install to meet the requirements.

2.2 PROJECT COST

Total capital investment for the proposed project activities is Rs. 276 Lacs. It includes land,

site development, construction, plant machineries, environment protection measures cost,

etc. Break up of proposed investment is shown in Table‐2.1.

TABLE‐2.1

BREAK UP OF PROPOSED INVESTMENT

SR. NO. PARTICULARS AMOUNT

( Rs. IN LACS) 1 Land 16.0

2 Office Building 1.0

3 Research & Development 5.0

4 Quality control lab 19.0

5 Production plant Equipment 123.0

6 Utilities building 20.0

7 Effuent Treatment plant 42.0

8 Green Belt 3.0

9 Storage Godown 15.0

10 Road, Parking & open sky 5.0

11 Solvent storage 5.0

12 Fuel storage 3.0

13 Toilets, Security, canteen, clock room, Rest room 5.0


14 Storage water 3.0

15 Storage (Hazadous Waste) 2.0

16 Storage (Hazardous chemicals) 3.0

17 Storage (Others) 3.0

18 Borewell 1.0

19 Sockpit 2.0

Total 276.0

TABLE‐2.1 (CONTD.)

MEANS OF FINANCE

SR. NO. PARTICULARS (Rs. IN LACS)

1 Member Contribution & Internal Accrual 76.0

2 Loan 200.0

TOTAL 276.0

2.3 MAIN PHASES OF THE PROJECT

2.3.1 PRE CONSTRUCTION ACTIVITIES

At project site, there is sufficient road communication is available so there is no need to

construct any approach road or site access. There is a clear provision for space and proposed

project activity is located on level ground which does not require any land filling for area

grading work. The site is to be cleaned and leveled in a way so that there is no additional soil

to be brought from out side. No major pre‐construction activities are anticipated.

2.3.2 CONSTRUCTION ACTIVITIES

All Construction and commissioning activities of proposed expansion project shall be carried

out after getting Environmental Clearance from MoEF, New Delhi. Erection of various

machineries shall start simultaneously.

• Construction of building, Plant & infrastructure facilities.

• Construciton of sheds and other essential utilities shall be carried out.

Construction materials required for the project activity like steel, cement, crushed stones,

sand, rubble, etc. shall be procured from the local market of the region.


2.3.3 MANUFACTURING ACTIVITIES

Manufacturing activities proposed in the project include various processes as a part of

manufacturing existing as well as proposed products. The activities shall also include

operation of various utilities. The manufacturing process is described in details in following

sections. The list of products (existing as well as proposed) and their capacity is given in Table

1.1.

2.3.3.1 1‐BENZYLPIPERAZINE, 99%

2.3.3.1.1 Process Description

Benzylchloride is reacted with piperazine in the presence of an organic solvent such as

toluene at 70 °C for 8 hours to give 1‐Benzylpiperazine hydrochloride. Hydrochloride salt of

the 1‐Benzylpiperazine neutralise with sodium hydroxide to give 1‐Benzylpiperazine, sodium

chloride and water. The by product sodium chloride is filltered off in pure form (while water

generated during neutralization will be retained by the wet cake of sodium chloride which will

be lost during drying). After filtration organic layer taken for distillation to remove the solvent.

The final product (1‐Benzylpiperazine) is dried under vaccum to remove traces of moisture.

2.3.3.1.2 Chemical Reaction


2.3.3.1.3 Material Balance

Input Qty in kg Output Qty in kg

Benzyl chloride 7.182 1‐Benzylpiperazine 10.000

Piperazine 4.886 Sodium chloride 3.314

Solvent (toluene) 10.000 Water 1.022

Sodium hydroxide 2.268 Solvent (toluene) 10.000

Total 24.336

Total 24.336

Note: Water generated during the process will be retained by the wet cake of the sodium

chloride which will be lost during the drying.


2.3.3.2 DIBUTYL OXALATE, 98%


Oxalic acid is reacted with n‐Butanol in the presence of organic solvent such as toluene at 100

°C for 4 hours and then remove water by azeotropic distillation. (theoretical quan tites). After

removal of water start distillation of solvent. The final product (Dibutyl oxalate) is dried under

vaccum to remove traces of moisture.




Oxalic acid 4.452 Dibutyl oxalate 10.000

n‐Butanol 7.328 Water 1.780

Solvent (toluene) 10.000 Solvent (Toluene) 10.000

Total 21.780

Total 21.780

Note : Water generated during the process is as good as distilled water, because in the

process water is removed by azeotropic distillation.


2.3.3.3 1,4‐PIPERAZINEDICARBOXALDEHYDE, 99%


Formic acid (85%) is reacted with piperazine in the presence of an organic solvent such as

Xylene at 110 °C for 11 hours (slow addition of formic acid, 85%). After then remove water by

azeotropic distillation to give 1,4‐Piperazinedicarboxaldehyde. Cool the reaction mixture

under strring to room temperature, filter the solid and reuse the solvent directly for the next

step.




Formic acid (85%) 7.617 1,4‐Piperazinedicarboxaldehyde 10.000

Piperazine 6.058 Water (from acid & rxn.) 1.780

Solvent (Xylene) 10.000 Solvent (Xylene) 10.000

Total 23.675

Total 23.675

Note: Water generated during the process is as good as distilled water, because in the

process water is removed by azeotropic distillation.

D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 7

2.3.3.4 1,4‐DIBROMOBUTANE, 99%


1,4‐Butanediol is reacted with hydrobromic acid (48%) in the presence of an organic solvent

such as toluene at reflux temp and slowly remove water by azeotropically distillation

contineously till end of reaction. After completion of the raction distilled out solvent. The final

product 1,4‐Dibromobutane is dried under vaccum to remove traces of moisture.




1,4‐Butanediol 8.347 1,4‐Dibromobutane 20.000

Hydrobromic acid (48%) 31.223 Water (from acid & rxn.) 19.570

Solvent (Toluene) 20.000 Solvent (Toluene) 20.000

Total 59.570

Total 59.570

Note: Water generated during the process is as good as distilled water, because in the process

water is removed by azeotropic distillation.


4-Fluoroaniline Bis(2-chloroethy Pottasium 1-(4-Fluorophenyl) piperazine Pottasium Water

amine)HCl carbonate Chloride

F NH2 NH.HCl

Cl

Cl

K2CO3Isopropyl aclohol

80 deg C for 12 hrs.N NHF KCl H2O

2.3.3.5 1‐(4‐FLUOROPHENYL) PIPERAZINE, 99%


4‐Fluoroaniline is reacted with Bis(2‐chloroethylamine)HCl in the presence of an organic solvent

such as IPA & pottasium carbonate at 80 °C for 12 hours to give 1‐(4‐Fluorphenyl)pierazine and

pottasium chloride. Reaction continues till no more carbon dioxide is evolved. The by product

pottasium chloride is filltered off in pure form (while water generated during

reaction/neutralization will be retained by the wet cake of pottasium chloride which will be lost

during drying). Filltrate taken for distillation to remove the solvent. The final1‐(4‐

Fluorphenyl)piperazine, 99% is dried under vaccum to remove traces of moisture/solvent.




4‐Fluoroaniline 3.082 1‐(4‐Fluorophenyl) piperazine 5.000

Bis(2‐Chloroethylamine) HCl 4.951 Potassium chloride 6.203

Potassium carbonate 5.750 Water 0.750

Isopropyl alcohol 20.000 Carbon dioxide 1.830

Isopropyl alcohol 20.000

Total 33.783

Total 33.783

Note: Water generated during the process will be retained by the wet cake of the

potassium chloride which will be lost during the drying.


2.3.3.6. 1‐BENZYLDIETHANOLAMINE, 98%


Benzyl chloride is reacted with Diethanolamine in the presence of an organic solvent

(Methylene dichloride) and sodium carbonate at 30 °C for 20‐22 hrs. to give 1‐

Benzyldiethanolamine and sodium chloride and water. The by product sodium chloride is

filtered off in pure form (while water generated during neutralization will be retained by the

wet cake of sodium chloride which will be lost during drying). After filtration organic layer taken

for distillation to remove the solvent. The final product (1‐Benzyldiethanolamine) is dried under

vaccum to remove traces of moisture.




Benzyl chloride 16.230 1‐Benzyldiethanolamine 25.030

Diethanolamine 13.480 Sodium chloride 7.500

Sodium carbonate 6.795 Water 1.154

Methylene dichloride 40.000 Carbon dioxide 2.821

Methylene dichloride 40.000

Total 76.505

Total 76.505

Note: Water generated during the process will be retained by the wet cake of the sodium

chloride which will be lost during the drying.


Cl

NH2 NH.HCl

Cl

Cl

1-(3-Chloropheny)piperazine

3-Chloroaniline

Bis(2-Chloroethylamine)hydrochloride

Sodium hydroxide, water

N NH

Cl1-(3-Chlorophenyl)piperazine

NaCl

Sodium chloride

M.W. 127.57

M.W. 178.49

M.W. 40

M.W. 196.68M.W. 58.44

Toluene

2.3.3.7 1‐(3‐CHLOROPHENYL)PIPERAZINE, 99 % 2.3.3.7.1 Process Description Into reactor, charge 745 Kg water, 305 Kg 3‐chloroaniline, 427 Kg Bis (2‐Chloroethyl) amine hydrochloride and 287 Kg sodium hydroxide at room temperature. Take temperature 90 °C within 15 hours. Monitor the reaction performance by analytical method. After completion of reaction cool to 35 °C and add 916 lit Toluene at 35 °C in 2 hrs. Stirr for 1 hrs and filter the sodium chloride (inorganic salts) slurry and collect the filtrate separately. Separate organic layer and take for the solvent recovery. After solvent recovery finally apply full vacuum to distill final product 1‐(3‐Chlorophenyl) piperazine. Expected weight is 400 Kg.


2.3.3.7.3 Material Balance Total number of batches: 20 numbers

Input Qty in kg Output Qty in

kg

3‐Chloroaniline 305 1‐(3‐Chlorophenyl)piperazine 400

Bis‐(2‐Chloroethyl)amine hydrochloride

427 Sodium chloride 420

Sodium hydroxide 287 Water 745

Toluene 916 Water generated from reaction 129

Water 745 Recovered Toluene 885

Toluene Loss 31

Distillation Residue 71

Total 2680

Total 2680


2.3.3.8 1‐[2‐(2‐HYDROXYETHYL)ETHOXY]PIPERAZINE, 99 %


Into reactor, charge 818 Kg Water and 495 Kg piperazine at room temperature. Add 238 kg 2‐chloroethoxyethanol at 60 °C in 180 minutes. Stir for 12 hrs at 70 °C and monitor the reaction performance by analytical method. After completion of reaction, add 77 kg sodium hydroxide and 715 lit methanol and stirr for 3 hours. Filter the inorganic solid. Distilled out methanol, water, excess piperazine and finally product under high vaccum. Expected weight is 300 Kg. 2.3.3.8.2 Chemical Reaction


Total number of batches: 10 numbers


2‐Chloroethoxyethanol 238 1‐[2‐(2‐Hydroxyethyl)ethoxy]‐piperazine

300

Piperazine 495 Recovered Piperazine 330

Water 818 Sodium chloride 112


Methanol 715 Water generated from reaction 35

Recovered Methanol 691

Methanol Loss 24


Total 2343

Total 2343


N NH

Cl

Br Cl

N

Cl

N Cl.HCl

1-(3-Chloropropyl)-4-(3-Chlorophenyl)piperazine hydrochloride

Sodium hydroxide

TolueneConc. HCl , Isopropyl alcohol

1-(3-Chlorophenyl)piperazine(M.W. 196.68)

1-Bromo-3-chloropropane(M.W. 157.44)

(M.W. 40.00)

(M.W. 36.5)

2.3.3.9 1‐(3‐CHLOROPROPYL)‐4‐(3‐CHLOROPHENYL)PIPERAZINE HYDROCHLORIDE, 98 %


Charge 414 Kg 1‐(3‐Chlorophenyl) piperazine, 829 kg water and 84 kg sodium hydroxide at

room temperature into clean reactor. Add 1‐Bromo‐3‐chloropropane 332 kg in 2 hrs at 30‐40

°C. Raise the temperature up to 70 deg C. Monitor the reaction performance by analytical

methods. After completion of reaction, cool the mass to 25 to 30 °C and add toluene 1657 lit,

filter the inorganic product (sodium bromide). From the filtrate separate organic layer and

distilled toluene under vaccum. After distillation of toluene add 1243 lit Isopropanol and conc.

HCl (30%) 256 kg under cooling. Cool to 15 °C. Centrifuge the product and dry the product

under vacuum. Filtrate taken for the solvent recovery. Unload and dry the material at 45 to 50

°C in vacuum tray drier (VTD) till to reach the required LOD (Loss on Drying) of the product.

Expected weight is 245 Kg.






1‐(3‐Chlorophenyl)piperazine 414 1‐(3‐Chloropropyl)‐4‐(3‐chloroph‐enyl)piperazine HCl 98 %

600

1‐Bromo‐3‐chloropropane 332 Sodium bromide 217

Water 829 Water 1008

Sodium hydroxide 84 Water generated from reaction 38

Conc. HCl (30%) 256 Recovered toluene 1491

Isopropyl alcohol 1243 Toluene Loss 166

Toluene 1657 Recovered IPA 1118

IPA Loss 124


Total 4814

Total 4814


2.3.3.10 1‐(2‐METHOXYPHENYL) PIPERAZINE HYDROCHLORIDE, 98 %


Into reactor, charge 313 Kg water, 127 Kg o‐anisidine, 184 Kg Bis(2‐Chloroethyl)amine hydrochloride and 123 Kg sodium hydroxide at room temperature. Take temperature 90 °C within 15 hours. Monitor the reaction performance by analytical method. After completion of reaction cool to 35 °C and add 916 lit Toluene at 35 °C in 2 hrs. Stirr for 1 hrs and filter the sodium chloride (inorganic salts) slurry and collect the filtrate separately. Separate organic layer and take for the solvent recovery. After solvent recovery add isopropyl alcohol 380 lit, and IPA.HCl 171 kg under cooling. Stirr for 3 hours. Centrifuge the product and dry the product under vacuum. Filtrate taken for the solvent recovery. Unload and dry the material at 45 to 50 °C in vacuum tray drier (VTD) till to reach the required LOD (Loss on Drying) of the product. Expected weight is 200 Kg.





Input Qty in

kg Output Qty in kg

o‐Anisidine 127 1‐(2‐Methoxyphenyl)piperazine HCl

200

Bis(2‐Chloroethyl)amine Hydrochloride

184 Sodium chloride 180

Water 313 Water 314


Toluene 380 Recovered toluene 367

IPA.HCl 171 Toluene loss 13

Isopropyl alcohol 380 Recovered IPA 479

Isopropyl alcohol Loss 34


Total 1678

Total 1678


2.3.3.11 ISOVALERYL CHLORIDE, 98 %


Into reactor, charge 305 Kg Thionyl chloride and 262 Kg Isovaleric acid at room temperature. Heat the mass to 90 °C and reflux for 10 hrs. During reaction evolution of hydrochloric acid and sulphur dioxide gas scrub with water and caustic solution respectively. After 10 hours monitor the reaction performance by analytical methods. After completion of reaction distilled out the product under vaccum. Expected weight is 300 Kg



Total Number of batches: 5 numbers


Isovaleric acid 262 Isovaleryl chloride 300

Thionyl chloride 305 Hydrochloric acid 94

Sulphur Dioxide 164


Total 567

Total 567


2.3.3.12 2‐METHOXYBENZYLAMINE, 98 %


Into pressure reactor, charge 1335 liter Methanol, 167 Kg ammonia, 13 Kg Raney Ni and 267 Kg 2‐Methoxybenzaldehyde at room temperature. Flush reactor with nitrogen, take pressure of hydrogen 3 kg/cm2 and take temp of 50‐60 °C. Pass hydrogen gas till consumption is going on. After hydrogen consumption completed, Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and Filter the reaction mixture and separate Raney Ni. Collect the Mother Liquor and do the distillation of the mix. Initially ammonia scrub through scrubber. Distilled methanol and finally product under high vaccum. Expected weight is 250 Kg.





2‐Methoxybenzaldhyde 267 2‐Methoxybenzylamine 250

Ammonia gas 167 Recovered ammonia 127

Raney Nickel 13 Ammonia loss 6.5

Hydrogen gas 4 Recovered Raney Ni 13

Methanol 1335 Recovered methanol 1268

Methanol Loss 67


Water generated from reaction 35.5

Total 1786

Total 1786


2.3.3.13 1‐BENZYL‐4‐PIPERIDONE, 98 %


Into reactor, charge 803 lit Methanol, 268 Kg Methyl acrylate and 167 Kg Benzylamine at room

temperature. Heat the mass to 45 °C and stir for 10 hrs at 45‐50 °C. Monitor the reaction

performance by analytical methods. After completion of reaction, distilled out methanol under

vacuum till the pot temp reaches 80 °C. Cool reaction mass to room temperature. Add 2171 lit

Xylene and 84 kg sodium methoxide under cooling. Heat slowly and maintain temp 70 °C for 10

hours. Monitor the reaction performance by analytical methods. After completion of reaction,

add conc. HCl (30%) 378 kg, water 28 kg, and stir for 2 hr at the 35 °C. Separate the aqueous

layer and remove Xylene layer. Xylene layer taken for the distillation. And aqueous layer is

basify with 107 kg potassium carbonate and extract product in 1303 lit toluene. After extraction

distill toluene and finally product under full vacuum.Expected weight is 250 Kg.






Benzylamine 167 1‐Benzyl‐4‐piperidone 250

Methyl acrylate 268 Recovered Methanol 763

Methanol 803 Methanol Loss 40

Sodium methoxide 84 Sodium chloride 91

Xylene 2171 Methanol generated from reaction 149

Conc. HCl (30%) 378 Carbon dioxide 68

Potassium carbonate 107 Potassium chloride 116

Toluene 1303 Water 279

Water 28 Carbon dioxide from carbonate 34

Recovered Xylene 2062

Xylene loss 109

Recovered toluene 1237

Toluene loss 65

Distillation residue 44

Total 5307

Total 5307


Veratraldehyde

OH

OCH3

CHO(CH3)2SO4

OCH3

CHO

OCH3

Vanillin

Dimethyl sulphate

Veratraldehyde

(M.W. 152.15)

(M.W. 126.13)

(M.W. 166.18)

2.3.3.14 VERATRALDEHYDE, 98 %


Into reactor, charge 731 lit Dichloromethane, 64 Kg Sodium hydroxide, 12 Kg Tetrabutylammonium bromide, 64 kg water at room temperature. Raise the temperature to 50 °C and add 202 kg dimethyl‐ sulphate slowly within 5‐6 hours. Stir for additional 3 hours. Monitor the reaction performance by analytical methods. After completion of reaction, cool to room temperature and Filter the mass and separate inorganic salt. From filtrate separate organic layer. Take organic layer for distillation and distill dichloromethane and finally product under full vacuum. Expected weight is 250 Kg.




Input Qty in

kg Output Qty in kg

Vanillin 244 Veratraldehyde 250

Dimethyl sulphate 202

Dichloromethane 731 Methane sulfonic acid sodium salt 215

Sodium hydroxide 64 Recovered dichloromethane 688

Tetrabutyl ammonium bromide 12 Dichloromethane loss 44

Water 64 Water generated from reaction 29

Water 64

Tetrabutyl ammonium bromide 12


Total 1317

Total 1317


Cl O

AlCl3

3-Phenylpropionyl chloride

Anhydrous aluminium chloride

Dichloromethane

Sodium hydroxide

O

HCl

(M.W. 168.62)

(M.W. 133.34)

(M.W. 40)

1-Indanone (M.W. 132.16)

Hydrochloric acid(M.W. 36.5)

2.3.3.15 1‐INDANONE, 98 %


Charge 1358 Lit dichloromethane at room temperature into clean reactor. Add 274 kg aluminium chloride and 339 kg 3‐phenylpropionyl chloride in 8 hours at 20‐30 °C. Raise the temperature up to 40 °C and maintain reaction for 5‐6 hours. Monitor the reaction performance by analytical methods. After completion of reaction, cool the mass to 5 to 10 °C and add mixture of 25 kg conc. Hydrochloric acid (30%) and 1018 lit water in to reaction mix under stirring. Separate the organic layer and distilled out dichlomethane up to 60 °C at atmospheric pressure and finally apply full vaccum to distilled out product. Expected weight is 250 Kg.





3‐Phenylpropionyl chloride 339 1‐Indanone 250

Aluminium chloride anhydrous 274 Aluminium chloride 274

Dichloromethane 1358 Water 1018

Water 1018 Conc. HCl 25

Conc. (30%) 25 Recovered Dichloromethane 1312

Dichloromethane Loss 45

Hydrochloric acid gas 73


Total 3013

Total 3013


F NH2NH.HCl

Cl

Cl4-FluoroanilineBis(2-Chloroethylamine)hydrochloride(M.W. 111.12)

(M.W. 178.49)

Sodium hydroxide

Toluene

N NHF NaCl

1-(4-Fluorophenyl)piperazineSodium chloride

(M.W. 40.00)

(M.W. 180.23)(M.W. 58.46)

2.3.3.16 1‐(4‐FLUOROPHENYL) PIPERAZINE, 98 %


Into reactor, charge 458 Kg water, 178 Kg 4‐Fluoroaniline, 258 Kg Bis(2‐Chloroethyl)amine hydrochloride and 192 Kg sodium hydroxide at room temperature. Take temperature 90 °C with in 15 hours. Monitor the reaction performance by analytical method. After completion of reaction cool to 35 °C and add 533 lit Toluene at 35 °C in 2 hrs. Stirr for 1 hrs and filter the sodium chloride (inorganic salts) slurry and collect the filtrate separately. Separate organic layer and take for the solvent recovery. After solvent recovery finally apply full vacuum to distill final product 1‐(4‐Fluorophenyl)piperazine. Expected weight is 251 Kg.





4‐Fluoroaniline 178 1‐(4‐Fluorophenyl)piperazine 251

Bis‐(2‐chloroethyl)amine hydrochloride 285 Sodium chloride 280

Water 458 Water 458


Toluene 533 Recovered tolune 515

Toluene loss 18


Total 1644

Total 1644


HN COOHO

O O

COOHNO CH3COOH

Isonipecotic acid Acetic anhydride

N-Acetyl-4-piperidinecarboxylic acidAcetic acid

(M.W. 129.16) (M.W. 102.09)

(M.W. 171.20)(M.W. 60.05)

2.3.3.17 N‐ACETYL‐4‐PIPERIDINECARBOXYLIC ACID, 99 %


Into reactor, charge 1218 lit water and 406 Kg Isonipecotic acid at room temperature. Add 321

Kg acetic anhydride at 30 °C in 3‐4 hours. Stir for 20 hrs at 30 °C and monitor the reaction

performance by analytical method. After completion of reaction, Filter the slurry and collect the

Mother Liquor separately. Unload and dry the material at 65 °C in vacuum tray drier (VTD) till to

reach the required LOD (Loss on Drying) of the product. Expected weight is 501 Kg.





Isonipecotic Acid 406 N‐Acetyl‐4‐piperidinecarboxylic acid 501

Acetic anhydride 321 Acetic acid 189

Water 1218 Water 1218


Total 1945

Total 1945


Cl

O

Cl

OH

NaBH4

Methanol

Sodium hydroxide

4'-Chlorobenzopheone

Sodium borohydride

4'-Chlorobenzhydrol

(M.W. 216.67)

(M.W. 40)

(M.W. 37.83)

(M.W. 218.68)

2.3.3.18 4'‐CHLOROBENZHYDROL, 98 %


Into reactor, charge 800 lit methanol, 267 Kg 4’‐chlorobenzophenone at room temperature. Add solution of 12 kg sodium borohydride, 83 lit water and 13 kg sodium hydroxide with in 4‐5 hours. Than stirr the reaction mixture for about 5‐6 hours at 40 °C. Monitor the reaction performance by analytical method. After completion of reaction distilled methanol under vaccum and than add 800 lit. toluene, stirr for 6 hours. Separate the toluene layer and distilled toluene under vaccum and finally product under high vacuum. Expected weight is 250 Kg.


2.3.3.18.3 Material Balance Total Number of batches: 2 numbers


4'‐Chlorobenzophenone 267 4'‐Chlorobenzhydrol 250

Sodium borohydride 12 Sodiumborate 26

Methanol 800 Water 67

Sodium hydroxide 13 Sodium hydroxide 13

Water 83 Recovered toluene 752

Toluene 800 Toluene loss 48

Recovered methanol 752

Methanol loss 48


Total 1973

Total 1973


2.3.3.19 HEPTYLAMINE, 99 %


Into pressure reactor, charge 1332 liter Methanol, 199 Kg ammonia, 13 Kg Raney Ni and 266 Kg Heptaldehyde at room temperature. Flush reactor with nitrogen, take pressure of hydrogen 3 kg/cm2 and take temp of 50‐60 °C. Pass hydrogen gas till consumption is going on. After hydrogen consumption completed, Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and Filter the reaction mixture and separate Raney Ni. Collect the Mother Liquor and do the distillation of the mix. Initially ammonia scrub through scrubber. Distilled methanol and finally product under high vaccum. Expected weight is 250 Kg.




Heptaldehyde 266 Heptylamine 250

Ammonia 199 Recovered ammonia 151

Raney Ni 13 Ammonia Loss 8

Methanol 1332 Recovered Raney Ni 13

Hydrogen 5 Recovered methanol 1266

Methanol loss 67

Water generated from reaction 42


Total 1815

Total 1815


CH2Cl NaO NO2

CH2 O NO2

MonoethyleneglycolToluene

CH2 O NH2.HCl

4-Benzyloxyaniline Hydrochloride

4-Benzyloxynitrobenzene

Benzyl chloride p-Nitrophenol sodium sal

(M.W. 229)

(M.W. 235.71)

(M.W. 126.56) (M.W. 161.00)

HydrogenMethanol Raney Ni

2.3.3.20 4‐BENZYLOXYANILINE HCL, 98 %


Into the reactor charge 205 Kg p‐Nitrophenol sodium salt and 242 lit Monoethyleneglycol at room temperature. Add 161Kg Benzyl chloride and 483 lit. toluene into the mass in 7 hrs at 70 °C. Cool to 50 °C and stir for 12 hrs. Monitor the reaction performance by analytical methods. After completion of reaction cool the mass to room temperature. Into the mass add 483 Kg Water and separate the layers and distill out toluene from organic layer completely at below 70 °C under vaccum. Reaction mass transfer in to pressure reactor and add 1026 lit Methanol and 13 kg Raney Ni under nitrogen. Heat the mix up to 50 °C and Pass hydrogen gas take pressure 3 kg/cm2. And continued till consumption is going on. After hydrogen consumption completed, Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and Filter the reaction mixture and separate Raney Ni. Collect the Mother Liquor and add 136 kg conc. HCl (30%) under stirring. Stirr for 2 hours and filter the product. Unload and dry the material at 45 to 50 °C in vacuum tray drier (VTD) till to reach the required moisture content of the product. Expected weight is 250 Kg.





Benzyl chloride 161 4‐Benzyloxyaniline hydrochloride 250

p‐Nitrophenol sodium salt 205 Sodium chloride 75

Monoethyleneglycol 242 Recovered toluene 454


Water 483 Toluene loss 29

Methanol 1026 Monoethylene glycol 242

Raney Ni 13 Recovered Raney Ni 13

Hydrogen 7 Water from reaction 41

Conc. HCl (30%) 136 Recovered methanol 954

Methanol loss 72


Total 2755

Total 2755


O O

O OBr Br

NaOC2H5

Toluene

Diethyl malonate1,3-Dibromopropane

Sodium ethoxide(M.W. 68.05)

(M.W. 160.08)(M.W. 201.89)

COOC2H5

COOC2H5

Diethyl 1,1--cyclobutanedicarboxylate Potassium hydroxideKOH

(M.W. 56.11)Methanol, Conc. HCl, Ethyl acetate

COOHCO2

Cyclobutanecarboxylic acidCarbon dioxide

(M.W. 200.24)

(M.W. 100.12)(M.W. 46.00)

2.3.3.21 CYCLOBUTANECARBOXYLIC ACID, 98 %


Into reactor, charge 1535 Kg Toluene, 512 Kg Diethyl malonate, 645 Kg and 1,3‐Dibromopropane at room temperature. Raise the temperature to 50 °C and add 435 kg sodium ethoxide under stirring with in 12 hr at 50‐60 °C. After addition stirr for additional 4 hours. Monitor the reaction performance by analytical methods. After completion of reaction, filter the product and distill out toluene form filtrate under vaccum till pot temp 75 deg C. In the reaction mass add 1632 lit methanol. Take temp up to 50 °C, add 359 kg potassium hydroxide within 4‐5 hours. Reflux the mix for 3 hours. Monitor the reaction performance by analytical methods. After completion of reaction, distill out methanol till pot temp 80 °C under vacuum. Add 1632 lit ethyl acetate in to the mix. Cool the mixture up to 25 °C and add 661 kg conc. HCl (30%). Separate the organic layer and distilled out ethyl acetate and than heat the mix till pot temp 130‐140 °C, during this decarboxylation is going on. After decarboxylation distilled product under vaccum. Expected weight is 250 Kg.






Diethyl malonate 512 Cyclobutanecarboxylic acid 250

1,3‐Dibromopropane 645 Sodium bromide 658

Sodium ethoxide 435 Ethyl alchol form reaction 544


Potassium hydroxide 359 Toluene loss 77

Methanol 1632 Potassium chloride 405

Conc. Hydrochloric acid (30%) 661 Carbon dioxide 120

Ethyl acetate 1632 Water 517

Recovered methanol 1542

Methanol loss 90

Recovered Ethyl acetate 1526

Ethyl acetate loss 106


Total 7408

Total 7408


O O

O OBr

Br

NaOC2H5

Toluene

Diethyl malonate

Sodium ethoxide(M.W. 68.05)

(M.W. 160.08)

1,4-Dibromobutane

COOC2H5

COOC2H5

(M.W. 215.92)

Diethyl 1,1-cyclopentanedicarboxylate(M.W. 214.26)

2.3.3.22 DIETHYL CYLOPENTANCEABOXYLATE, 98 %


Into reactor, charge 1535 Kg Toluene, 215 Kg Diethyl malonate, 290 Kg and 1,4‐Dibromobutane

at room temperature. Raise the temperature to 50 °C and add 183 kg sodium ethoxide under

stirring with in 12 hr at 50‐60 °C. After addition stirr for additional 4 hours. Monitor the reaction

performance by analytical methods. After completion of reaction, filter the inorganic salt and

distill out toluene form filtrate under vaccum till pot temp 75 °C. And finally apply full vacuum,

distilled the product. Expected weight is 250 Kg.




Diethyl malonate 215 Diethyl 1,1‐cyclopentanedicarboxylate, 98% 250

1,4‐Dibromobutane 290 Sodium bromide 277

Sodium ethoxide 183 Ethanol from reaction 124


Toluene loss 32


Total 1333

Total 1333


NH2 NaNO2

Conc. HCl

KI

Toluene

I

1-Naphthylamine

Sodium Nitrate Potassium iodide

1-Iodonapthalene

(M.W. 143.00) (M.W. 254.07)

2.3.3.23 1‐IODONATHALENE, 98 %


Into reactor, charge 715 Kg conc. HCl (30%) at room temperature. Then add 168 Kg

1‐Napthylamine in 30 minutes at room temperature. Cool the mass to 0‐5 °C, add 81 kg sodium

nitrate slowly under stirring with in 3‐4 hours. And stir for 4 hrs at the same temperature.

Monitor the diazotization reaction performance by analytical methods. After diazotization of

reaction, dump the reaction mix in to mix having 195 kg potassium iodide, 639 lit water and 504

lit. toluene. Stirr the mix at 30 °C. Separate the toluene layer and distilled out toluene under

vaccum and finally the final product under full vacuum. Expected weight is 250 Kg.




1‐Napthylamine 168 1‐Iodonapthalene, 98% 250

Conc. HCl (30%) 715 Conc. HCl 429

Sodium nitrate 81 Nitrogen 33

Potassium iodide 195 Potassium chloride 88

Toluene 504 Sodium chloride 69

Water 639 Water 882

Recovered toluene 477

Toluene loss 28


Total 2302

Total 2302


ClHN N

Sodium hydroxide

MEKImidazoleAllyl chloride(M.W. 76.56) (M.W. 68.08)

(M.W. 40)N

N

1-Allylimidazole(M.W. 108.14)

2.3.3.24 1‐ALLYL IMIDAZOLE, 98 %


Into reactor, charge 104 Kg water, 104 Kg Sodium hydroxide and 177 Kg Imidazole at room

temperature. Raise the temperature to 40 °C and add 199 kg Allyl chloride with in 5‐6 hours.

Stir for 6 hours at 40 °C. Monitor the reaction performance by analytical methods. After

completion of reaction, cool to room temperature and add 597 lit MEK, stir for 20 min.

Separate the organic layers. Take organic layer for distillation, first remove MEK under vaccum

and finally distilled out product under high vacuum. Expected weight is 250 Kg.




Allyl chloride 199 1‐Allylimidazole, 97% 250

Imidazole 177 Sodium chloride 152

Sodium hydroxide 104 Recovered MEK 558

Water 104 MEK Loss 39

MEK (Methyl ethy ketone) 597 Water 151


Total 1181

Total 1181


NH2

NH2

NH2 NH2

O

NH

NHO

POCl3

NaOH NH

NCl

o-Pheneylenediamine Carbamide

Xylene

Benzimidadazol-2-one

Phosphorus oxychloride

Sodium hydroxide2-Chlorobenzimidazaole

(M.W. 108.14) (M.W. 60.06)

(M.W. 134.14)

(M.W. 153.33)

(M.W. 40.00) (M.W. 152.58)

2.3.3.25 2‐CHLOROBENZIMIDAZOLE, 98 %


Into reactor, charge 1022 Kg Xylene, 255 Kg o‐Phenylenediamine and 142 Kg carbamide at

room temperature. Heat the mass to 130 °C and stir for 8 hrs at reflux temperature. Monitor

the reaction performance by analytical methods. After completion of reaction cool to 20 °C

temperature and stir for 2 hr at the same temperature. Filter the slurry. Collect the Mother

Liquor and take for recovery i.e. Xylene distillation. Unload and dry the material at 60 °C in tray

drier till to reach the required LOD (Loss on Drying) of the product. Expected weight is 311 Kg.

Unload the material from dryer and charge into clean reactor. Add 355 Kg phosphorus

oxychloride and heat to 90 °C. Stir for 15 at 90 °C. Cool the mass and dump in to 1863 lit water

below 40 °C. After dumping take pH neutral using 555 kg sodium hydroxide and than extract in

to chloroform. Separate the organic layer and distilled out chloroform. Filter the slurry dry in

tray dryer till to reach the required LOD (Loss on Drying) of the product. Expected weight is 300

Kg.






o‐Phenylenediamine 255 2‐Chlorobenzimidazole, 97% 300

Carbamide 142 Ammonia gas 80

Xylene 1022 Recovered Xylene 988

Phosphorus oxychloride 355 Xylene loss 34

Chloroform 931 Recovered chloroform 880

Water 1863 Chloroform loss 51


Sodium phosphate tribasic 379

Sodium chloride 406


Total 5123

Total 5123


Cl

CN Br Br

KOH

Cat. TBAB

Toluene

Potassium hydroxide

1,3-Dibromopropane4-Chlorobenzylcyanide

Cl

CN

1-(4-Chlorophenyl)cyclobutanecarbonitrile

(M.W. 151.60)(M.W. 201.89)

(M.W. 56.11)

(M.W. 191.66)

2.3.3.26 1‐(4‐CHLOROPHENYL)CYCLOBUTANECARBONITRILE, 98 %


Into reactor, charge 667 lit Toluene, 222 Kg 4‐Chlorobenzylcyanide, 296 Kg and 1,3‐Dibromopropane at room temperature. Raise the temperature to 50 °C and add 194 kg potassium hydroxide under stirring with in 12 hr at 50‐60 °C. After addition stirr for additional 4 hours. Monitor the reaction performance by analytical methods. After completion of reaction, filter the inorganic salt and distill out toluene form filtrate under vaccum till pot temp 75 °C. And finally apply full vacuum, distilled the product. Expected weight is 250 Kg.





4‐Chlorobenzyl cyanide 222 1‐(4‐Chlorophenyl)cyclobutanecarbonitrile, 97% 250

1,3‐Dibromopropane 296 Potassium bromide 349

Potassium hydroxide 194 Recovered cat. TBAB 11

Water 194 Recovered toluene 634

Cat. TBAB 11 Toluene loss 33



Total 1583

Total 1583


OH Br2

Ethylenedichloride

OH

Br

Cuprous CyanideCuCNDMF

OH

CN

2,6-Dimethylphenol2,6-Dimethyl-4-bromopheno

2,6-Dimethyl-4-cyanophenol

(M.W. 122.17)(M.W. 201.00)

(M.W. 159.81)

(M.W. 89.56)

(M.W. 147.17)

2.3.3.27 3,5‐DIMETHYL‐4‐CYANOPHENOL, 98 %


Into reactor, charge 797 Kg Ethylene dichloride and 266 Kg 2,6‐dimethylphenol at room

temperature. Then add 347 Kg Bromine in 6‐7 hours at 40. Stirr the reaction mix for 6‐7 hours.

Monitor the reaction performance by analytical methods. After completion of reaction, heat

the mass distilled out ethylene dichloride under vacuum till pot temp reaches 70 °C. Add 804 kg

dimethyl formamide and 179 kg cuprous cyanide heat the reaction mix up to 90‐100 °C. And

maintain for 8‐10 hours. Monitor the reaction performance by analytical methods. After

completion of the reaction, distilled dimethyl formamide under vaccum till pot temp 100 °C.

Add 1206 lit water and maintain temp 50‐60 deg , till reaction mixture completely decompose.

Filter the slurry and collect the Mother Liquor separately. Unload and dry the material at 65 °C

in vacuum tray drier (VTD) till to reach the required LOD (Loss on Drying) of the product.

Expected weight is 420 Kg.






2,6‐Dimethylphenol 266 3,5‐Dimethyl‐4‐cyanophenol, 98% 250

Bromine 347 Hydrobromic acid (gas) 176

Ethylene dichloride 797 Recovered Ethylene dichloride 757

Cuprous cyanide 179 Ethylene dichloride loss 40

Dimethyl formamide 804 Recovered dimethyl formamide 748

Water 1206 Dimethyl formamide loss 57

Cuprous bromide 287

Water 1206


Total 3597

Total 3597


CH2 N

O

.HCl

5% Pd on carbon

MethanolHydrogen

.HClN

O

H

1-Benzyl-3-piperidone hydrochloride (3-Piperidone hydrochloride)

Di-tert-butylcarbonate

Sodium hydroxideNaOH

N

O

O

O

1-Boc-3-piperidone(M.W. 199.25)

(M.W. 225.72)

(M.W. 40.00)

(M.W. 218.15)

2.3.3.28 1‐BOC‐3‐PIPERIDONE, 97 %


Into pressure reactor, charge 1593 litre Methanol, 16 kg 5% on palladium on carbon and 319 kg

1‐Benzyl‐3‐piperidone hydrate hydrochloride under nitrogen at room temperature. Flush

reactor with nitrogen, take pressure of hydrogen 3 kg/cm2 and take temp of 50‐60 °C. Pass

hydrogen gas till consumption is going on. After hydrogen consumption completed, Monitor

the reaction performance by analytical methods. After completion of reaction cool to room

temperature and Filter the reaction mixture and separate 5% Pd on carbon. Filtrate cool to 0‐5

°C and add 57 kg sodium hydroxide below 5 °C, followed by addition of di‐tert‐butyldicarbonate

with in 4‐5 hours. Monitor the reaction performance by analytical methods. After completion

add 16 kg activated carbon filter the inorganic solid. Distilled methanol under vacuum till pot

temp 60 °C and than collected main product using high vacuum distillation. Expected weight is

250 Kg.






1‐Benzyl‐3‐piperidone hydrate hydrochloride 319 1‐Boc‐3‐piperidone, 97% 250

5% Pd on carbon 16 tert‐Butanol 105

Methanol 1593 Carbon dioxide 62

Hydrogen 3 Recovered 5% on carbon 16

Activated carbon 16 Sodium chloride 83

Di‐tert‐butyldicarbonate 308 Water 26

Sodium hydroxide 57 Recovered Methanol 1513

Methanol loss 80

Toluene 130


Recovered activated carbon 16

Total 2311

Total 2311


1-(3-Chloropropyl)-1,3-dihydro-2H-benzimidazol-2-one

NH2

NH2

O

O ONH

NO

NO

N

Cl

ON

Cl

NH

Xylene

o-Phenylenediamine Methylacetoacetate

(M.W. 108.14) (M.W. 116.12) Stage-1

Stage-21-(3-Chloropropyl)-1,3-dihydro-2H-benzimidazol-2-one

Br Cl1-Bromo-3-chloropropane

(M.W. 157.44)

NaOH(M.W. 40)

Cat. TBAB

Methanol

Conc. HCl

(M.W. 174.20)

(M.W. 210.66)

2.3.3.29 1‐(3‐CHLOROPROPYL)‐2‐BENZIMIDAZOLIDINONE, 98 %


Into reactor, charge 824 lit Xylene, 206 Kg o‐Phenylenediamine and 221 Kg Methylacetoacetate at room temperature. Heat the mass to 135‐140 °C and remove water and methanol by azeotropic distillation within 8‐10 hours. Maintain the same temp till water‐methanol mixture completely remove. Monitor the reaction performance by analytical methods. After completion of reaction cool to 10 °C and stir for 2 hr at the same temperature. Filter the slurry. Dry the material. Weight of the material is 282 kg. Charge 282 kg material into clean reactor. 255 kg 1‐Bromo‐3‐chloropropane, 282 lit water, 65 kg sodium hydroxide, 14 kg cat. TBAB and 846 lit toluene. Heat to 50 °C. Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and stir for 2 hr at the same temperature. Filter the slurry and separate the aqueous layer. Distilled off toluene under vaccum till pot temp. 60 °C. Cool the mix to room temp add 846 lit methanol and 197 kg conc. HCl (30%), heat the mix up to 50 °C, and stirr for 4 hours. Monitor the reaction performance by analytical methods. After completion of reaction cool to 5 °C and stirr at 5 °C for 2 hours. Filter the slurry. Take filtrate for the recovery of methanol. Unload the material and dry material till to reach the required LOD (Loss on Drying) of the product. Expected weight is 300 Kg.






o‐Phenylenediamine 206 1‐(3‐Chloropropyl)‐2‐benzimidazolidinone, 98% 300

Methyl acetoacetate 221 Water 511

Xylene 824 Recovered Xylene 796

1‐Bromo‐3‐chloropropane 255 Xylene loss 28

Water 282 Sodium bromide 166

Sodium hydroxide 65 Recovered Tolune 761

Cat. TBAB 14 Toluene loss 85

Toluene 846 Recovered methanol 822

Conc. HCl (30%) 197 Methanol loss 85

Methanol 846 Isopropanol 97

Cat. TBAB 14


Total 3754

Total 3754


NH

Toluene Potassium carbonateK2CO3

Cl CN

N

CNPyrrolidine

(M.W. 71.12) 4-Chlorobutyronitrile(M.W. 103.55)

1-Pyrrolidinebutanitrile(M.W. 138.21)

(M.W. 138.21)

2.3.3.30 1‐PYRROLIDINEBUTANENITRILE, 98 %


Into reactor, charge 411 lit Toluene and 137 Kg pyrrolidine at room temperature. Then add 200

kg 4‐chlorobutyronitrile and 133 kg potassium carbonate in 30 minutes at room temperature.

Heat the mass to 70‐80 °C and stirr for 4 hrs at the same temperature. Monitor the reaction

performance by analytical methods. After completion of reaction, filter the inorganic and

distilled toluene under vaccum and finally product under high vaccum. Expected weight is 250

Kg.




Pyrrolidine 137 1‐Pyrrolidinebutanenitrile, 98% 250

4‐Chlorobutyronitrile 200 Potassium chloride 144


Potassium carbonate 133 Toluene loss 41

Carbon dioxide 42

Water 17


Total 881

Total 881


N OO

O

Br ClMg

THF

Cl

MgBr

NO

OOH OH

HN

N-Carbethoxy-4-piperidone 4-Chlorobromobenzen

1-(4-Chlorophenyl)-4-hydroxypiperidin

(M.W. 171.20) (M.W. 191.45)

(M.W. 24.30)

(M.W. 211.69)

KOHPotassium hydroxide

(M.W. 56.11)

HCl(M.W. 36.5)

IPA(Intermediate)

2.3.3.31 1‐(4‐CHLOROPHENYL)‐4‐HYDROXYPIPERIDINE, 98 %


Into the reactor charge 1248 lit Tetrahydrofuran and 35 kg Magnesium turnings under at room

temperature. Heat the mix up to 50 °C. Add 4‐bromo‐1‐chlorobenzene under stirring at 50‐60

°C with in 4‐5 hours. Stirr the reaction mass at this temp for 2 hours. Monitor the reaction

performance by analytical methods. After completion of reaction add N‐Carbethoxy‐4‐

piperidone in to the reaction mix at 40‐50 °C with in 4‐5 hours. Maintain temp 2 hours at 50‐60

°C. Monitor the reaction performance by analytical methods. Cool the mass to room

temperature. Into the mass add 177 lit conc. HCl below 10 °C. Separate the organic layer. Distill

off Tetrahydrofuran under vaccum till pot temp 70 °C. Cool the mass and add 999 lit

Isopropanol and 192 kg potassium hydroxide. Reflux the reaction mass for 12 hours. Monitor

the reaction performance by analytical methods. Cool the reaction mix up to 10 °C. Filter the

slurry. Unload the material and dry material till to reach the required LOD (Loss on Drying) of

the product. Expected weight is 250 Kg.





N‐Carbethoxy‐4‐piperidone 250 1‐(4‐Chlorophenyl)‐4‐hydroxypiperidine 250

4‐Bromo‐1‐chlorobenzene 279 Recovered Tetrahydrofuran 1148

Magnesium turnings 35 Tetrahydrofuran Loss 100

Tetrahydrofuran 1248 Recovered Isopropanol 929

Conc. HCl (30%) 177 Loss Isopropanol 70

Isopropanol 999 Potassium hydroxide 192

Potassium hydroxide 192 Carbon dioxide 65

Ethanol 68

Water 124

Magnesium bromide hydroxide 177


Total 3181

Total 3181


2.4 RAW MATERIAL CONSUMPTION, STORAGE AND HANDLING

The raw materials are received in tanks, HDPE/fibre drums, HMHDPE Carboys and cylinders as

well as through tankers and stored at ambient temperature. All the storage tanks of hazardous

flammable substances are located within premises in separate storage area i.e. solvent farm

area at ambient temperature. Solvents like Methanol, Toluene, IPA, Xylene, etc. shall be stored

in undergroungd storage tank with all precautionary process instrumentation and safety

appliances. Large area shall be covered by well‐designed warehouse, which is containing store

office, raw material store, finished product store, etc. The personnel protective equipments like

hand gloves, safety shoes, goggles, helmet, clothing, etc. are provided to those handling

hazardous chemicals as per requirement. All the motors and electrical connections are flame

proof. After proposed expansion, these procedures are following as exsting scenario and

develop additional infrasture as per requirement. List of raw material are given in Table‐2.2.

TABLE ‐ 2.2

RAW MATERIAL REQUIREMENT (EXISTING SCENARIO)

SR.

NO.

RAW MATERIALS QUANTITY

(MT/MONTH)

1‐Benzylpiperazine, 99%

Benzyl chloride 0.072

Piperazine 0.049

Toluene 0.100

1

Sodium hydroxide 0.023

Dibutyl oxalate, 98%

n‐Butanol 0.073

2

Toluene 0.100

1,4‐Piperazinedicarboxaldehyde, 99%

Piperazine 0.076

Formic acid (85%) 0.061

3

Xylene (mix.) 0.100


1,4‐Dibromobutane, 99%

1,4‐Butanediol 0.042

Hydrobromic acid (48%) 0.156

4

Toluene 0.100

1‐(4‐Fluorophenyl)piperazine, 99%

4‐Fluoroaniline 0.015

Bis(2‐Chloroethylamine)hydrochloride 0.025

Isopropyl alcohol 0.100

5

Potassium carbonate 0.029

1‐Benzyldiethanolamine, 98%

Benzyl chloride 0.033

Diethanolamine 0.027

Methylene dichloride 0.080

6

Sodium carbonate 0.014

TABLE ‐ 2.2 (CONTD.)

RAW MATERIAL REQUIREMENT (PROPOSED SCENARIO)

SR.

NO.

RAW MATERIALS QUANTITY

(MT/MONTH)

1 1,3‐Dibromopropane 2.470

2 1,4‐Dibromobutane 0.580

3 1‐Benzyl‐3‐piperidone hydrate hydrochloride 0.640

4 1‐Bromo‐3‐chloropropane 5.000

5 1‐Napthylamine 0.340

6 2,6‐Dimethylphenol 0.530

7 2‐Chloroethoxyethanol 2.380

8 2‐Methoxybenzaldehyde 0.530

9 3‐Chloroaniline 6.110


10 3‐Phenylpropionyl chloride 2.720

11 4‐Bromo‐1‐chlorobenzene 0.840

12 4'‐Chlorobenophenone 0.530

13 4‐Chlorobenzyl cyanide 0.890

14 4‐Chlorobutyronitrile 0.800

15 4‐Fluoroaniline 0.360

16 5 % Pd on carbon 0.030

17 Acetic Anhydride 0.640

18 Activated Carbon 0.030

19 Allyl Chloride 0.200

20 Aluminium chloride anhydrous 2.190

21 Ammonia 4.310

22 Benzyl Chloride 0.320

23 Benzylamine 1.330

24 Bis(2‐Chloroethyl)amine Hydrochloride 10.000

25 Bromine 0.690

26 Carbamide 0.710

27 Cat. TBAB 0.190

28 Chloroform 2.000

29 Conc. Hydrochloric Acid (30 %) 10.000

30 Cuprous Cyanide 0.360

31 Dichloromethane 5.000

32 Diethyl Formamide 1.450

33 Dimethyl Malonate 2.000

34 Dimethyl Sulphate 0.400

35 Di‐tert‐butyldicarbonate 0.620

36 Ethyl Acetate 2.000

37 Ethylene dichloride 1.500


38 Heptaldehyde 5.330

39 Hydrogen Gas 0.120

40 Imidazole 0.180

41 IPA.HCl 1.710

42 Isonipecotic Acid 0.810

43 Isopropyl Alcohol 10.000

44 Isovaleric Acid 1.310

45 Magnesium turnings 0.110

46 MEK (Methyl Ethyl Ketone) 0.600

47 Methanol 20.00

8 Methyl Acetoacetate 2.210

49 Methyl Acrylate 2.140

50 Monoethyleneglycol 0.600

51 N‐Carbethoxy‐4‐piperidone 0.750

52 o‐Anisidine 1.270

53 o‐Phenylenediamine 3.340

54 Phosphorus Oxychloride 1.770

55 Piperazine 4.950

56 p‐Nitrophenol sodium salt 0.410

57 Potassium Carbonate 1.390

58 Potassium Hydroxide 2.070

59 Potassium Iodide 0.390

60 Pyrrolidine 0.550

61 Raney Ni 0.320

62 Sodium Borohydride 0.020

63 Sodium Ethoxide 1.230

64 Sodium Hydroxide 10.000

65 Sodium Methoxide 0.670


66 Sodium Nitrate 0.160

67 Tetrabutyl ammonium bromide 0.020

68 Tetrahydrofuran 2.000

69 Thionyl Chloride 1.530

70 Toluene 15.000

71 Vanillin 0.490

72 Xylene 5.000

2.4.1 DETAILS OF SOLVENT RECOVERY PLAN

M/s. Allchem Laboratories, Vadodara has adopted standard operating procedure for the

solvent recovery from mother liquor. At M/s. Allchem Laboratories all the solvent/mother

liquors divided in to two categories

Category A: Non‐protic solvent (Chloroform, Dichloromethane, ethylene dichloride, methyl

ethyl ketone, toluene, xylene)

Category B: Protic solvent (Dimethyl formamide, ethyl acetate, isopropyl alchol, methanol,

mono ethylene glycol, Tetrahydrofuran, Acetone)

2.4.1.1 EQUIPMENT AND UTILITIES REQUIREMENT DURING DISTILLATION

• Distillation vessels/reactors is clean and empty.

• It is fully equipped with addition vessels, distillation column length min 1‐2 meter, heating,

primary condenser (cooling tower water circulation), secondary condenser (chilling water

circulation), product cooler (chilling water circulation), receiver & condenser vent

connected to scrubber.

2.4.1.2 IMPORTANT MEASURE TAKES DURING SOLVENT RECOVERY

• Distillation vessels/rectors is perfectly earth to remove any static charge produce during

distillation.

• Maintain temperature constantly


• Circulation of cooling tower and chilling plant water in condenser without interruption to

avoid solvent loss.

• Heating cut off as soon as rise in standard vapour Temprature.

2.4.1.3 SOLVENT RECOVERY FOR THE CATEGORY A: NON‐PROTIC SOLVENT

(Chloroform, Dichloromethane, Ethylene Dichloride, Methyl Ethyl Ketone, Toluene,

Xylene)

• Transfer solvent/mother liquors from the storage tank / containers (drums) in to the

distillation vessels/reactors using Teflon diaphragm pump using air/nitrogen.

• Start stirring and add 10% v/v solution 1.25 N NaOH solution under stirring to

remove all the acidic impurities. Stirr the mixture for 30 min. After 30 min. stop

stirring and kept for the settling. Separate the aqueous layer.

• Than add 10% v/v solution 1.25 N HCl solution under stirring to remove all the basic

impurities. Stirr the mixture for 30 min. After 30 min. stop stirring and kept for the

settling. Separate the aqueous layer.

• After base and acid wash, again wash organic solvent with 10% v/v with DM water to

remove all the inorganic part which is trap in to the solvent. Stirr for the 30 min. and

separate aqueous layer perfectly.

• Start heating under stirring. Distilled out low boiling cut till vapour temp. of the

solvent reached at standard distillation temperature. Recycled this low boiling cut in

next distillation.

• Check the moisture content and purity. (M/C NMT 0.5% and Purity NLT 99.0%).

Heating, stirring and cooling parameters are continuously maintained till get the

right results.

• After distillation, cool the mass and collect the residue in to the suitable container

from the bottom and send for incineration.


2.4.1.3 SOLVENT RECOVERY FOR THE CATEGORY B: PROTIC SOLVENT

(Dimethyl Formamide, Ethyl Acetate, Isopropyl Alchol, Methanol, Mono Ethylene

Glycol, Tetrahydrofuran, Acetone)

• Distillation carried out in min. 3‐5 meter distillation column.

• Transfer solvent/mother liquors from the storage tank / containers (drums) in to the

distillation vessels/reactors using Teflon diaphragm pump using air/Nitrogen.

• Start heating under stirring. Distilled out low boiling cut till vapour temp of the

solvent reached at standard distillation temperature. Recycled this low boiling cut in

next distillation.

• Check the moisture content and purity. (M/C NMT 4‐5% and Purity NLT 98.0%).

Heating, stirring and cooling parameters are continuously maintained till get the

right results.

• After distillation, cool the mass and collect the residue in to the suitable container

from the bottom and send for incineration.

List of Solvent along with total recovery is shown in Table‐2.3.


TABLE ‐ 2.3

LIST OF SOLVENTS ALONGWITH TOTAL RECOVERY

No. Solvent Capacity Total input %

Qty. of Water Actual Qty. Qty. of Loss % % %

Moisture Recovered inputSolvent

RecoveredResidue

Recovered Ltr. Recovery Loss ResidueLtr. Ltr. Ltr. Ltr. Ltr. Ltr.

1 Methanol 20000 20000 8% 1600 18400 17112 1240.16 47.84 93% 0.26% 6.74%2 Toluene 15000 15000 3% 450 14550 13823 692.58 34.92 95% 0.24% 4.76%3 Isopropyl alcohol (IPA) 10000 10000 8% 800 9200 8648 534.52 17.48 94% 0.19% 5.81%4 Dichloromethane (MDC) 5000 5000 3% 150 4850 4462 375.875 12.125 92% 0.25% 7.75%5 Xylene 5000 5000 3% 150 4850 4608 233.285 9.215 95% 0.19% 4.81%6 Chloroform 2000 2000 3% 60 1940 1804 131.92 3.88 93% 0.20% 6.80%7 Ethyl acetate (EA) 2000 2000 6% 120 1880 1767 108.476 4.324 94% 0.23% 5.77%8 Tetrahydrofuran (THF) 2000 2000 8% 160 1840 1711 123.832 4.968 93% 0.27% 6.73%9 Ethylenedichloride (EDC) 1500 1500 4% 60 1440 1368 68.256 3.744 95% 0.26% 4.74%

10 Dimethyl formamide (DMF) 1450 1450 8% 116 1334 1241 90.1784 3.2016 93% 0.24% 6.76%11 Methyl ethlketone (MEK) 600 600 5% 30 570 536 33.003 1.197 94% 0.21% 5.79%12 Monoethylene glycol (MEG) 600 600 10% 60 540 491 47.358 1.242 91% 0.23% 8.77%13 Acetone 1000 1000 7% 70 930 865 62.589 2.511 93% 0.27% 6.73%


2.5 INFRASTRUCTURE FACILITIES

2.5.1 LAND

The land area occupied by M/s. Allchem Laboratories is about 1,125 m2 as existing scenario and

after proposed expansion is about total 8,189 m2. Provisions are made for administrative

building, laboratory, plant area, hazardous waste storage area, effluent treatment plant,

environment analysis lab, chemical storage area, utilities area, security area, vehical parking,

etc. The proposed project activities will take place in the company premises. The break up of

total land area is given in Table‐2.4.

TABLE – 2.4

LAND BREAK‐UP OF THE PLANT

AREA

(SQ. MT.)

SR.

NO.

LAND USE

EXISTING TOTAL AFTER

PROPOSED EXPANSION

1 Office Building 46.37 66.37

2 Research & Development 29.88 87.88

3 Quality control lab 21.72 51.72

4 Kilo Lab 142.98 142.98

5 Production plant building ‐ 1040.0

6 Utilities building ‐ 448.0

7 Effuent Treatment plant 23.37 223.37

8 Green Belt 258.75 2789.75

9 Storage Godown 60.98 320.98

10 Road, Parking & open sky 432.0 2282.0

11 Solvent storage 25.0 225.0

12 Fuel storage ‐ 62.0

13 Toilets, Security, canteen, clock room, Rest room

39.9 128.9


14 Storage water 4.0 24.0

15 Storage (Hazadous Waste) 1.72 63.72

16 Storage (Hazardous chemicals) ‐ 130.0

17 Storage (Others) 32.83 85.83

18 Borewell 0.5 1.5

19 Sockpit 5.0 15.0

Total 1,125 8,189

2.5.2 TRANSPORTATION FACILITIES

Transportation of all the raw material and products are primarily by road only and will remain

same after proposed expansion.

2.5.3 WATER AND WASTEWATER

In existing scenario, the total water requirement at M/s. Allchem Laboratories is 1550 Liter/day

which is met through ground water supply. Water consumption is primarily for processing,

washing, gardening and domestic purposes. Total waste water generation is 550 Liter/day.

After proposed expansion, water requirement and waste water generation will increase up to

52,950 Liter/day & 24,950 Liter/day respectively. Additional water requirement shall also meet

through ground water supply and M/s. Allchem Laboratories has applied for grant of permission

for abstraction of ground water to Central Ground Water Authoriy, New Delhi. Details of water

consumption and wastewater generation are given in Table‐2.5 and Water Balance Diagram is

shown in Figure‐2.1.


TABLE‐2.5

WATER CONSUMPTION & WASTE WATER GENERATION (EXISTING & PROPOSED SCENARIO)

Existing scenario

(Liters/day)

Total after Proposed Expansion

(Liters/day)

Sr.

No.

Section

Water

consumption

Waste water

generation

Water

consumption

Waste water

generation

1 Process 20 20** 3,420 3,420

2 Boiler ‐ ‐ 7,500 1,500

3 Cooling

Tower

‐ ‐ 3,500 1,500

4 RO Plant ‐ ‐ 14,000 5,000

5 Washing

(Floor)

30 30** 8,030 8,030

6 Domestic 500 500* 5,500 5,500*

7 Gardening 1,000 ‐ 11,000 ‐

Total 1,550 550 52,950 24,950

* In existing scenario, domestic wastewater is disposed in Septic Tank/Sock Pit and after proposed expansion; additional domestic waste water quantity will also be disposed in manner as existing scenario. ** In existing scenario, waste water from process and washing is treated in existing ETP and final treated effluent is reused for gardening purpose.


FIGURE‐2.1

WATER BALANCE DIAGRAM (EXISTING)

Domestic 500 Liter/day

Proecess20 Liter/day

Washing (Floor)30 Liter/day

Gardening1000 Liter/day

Water Consumption 1,550 Liter/day

Domestic W/W 500 Liter/day

Wastewater (W/W)50 Liter/day

ProecessW/W 20 Liter/day

Washing (Floor)W/W 30 Liter/day

ETP

Septic Tank/ Sock PIt

Reused for Gardening Purpose


FIGURE‐2.1 (CONTD.)

WATER BALANCE DIAGRAM (TOTAL AFTER PROPOSED EXPANSION)

Process W/W 3,420 Liter/day

Domestic 5,500 Liter/day

Boiler 7,500 Liter/day

Washing (Floor)8,030 Liter/day

Gardening11,000 Liter/day

Water Consumption52,950 Liter/day

Domestic W/W 5,500 Liter/day

Cooling3,500 Liter/day

Wastewater19,450 Liter/day

Boiler W/W 1,500 Liter/day

Washing (Floor)W/W 8,030 Liter/day

CoolingW/W 1,500 Liter/day

Proposed ETP

Septic Tank/ Sock PIt

Process 3,420 Liter/day

Send to CETP/Reuse

RO Plant14,000 Liter/day

RO PlantW/W 5,000 Liter/day


2.5.3.1 TREATMENT PROCESS

M/s. Allchem Laboratories has an Effluent treatment plant. The details of Existing ETP are as

follows.

2.5.3.1.1 EXISTING ETP PROCESS DESCRIPTION

Primary Treatment Tank (Collection cum Neutralization Tank):

Tank acts collection cum Neutralization Tank. Effluent generated is collected and neutralized in

this tank. Lime solution or Hydrochloric Acid is added as per requirement in the collection cum

neutralization tank for adjust neutral pH. The equalization & mixing carried out by help of

pressurized air. Neutralized effluent being pumped into settling tanks at the high levels.

Settling Tank:

This tank acts as a buffer between the primary treatment tank and the overflow tank into which the

settled water flows by gravity.

Effluent after neutralization flow in settling tanks (2 nos.) & then the poly electrolyte powder

added as flocculating agent in the effluent. Flocculation is completed with help of agitation.

Then the effluent is retained for the certain period in a relatively quiescent state. Thus,

Chemical flocs having higher specific gravity than the liquid tend to settle to the tank bottom.

The supernant is transfered to gravity filter. The settled sludge at the bottom is transfer to the

designated sludge drying beds.

Overflow Tank:

Overflow tank has two compartments to allow for settling of particulate matter which might have

escaped from the settling tank.

Charcoal/Sand Filter:

Charcoal/Sand Filter tanks retain any suspended solid and trace of organic material, if present.


Holding Tank:

This tank, situated next to the charcoal/sand filter tank at the ground level, collects the water comes

out of the charcoal filter. The effluent collected in holding tank then reused for gardening purposes.

List of ETP units are given in Table‐2.6. & Flow diagram is given in Figure‐2.2.

TABLE‐2.6

LIST OF ETP UNITS (EXISTING)

Sr. No. Name of unit No. of

unit

Dimension in

(meter)

Volume

Capacity (m3)

1. Primary Treatment Tank (Collection

cum Neutralization Tank)

1 2.6 x 2.9 x 1.46 11

2. Settling Tank 2 1.2 x 1.2 x 1.2 1.72

3. Overflow Tank 2 1.1 x 1.1 x 0.5 0.6

4. Charcoal/Sand Filter 1 + 1 0.92 x 0.92 x 0.5 0.42 (each)

5. Holding Tank 1 1.4 x 1.4 x 1.13 2.2


FIGURE‐2.2

FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (EXISTING)

Primary Treatment Tank

(Collection cum Neutralization Tank)

Raw Effluent

Settling Tank

(2 Nos.)

Overflow Tank

(2 Nos.)

Sand Filter

Charcoal Filter

Holding Tank

Treated Effluent is reused for Gardening


2.5.3.1.2 PROPOSED ETP PROCESS DESCRIPTION

After proposed expansion, effluent load will be increased.

Wastewater from the proposed project will be generated from following strems

• Process

• Washing

• Cooling tower blow down

• Boiler blow down

• Softening plant regeneration and RO plant reject water

• Scrub liquid

are separated in the systematic ways and treated in following ways

Option ‐1: To treat the additional effluent load, company is proposing a new ETP consists of primary treatment facility. Details

of the proposed ETP plant with unit dimensions are given below.

Raw effluent from all the plants will be collected in oil Greece sperator where oil or hyrdrocarbon shall be

separated and than collect the effluent in Collection tank. After collection of effluent, transfer in the neutralization

tank in which one No. of agitator shall be provided in CET to keep all suspended solids in suspension and to provide

proper mixing.

The effluent is then pumped to Neutralization Tank (NT), where the continuous addition and stirring of lime slurry

from Lime Dosing Tank (LDT) is done to maintain the pH of wastewater. Then after, neutralized wastewater shall

go to Flash Mixer (FM) by gravity. Alum/ Polyelectrolite shall be dosed from Alum Dosing Tank (ADT)/

Polyelectrolite Dosing Tank (PEDT) respectively into FM to carry out coagulation by using a Flash Mixer mechanism

(FMM).

Then after, neutralized wastewater shall go to primary Settling Tank (PST) and secondary settling tank (SST) by pipe

where the suspended solids are allowed to settle down. decanted effluent and from sluge drying bed i.e. filltrate

passes to Intermediate Sump (IS), where aeration or hydrogen peroxide trement is given.

Then after, the wastewater shall be pumped to Pressure Sand Filter (PSF) and Activated Carbon Filter (ACF) before

final discharge to remove any left out impurities such as Color, SS, COD, etc.

Treated effluent shall be collected in Treated Effluent Sump (TES) and will be sent to CETP of M/s. EICL for further

treatment and final disposal. If, required Hydrogen Peroxide or areation dosing can be carried out in Treated

Effluent Sump to meet the discharge or reuse norms.


Primary sludge settled in Primary Settling Tank shall be dewatered in Sludge Drying Beds (SDB). Filtrate Water shall

be collected in CET.

List of ETP units are given in Table‐2.7. & Flow diagram is given in Figure‐2.3.

TABLE‐2.7

LIST OF ETP UNITS (PROPOSED) (CAPACITY ~ 3 LAC LITRES)

Sr. No. Name of Units Size (m x m x m) Capacity

(Liters)

1 Oil and Grease Seperator 2.0 x 2.0 x 1.2 4800.00

2 Effluent Collection Sump 4.0 x 4.0 x 2.0 32000.00

3 Neutralization Tank 4.0 x 4.0 x 2.0 32000.00

4 Primary Settler Tank 3.46 x 3.46 x 2.5 29929.00

5 Secondary Settler Tank 3.46 x 3.46 x 2.5 29929.00

6 Aeration Tank 4.0 x 4.23 x 2.0 33840.00

7 Pressure Sand Filter 2.0 x 2.0 x 1.5 6000.00

8 Activated Carbon Filter 2.0 x 2.0 x 1.5 6000.00

9 Sludge Drying Bed 15.85 x 2.0 x 1.5 47550.00

10 Treated Effluent Sump 7.0 x 4.0 x 2.5 70000.00

Option‐2: Concentrated process effluent liquid is taken to own effluent treatment plant comprising of

primary treatment units where wastewater is treated by physico chemical treatment and than

it will be sent to EICL, Umraya, and Vadodara for the treatment and final disposal.

Rest of the Industrial effluent generation is taken to own effluent treatment plant comprising of

primary treatment units where wastewater is treated by physico chemical treatment. The

treated waste water is further passed through Multiple Effect Evaporator followed by Thin Film

Dryer. After evaporation and condensation, outlet water confirming to the GPCB norms is

reused as boiler feed water, in process or disposal on land will be utilized for gardening purpose

within premises after blending it with fresh water (which is used in gardening). “


FIGURE‐2.3

FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (PROPOSED)


2.5.3.2 REVERSE OSMOSIS (RO) SYSTEM

M/s. Allchem Laboratories will be installed Reverse Osmosis (RO) System. The details are as

follows.

Water Treatment scheme is designed to produce product water at the flow rate of 1000 LPH

based on Reverse Osmosis Technology.

Unit Process Description

Sr. No. Description Specification

1 Raw Water Pump To feed raw water to the system

2 Pressure sand filter Removal of suspended impurities

3 Activated Carbon filter Removal of odor & color

4 Micron filtration Silt density index (SDI) reduction

5 Anti‐scalant dosing Scale inhibition; by lowering the LSI

6 Reverse osmosis Primary desalination (TDS reduction)

Treated Water Quality


1 pH 6 + Mildly acidic

2 RO plant salt rejection > 90% after 3 days

3 Organics & bacteria removal 99%

4 TDS less than 100


DETAILED SPECIFICATIONS:

Process flow diagram

Operating Specifications


1 Product water flow rate 1000 LPH

2 Overall system recovery 60%

3 System salt rejection > 90% nominal (90%min)

4 Feed water flow rate 1600 LPH

5 Reject water flow rate 600 LPH

6 Design temperature 30 oC

Raw Water Pump : 1 no.

Pressure sand filter : 1 no.

Activated Carbon filter : 1 no.

Micron filtration : 1 no.

Anti‐scalant dosing System : 1 no.

RO Feed Pump : 1 no.

RO Membrane Assembly : 1 no.

Product Water storage (by client)


Equipment Offered


1 Raw Water Pump 1 No.

2 Pressure sand filter 1 No.

3 Activated Carbon filter 1 No.

4 Micron filtration 1 No.

5 High Pressure Pump and Motor 1 No.

6 RO Membranes 1 No.

7 RO Membranes Housing 1 No.

8 RO Instrumentation & controls 1 No.

9 RO Control panel, R.O. Frame 1 No.

Operating Specifications


1 Raw Water Pump 1 No.

2 HP 1

3 Make Kirloskar/ Beacon/ Equivalent

4 Type CI monoblock centrifugal with gland packing

5 Delivery 2.8 m3/hr. at 25 meter head

6 Pipe line 25 mm Rigid PVC

Pressure Sand FIlter


1 No. of units 1 No.

2 Capacity 2.0 m3/hr. max

3 Dimensions 300 mm Dia ¢ 1200 mm Height

4 MOC FRP

5 Inlet TSS 30 ppm max


6 Outlet TSS 3 max

7 Design pressure 3 bar

8 Main pipeline size 40 NB

9 Pressure Gauge 1 No.

10 Valves 40 NB multiport

Activated Carbon FIlter




3 Dimensions 300 mm Dia ¢ 1200 mm Height

4 MOC FRP


6 Main pipeline size 25 NB

7 Pressure Gauge 1 No.

8 Valves 25 NB multiport

Micron FIlter




3 Delta across clean filter 0.4 bar

4 End of filtration delta 0.8 bar


6 Centrifuge 1 Set

7 Housing 1 No.


Chemical Dosing System: 1 No. (Antiscalent)



2 Solution holding tank 1 no; 100 ltrs;

3 Metering Pump 1 no; 3 LPH @ 3.5 bar; PP wetted parts

220 V; 50 Hz; e dose/equi

4 Piping 3/8” Flexible PVC tuning;

5 Valves 1 no ea; PP fool valve & NRV provided

High Pressure Pump with motor


1 Quantity 1 No.

2 Delivery 2000 lph @ 14 bar

3 MOC SS

4 Make Bell/ Nan fang/ Equiv.

5 Motor rating 3 HP, 440 Volts, 50 Hz, 1440 RPM

6 Type Multistage

RO Membranes


1 No 4 Nos.

2 Elements Type TFC Spiral wound

3 Membrane Polymer Composite polyamide

4 Model Hydronautics/ Koch membrane –

USA/Equiv.

5 Membrane array (1 ¢ 2) (1 ¢ 2)


RO Membrane Housing


1 Qty. 2 no.

2 MOC FRP

3 Pressure Rating 17 Kg

4 Membrane per housing 2 no.

RO Instrumentation & Controls


1 High pre. shut off switch 1 no.

2 Liquid filled Pr. Gauges 2 nos; SS; 0‐20 bar; Hg/Equiv.

3 Tubular Rota meters 2 nos; acrylite; Aster/ Equiv.

4 Conductivity indicator 1 no.; Aster/ Equiv.

5 Control Valves Flow – 1 no; SS; Globe; 25 NB

6 Piping High Pressure – CPCV

High pressure tubing – CPVC

Pressure tubing ‐ CPCV


FIGURE‐2.4

FLOW DIAGRAM OF RO PLANT


2.5.4 DETAILS OF UTILITIES

Various utilities are required for proper functioning of manufacturing plants. These utilities include boiler, thermic fluid heater,

cooling tower, brine plant, chilling Plant, RO water plant, air compressor, DM water plant, DG set, etc. Details of utilities services are

in Table 2.8.

TABLE ‐ 2.8

THE DETAILS OF UTILITIES

SR.

NO.

NAME OF EUIPMENT TYPE MAKE CAPACITY LOCATION

1 Boiler IBR Energy Process Equipment 800 kg/hour Boiler house, Utilities building

2 Thermic fluid heater IBR Energy Process Equipment 2 lac KL/hour Boiler house, Utilities building

3 Cooling tower Natural Draft Matangi 80 TR Above utilities building

4 Cooling tower Natural Draft Matangi 80 TR Above utilities building

5 Cooling tower Natural Draft Matangi 300 TR Production building

6 Chilling plant R‐22 gas Refcon 40 TR at ‐5 deg C Utilities building

7 Brine plant R‐22 gas Refcon 20 TR ‐20 deg C Utilities building

8 Air compressor Reciprocating Khosla 50 m3/hour Utilities building

9 RO water Ion exchange BT associates 1000 litr/hour Utilities building

10 DM water Softener BT associate 500 lit/hour Utilities building

11 DG set Diesel Greaves Make 100 KVA Utilities building


2.5.5 ELECTRICITY REQUIREMENT

The power requirement at M/s. Allchem Laboratories is meeting through 22 KW connecting

load of GEB. After proposed expansion, total power requirement will be increased up to 100

KW which will also be fulfilled by GEB and D.G. set of 100 KVA will be installed for used in

emergency only.

2.6 POLLUTION POTENTIAL AND ITS CONTROL MEASURE

2.6.1 AIR POLLUTION AND CONTROL SYSTEM

At M/s. Allchem Laboratories, there are no stacks/vents within existing plant so no air pollution

is involved in production as well as utilities. After proposed expansion, company will be

installed one Steam Boiler, one Thermic Fluid Heater, one D.G. set of Capacity 100 KVA for

emergency use only and Process Vents. To control the emission from process vents, adequate

water scrubber, alkali scrubber, water scrubber followed by alkali scrubber will be installed. The

details of stack & vent are given below in Table 2.9.

TABLE ‐ 2.9

THE DETAILS OF SOURCE OF EMISSION & CONTROL MEASURES (PROPOSED SCENARIO)

Sr.

No

Source of

Emission

Type of

Emission

Stack

Height

(meter)

Stack

Diameter

(meter)

Fuel

name

and

Quantity

Pollution Control

Equipment

1 Steam Boiler SPM

SOx

Nox

12 0.225 Biomass

(Agro Waste)

1 MT/day

‐

2 Thermic Fluid

Heater

SPM

SOx

NOx

12 0.225 Biomass

(Agro Waste)

1 MT/day

‐


3 Process Vent‐I SO2

15

0.3

‐ Alkali scrubber

4 Process Vent‐II HCl

15

0.3 ‐ Water scrubber

followed by Alkali

scrubber

5 Process Vent‐III Ammonia

15

0.3

‐ Two stage Water

scrubber

6 Process Vent‐IV CO2

‐ ‐ ‐ Open vent or

Alkali scrubber

7 Process Vent‐V HBr 15 0.3

‐ Water scrubber

followed by Alkali

scrubber

8 D.G. Set – 100 KV

(Stand by

Arrangement)

SPM

SOx

NOx

7 0.115 Diesel

(15 Liter/hour)

‐

2.6.1.1 BOILER DETAIL

Steam Boiler

Capacity : 800 kg/hour

Type : IBR

Make : Energy Process Equipment

Stack Height : 12 meter

Stack Diameter : 0.225 meter

Fuel name and Quantity : Biomass (Agro Waste) & 1 MT/day

Thermic fluid heater

Capacity : 2 lac KL/hour


Type : IBR

Make : Energy Process Equipment

Stack Height : 12 meter

Stack Diameter : 0.225 meter

Fuel name and Quantity : Biomass (Agro Waste) & 1 MT/day

2.6.1.2 SCRUBBER SYSTEM

At M/s. Allchem Laboratories, Process Vents will be attached to scrubbing system to reduce the

emission. The design parameters are as follows.

Scrubber System‐I

Pollutant: HCl, HBr

Srubbing Media: Caustic Soln.

Scubber MOC: HDPE

Scrubber Diameter: 300 mm

Scrubber Height: 4 meter

Scrubber System‐II

Pollutant: Ammonia

Srubbing Media: Water

Scubber MOC: HDPE



Scrubber System‐III

Pollutant: SO2

Srubbing Media: Caustic

Scubber MOC: HDPE



The flow diagram of of scrubber stystem are given in Figure‐2.5.


FIGURE‐2.5

SCRUBBER SYSTEM‐I



SCRUBBER SYSTEM‐II



SCRUBBER SYSTEM‐III

vent from reactor


2.6.2 NOISE LEVEL AND CONTROL SYSTEM

The sources of noise pollution at site will be pumps, blowers, D.G. Set (stand by) etc. Extensive

oiling and lubrication and preventive maintenance shall carried out to reduce noise generation

at source to the permissible limit. However, at place where noise levels can exceed the

permissible limit, Earplugs and Earmuffs shall be provided to those working in such area.

2.6.3 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM

Six categories of hazardous wastes are generated at M/s. Allchem Laboratoires. Mode of

disposal followed is as per HW (Management, Handling and Transboundary Movement) Third

Amendment Rules, 2010 of Environment Protection Act, 1986.

In existing scenario, hazardous waste generation is ETP sludge and used containers. ETP sludge

is sent to TSDF of NECL, Nandesari for final disposal. Used containers are sold to actual recycler

after decontamination.

After proposed expansion, quantity of ETP sludge and Used containers will be increased and will

be disposed in same manner as existing. Additional hazardous waste generation will be used oil,

distillation residue, spent carbon and spent solvent. Used oil will be sold to Registered Refiner.

Distillation Residue will be sent to NECL, Nandesari for incineration. Spent Carbon will be sent

to TSDF of NECL, Nandesari for final disposal. Spent solvent will be given to end user or sent to

NECL, Nandesari for incineration.

Hazardous waste generation quantity, physical characteristics and mode of disposal are given in

Table‐2.10.


TABLE‐2.10

HAZARDOUS & SOILD WASTE GENERATION QUANTITY, PHYSICAL CHARACTERISTICS AND MODE OF DISPOSAL

Quantity Sr. No. Name

of

Waste

Category Waste

generating

process / step

Physical

characteristicsExisting

Total after

Proposed

Expansion

Mode of

disposal

1 Used Oil 5.1 Plant Maintenance Liquid ‐ 30 Liter/Month Collection, Storage,

Transportation, Disposal by

Selling to Registered Refiner

2 Distillation Residue

20.3 Process Semi Liquid ‐ 8 MT/Month Collection, Storage,

Transportation, Disposal at

NECL for incineration

3 Spent Carbon 35.3 Process Solid ‐ 0.5 MT/Month Collection, Storage,

Transportation, Disposal at

TSDF of NECL, Nandesari


4 Spent Solvent 28.5 Process Liquid ‐ 8 MT/Month Given to end user /Incineration at

CHWI

5 Used Container

33.3 Process Solid 144 No./Month

400 No./Month

Collection, Storage,

decontamination and send to

actual recycler

6 ETP Sludge 34.3 ETP Semi‐solid 0.03 MT/Month

15 MT/Month

Collection, Storage, Transportation,

Disposal at TSDF of NECL,

Nandesari


2.6.4 DETAILS OF GREENBELT

The main objective of the green belt is to provide a barrier between the plant and surroundings

areas. M/s. Allchem Laboratories has developed green belt within factory premises. In existing

scenario, about 1,125 sq. meter of the total land area is available at site; out of this area about

258.75 sq. meter (23 %) area is covered as greenbelt and other forms of greenery. After

proposed expansion, total about 8,189 sq. meter of land area shall be available; out of this area

total about 2,789 sq. meter (34.05 %) area will be developed as greenbelt and other forms of

greenery.

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