PREFEASIBILITYREPORT
OF
M/SJayveerPharmachem.
SurveyNo.:1187&1184,
Becharpura‐ChitrodipuraRoad
Village:Basana,Taluka:Visnagar,District:Mehsana384001
Mr.RiteshR.Chaudhary
(M)09825095477
E‐mail:[email protected]
PreparedBy:
T.R.ASSOCIATES
C‐605/A,GaneshMeridian,Opp.KargilPetrolPump,
S.G.Highway,Ahmedabad.
Mo.No.:9825371099
EmailID:[email protected];
1. Executivesummary
M/s.JayveerPharmaChemisproposingtomanufacturePharmaceuticalDrugs
& their Intermediates at Survey No. : Survey No. : 1187 & 1184, Becharpura‐
Chitrodipura Road Village: Basana, Taluka: Visnagar, District: Mehsana 384001
ProposedunitwillmanufacturePharmaceuticalDrugsforsellpurpose.
Thetotallandareaofcompanyis15653m2outofwhich5342Sq.Mt.landwillbe
usedforgreenbeltareadevelopment.TheestimatedcostoftheResinprojectis9.0
Crores.TotalbudgetallocationtowardsEnvironmentalManagementFacilitieswill
be Rs. 75 Lacs. Total 20 persons will be employed including skilled persons,
unskilledpersonsandofficestaff.
M/s.T.R.AssociatesiscarriedoutEIA/EMPstudiesforEnvironmentalClearance.
Productiondetailsaregivenbelow:
Sr.No. NameOfTheProductQuantity
MT/Month
1 N‐Methyl4Piperidone(NMP) 4.25
2 N–Methyl4ChloroPiperidine(NMCP) 1.8
3D‐75‐Chloro1‐(4‐Piperidyl)2‐Benzimidazolonone
3
4D‐21–(3–Chloropropyl)‐1‐Dihydro–2–1‐1–Benzimidazolone
2.64
5
DompiridoneChloro–1–(1–(3–(2–Oxo–1–Benzimidazolinyl)Propyl)–4–Piperidyl)–2‐Benzimidaz
5
6Chlorzoxazone(5–Chloro–3–HBenzooxa‐zolonone)OR5–Chloro–2–Benzoxazolione
9.6
7 4Chloro2AminoPhenol(4CAP) 12
8 2.5DichloroPeraphenyleneDiamine 10
SalientFeatureswithin10kmradiussurroundingsareaasfollows:
S.No ImportantFeatures Description
1 Location Survey No. 1187 & 1184, Becharpura‐
ChitrodipuraRoad, Village:Basana,Taluka:
Visnagar,District:Mehsana384001
2 Topomap F43A7
3 Longitude 23°36'59.90"N
4 Latitude 72°28'37.10"E
5 MSL 107m
6. Nearestpowerstation UGVCL(UttarGujaratVijCompanyLtd.)
7 ProponentName Mr.RiteshR.Chaudhary
8 Corporateofficeaddress JaC/OJayTradingCompany,Opp.GujaratPrintery,Nr.SarvajanikVidyalaya,PanchLimdi,Mehsana‐384001
9 Temperaturerange 140Cto430C
10 AnnualRainfall 900mm
11 NearestHWRoad SH56(3.4Km)
12 NearestRailwaystation MehsanaRailwayStation–12Km
13 Nearestcity Mehsana–8.5Km
14 Nearestvillage Bacharpura–1.4Km
15 NationalHWNO NH8(50Km)
16 SeismicZone Zone‐III(LessActive)
17 NationalParks/Sanctuary Nonewithin10Kmradius.
2. Projectbackground.
Pharmaceutical Drugs & their Intermediates used in treating different diseases
andhealthissues.Fore.g:Domperidoneisusedtorelievesymptomsoffeelingsick
(nausea) and sickness (vomiting). The proposed product have good market
demand.
ExportPossibility.
There is good possibility for export. But currently we are focused to local sale
marketfordistribution.
EmploymentGeneration(DirectandIndirect)duetotheproject.
Thisprojectwillprovidedirectemploymentto20peoplewhereasitwillprovide
employmenttomanyothersindirectly.
3. ProjectDescription
(i) Typeofprojectincludinginterlinkedandinterdependentprojects.
Pharmaceutical Drugs & their Intermediates used in treating different
diseases and health issues. It is sometimes dependent on units producing
Intermediateproducts.
(ii) Location
Longitude: 72°24'32"E
Latitude: 23°30'40"N
GoogleImageofProposedLocation.
Project site
(iii) Projectdescriptionwithprocessdetails(iv) ManufacturingProcess
1. N‐METHYL–4‐PIPERIDONE(NMP) Take430KgMethylAcrylateindryreactorat25–30°C. Charge 30% Mono Methyl Amine solution of 243 Kg (73 kg MMA in 170 kg
Methanol)inreactorat20°Cfor3hrs.Keepstirring. Maintain20‐25°Ctempfor6to8hrs. Checksample.IfG.C.isokthanmaintaintemperature30‐35°Cfor2‐4hrs SendsampleforG.C.ifG.C.isokthancoolreactionmassto0°C. NowchargeweightwiseSodiumMethoxidepowder136Kgattemp0‐10°Cin
8hrs. Aftercompletionofaddition,heatthereactionmassto40°C. Maintain40°Cfor6hrsandcheckT.L.C. Afterthischarge1020LitofD.M.Water&1020LChloroform.Slowlytemperature
risesupto55‐60°C.Maintaintemperaturefor2hrs. SendsampleforT.L.C.,ifT.L.C.isokthancoolupto35‐40°C. Reactionmassextractwithchloroformat40‐45°C. Total1020Litchloroformextract(4x255Lit). Collecttotalchloroformextractinotherdistillationreactor. Distilledouttotalchloroform. Coolupto25‐30°C.Transferthematerialsinvacuumdistillationreactor. Startvacuumdistillationandcollectmaterialsattemperature90‐120°C. FinallygetproductN‐METHYL–4‐PIPERIDONEupto170Kg.
MassBalanceTable:Input Kgperbatch Output Kgperbatch
MethylAcrylate 430 NMP 170
MMA30% 73 Effluent1445kg(1020
Liter)
(Methanol) 170 Chloroform 1000
SodiumMethoxide 136 Methanol 170
D.MWater 1020 WasteResidue 42
Chloroform 1020 WetScrubber 22
TOTAL 2849 2849
PROCESSFLOWDIAGRAMOFN‐METHYL–4‐PIPERIDONE
S.S.Reactor
430KgMethylAcrylate
243Kg30%MMAsoln
(73kgMMAin170Kgmethanol)
136KgSodiumMethoxidepowder
1000LitChloroform
170KgMethanolforreused
170kgMethanol
1020litChloroform
170KgsFinishedNMP
VaccumDistillation
1020litwaste
42KgWasteResidue
REACTIONFLOW
215 Kg 215 Kg 73 Kg
244 Kg
170 Kg 136 Kg)
550 Kg
1020 Kg 1020 Kg
2590 Kg
214 Kg
1404 Kg Total258 Kg
136 Kg
1020 Kg
1000 Kg
170 Kg
Wet scrubber 22 Kg
42 Kg
170 Kg/Batch (25 Batch/Month)
2 N‐METHYL–4‐CHLORO–PIPERIDINE(NMCP)
ChargeN‐Methyl 4‐ Piperidone 250Kg (Aqueous Solution of 250KGNMP and250KgD.M.Waterinhydrogenatorat25–30°C)inhydrogenator.ThenchargeRannyNicklecatalystof10Kgandclosethemainhole.
PurgeN2gasforremovalofO2gasandpurgeH2gas forremovalofO2&N2gas.Pass&purgehydrogengasat4‐6Kgpressure.
StarthydrogenatorandpassH2gasuptoconsumptionofH2shouldbenil. ChecksampleforG.C.&T.L.C.ifokthanfilterthematerialsandcollectcatalyst. Collectmotherliquorinvacuumdistillationreactor. Startvacuumdistillationupto110°C.Recovered250Litofwaterandreused. 250KgofN‐Methyl–4‐HydroxyPiperidine(NMHP)isobtained. Take75Litoftolueneand250KgNMHPandmixit. Charge400KgofThionoylChloride inglass line reactorwith1000L tolueneat
25‐30°C. StartchargingofmixtureoftolueneandNMHPinglasslinereactoratbelow60°C
for5‐6hrs. Raisethetemperatureupto60‐65°Cfor1hrandmaintainitfor6hrs.Nowcoolit
at20‐25°C. ChargeslowlyD.M.Waterof350Litat25‐30°Candstirfor1hr. Settle and separate product (aqueous) layer. Now take this aqueous layer in
anotherreactor. Slowlyadd300Litofsodasolution25%(75Kgsodaashin250Litwater)for3‐4
hrs. Add100Kgofcaustic lyeupto50°C for1‐2hrandadd525Litchloroformfor
extraction. Collect extract chloroform in distillation reactor anddistil out chloroformup to
110°C.Coolupto30‐35°C. NowstarthighvacuumdistillationandcollectfinalproductNMCPat80‐110°C. Finaloutput225KgofNMCPisobtained. LiquidEffluent650lit.isalsoobtained.
MassBalanceTable:Input Kgperbatch Output Kgperbatch
NMP 250 NMCP 225
DMWater 600 SpentCatalyst 10
R.Nickle 10 Chloroform 515
Thionylchloride 400 Toluene 1060
Toluene 1075 Effluent 1175kg(650liter)
Soda 75 Residue 25
CausticLye 100 WetScrubber 25
Chloroform 525
TOTAL 3035 TOTAL 6070
PROCESSFLOWDIAGRAMOFN‐METHYL–4‐CHLOROPIPERIDINE
O2 Gas
N2GasHydrogenator
250KgNMP
10KgsRannyNickle
H2Gas
Reactor
Glass Lined Reactor
400KgThionylChloridein1075litresToluene
350LitD.Mwater
10KgSpentCatalystforresell
VaccumDistillationNMCP225Kg
515KgChloroformdistilledandreused
650LitreEffluent(1175Kg)
Distillationreactor
SeparationofAqueousLayer
1060KgToluenedistilledforreuse
25KgResidue
VaccumDistillation
FinalProductNMHP
25%300LitresSodaSoln
(75Kgsin250litreswater)
100KgCausticLye
Distillation
REACTIONFLOW
225 Kg/Batch (8 Batch/Month)
250 Kg
250 Kg 10 Kg
500 Kg
250 Kg
1075 Kg 350 Kg
400 Kg
1050 Kg
100 Kg
1100 Kg
300 lit
525 Kg
225 Kg
510 Kg
1125 Kg
650 lit
25 Kg
1550Liquid
3D‐7(5‐CHLORO–1(4–PIPERIDYL)2‐BENZIMIDAZOLONONE
Stage1–D3N‐CARBETOXY4‐PIPERIDONE(NCP)
Charge1350Lit tolueneand270KgEthylchloroformate(ECF) inreactorat25‐30°C.
Raisethetemperatureupto40‐45°C. Startadditionofmixtureof225Kg(N‐METHYL‐4‐PIPERIDONE)and180 lit
Tolueneat40‐45°Cwithin8hrs.Maintaintemperatureupto50‐55°Cfor6hrs.
CheckT.L.C.ifokthanadd225LitD.M.Water&27kgcausticLye.Settleandseparatetheaqueouslayerinotherdistillationreactor.
Start distillation up to 110‐125 °C for toluene recovery. Also start vacuumdistillationtorecoversolventtraces.
Coolitandtransfervacuumdistillationreactor.Startvacuumdistillationupto100‐125°C.
Collect 225 kg product NCP (N‐CARBETHOXY 4‐PIPERIDONE). Also collectwatereffluentupto225Lit.
MassBalanceTable:Input Kgperbatch Output Kgperbatch
Toluene 1530CarbethoxyPiperidine 225
ECF 270 Effluent477kg(225
Liter)
NMP 225 Toluene 1500
D.M.Water 225 Wasteresidue 45
CausticLye 27 WetScrubber 30
TOTAL 2277 2277
PROCESSFLOWDIAGRAMOFD‐3(NCP)
S.S.Reactor
1530LitToluene
270KgEthylchloroformate
225KgNMP
225LitD.M.Water
Extraction/Separation
Distillation
225KgN‐CARBETHOXYPIPEDINE
225Lit7.0pHwater
Effluent(477Kgs)
1500literTolueneReuse
30KgWetScrubbers
45Kg residueSolidwaste
Stage‐2‐D‐4,4–AMINO‐NCP
ChargeNCP 750Kg at 25‐30 °C in hydrogenator. Also charge 900 LitMethanolundervacuum.
Charge15kgofRannynickelcatalystat25‐30°C.Removenitrogenwithvacuumandcoolto10‐15°C.
Charge 900 L Ammonical nitrogen at 15‐20°C. Pass hydrogen gas until thepressure0.8to1Kg/Cm2at20‐25°C.
Maintain H2 pressure 0.8 to 1.0 Kg at 25‐30 °C for 12 hrs or up to H2 gasconsumptionshouldbenil.
SendthesampleforG.C.&T.L.C.IfitisokthanreleasetheH2bypassingN2gas. Filterthebatch&collectusedcatalyst.Collectmotherliquorindistillationreactor.
Start distillation up to 110‐115°C. Also apply vacuum for 1‐2 hrs at 110‐115°C.Coolitupto25‐30°Candcollectindrum.
Finalproductof750KgD‐4,4–Amino–N–CarbethoxyPiperidine(NCP)willbeobtained.
MassBalanceTable:Input Kgperbatch Output Kgperbatch
NCP 750 4‐AminoNCP 750
AmmonicalMethanol15% 900 SpentNickle 15
R.Nickle 15AmmonicalMethanol15% 850
Residue 50
TOTAL 1665 1665
PROCESSFLOWDIAGRAMOFD‐4–4–AMINONCP
HYDROGENATOR
750KgNCP
900LitAmmonicalMethanol16%
15 K R Ni kl l
Distillation
250Lit7.0pHwaterffl t
850KgAmmonicalMethanol15%forreuse
50 Kg Residue
SpentNicklecatalyst15Kgforresale
750Kg4‐ AMINONCP
REACTIONFLOW
27 Kg1350 Kg
225 Kg
225 Kg
270 Kg
405 Kg(225 lit
135 Kg
225 Kg
225 Kg
Step‐3D‐5,DINITRO(4‐(2‐NITRO–5‐CHLOROANILINE)NCP)
Charge225Kg4‐Amino‐NCPat25‐30°C Charge 270 Kg 2, 5 DCNB, 90 Kg Soda Ash and 90 gm Potassium Iodide with
stirringat25–30°C. Slowlyraisetemperatureupto100‐105°Cin1hrandmaintainitfor1hr. Nowagainslowlyraisetemperatureupto135‐140°Cin1hrandmaintainit for
10hrs. ChecksampleforT.L.C.,ifokthencoolitto70°C. Charge720LitD.M.Water.Stirfor1hrandcoolto40°C. Centrifugethemassandcollecttheeffluent. Packtheproductofnitrocompoundof405kgsinbags.
MassBalanceTable:Input Kgperbatch Output Kgperbatch
4‐AminoNCP 225 D5DINITRO 405
2.5DCNB 270 Effluent900.09kg(720
liter)
SodaAsh 90
PotassiumIodide 0.09
D.M.Water 720
TOTAL 1305.09 1305.09
PROCESSFLOWDIAGRAMOFD‐5DINITRO
`
Water720Lit
S.S.Reactor
225Kg4‐AminoNCP
270Kg2.5DCNB
90KgSodaAsh
WashwithD.M.Water
CentrifugeFiltrate 720Litwatereffluents(pH8.0,900.09Kg)
405 Kg4‐ AMINONCP
Stage–4‐D‐6–DIAMINE(4‐(2‐AMINO‐5‐CHLOROANILINE)‐N‐CARBETHOXYPIPERIDINE)
Take 486 Lit Methanol and 486 Lit Toluene in Hydrogenator at 25‐30°C. Alsocharge405KgD‐5,DINITROcompounds.
Charge9KgRannyNickel catalyst at 25‐30°C. Closemainhole of hydrogenatorandpassingN2gasforremovalofO2gas.
PassedH2gasforremovalofoxygenandNitrogen. PassingH2gasupto6kgpressure,105°Ctemperature. MaintainH2Pressure6kgup to consumptionNIL.Approximately114M3H2gas
willbeconsumed. CheckT.L.C.,ifokthanfilterthebatchandcollectcatalystandmotherliquor. Collectmotherliquorindistillationreactor. Distiloutsolventupto100‐110°Cforreuse.120literDistilledwaterforreuseand
CoolthebatchuptoR.T. Filterinvacuumnutchandcentrifugethemass. 300KgofDiamineproductisreadyforpack.
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
Methanol 486 D6Diamine 300
Toluene 486 SpentNickle 9
D5DiNitro 405 MixSolvent 933
R.Nickle 9 Distilledwater 120kg(120Liter)
H2Gas 9Kg WetScrubber 33
TOTAL 1395 1395
PROCESSFLOWDIAGRAMOFD‐6–DIAMINE(4‐(2‐AMINO‐5CHLOROANILINE)‐NCP)
SolventRecovery 120LDistilledwater
HYDROGENATOR486LitMethanol
486LitToluene
405KgD5
9 Kg R. Nickle catalyst Distillation/Chilling 933LmixSolvent
SpentNicklecatalyst
9kgforresale
300 KgDIAMINE
REACTIONFLOW
225 Kg 270 Kg
90 Kg 90 gms
720 lit.
900 Kg 720 Kg 90 Kg
405 Kg
405 Kg
486 lit
486 lit 9 Kg
825 lit
300 Kg
72 lit
300 Kg 120 lit
Wet scrubber
42 lit
Stage–5–D‐7(5‐CHLORO‐1(4‐PIPERIDYL)‐2‐BENZ‐IMIDAZOLONONE) Charge300KgofD6‐DIAMINEinreactorwith150KgUreaat25‐30°C. Slowly raise the temperature up to 180‐185°C for 2 hrs and maintain same
temperaturefor6hrs. ChecksampleforT.L.C.,ifO.Kthancoolthematerialat100‐110°C. Nowcharge600LitD.M.Waterand36KgCausticlyeatbelow110°C. Transfer thebatch intoother reactorandcharge1200LitD.M.Water&600Kg
48%causticlyeatbelow80‐85°C. Raisethetemperatureupto99‐101°Candmaintainfor10hrs. CheckthesampleforT.L.C,ifokthancoolthematerialupto80‐85°Candcharge9
Kg Carbon. Stir it for 1 hr and filter the batch. Collect mother liquor in otherreactorandcoolto25‐30°C.
NowchargeAmmoniumChloride(240kgin600LitWater)solutionat25‐30°C. Centrifugethematerials&spindryfor45min. Unloadthecake Inglasslinereactor,charge1500LitD.M.WaterandchargematerialcakeatR.T.
AdjustpH2.0byadding120LitHClat20‐25°C. Coolto10°Candstirfor1hr.Centrifugethematerial.Unloadthematerialcake. Charge1500LitD.M.Waterand600Lit25%AmmoniaSolutioninreactor. ChargematerialscakeatR.T.Slowlyapplyheatupto50‐55°Candmaintainfor6
hrs. Centrifugethematerialsatsametemperature.Unloadthematerialanddryat80‐
90°Ctillmoisturecontentbelow1.0%. Pack the 300 Kg quantity of D‐7 (5‐CHLORO ‐1 (4‐PIPERIDYL)‐2‐BENZ‐
IMIDAZOLONONE) CollectedEffluentquantityisalso6000Lit.
MassBalanceTable:Input Kgperbatch Output Kgperbatch
D6diamine 300 D‐7 300
Urea 150 Spentcarbon 9
Causticlye 636 Effluent6906kg(6000
liter)
D.M.water 4800
carbon 9
AmmoniumChlorideSolution 600
HCL 120
AmmoniaSolution 600
TOTAL 7215 7215
PROCESSFLOWDIAGRAMOFD‐7(5‐CHLORO‐1(4‐PIPERIDYL)‐2‐BENZ‐IMIDAZOLONONE)
9 KgCarbon
S.S.Reactor/Hydrolysis
300kgD‐6
150KgUrea
36KgCausticLye
S.S.reactor
Reactor
300KgD‐7
600KgCausticLye
1200KgD.M.Water
AmmoniumChlorideSolution25%(600kg)
CentrifugeandSpinDry
2400Lit10‐12pHalkalineeffluent(2700Kg)
GlasslineReactor
1500KgD.M.Water
120KgHCl
Afterfiltration
1500Lit2‐3pHacidicffl t (1620 K )
S.S.Reactor
1500KgD.M.Water
600Kg25%NH3Solution
Afterfiltration
2100Litalkaline
REACTIONFLOW
300 Kg
150 Kg
36 Kg
600 Kg 1200 lit
600 Kg
9 Kg
600 lit
2700 Kg
360 Kg
1620 Kg 2100 Kg
300 Kg
1500 lit
120 lit. 1500 lit.
600 lit.
360
Kg
300 Kg
4. D‐2[1–(3‐CHLOROPROPYL)‐1‐DIHYDRO‐2‐H‐BENZIMIDA‐ZOLONE]
Stage–1–D‐1 Charge1665KgofO–Xyleneinreactorat25‐30°C. Raisethetemperatureupto140°Candrefluxforremovalofmoisturefor2hrsat
140°C. Now charge weight wise 250 Kg Ortho Phenylene Diamine (OPD) and 300 Kg
MethylAcetoAcetate(MAA)at140°Ceverytwohrsandcollectwater. Maintain140C°temperaturefor10hrsandcheckthesampleforT.L.C.IfT.L.C.is
okthendistiloutO‐Xyleneforreused. Cool to R. T. than chill up to 10°C. Centrifuge thematerials andwashwith 1:3
volumeasO‐xylene:Hexane(21.5Kg+49.5Kg). Spindry thecake for45minandunload thematerials.Dry thematerialsat60‐
70°C.Sowegetmaterialcake. Charge1765LitwaterandmasscakeinS.S.reactor. Stirfor15minandraisetemperatureupto45°C. AdjustpH12‐13byadditionof250kgcausticlyeat45°Cuptodissolution. Stirfor1hrat45‐50°Ctillsolutionshouldbeclear.Charge5Kgcarbonandstir
for1hr. Clarifythematerials.Collectfiltrateinotherreactor.AdjustpH4.0byadding200
KgHCLat30‐35°C. Centrifugethematerialsandwashwith131LitD.M.Water.Spindryfor45min. Unloadthemassanddryat60‐70°C.Weget300KgD‐1. About1800Litwatereffluentwillbegenerated.
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
O‐Xylene 1686.5 D‐1 300
OPD 250 carbon 5
MAA 300 O‐Xylene 1636
DMwater 1896 Effluent2684kg(1800
liter)
Hexane 49.5 WetScrubber 12
CausticLye 250
carbon 5
HCL 200
TOTAL 4637 Total 4637
PROCESSFLOWDIAGRAMOFD‐1
S.S.Reactor
1665kgO‐Xylene
250KgOPD
300KgMAA
Reflux140oC
Centrifuge/SpinDry
CentrifugeandSpinDry
S.S.Reactor1765LitD.M.Water
250KgCausticLye
5 Kg Carbon
Reactor200KgHCL
131LitD.M.Water
300KgFinishproductD‐1
5KgSpentCarbon
1800Liteffluent(2684Kg)
1636KgO‐Xylene
Distilled&reuse
21.5kgO‐Xylene
49.5kgHexane
Stage‐2–D‐2
Charge895KgAcetoneat25‐30°Cinreactor.Alsocharge300KgD‐1materialat25‐30°C.
Stirfor1hrtillsolutionshouldbeclear.Add150Kgcausticlyetoreactionmassat25‐30°Cin3‐4hrsthanadd5KgTEBACascatalyst.
Maintaintemperatureupto15‐20°Cfor2hrs. Add350Kg(1‐Bromo‐3Chloro‐Propane)BCPat30‐35°Cfor3‐4hrs. Maintaintemperatureupto25‐30°Cfor10hrs. CheckT.L.C. of sample if ok thensettle thebatch for1hr. separate theaqueous
layerincleancontainer. Nowcollectoilyaqueouslayeringlasslinereactor.Chargedilutes625kgHClat
25‐30°Candraisesthetempupto55‐60°Cfor4hrs. Coolthemassto30‐35°Candobservethematerialformation.Maintainthesame
tempfor1hr. Centrifugethemass.Spindryfor45minandunloadthedrymaterialsat55‐60°C. Weget330KgD‐2.
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
Acetone 895 D‐2 330
D‐1 300 Acetone 880
TEBAC 5 Effluent1088kg(730
liter)
BCP 350 Residue 12
CausticLye 150 WetScrubber 15
HCL 625
TOTAL 2325 TOTAL 2325
PROCESSFLOWDIAGRAMOFD‐2
S.S.Reactor
895KgAcetone
300KgD‐1mass
5KgTEBAC
Centrifuge/SpinDry
GlassLineReactor
625KgHCL
880KgrecoverAcetonefordistil&reuse
15 K W S bb
330KgFinishproductD‐2
12kgOrganicResidue
730Lit7.0pHwatereffluents(1088Kg)
GlassLineReactor
REACTIONFLOW
250 Kg
300 Kg
200 Kg
131 lit
1765 lit
250 Kg 366 Kg
300 Kg
2684 Kg
1800 lit Water + Nacl + 12 Kg Wet Scrubber
300 Kg
350 Kg 150 Kg 895 Kg
625 lit
330 Kg
1088 Kg
730 lit
330 Kg/Batch (8 Batch/Month)
180 lit 1636 Kg
1665 Kg
5. DOMPIRIDONE5‐CHLORO‐1‐(1‐L3‐L2‐OXO‐1‐BENXIMIDAZOLINYL)PROPYL)‐4‐PIPERIDYL)‐2‐BENZIMIDAZProcess
Charge130kgM.I.B.Kat25‐30°Cinreactor.Nowcharge110KgD‐2,125KgD‐7and1.25KgPotassiumIodideat25‐30°Cinsamereactor.
Raisethetemperatureto88‐90°C.Addthe90KgweightwiseSodaashforevery45minandrecordthetemperature.
Maintaintemperature88‐90°Cfor9to10hrs.Coolthemassto30‐35°Candstirfor30‐35°Cfor1hr.
Centrifugethematerialsandunloadthewetcake. Nowcharge1094LitD.M.Waterintoanotherreactor.AndaddwetcakeatR.T.
Raisetemperatureto65‐70°C. Charge Ammonium Chloride solution (124 Kg in 625 Lit) at 60‐65°C. Raise the
tempto65‐72°Candmaintainforthesamefor2hrs. CooltoR.T.andmaintainfor1hr. Centrifugethematerials. Spindryfor45min. Drytheproductandget200KgDOMPIRIDONEAT80‐90°C Collect1125Liteffluent.
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
M.I.B.K 130 Dompiridone 200
D‐2 110 M.I.B.K 120
D‐7 125 Effluent1845.25kg(1125Liter)
potassiumIodide 1.25 WetScrubber 10kg
Sodaash 90
D.MWater 1094
AmmoniumChloridesolution 625
TOTAL 2175.25 TOTAL 2175.25
PROCESSFLOWDIAGRAMOFDOMPIRIDONE
S.S.Reactor130KgM.I.B.K.
110KgD‐2
125KgD‐7
1.25KgPotassiumIodide
Centrifuge/SpinDry
S.S.Reactor469LitD.M.Water
625Kgsoln.ofAmmoniumChloride
120kgM.I.B.K.solventfordistillationandreuse
10KgwetScrubber
200KgFinishproductDOMPIRIDONE
1125Lit7.0pHwatereffluent(1845.25Kg)
Centrifuge
REACTIONFLOW
110 Kg 125 Kg
130 Kg
90 Kg 1.25 Kg
325 Kg
938 lit.
625 lit. 150 lit.
200 Kg
1845 Kg
130
Kg
6. 4‐CAP(4‐CHLORO2–AMINOPHENOL)
Process
Take3330KgDMwaterinAutoclave. Charge400KgCausticflakesor830KgCausticlyeunderstirring.Alsocharge665Kg
2.5DCNBslowlywithstirring.Closethemainhole. Startheatingupto145‐148°Candmaintainsametemperaturefor6hrs.Takesample
andcheckmeltingpointandT.L.C. Coolto100°Candreleasepressure. TransferthematerialsinotherM.S.openreactor. Coolto20‐25°Cbyaddingcoolingwater. Filterthebatchinnutchfilterandcentrifugethematerials. Checkthepurityandmoisture. Collecttheeffluent2000Lit.
Hydrogenation
Take2000LitDMwaterinhydrogenatorandchargenitrowetcakeinhydrogenator. AdjustpH12.5to13byaddingcausticlye. NowchargePlatinum/Carboncatalyst. ClosethemainholeandstartpurgeofN2gasforremovalofO2gasuptoNil. StartpurgingofH2gastwotimesforremovalofN2&O2gas.Takepressure5KgofH2
gas. Startstirringandmaintain5kgpressureuptoreductioncompleted. CheckT.L.C.,ifitisokthenfilterthebatchandcollectcatalystforrecycleandreuse. CollectmotherliquorinHDPEreactor.AdjustpHupto4‐4.5byaddingHCl. Filterthemassbynutchfilter,centrifugeit,dryandpackit. Collecttheeffluent1665Lit.
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
Water 5665 4CAP 400
2.5DCNB 665 catalyst 5.5
CausticFlakes 400 Effluent6530Kg(5665
Liter)
PlatinumCatalyst 5.5
HCL 200
TOTAL 6935.5 6935.5
PROCESSFLOWDIAGRAMOF4‐CHLORO–2–AMINOPHENOL
M.S.Autoclave3330LitDMwater
665Kg2.5DCNB
HDPEReactor
Hydrogenator
2000LitDMwater
5.5KgPlatinumcatalyst
H2gas
(240m3H2gas)
3665 LitAlkalineeffluent
With salt (4065 Kg)
400KgFinishproduct4CAP
2000Litwatereffluent (2465Kg)
Filter 5.5KgRecoveredcatalystforreuse
Filter/Centrifuge
HCL200KG
Filter
REACTIONFLOW
665
3330
400
3665
2000
665
400
200
2465
7. CHLOROXAZONE (5‐CHLORO‐3‐H BENZOOXA‐ZOLONONE) OR5‐CHLORO‐2‐BENZOXAZOLIONE
Process
Take625KgHCLinglasslinereactor.Charge400Kgreal4–CAPwetcakeinglasslinereactorwithstirring.Stirforhalfhour.
Nowadd533KgUrea in glass line reactorwith stirring. Close themainhole ofreactor.
Startheatingslowlyupto100‐101°Cforreflux.Refluxfor5‐6hrsuptoT.L.C.ofsampleshowsok.
CheckthepH,itshouldbe6.0‐6.5. CoolthemasstoR.T. Filterthebatchandcentrifugeit. Collecteffluentwaterquantityof1000Lit(1158Kg).Purification
Take500Kg80%Methanolandchargecrudewetcakewithstirring. Heatupto65‐70°Cforreflux.Add10Kgcarbonandrefluxfor2hrs. Filterthebatchandcollectmotherliquorinotherreactor. Coolthemassto0‐5°C. Nowfilterthemass¢rifugefordrying. Drythematerialsandpack.
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
Real4CAPwetcake 400 CHLOROXAZONE 400
Urea 533 Effluent1158kg(1000
liter)
HCL 625 Carbon 10
Methanol(80%) 500 Methanol (80%) 500
Carbon 10
TOTAL 2068 Total 2068
PROCESSFLOWDIAGRAMOFCHLORZOXAZONE
GlassLineReactor
400KgReal
4‐CAPwetcake
533KgUrea
5 l
Centrifuge/Chilling
S.S.Reactor
500Kg80%Methanol
10KgCarbon
1000 Lit6.5to7.0pH
ff ( )
400KgFinishproductsCHLOROXAZONE
500KgMethanol(80%)recoveredforreuse
Centrifuge
800 kg
Reflux&FilterSolidwaste10Kgcarbon
REACTIONFLOW
400
533 625
1000 293
500
500
8. 2‐5DichloroPeraPhenyleneDiamine
Process Take1500LitmixsolventinHydrogenator.
Charge300Kg2.5DCPNA&stirringatR.T.
Chargepalladium/carboncatalyst2.1kg.
Closethemainhole&startN2gaspurgeforremovingOxygen.
PurgeH2gasupto5.65kgPressure
Starthydrogenation
Heatupto80–82ºC.
HydrogenationcontinuousuptoH2gasconsumptionnil
Takesample&checkT.L.C.
IfT.L.C.okthanfilterthebatch
Collectfiltrateinotherreactor
Chillupto5–10ºC.
NutchtoC/Fthematerials.Solventfordistillation&reuse.
Drythematerials250kg.&packed
MassBalanceTable:
Input Kgperbatch Output Kgperbatch
Mixsolvent 1500 2.5DCPPD 250
2.5DCPNA 300 catalyst 2.1
Pd/Cocatalyst 2.1 MixSolvent 1477.5
Residue 50
WetScrubber 22.5
TOTAL 1802.1 1802.1
PROCESSFLOWDIAGRAMOF2‐5DICHLOROPERAPHENYLENEDIAMINE
Reactor
1500litmixsolvent
300kg2.5DCPNA
2.1kgPd/Ccatalyst
Chilling/NutchFilter 50KgResidue
1477.5KgMixSolvent
22.5kgwetscrubber
2.1Kg.catalystrecycledorreuse
2.5DCPPD
250Kg
Filter/Centrifuge
REACTIONFLOW
ANNEXURE–4
ListofRawMaterials
No. Product RawMaterialsQty
PerMonth
1 N‐METHYL–4‐PIPERIDONE
MethylAcryalate 10750Kgs
MonoMethylAmine
(30%SolutioninMethanol)
6075Kgs
SodiumMethoxidePowder 3400Kgs
Chloroform 12000Kgs
D.M.Water 25500Lit
2N‐METHYL–4‐CHLORO–PIPERIDINE
(NMCP)
N‐Methyl–4–Piperdone 2000Kgs
NickleCatalyst 80Kgs
D.M.Water 4800Lits
HydrogenGas 125m3
ThionylChloride 3200Kgs
Toluene 3000Kgs
CausticLye 800Kgs
SodaAsh 600Kgs
Chloroform 2500Kgs
3
D‐7
5‐CHLORO‐1‐(4‐PIPERIDYL)‐2–
BENZIMIDAZOLONONE
N‐Methyl–4‐Piperidone 2250Kgs
EthylChloroFormate 2700Kgs
Toluene 7000Kgs
D.M.Water 70000Lits
AmmonicalMethanol
(15To17%Solution)
2700Kgs
RannyNickleCatalyst 150Kgs
HydrogenGas 1500m3
2,5,DichloroNitroBenzene 2700Kgs
SodaAsh 1500Kg
Urea 1500Kg
Methanol 2000Kgs
CausticLye 6600Kgs
AmmoniumChloride 2400Kgs
HCl 2000Kg
NH3Liq.25%Soln 6000Kg
Carbon 300Kg
NitrogenGas 300m3
4
D‐2
1–(3‐CHLOROPROPYL)‐1‐DIHYDRO‐2‐1‐1‐
BENZIMIDA‐ZOLONE
OrthoPhenyleneDiamine(OPD) 2000Kg
O‐Xylene 4500Kg
MethylAcetoAcetate(MAA) 3000Kg
CausticLye 2550Kg
HCl 6400Kg
N‐Hexane 495Kg
1‐Bromo‐3‐ChloroPropane(BCP) 2800Kg
Tebac(Catalyst) 40Kg
Acetone 2500Kg
D.M.Water 19800Lit
5
DOMPIRIDONE
5‐CHLORO‐1‐(1‐L3‐L2‐OXO‐1‐BENXIMIDAZOLINYL)
PROPYL)‐4‐PIPERIDYL)‐2‐BENZIMIDAZ
D‐2 2640Kg
D‐9 3000Kg
M.I.B.K.(MethylIsoButylKetone) 1000Kg
SodaAsh 2525Kg
AmmoniumChloride 3500Kg
D.M.Water 41000Lit
6
CHLORZOXAZONE
(5‐CHLORO‐3‐HBENZOOXA‐ZOLONONE)
OR5‐CHLORO‐2‐BENZOXAZOLIONE
4‐CAP 10000Kg
HCl 15000Kg
Urea 12792Kg
Methanol 5000Kg
Carbon 240Kg
74‐CAP
(4‐CHLORO2–AMINOPHENOL)
2,5DichloroNitroBenzene(2,5DCNB) 19950Kg
CausticFlakes 12000Kg
D.M.Water 170000Lit
Platinum/CarbonCatalyst 165Kg
HCl 6000Kg
HydrogenGas 6000m3
NitrogenGas 250m3
8 2.5DICHLOROPARAPHENYLENEDIAMINE
MixSolvent 5000Kg
2.5Dichloroparanitroaniline 12000Kg
Pd/Cocatalyst 85Kg
HydrogenGas 3600m3
1. Resourceoptimization/recyclingandreuseenvisagedintheproject,ifany,shouldbebrieflyoutlined.
OurmainrawmaterialsareeasilyavailablefromdevelopmentalcitylikeBaroda,Surat,etc.
2. Availabilityofwateritssource,Energy/powerrequirementandsourceshouldbegiven.
Watersource:Borewell/DMwater(outsource)
Energy/powerrequirement:105HPfromUGVCL
3. Quantityofwastestobegenerated(liquidandsolid)andschemefortheirManagement/disposal.
Solidwastegenerationanddisposal
Sr.no.
Description Category TotalQuantityperMonth
ModeofDisposal
1 Usedoil/SpentOil
5.1 0.1MT Collection,storageandUsewithinpremisesasalubricant/selltoregisteredrecycler
2 DiscardedPlasticBags/
Drums
33.3 0.8MT Collection,storageandreusewithinpremises/selltoapprovedscrapvendor.
3 WasteResidue 28.1 0.4MT Collection,storageandincineratedatauthorizedCHWIFsite.
4 SpentCarbon 28.2 0.3MT Collection,storageandincineratedatauthorizedCHWIFsite.
5 SpentCatalyst 28.2 0.3MT Collected,StoredandsoldtoregisteredRecycler.
6 ETPSludge&MEEresidue
34.3 22.2 MT Collection,storageanddisposalatauthorizedCHWISsite.
WastewatergenerationandDisposalfacility
DETAILSOFEFFLUENTTREATMENTPLANT
LiquidandHazardousWasteGenerationwithestimatequantities;
Sr
NoProduct
Capacity
kg/batch
Batch/month
Quantityof
liquideffluentinlit/batch
Quantityof
liquideffluentinlit/month
Contentsof
liquideffluent
Quantityofresiduesandwastematerials
Inkg/batch
Quantityofresidueinkg/month
Qualityof
residues
1N‐Methyl‐4Piperidone[NMP]
170 25 1020 25500
1020litWater
248kgSodiumsalts
135kg
Methanol
44 1100 Organic
2N‐Methyl4ChloroPiperidone
225 8 650 5200
650litWater
475kgSaltsofSodiumChloride
25 100Distillation
[organic]
10 40 RaniNickel
andSodiumSulfate
3
D‐7
[5‐Chloro‐1(4‐Piperdyl)2
Benzimidazalonone]
1stStage
N‐Carbethoxy225 10 225 2250
225litWater
27kgCausticlye
153kgSaltofEthylChloroform[CH3Cl]
9 180 Distillation
2ndstage.
D4‐(4AminoNCP)750 15 300
Spentcatalyst
3rdStage
D5‐
D5‐DiNitro(4‐(2‐Nitro‐5‐Chloroaniline)NCP
405 10 720 7200720litWater
90kgNaCI
4thStage
Amino(4‐(2‐Amino5Chloroaniline)
300 10 120 1200
120lit/Water
30kgOrganiccompoundsconsisting
9
90
RaniNickel
Organic
(NCP) mainlymethanolandtoluene
6 60
Residue
D‐7
(5CHLORO‐1(4‐Piperidyl)‐2‐Benzaimidazolonone
300 10 2400 24000
2400LitWater
150KgAmmoniumChloride
150kgCaustic
9 90 Carbon
10 1500 15000
1500litWater
120kgSodiumChloride
10 2100 21000
2100litwatercontainingammonia
4
D‐2
1‐(3‐chloropropyl)‐1‐Dihydro‐2‐H‐Benzaimidazolonone
Stage‐1‐D2 300 8 1800 14400
1500lit/water305kgSodiumChloridesalts+TracesofOrganicSaltsof
10 80 Distillation
OrthoXylene+
MethylAcetoAcetate
330 8 720 5760
730litwater293kg(SodiumChloride+NaBr+TracesofAcetone)
2
4
2
16
32
16
Carbon
Organicresi.
Metalcatalyst
5
Dompiridone‐(5Chloro‐1(1‐c3(2OXO‐1‐BENZIMIDAZOLInyl)propyl)‐4piperridyl)‐2‐benzimidazo)
200 25 1266 31650
1266litwater87kgSodaAshSalts
505kgAmmoniumChlorideSalts
64CAP
(4Chloro‐2aminophenol)400 30 3665 91625
3330litwater
400kgCaustic
30 2000 60000
2000litwater
265kgHCL+TracesOfOrganicCompoundsof4
chloro2nitrophenol
7Chlorzoxazone‐2‐(5‐chloro‐3‐H‐Benzooxazolonone)
400 24 1000 240001000kgeffluentmainlyAmmonium
10 240 Carbon
82‐5‐DichloroParaPhenyleneDiamine
250 40 25 1000DistillationResidue
TotalQuantity/Month 328785
EffluentQuantityinlit/day 10960
MaximumEffluentQuantitygenerationinlit/day 13945
TotalResidueinkg/month 3344
MaximumResidueinkg/day 111.46
Say,kg/day 112
Sr
No
Product Quantityofliquideffluentinlit/batch
Contents of liquideffluent
EffluentCharacteristicsbasedonTheoreticalCOD
1 N‐Methyl‐4
Piperidone[NMP]
1020 1020 lit Water
248kgSodium
salts
135kgMethanol
pH7‐8
COD‐200000mg/l
TDS‐ 240000mg/l
2 [N‐Methyl 4Chloro
Piperidone
650 650 lit Water
475kgSaltsof
SodiumChloride
andSodiumSulfate
pH> 8
TDS‐700000mg/l
3 D‐7
[5‐Chloro‐1(4‐
Piperdyl)2
Benzimidazalonone]
1stStage
N‐Carbethoxy
225 225 lit Water
27kgCausticlye
153kgSaltofEthyl
Chloroform
[CH3Cl]
pH>9
COD‐768000mg/l
2ndStage
D4–(4AminoNCP)
3rdStage
D5‐
D5‐DiNitro
(4‐(2‐Nitro‐5
Chloroaniline) NCP
720 720 lit Water
90kgNaCI
pH6‐7
TDS‐ 125000mg/l
4th Stage 120 120 lit/ Water pH6‐7
Sr
No
Product Quantityofliquideffluentinlit/batch
Contents of liquideffluent
EffluentCharacteristicsbasedonTheoreticalCOD
Amino
(4‐(2‐Amino5
Chloroaniline) (NCP)
30 kg Organic
compounds
consistingmainly
methanoland
toluene
COD‐538000mg/l
D‐7
(5CHLOR0‐1(4‐
Piperidyl)‐2‐
Benzaimidazolonone)
2400 2400 lit Water
150kgAmmonium
Chloride
150kgCaustic
pH>9
Ammonicalnitrogen ‐
30000mg/l
1500 1500 lit Water
120kgSodium
Chloride
pH8‐9
TDS‐80000mg/l
2100 2100 lit Water
containing
Ammonia
pH>9
Ammonia‐70000mg/l
4 D‐2
1‐(3‐Chloropropyl)‐1‐Dihydro‐2‐H‐
Benzaimidazolonone
Stage‐1‐D2 1800 1800 lit/ Water
305kgSodium
Chloridesalts
+TracesofOrganic
Saltsof
Ortho Xylene
pH7‐8
COD‐20000mg/l
TDS‐200000mg/l
Sr
No
Product Quantityofliquideffluentinlit/batch
Contents of liquideffluent
EffluentCharacteristicsbasedonTheoreticalCOD
+
MethylAceto
Acetate
720 720 lit Water
293kg(Sodium
Chloride+NaBr
+traces ofAcetone)
pH7‐8
COD‐20000mg/l
TDS‐400000mg/l
5 Dompiridone‐(5
Chloro‐1(1‐C3‐
(20X0‐1‐
Benzimidazolinyl)Propyl)‐4Piperidyl)‐2‐
Benzimidazo)
1266 1266 lit Water
87kgSodaAsh
Salts
505kgAmmonium
ChlorideSalts
pH8‐9
AmmonicalNitrogen‐150000mg/l
TDS‐70000mg/l
6 4CAP
(4Chloro‐
2Aminophenol)
3665 3665 lit Water
400kgCaustic
pH‐>10
2000 2000 lit Water
265kgHCI+
TracesofOrganic
Compoundsof 4
Chloro2
Nitroohenol
pH‐Acidic
COD‐20000mg/l
Phenol‐50mg/l
7 Chlorzoxazone‐
2‐(SChloro‐3‐H‐
Benzooxazolonone)
1000 1000 kg effluent
mainly Ammonium
Chloride
pH>9
AmmonicalNitrogen‐
20000mg/l
Sr
No
Product Quantityofliquideffluentinlit/batch
Contents of liquideffluent
EffluentCharacteristicsbasedonTheoreticalCOD
8 2‐5DichloroPara
PhenyleneDiamine
SegregationofeffluentStreams:
Sr
NoProduct
Quantityof
liquideffluentinlit/batch
EffluentCharacteristicsbasedonTheoreticalCOD
EffluentquantityforMEE
EffluentquantityforairstrippingofAmmonia
EffluentquantitytoeffluentTreatmentPlant
11N‐Methyl‐4Piperidone[NMP]
1020
pH7‐8
COD‐200000mg/l
TDS–240000mg/l
1020 ‐ ‐
2N‐Methyl4ChloroPiperidone
650pH>8
TDS‐700000mg/l‐ ‐ 650
3
D‐7
[5‐Chloro‐1(4‐Piperdyl)2
Benzimidazalonone]
41stStage
N‐Carbethoxy225
pH>9
TDS‐768000mg/l
225 ‐ ‐
52ndstage.
D4‐(4AminoNCP)
6
3rdStage
D5‐
D5‐DiNitro(4‐(2‐Nitro‐5‐Chloroaniline)NCP
720pH6‐7
TDS‐125000mg/l‐ ‐ 720
7
4thStage
Amino(4‐(2‐Amino5Chloroaniline)
(NCP)
120pH6‐7
TDS‐538000mg/l 120 ‐ ‐
D‐7
(5CHLORO‐1(4‐Piperidyl)‐2‐
2400pH>9
Ammonicalnitrogen‐30000
‐ 2400 ‐
Benzaimidazolonone mg/l
1500pH8‐9
TDS‐80000mg/l ‐ ‐ 1500
2100
pH>9
Ammonia‐70000mg/l
‐ 2100 ‐
4
D‐2
1‐(3‐chloropropyl)‐1‐Dihydro‐2‐H‐Benzaimidazolonone
Stage‐1‐D2 1800
pH7‐8
COD‐20000mg/l
TDS‐200000mg/l
‐ ‐ 1800
720
pH7‐8
COD‐20000mg/l
TDS‐400000mg/l
‐ ‐ 720
5
Dompiridone‐(5Chloro‐1(1‐c3(2OXO‐1‐Benzimidazolinyl)propyl)‐4piperridyl)‐2‐benzimidazo)
1266
pH8‐9
AmmonicalNitrogen‐150000mg/l
TDS‐70000mg/l
‐ 1266 ‐
64CAP
(4 Chloro‐2aminophenol) 3665 pH>10 ‐ ‐ 3665
2000
pH‐Acidic
COD‐20000mg/l
Phenol‐50mg/l
‐ ‐ 2000
7 Chlorzoxazone‐2‐(5‐chloro‐3‐H‐
1000pH>9
AmmonicalNitrogen
‐ 1000 ‐
Benzooxazolonone) 20000mg/l
82‐5‐DichloroParaPhenyleneDiamine
TotalEffluentQuantity 1365 6766 11055
.
DescriptionofETPProcess
TheWastewaterfromtheprocesswillbedividedintothreestreams:
1) HighCODstream2) StreamwithhighAmmonicalNitrogen3) OtherEffluents‐LowCODStream(Biodegradable)
ThestreamwithhighCODwillbetreatedinMultiEffectEvaporatorfollowedbyATFD.
TheStreamwithhighAmmonicalNitrogenwillbepassedthroughAmmoniastripper.Thenitwillbeaddedwiththeothereffluentstream.
Theothereffluent(lowCODstream)Streamwillbegivencompletetreatmentasfollows:
Firstofall,theeffluentisgivenPrimarytreatment. Theeffluentwillbecollectedinacollectiontank. ThenitwillbepassedthroughOil&GreaseremovalTankfromwhereOilwill
becollectedinDrums. ThentheeffluentwillbegivenLime‐AlumtreatmentinNeutralizationcum
EqualizationTankwhichwillbefollowedbyPrimarySettlingTankforchemicalsludgeremoval.
Afterthis,BiologicaltreatmentwillbegivenbymeansofAerationTankwheremicrobeswillconsumetheCOD.
Thiswillbefollowedbysecondarysettlingtankwherebiologicalsludgewillberemoved.
NowthistreatedeffluentwillbecollectedinTreatedeffluentsumpfromitwillbegiventertiarytreatment.
ThetreatedeffluentwillbepassedthroughPressureSandFilterandActivatedCarbonFilterandcollectedinTreatedWaterSump.
Fromthere,thewaterwillbegivenpretreatmentforReverseOsmosisinformofUltrafiltration.
FinallythiswaterwillbetreatedbyReverseOsmosisplantintwostageandreusedinGardening,BoilerandCoolingTower.
ThehighTDSRejectwaterfromUltrafiltration&ReverseOsmosisPlantwillbesenttoMultiEffectEvaporatorfordistillation.HighConcentratedslurryfromMEEwilbefurthersolidifiedinATFD&disposedofftoCHWIS.
ETPProcess
4. Schematic representations of the feasibility drawing which give
informationofEIApurpose.
The acceptability of the S.O.1533 for the expansion project was explored byconsidering different possibilities & provision made in the said notification.Consideringtheproducts&project’slocationoftheproposedExpansionproject,It is notified that the proposed project falls under Category 5(f)”B” of thescheduleofEIAnotificationanditsamendments.
Aspertheprovisionsofthenotification,itisnecessarytogetEnvironmentalClearancebyapplyingtoMoEForSPCB,alongwiththeEnvironmentalImpactAssessmentreportfortheexpansionprojectpriortocommissioningoftheexpansionactivities.ThereforetheEIAisrequiredtoconduct.
4. SiteAnalysis
(i) Connectivity.
NearestRailway
stationMehasana 7Km
NearestAirport Mehasana 12Km
NearestStatehighway SH56 0.86Km
(ii) LandForm,LanduseandLandownership.
Fig:1Landusepattern
(iii) Topography(alongwithmap).
Fig:2LegendrymapofSurendranagardistrict
Project site
(iv) Existinglandusepattern.
Existinglandusepatternshowninfigno:1
(v) ExistingInfrastructure.
(1) Nearestrailwaystation:JagudanRailwaystationis0.66KminNWdirectionfromtheprojectsite
(2) NearestHighway:statehighway41is0.86kminWdirectionfromtheprojectsite.
(3) NearestAirport:Ahmedabadis53.5kminSSEdirectionfromtheprojectsite.(4) Power:105HPfromUttarGujaratVijCompanylimited.(5) Water:SourceofthewaterisGroundwater?DMwater(outsource)(6) Basicamenities:
Educationalfacility:‐ GujaratPolytechnicis0.42kminwestdirectionfromtheprojectsite.
Hotel:TheHolidayInnis4.0kmawayinSouthdirectionfromtheprojectsite.
PostOffice:‐Postoffice,Saylais1.2kmawayfromtheprojectsite.
Hospital:‐Saylais1.5kmawayfromtheprojectsite.
(vi) SoilclassificationofdistrictMahesana
DominantlytheSoilsareverydeep,welldrainedandfineandmediumtextured.They
areslightlyalkaline,slighttostrongsaline.SoildepthinUttarGujaratiswelldistributed
in two parts. The Soils in western side are dominantly very deep followed by
moderately deep and in eastern part soils are dominantly shallow followed by
moderately shallow. The Soils in Mehsana District is dominantly distributed to very
deepsoildepthclassfollowedbyshallowdepthmoderatelydeepsoilarealsoobserved,
Soil salinity in Uttar Gujarat varies from slight to strong salinity class. In Mehsana
Districtsoilsalinitybelongstoslighttomoderate.
(vii) Climaticdatafromsecondarysources.
MonthAirTemperature,°C Humidity,% MeanWind
Speed,
Km/hr.
Predominating
Wind
DirectionMax. Min. Max. Min.
July2013 37 22.2 98 48 7 SW
August2013 34.2 23.5 98 56 8 SW
September2013 38.4 23.3 100 40 7 NW
October2013 36 17.4 98 26 4 N
November2013 35.8 12.8 91 24 5 NE
December2013 32 8.3 97 23 5 N
January2014 30.7 7 96 20 7 NE
February2014 33.6 7.8 91 17 5 NE/NW
March2014 38.7 12.4 87 14 5 WNW
April2014 43.2 19.4 83 16 5 WNW
May2014 44.5 24.4 82 12 7 SW
June2014 45 27.5 81 22 11 SW
5. PlanningBrief
(i) PlanningConcept(typeofindustries,facilitiestransportationetc)Town
andCountryPlanning/DevelopmentauthorityClassification.
Total available area is6779 sq.meteroutof it 2873 sq.meter areawill be
providedasagreenbeltarea.
(ii) PopulationProjection
In 2011,Mahesana had population of 2,035,064 ofwhichmale and femalewere1,056,520 and978,544 respectively. In 2001 census,Mahesanahad apopulation of 1,837,892 of which males were 953,842 and remaining884,050werefemales.STherewaschangeof10.73percentinthepopulationcompared to population as per 2001. Average literacy rate ofMahesana in
2011 were 83.61 compared to 75.22 of 2001. If things are looked out atgender wise, male and female literacy were 91.39 and 75.32 respectively.With regards to Sex Ratio in Mahesana, it stood at 926 per 1000 malecomparedto2001censusfigureof927.
(iii) Landuseplanning(breakupalongwithgreenbeltetc).
1 BuiltUpArea 1960Sq.mt
2 Greenbeltarea 2873Sq.mt
3 Open/Roadarea 1946Sq.mt
TotalArea 6779Sq.mt
(iv) AssessmentofInfrastructureDemand(Physical&Social).
SuperSpecialtyandmodernhealth facilitiesandmedical storesareneeded
around.
(v) Amenities/Facilities.
Industrywillprovide2.5%oftotalprofitforCSRactivity.
6. ProposedInfrastructure
(i) IndustrialArea
Industrywillprovide3232squaremetersbuiltupareaforindustrialprocess
activity.Whichprovideall needed facility includingproperventilation, safe
handlingsystem,etc.
(ii) ResidentialArea
Industrywill notprovide laborquarter for their laborsbutwill provide all
basicfacilitiestothem.
(iii) GreenBelt.
5342 sq. meter area will be proposed for greenbelt development. Approx
3000sq.mtareawillbeproposedfortreecoverarea(approx400trees).
(iv) SocialInfrastructure.
ThePPproposesthefollowingsocial infrastructurefacilitieswithin10.0kmperipheryoftheproposedproject.
EducationFacilities:‐Many Facilities for village schools like game kits,drawing kits, table‐chairs; school construction (classroom/toilet/schoolboundary),ceilingfans/coolersorbooksforschoollibraryareproposed.
Health Facilities:‐The PP proposes to provide assistance to existing
healthfacilitiesinNearestHospital,forimprovementinhealthfacilitiesorservices.
(v) Connectivity
ThenearestTown isMehsana inN‐direction.Approachingroadstatehighway
no56is3.5kmawayfromtheprojectsite.
(vi) DrinkingWaterManagement
0.1 KL/DaywaterwillbeusedfordrinkingPurpose.Sourceofdrinkingwaterwillbeborewell.
(vii) SewerageSystem.
Domesticwastewater0.9KL/daywillbetreateddisposedinsoakpitviaseptic
Tank.
(viii) IndustrialWasteManagement.
14.24KL/daywastewaterwillbegeneratedfromtheprocessactivity.Itwill
betreatedineffluenttreatmentplantandmaintainZerodischarge.
(ix) SolidWasteManagement
Used oil, ETP waste & MEE Residue, discarded bags are the main solid
hazardouswastegeneratedfromtheproposedunit.Usedoilwillbesendto
registerrecycler,ETPsludge&MEEResiduewillcollectedfromsludgedrying
bed,storedintosolidwastestorageareaanddisposedtoauthorizedCHWIS.
Discarded bags will be sold to approve vendor. Spent carbon and Waste
residuewillbesenttoauthorizedCHWIFforIncineration.
(x) PowerRequirement&Supply/source
105HPfromUGVCL.
7. ProjectSchedule&CostEstimates
(i) Likelydateofstartofconstructionandlikelydateofcompletion
Startconstructionwork:1stweekofJune,2017
Completionofconstructionwork:September,2017
(ii) Estimatedprojectcostalongwithanalysisintermsofeconomicviabilityofthe
project.
TotalprojectcostofProjectisaround9crores.
