PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0_05_Aug_2015... · XI...

PRE-FEASIBILITY REPORT

(Synthetic Organic Chemicals, Cosmetics manufacturing unit and R&D facility)

of

M/s. Vivimed Labs Limited, Unit II, Sy. nos. 202, 207A, 207AA, 207E, 208A, 208AA, 208E,

208EE, 209, 217 Bonthapally (V), Jinnaram (M)

Medak District, Telangana

August 2015

i

Contents

S. No. Description

Page No.

1.0 Executive Summary 1

1.1 Salient Features of the Project 1

2.0 Introduction 3

2.1 Identification of the Project and project proponent 3

2.2 Brief description of Nature of the Project 4

2.3 Need for the Project and its importance to the country and or region 4

2.4 Demand and Supply Gap 4

2.5 Imports Vs. Indigenous production, Export Possibility, Domestic/Export Markets 5

2.6 Employment Generation due to the proposed expansion project 5

3.0 Project Description 5

3.1 Type of the project including interlinked an interdependent projects if any 5

3.2 Location 5

3.3 Alternate sites 6

3.4 Size or magnitude of operation 6

3.5 Project description with Process Details 8

3.6 Raw materials 8

3.7 Resources optimization / recycling and reuse 9

3.8 Availability of water and Energy 9

3.9 Quantity of Wastes Generation and their Management /Disposal 10

3.9.1 Water requirement and Wastewater Generation and their Management /Disposal

10

3.9.2 Hazardous / Solid Waste Generation, Handling and their Disposal 12

3.10 Schematic flow sheet for EIA procedure 14

4.0 Site Analysis 14

4.1 Connectivity 14

4.2 Land Form, Land use and Land ownership 14

4.3 Topography 14

4.4 Existing Land use pattern 14 4.5 Existing Infrastructure 15 4.6 Soil Classification 15 4.7 Climate data from Secondary sources 15

ii

4.8 Social Infrastructure 16 5.0 Planning 16

5.1 Planning Concept 16 5.2 Population Projection 16 5.3 Land use planning 16 5.4 Assessment of Infrastructure Demand 17 5.5 Amenities/Facilities 17

6.0 Proposed Infrastructure 17 6.1 Industrial Area 17 6.2 Residential Area 17 6.3 Green Belt 17 6.4 Social Infrastructure 17 6.5 Connectivity 18 6.6 Drinking Water management 18 6.7 Sewerage System 18

6.8 Industrial Waste Management 18

6.8.1 Process Emissions Management 18 6.8.2 Fugitive Emissions (Solvents management) 19 6.8.3 Emissions – Utilities 20 6.8.4 Noise Environment 20 6.9 Hazardous/ Solid Waste Management 21 6.10 Power Requirement & Supply / Source 21

7.0 Rehabilitation and Resettlement (R&R) Plan 21

8.0 Project Schedule & Cost Estimates 21 8.1 Time Schedule for the project construction 21 8.2 Estimated project cost 21

9.0 Analysis of proposal (Final Recommendations) 22

9.1 Budgetary allocation for Pollution Control Measures 22

iii

List of Tables

Table Title Page

1 Coordinates of all corners of the Project site 6

2 Permitted (Existing) Products and their Capacities 6

3 Proposed Products, their Capacity and Therapeutic Category 7-8

4 Existing Water Requirement, Wastewater Generation and its Treatment 10

5 Proposed Water Balance, Segregation and Treatment Method 11

6 Effluent Treatment Flow for as per Segregation 12

7 Hazardous Waste Generation from the Existing Products 13

8 Hazardous/ Solid Waste Generation from the Proposed Products 13

9 Environmental Components shortest distance from Project periphery 15

10 Break up of land use pattern 16

11 Maximum Quantity of Process Emission for Existing Products 18

12 Maximum Quantity of Process Emission for Proposed Products 19

13 Stack Emission Details – Proposed 20

14 Budgetary allocation for pollution Control Measures 23

iv

LIST of Annexures

Annexure No. Title Page

No. I Environmental Clearance Copy (2008) 24

II CFE-CPM for change of products (2009) 30

III Consent for Operation from TSPCB (2015) 36

IV General Location Map 44

V Specific Location Map (Route Map) 45

VI Google Map showing the Project Coordinates 46

VII Plant Layout 47

VIII Process Description and Flow Chart of the Proposed Products 48

IX List of Chemicals (raw materials) 110

X List of Hazardous Chemicals 138

XI Project site Ground Water Analysis Report 139

XII ETP Flow Diagram 140

XIII Schematic Flow Sheet for EIA Procedure 140-141

XIV Topography Map within 10 km radius 142

XV Soil Analysis Report 143

M/s Vivimed Labs Limited, Unit II Pre-Feasibility Report

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Pre-Feasibility Report for Expansion of Synthetic Organic Chemicals, Cosmetics

manufacturing unit and R&D Facility

1.0 Executive Summary

M/s. Vivimed Labs Limited, Unit II proposes to expand its Synthetic Organic Chemicals, Cosmetics

manufacturing unit and R&D facility in the existing premises with extended land of 6.51 Ha

(65154.38 sq.m). The Unit is located at Sy. No. 202, 207A, 207AA, 207E, 208A, 208AA, 208E,

208EE, 209 & 217, Notified Industrial Area, Bonthapally village, Jinnaram Mandal, Medak District,

Telangana State with a total investment of Rs.155.5 Crores including the existing investment of

Rs.14.85 Crores.

The proposed expansion project falls under the Category ‘A’, project or activity 5(f)

according to the EIA Notification 2006.

1.1 Salient Features of the Project:

• Proposing expansion in the existing area with extension of land from 3.64 Ha to 6.51 Ha.

• The proposed project is to manufacture 50 Synthetic Organic Chemicals, Cosmetics with a

production capacity of 8102 TPA (existing 108 TPA) from 22 regular & campaign basis i.e.,

12 (twelve) regular products of Group A, any 5 (five) products from Group B, any 5 (five)

products from Group C & R&D activity at a time.

• Total Greenbelt area is 2.55 Ha (39.27 %).

• Industry’s obtained Environmental Clearance for Existing activity vide order no. J-

11011/802/2007-IA II (I) dated 20-03-2008 in the name of M/s. Vivimed Labs Ltd (Annexure

– I).

• Industry obtaining regular consent renewals from APPCB, Now TSPCB and obtained CFE

for change of product mix with no increase in pollution load from APPCB vide order no.

386/PCB/CFE/RO-RCP-II/HO/2008-2076 dated 7-12-2009 (Annexure – II). Latest CFO was

issued by TSPCB vide order no. TSPCB/RCP/MDK2/386/HO/CFO/2015-743 dated 09-07-

2015 (Annexure – III).

• This proposed expansion project site is located at an aerial distance of

i. This proposed expansion project site is adjacent to Narsapur- Hyderabad State

Highway No. 6

ii. Bonthapally village at 0.8 km SW direction

iii. Jinnaram at 5.6 km in SSW

iv. Medak at 42 km in NNW

v. Sangareddy at 30 km (WSW)

vi. Shamshabad Airport, Hyderabad at 47 km in S


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vii. Hyderabad ORR at 9 km (SSW).

• Total cost of the expansion is Rs. 155.5 crores. Total capital cost allocated towards

environmental pollution control measures is Rs. 20 crores including existing investment of

Rs. 3.75 Crores. Recurring cost after expansion will be about Rs. 26.1 crores per annum.

• Total 550 employees including Existing project will be benef itted due to the proposed

expansion project. Out of which direct 250 and indirect 300 employees.

• Coal is about 85 TPD will be used in the proposed boilers for 10, 5 & 3 TPH, 2 nos. of 4 lac

K.cal/hr Thermic fluid Heater and existing 3 TPH coal fired boiler.

• Diesel of about 480 lit / hr will be used in the proposed 530 KVA, 2 nos. of 630 KVA, DG sets

and existing DG sets of 600 KVA.

• The proposed power requirement of the plant is 4000 KVA including existing 1500 KVA. DG

sets are used as standby during power failure.

• Industry will provide additional dual scrubbers based on t he characteristics of process

emissions. Economizer, multi-cyclone separator & bag filter for Boiler emissions will be

provided to reduce the particulate emissions into atmosphere.

• Total water requirement will be about 751 KLD of which fresh water requirement will be

396KLD and balance 355 KLD will be recycled water from ETP-ZLD. Fresh water will be met

from Groundwater supply through private tankers.

• The wastewater generated from the plant will be about 403 KLD from process, washing,

utilities, DM regeneration, Scrubber, Q.C, R&D and domestic wastewater.

• The effluent will be pumped to the above ground level R.C.C lined tanks for storage and

neutralization then sent to proposed upgraded ETP-ZLD of 500 KLD capacity within the

premises.

• Domestic wastewater will be sent to septic tank and the overflow to ETP - ZLD.

• Hazardous waste will be segregated and collected in the HDPE drums / bags as appropriate

and will continue to be stored in the covered and raised platform with provision of leachate

collection system.

• Solid waste like boiler ash will continue be sent to cement brick manufacturers.

• Compressors, Boilers and DG sets will be the major noise generating units in the plant. Out

of these, the generator will be functioning at the time of power failure. Acoustic enclosures

provided at each generator unit to minimize the noise levels. However the workers in this

area will be provided with ear muffs.


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Industry has uploaded Form-I along with draft Terms of Reference (ToR) in MoEF&CC

website, in the process of obtaining ToR for preparation of EIA, in line with issue of Environmental

Clearance. Hence, a technical pre-feasibility report highlighting the expansion project and t he

various operations including waste generation and mitigation measures are prepared & submitted

to the Environmental Appraisal Committee (EAC) for issuing ToR.

2.0 Introduction

2.1 Identification of the Project and Project Proponent

M/s. Vivimed Labs Limited is a world-leading organization (ISO9001:2008, ISO14001:2004,

OHAS 18001:2007 & SA 8000:2008 certified via TUV Nord) with a unique portfolio of products,

focused on Synthetic Organic Chemicals like Pharma, Personal Care and Colour Chemistry;

Manufacture and supply of speciality chemicals and active pharmaceutical ingredients. Vivimed

provides high performance products of quality and v alue to improve the lives of its clients'

consumers.

Vivimed is headquartered in Hyderabad, India, with five different functional manufacturing

centres in proximity to the central office hub. Vivimed has a new state-of-the-art R&D facility close

to the central office, and parallel R&D facilities in the UK, which also incorporates the European

office for finance, marketing and administration. Within this UK facility is the Company's dedicated

REACH compliance unit. A Sale and distribution hub in NE USA and a representative’s office in

Guangzhou, China completes the division profile. The Industry began as a small, entrepreneurial

family-operated business now provides a diverse portfolio of products to consumers across nearly

50 countries. Vivimed has Memberships & Associations with British Association for Chemical

Specialities, Cosmetic, Toiletry and Perfumery Association, American Cleaning Institute and

REACH Ready - subsidiary of the Chemical Industries Association.

Starting in the 90s, the Pharma Division of Vivimed is today seen as a preferred partner by

large global players in the areas of collaborative research, joint exploration of new markets and as

an efficient supply chain partner who can leverage globally benchmarked plants. The Specialty

Pharma division of Vivimed is a merged entity of VVS Pharma and C reative Healthcare. The

Specialty Pharma Division has its inherent strengths in drug delivery and drug discovery. The

division is focused on providing cures in oncology space, arthritis, syndrome X, macular

degeneration, psoriasis and stress.

Throughout the day, Vivimed brands touch the lives of people around the world. From the

active ingredients in your toothpaste, preservatives and moisturisers in face creams, UV filters in

sunscreens, through to the colorants in your hair and photochromic dyes in eyewear.


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The unit was established in the year 1985 located at Sy. No. 202, 207A, 207AA, 207E, 208A,

208AA, 208E, 208EE, 209, 217, Industrial Cluster, Bonthapally Village, Jinnaram Mandal,

Medak District of Telangana State. The location is at a distance of 27 Kms from Hyderabad.

M/s. Vivimed Labs Limited proposes to expand its Synthetic Organic Chemicals, Cosmetics

manufacturing unit and R&D facility in the existing premises with extended land of 6.51 Ha. (65154

sq.m). It is a Synthetic Organic Chemical industry under 5 (f) of EIA Notification 2006.

2.2 Brief Description of Nature of the Project

This is an expansion of existing Synthetic Organic Chemical & Cosmetics manufacturing

unit. The products manufactured are used as active ingredients in your toothpaste, preservatives

and moisturisers in face creams, UV filters in sunscreens, through to the colorants in your hair and

photochromic dyes in eyewear.

2.3 Need for the Project and its Importance to the Country and or Region

The Indian pharmaceutical industry valued at $16 bi llion has portrayed tremendous

progress with reference to infrastructure development, technology base creation and a wide range

of production. India ranks 4th worldwide accounting for 8 per cent of the world's production (in

terms of volume) and 1 3th in terms of value. It is estimated that by the year 2015, the Indian

pharmaceutical industry has the potential to achieve over Rs.2,00,000 Crore in formulations and

bulk drug production. The industry now produces bulk drugs belonging to all major therapeutic

groups requiring complicated manufacturing process and has also developed Good Manufacturing

Practices (GMP) facilities for the production of different dosage forms. The pharma industry

exports APIs and pharmaceuticals worth over $ 14.9 billion in 2013-14. It ranks 17th in terms of

export value of bulk activities and dosage. Indian exports cover more than 200 countries including

the highly regulated markets of USA, Europe, Japan and Australia.

At a growth rate of 7 per cent per year, the pharmaceutical industry in India is well set for

rapid expansion. As a result of the expansion, the Indian pharmaceutical and healthcare market is

undergoing a s purt of growth in its coverage, services, and s pending in the public and pr ivate

sectors.

2.4 Demand and Supply Gap

The products manufacture by the Project Proponent has demand from about 50 countries

like China, USA, Japan, Middle East, Latin American countries and other Asian countries etc. In

addition, the products are consumed in domestic market. It is reported that there is increase in the

consumption of these products by about 5-6% every year.


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2.5 Imports vs. Indigenous production, Export Possibility, Domestic/Export Markets

Presently China is dominating the market the world over. India is importing all major

speciality chemicals and intermediate chemicals required for manufacturing personal care,

cosmetic products etc. Most of our imports are from Chinese companies and thus we are losing

our valuable foreign reserves to China. As mentioned above, the imports have gone up from $ 2.9

billion in 2011 to about $ 4.6 billion in 2012 on account of APIs, Pharmaceuticals and Speciality

fine chemicals. During the same period the imports of formulations has also doubled. The

Chinese, American and European markets play a very vital role in the supply of these final

consumer products to our country. This clearly indicates that there is tremendous scope for

developing the indigenous products by reducing the imports and thus saving the foreign exchange

reserves of the country. This potential can be utilized to the fullest extent possible by increasing

the production capacity of the existing industries or by establishing new industries to meet the

market demand of the products.

As it is a well known fact that Indian products are well accepted abroad for its quality and

marketing flexibility. The exports from the Indian companies to other foreign countries such as

Europe, America, Japan and other African countries has been increasing from Rs.8007 in 2005 to

Rs.16565 Crores in 2009. This shows the acceptability of the products produced in India. The

formulations market has shown a t remendous increase in the exports from about Rs.9500 to

Rs.23700 Crores during the same period.

2.6 Employment Generation due to the Proposed Expansion Project

The expansion facility will generate direct and indirect employment to scores of local

people. About 550 employees (including existing 200 employees) will be benefitted due to the

proposed project. About 250 nos. will be direct and 300 nos. will be indirect employees.

3.0 Project Description

3.1 Type of the project including interlinked and interdependent projects, if any:

Proposed expansion project of Synthetic Organic Chemical & Cosmetics falls under

category ‘A’ as per EIA Notification 2006 under the item No. 5 (f). There are no interlinked projects.

3.2 Location: The Unit is located at Sy. No. 202, 207A, 207AA, 207E, 208A, 208AA, 208E,

208EE, 209, 217, Notified Industrial Area, Bonthapally, Jinnaram Mandal, Medak District,

Telangana State. Project site co-ordinates of all corners are presented in Table 1. The study area

represents Rural Environment.


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Table 1: Co-ordinates of all corners of the Project site

Sl. No. Latitude Longitude Sl.

No. Latitude Longitude

1 17°40'5"N 78°22'21"E 9 17°40'0"N 78°22'33"E 2 17°40'3"N 78°22'28"E 10 17°40'0"N 78°22'29"E 3 17°40'5"N 78°22'29"E 11 17°40'0"N 78°22'29"E 4 17°40'5"N 78°22'30"E 12 17°39'58"N 78°22'27"E 5 17°40'5"N 78°22'36"E 13 17°39'58N 78°22'24"E 6 17°40'2"N 78°22'36"E 14 17°40'0"N 78°22'24"E 7 17°40'0"N 78°22'36"E 15 17°40'0"N 78°22'21"E

8 17°39'59"N 78°22'33"E

The map showing general location, specific location, Google map showing the Co-

ordinates and Plant layout of the project showing existing and proposed facilities are presented at

Annexures IV, V, VI, and VII respectively.

3.3 Alternate Sites

This proposed expansion project is in the existing and extended plant area at Notified

Industrial Area, Bonthapally village. Hence Alternate sites are not considered for the present

expansion project.

3.4 Size or Magnitude of Operation

Project Area: 6.51 Ha. (incl the existing)

Production Capacity: 8102 TPA from 22 out 50 products of Synthetic Organic Chemicals &

Cosmetics and R&D activity i.e., 12 (twelve) regular products of Group –A, any 5 (five) products

from Group –B and any 5 (five) products from Group –C on campaign basis.

The permitted and pr oposed products with its production capacities are presented in

Tables 2 & 3 respectively.

Table 2: Permitted (Existing) Products and their Capacities

SI. No Products Quantity (Kg/day)

Quantity (TPA)

Group-A 1. 2 -Hydroxy- 4- Methoxy Benzophenone 100 36 2 Avobenzone 150 54

3 2 - Hydroxy- 4 - Methoxy- 5 - Sulfonic Acid Benzophenone

150 54

Total (any 2 products at a time) 300 108


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Table 3: Proposed Products, their Capacity and Therapeutic Category

SI. No. Product Quantity

(Kg/day) Quantity

(TPA) Group A (Regular)

1 Avobenzone (AVIS) 2666.7 960 2 Chlorphenesin (Cosvat) 200 72 3 4-n-Butylresorcinol (Vivinol) 5 1.8 4 2-Ethylhexyl 4-(dimethylamino) benzoate (Padimate-O) 300 108 5 Trisodium ascorbyl-2-Phosphate (C-Vite) 200 72 6 Benzethonium Chloride (BZC) 66.7 24 7 Phenylbenzimidazole Sulfonic acid (PBSA) 166.7 60

8 1,3,5-Para Amino-2-ethylhexyl benzoate-2,4,6-triazine (Etone)

500

180

9 Piroctone Olamine (Dandoff) 666.7 240 10 Zinc Pyrithione (Dantuff-Z 48% / 38%) 8333.3 3000 11

2-Hydroxy propyl-3-trimethyl ammonium chloride Guar (Star Cat)

833.3

300

12 Silver Oxide - DTPA Complex (Viv Ag) 5000 1800 Group B (Campaign) 13 Vivtroze-H 333.3 120 14 Tinosarb M (Vivzole-M) 1000 360 15 Tinosarb-S (Vivtriaz-S) 666.7 240 16 Pyrrolidinyl diamino pyrimidine-N-oxide (Vividine) 3.3 1.2 17 Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (9-OXO) 33.3 12 18 Vintox 10 3.6 19 Menthyl Lactate (Vivfresh) 833.3 300 20 Ammonium Dinitrosalicylic acid (ADNSA) 13.3 4.8 21 2,6-Di-tert-butyl-5-hydroxybenzyl alcohol (DTBTBA) 6.7 2.4 22 Suntech 33.3 12 23 Trichlorocarbanilide (Vivilide) 333.3 120

Group C (Campaign) 24 3-Nitro-4-(2-hydroxyethyl) amino phenol (NHEAP) 6.7 2.4 25 4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (BHP) 100 36 26 Nitroblue (Blue 12) 8.3 3

27 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Jade Blue / Blue 15)

1.7 0.6

28 Methylamino dimethylamino Propylamino Propylbromide anthraquinone (BQB / Blue 16) 6.7 2.4

29 2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2)

13.3

4.8

30 2,4-Diamino phenoxyethanol Dihydrochloride (DPE HCl) 33.3 12 31 4-Hydroxyethylamino-3-nitro toluene (HNT) 3.3 1.2 32 2,4-Diamino phenoxyethanol Sulfate (DPE Sulfate) 16.7 6 33 2,4,5,6-Tetraaminopyrimidine Sulfate (TAPS) 3.3 1.2 34 Yellow-2 3.3 1.2 35 Straw Yellow 6.7 2.4 36 1-Acetoxy-2-methyl naphthalene (AMN) 3.3 1.2 37 2-Methoxymethyl-1,4-benzenediamine (MBB) 100 36 38 Madder Red 16.7 6.0 39 3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (Red BN) 16.7 6.0 40 5-Nitrobenzimidazole (5NBI) 16.7 6.0 41 1-Phenyl-3-Pyrazolidone (PHN) 66.7 24


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42 1-Phenyl-4-methyl-3-pyrazolidone (MPP) 66.7 24

43 4-(Hydroxymethyl)-4-methyl-1-phenyl pyrazolidin-3-one (HMP)

66.7

24

44 4,4-Dimethyl-1-phenyl pyrazolidin-3-one (DPP) 20.3 7.3 45 2-Methyl-5-hydroxyethylamino phenol (2M5HEAP) 16.7 6 46 1,2,4-Trihydroxybenzene (1,2,4 THB) 10 3.6 47 Platinum Gray 1.7 0.6 48 Volcanic Gray 3.3 1.2 49 Fountain Blue 1.7 0.6 50 Octenidine Dihydrochloride (Viv OCT) 16.7 6.0

R&D facility 1 R&D 0.5 0.18

Total : 50 products, 22 Products at a time on Regular and campaign basis 12 products of Group A : 6817.8 TPA 5 products from Group B : 1140 TPA 5 products from Group C : 144 TPA R&D : 0.18 ~ 0.2 TPA Total 8102 TPA from 22 products & R&D.

22505 8102

3.5 Project Description with Process Details

The manufacturing process of Synthetic Organic Chemicals and C osmetics consists of

chemical synthesis and multiple stages of processing extending to maximum of 10 stages

involving different types of chemical reactions. The entire process operations are operated by

various technical, skilled and uns killed persons with due c are to be m et various standards

prescribed by authorities.

Technology for manufacturing the products listed under proposed expansion is available

from in-house R&D & private consultants and proposes to adopt new technologies and techniques

that are continuously refined in every stage of manufacturing to meet global standards. Industry

will implement the proven technologies in the R&D for the cost effective & environment friendly

practices. Process description and flow chart of 50 products are presented at Annexure – VIII.

3.6 Raw Materials

The raw materials required for the manufacture of proposed products are the

chemicals/solvents and the fuel. The chemicals required for the process are mostly bought from

the local (indigenous) markets. Some of these raw materials will be imported from various

countries. Mode of transportation of all raw materials and finished products from the project site is

by road to local markets then by road / rail / air / sea based on the destination. Coal consumption

will be 85 TPD for the Boilers & TFH. Diesel of about 480 lit/hr will be used at full operation load in

the proposed & Existing DG sets. DG sets are used as standby during power failure. Total

proposed power requirement of the plant is 4000 KVA including existing 1500 KVA. The chemicals

(raw materials) required for the manufacture of proposed products are presented at Annexure–IX

and Hazardous chemicals list is presented at Annexure – X.


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3.7 Resources Optimization / Recycling and Reuse

All efforts will be made by the industry to carryout R&D on the wastes to recycle / reuse

wherever possible. However, R&D is a continuous process, where improvements in the processes

adopted by the industry, waste minimization etc. will be worked out as the project progresses.

Following are some of the recycle options proposed by the industry.

Industry proposes Zero liquid discharge plant to reuse all treated effluents as makeup

water for utilities like Cooling Tower and Boiler. This will reduce the fresh water

consumption.

Industry proposing dedicated reactors for few products thereby reducing the reactor

washings.

All solvents are recovered to the extent possible and reused in the process.

R&D is a continuous process to recover by-product from Inorganic / Forced Evaporation

Salts which will be sent to TSDF, Dundigal, RR District

Organic residue and spent carbon will be sent to Authorized Cement industries to burn in

Cement Kiln as an alternate fuel.

Waste / Used oil will be sent to Authorized Waste / Used oil Reprocessing units.

Container & container liners of hazardous chemicals, Polythene / HDPE Bags, broken

plastic drums shall be disposed of to outside agencies after complete detoxification

Boiler ash will be sent to Cement Brick manufacturing units.

Optimum utilization of solar energy.

Recycling and reuse of by-products generated during the process, solvents etc. will also be

planned properly thereby implementing the clean manufacturing techniques. There is tremendous

potential for implementation of clean technologies, recovery and reuse techniques in this proposed

products unit which will be explored and implemented after R&D process.

3.8 Availability of Water and Energy

Total water requirement is 751 K LD out of which Fresh water requirement is about 396

KLD which will be m et from Groundwater supply through private tankers. Characteristics of

Ground water are enclosed at Annexure–XI.

The proposed power requirement of the plant is 4000 KVA including existing 1500 KVA,

which will be m et from Telangana State Central Power Distribution Corporation limited

(TSCPDCL). Coal and Diesel will be procured from the distribution sources closer to the project

site.


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3.9 Quantity of Wastes Generation and their Management /Disposal

3.9.1 Water requirement and Wastewater Generation and their Management / Disposal

The permitted and p roposed water requirement and wastewater generation and i ts

proposed treatment is presented in Tables 4 & 5 respectively. The sources of wastewater

generation are from the process, floor & reactor washes, utilities, Q.C, R&D, scrubber and plant

domestic waste. Total proposed wastewater will be 403 KLD, which will be segregated into

HTDS/HCOD & LTDS/LCOD and collected by gravity into a c ollection tank separately. This

individual effluent will be pumped to the above ground level R.C.C lined tanks for storage and

neutralization then sent to ETP-ZLD. The effluents segregated quantity, characteristics and

treatment flow is briefly presented in Table 6.

Table 4: Existing Water Requirement, Wastewater Generation and its Treatment

Description Water

Requirement (KLD)

Wastewater Generation

in KLD Treatment Method

HTDS Effluents Process and

Washings

3.18

2.52

• Shall be stripped off for organics recovery.

• Stripper condensate to distillate for separation of organic compounds followed by disposal to cement plants for co-processing & distilled effluents shall be routed to CETP.

• Stripped effluents for forced evaporation in MEE followed by ATFD.

• Condensate from MEE & ATFD shall be routed to CETP.

• Salts to TSDF. LTDS Effluents

• PETL, Patancheru along with the condensate of MEE, after pre- treatment.

Washings 0.27 Boiler & Cooling Towers (make up)

14 0.6

DM Plant 0.1 0.1 Domestic effluents 0.8 0.8

Gardening 5.0 0 Total 23.08 4.29


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Table 5: Proposed Water Balance, Segregation and Treatment Method

Description

Input (KLD) Output (KLD)

Fresh Water

Recycled Water

Evaporation / Handling

Loss

Total Wastewater

Segregation type of Wastewater

Process (22 Products at a time)

235 -- 4 231 (267 Tons)

HCOD/HTDS

Washings (reactors (86), centrifuges (20), nutch filters, driers, blenders (30), containers, floor moping, etc.)

32 -- -- 32 LCOD/LTDS

Boiler (Proposed 10, 5, 3 TPH; Existing 3 TPH)

35 115 83 17 (Blow down) LTDS/LCOD

(30% make up)

50 (steam

condensate in MEE)

Cooling Tower 4000TR

- 240 220 20 (Bleed)

LTDS/LCOD

DM Regeneration 6 -- -- 6

Scrubber (10 Nos.) 20 -- -- 20 HTDS / LCOD

Q.C and R&D 5 -- -- 5 LTDS/LCOD Domestic (550 nos at 50 lpcd)

28 -- 6 22 LTDS/LCOD

Gardening (6.32 acres @ 5 kl/acre)

35 -- 35 0 --

Total

396 355 348 403

Stripper condensate 3 KLD; Moisture in salt and ETP sludge is 5 KLD, Water loss in ETP 40 KLD (Total water loss is 48 KLD = 12 %)

751 751

Note: 231 KLD is 267 Tons consists of 231 KLD liquid and 36 Tons of salts as per material balance.


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Table 6: Effluent Treatment Flow Chart as per segregation

Effluent Type Treatment Flow

Process, DM & Scrubber Qty.: 257 KLD HTDS/COD HTDS > 5000 mg/l HCOD > 5000 mg/l

Collection Equalization Neutralization Settling Holding tank Steam stripper MEE along with Scrubber & DM effluent MEE Condensate to ETP MEE Concentrate to ATFD ATFD Condensate to ETP. Salts to TSDF. Stripped solvents to SPCB authorized cement industries

Washings, Boiler, Cooling Tower, QC & R&D LTDS/LCOD Qty.: 124 KLD LTDS < 5000 mg/l LCOD < 5000 mg/

Collection Equalization Neutralization Settling Holding tank Biological treatment along with Domestic (overflow from septic tank) Dual Sand filter Activated carbon filter R.O. system Permeate to Utilities. R.O rejects Forced evaporation condensate to utilities. Salts to TSDF.

Domestic Qty.: 22 KLD

Septic tank overflow sent to ETP along with LTDS / LCOD Effluent

Existing treatment system will be enhanced to meet the proposed effluent quantities and

proposed ETP facility is enclosed as Annexure-XII. All the proposed treatment additional tanks

will be constructed / installed above the ground with water proof lining. This individual effluent will

be pumped to the R.C.C lined tanks for storage and neutralization then sent to upgraded ETP-ZLD

of 500 KLD capacity within the premises.

ETP – ZLD facility with primary (equalization and neutralization), secondary (stripper with

MEE, ATFD & biological) and t ertiary treatment (PSF, ACF & R.O) will be pr ovided. D omestic

wastewater will be sent to septic tank and the overflow to ETP (biological treatment). Concentrate

from MEE system will be sent to ATFD and the salts from the evaporation system will be collected

and sent to TSDF, Dundigal for safe disposal.

3.9.2 Hazardous / Solid Waste Generation, Handling and their Disposal

Hazardous /Solid waste will be segregated, detoxified and collected in the HDPE drums /

bags and will be stored in the covered and raised platform with Leachate collection system. The

existing, proposed solid waste with other waste generated, handling and disposal method from the

various stages of Synthetic Organic Chemicals & Cosmetics manufacturing plant is presented in

the Tables 7 & 8 respectively. Spillages such as wastewater / solid wastes / raw materials are

possible and the risk of this would be limited to within the premises of the manufacturing facility. A

precautionary measure like spillage control management is practiced in the industry.


13

Table 7: Hazardous Waste Generation from the Existing Products

Sl. No.

Name of the Hazardous Waste

Quantity of Waste (TPA)

Disposal Option

Hazardous Wastes with disposal option

1. Inorganic/ Forced Evaporation Salts 15.84 TSDF, Dundigal, Rangareddy District.

2. Process residues & wastes 38.52

Authorized cement plants for co- processing/TSDF, Dundigal, Rangareddy District for incineration.

Hazardous Wastes with Recycling Option 1. Waste Oil 120 LPA Authorized Reprocessors/ Recyclers.

2.

Container & container liners of hazardous chemicals & hazardous wastes

600 Nos/A After complete detoxification it shall be disposed of to outside agencies. 3. Polythene /HDPE Bags 360

4. Paper bags, broken plastic drums 360

Table 8: Hazardous / Solid Waste Generation from the Proposed Products

Sl. No. Source

Proposed Quantity

(TPD)

Handling Method Disposal

1 Organic residue 8.2 HDPE Drums

Sent to TSPCB

Authorized Cement industries / TSDF

2 Spent carbon 1.02

3 Distillation residue (1% of spent solvents)

0.2

4 Inorganic & Evaporation salt (Process)

37.05 HDPE Drums

Sent to TSPCB

Authorized Cement industries / TSDF 5 Evaporation salt

(Non-Process) 0.2

6 ETP Sludge 0.4

7 Boiler Ash 34 Stored in covered

area

Sold to Cement Brick Manufacturers

Other Hazardous Waste generation from the Plant

8

Detoxified Container / Liners drums, HDPE Carboys, Fiber Drums,

1000 Nos./ month Designate

d covered area

Disposed to TSPCB Authorized agencies

after complete detoxification

9 PP Bags 200 Kg/month

10 Spent solvents (with moisture) (solvents 139+water 6)

145 KLD Stored in Drums / Tanks

Sent to Inhouse Solvent Recovery

System 11 Recovered 125 KLD Tanks/ Reuse in process /


14

Solvents from spent solvents

Drums Authorized Recyclers

12

Spent Mixed solvents (from SRS & ETP) (14 + 3)

17 KLD Stored in Drums / Tanks

Sent to TSPCB Authorized Recyclers /

Cement industries

13 Waste oils & Grease 2 KL/A Stored in

Drums

Sent to TSPCB Authorized agencies

for reprocessing / recycling.

14 Used Lead acid Batteries

100 Nos. / annum

Designated covered

area

Sent to suppliers on buy-back basis.

15 Misc. Waste (spill control waste)

24 TPA Stored in Drums TSDF

16 Spent catalyst 0.1 TPD Stored in Drums

Sent to suppliers on buy back basis

** Solid waste quantities maximum on various combinations i.e., maximum 22 on Regular and campaign products at a point of time with R&D activity.

3.10 Schematic Flow Sheet for EIA Procedure

The schematic flow sheet for EIA procedure is depicted as Annexure -.XIII.

4.0 Site Analysis

4.1 Connectivity

This proposed expansion project site is adjacent to Narsapur- Hyderabad state highway

(No. 06) and about 0.8 km from Bonthapally village (SW); 5.6 km from Jinnaram (SSW); 42 km

from Medak (NNW); about 30 k m from District headquarters Sangareddy (WSW), about 47 km

from Shamshabad Airport Hyderabad (S); about 9 km from Hyderabad ORR (SSE).

4.2 Land Form, Land use and Land Ownership

The proposed expansion is in the existing and extended land located in Notified Industrial

Area, Bonthapally. Total land is 6.51 Ha. Plain land and is in possession of Project Proponent.

4.3 Topography

The Topography map with a 10 km radius is enclosed as Annexure-XIV.

4.4 Existing Land Use Pattern

The existing and proposed land use pattern of project area (core area) 6.51 Ha is Industrial

land and shortest distance environmental components in buffer area from the project periphery is

given in Table 9.


15

Table 9: Environmental Components shortest distance from Project periphery

Environmental Component

Distance (Direction w.r.t site)

Water bodies Ponds are located morethan 0.5 km

Forest

No high quality or scarce resources are present in the buffer zone. Following Reserved forest blocks are present such as • Narsapur R.F (Dense Mixed Jungle) >2.5 Km (W), • Nawabpet R.F (Fairly Dense Scrub) >9Km (NE)& • Kunkunta R.F (Dense Scrub) >8 Km (NE) • Wailal RF (Dense Mixed Jungle) >6 km (S) • Pottagadda RF (Dense Mixed Jungle) > 7.5 km (SW) • Kazipally RF (Dense Scrub) > 8 km (S) • Dundigal RF (Dense scrub) > 8 km (S)

National Park Nil Wild life sanctuary Nil Eco sensitive areas Nil Agricultural land 0.40 km (WSW) Industries All sides except in W direction Habitation 0.1 km Shapurnagar (SW)

4.5 Existing Infrastructure

Internal CC roads, Transportation facilities, Conference halls, Auditorium, Private Tanker

water supply, In-house ETP facility, Power supply, Primary Health Centre, Near by Ambulance,

Fire station, Telecommunication facility, etc., are available.

4.6 Soil Classification

The soil in the project site and in the study area is mostly brown in colour with sandy and

silty loam texture containing 38.13% sand, 36.28% silt and 25.59% clay. The soil analysis report of

the project site is enclosed at Annexure-XV.

4.7 Climate Data from Secondary Sources

The area enjoys pleasant, warm and dry climate. The coldest season is during December

and January, where the temperature touch a minimum of 13.6-15.8°C and w armest period is

during the month of April to May when the Mercury shoots up to 43 – 44.2°C.

The area experiences the maximum rainfall during the months of July to October and a

little rainfall during November and December due to North-East monsoon. Apart from these,

occasional rainfall is obtained from cyclonic storms and dep ression originating in the Bay of

Bengal. The normal annual rainfall of the area is around 951.7 mm. The rainfall is erratic and long

period of dry spells leading to drought conditions are frequent and periodic.


16

4.8 Social Infrastructure

Adjacent State Highway (6), Road network, Transportation facilities, Private water supply,

Power supply, Fire station, Hospitals, Telecommunication facility, Schools, Community centers,

etc., are available at Jinnaram (mandal headquarters) located at a distance of 5.6 km (aerial

distance) and also available in nearby villages.

5.0 Planning

5.1 Planning Concept

Type of Industry: Synthetic Organic Chemicals & Cosmetics manufacturing industry with R&D

facility.

Facilities: Industry proposed for expansion at existing and extended premises and Facilities

required for the project will be provided as per requirement.

Transportation: Existing industry well connected to Road, Rail and Airways. State Highway 6 is

adjacent.

Town and Country Planning Classification: This is private land, converted to industrial use and

is in possession of project proponent.

5.2 Population Projection

There is a s cope for increase in the population from the proposed expansion project.

Skilled workers prefer to stay in the nearby locations to avoid travelling from long distances. Local

Non-technical villagers will be pr eferred for the unskilled jobs such as gardening, movement of

materials, etc. Local / Non local Educated youth will be em ployed as semi-skilled workers and

training will be provided. Hence, there is a possibility of increase in population of the skilled and

semi-skilled. However, on the whole there is a possibility of little increase in population of the area.

5.3 Land use Planning

The expansion unit has been proposed in existing area of about 6.51 Ha i.e., 65154.38

sq.m. The Land use pattern of the proposed expansion is presented in Table 10.

Table 10: Break up of land use pattern

S. No. Description

Existing Area Additional Area Total Area

(SQ.M)

Percent (%)

(SQ.M)

Percent (%)

(SQ.M)

Percent (%)

1. Built-up area 10494.1 28.8 5327.3 18.54 15821.4 24.28 2. Roads 8738.85 24.0 2676.75 9.32 11415.6 17.52 3. Greenbelt 15150.5 41.6 10430.6 36.30 25581.1 39.27 4. Open Area 2038.25 5.60 10298.03 35.84 12336.28 18.93

Total 36421.7 100 28732.68 100 65154.38 100


17

5.4 Assessment of Infrastructure Demand

On assessment of infrastructure demand near the project area, Hospital with Ambulance facility

and Fire station is requirement for the nearby villages of project area. Project site located in

Notified Industrial area, Bonthapally in Medak District and is near to the state capital Hyderabad.

Required infrastructure is available in Hyderabad.

5.5 Amenities/Facilities

Industry will continue to provide and upgrade the following amenities / facilities in the

proposed expansion project.

• Canteen • Potable drinking water • Training block • Laying of Black top / Concrete internal roads • Fire hydrant facility • Eye/body wash showers • First Aid kits at all prominent places. • Head nurse for emergency medication. • Rest Room for employees • Seating facilities for those employees who do their work standing and ergonomically

designed seating facilities for those who do their work seating • Pre-employment and routine medical examinations and the necessary follow up actions • Communication systems like Phone, Internet with safety measures, etc. • Security system at the entrance etc.

6.0 Proposed Infrastructure

6.1 Industrial Area

Additional Production Blocks, Administration facilities, Utilities area, ETP area has been

proposed in the existing and extended area of 6.51 Ha.

6.2 Residential Area

There will be no residential area within the project site.

6.3 Greenbelt

The expansion unit has been proposed in existing with extension area about 6.51 Ha i.e.,

65154 sq.m. Out of which about 25581 sq.m for Greenbelt area which is equivalent to 39.27 % of

the total area.

6.4 Social Infrastructure

As a C orporate / Entrepreneur Social Responsibility (ESR), Industry will continue to

contribute for development of village social infrastructure.


18

6.5 Connectivity

There is no change in connectivity compare to existing facility and the State Highway 6 is

adjacent.

6.6 Drinking Water Management

Potable drinking water will be provided to additional employees. The source of drinking

water is Groundwater.

6.7 Sewerage System

Sewage will be generated from the Canteen and Toilets, which will be collected into

sewage collection tank through pipelines and septic tank respectively. Overflow of septic tanks will

be sent to Biological treatment of ETP–ZLD system which needs to be upgraded to meet the

expansion project demand.

6.8 Industrial Waste Management

Existing storage system needs to be enhancing to meet the expansion project demand.

The management of these wastes is to be h andled very sensitively and by adopting proper

segregation techniques.

Liquid Waste Management: The liquid wastes from the various industrial activities will continue to

be segregated and send to upgraded ETP-ZLD.

6.8.1 Process Emissions Management

Manufacturing of Synthetic Organic Chemicals & Cosmetics will result in gaseous

emissions. Maximum Process emissions from regular and campaign basis for existing and

proposed products are given in Table 11 & 12 respectively. Proposed gaseous emissions will be

scrubbed in two stages with water and caustic solution based on the characteristics of gases.

Table 11: Maximum Quantity of Process Emissions from Existing Products

Sl. No.

Process Emission

Maximum Quantity on various combinations

(kg/day) Treatment Method

1. CO2 12.16 • Dispersed into Atmosphere


19

Table 12: Maximum Quantity of Process Emissions from Proposed Products

Sl. No.

Process Emission

Maximum Quantity on various combinations

(kg/day) Treatment Method

1. HCl 529.9 • Scrubbed by using water & CS lye solution

2. NH3 562.66 • Scrubbed by using Chilled water

3. SO2 66.75 • Scrubbed by using CS lye solution

4. H2 10.47 • Diffused with Flame Arrestor

5. n-Butane 2.18 • Diffused with Flame Arrestor

6. O2 1676.5 • Dispersed into Atmosphere

7. CO2 1900.9 • Dispersed into Atmosphere

6.8.2 Fugitive emissions Management (Solvents management):

Solvents used in the manufacturing process will be stored in drums and bulk quantities will

be stored in above storage tanks with all safety measures.

Solvents are handled in closed conditions thereby reducing the losses in the form of

evaporation.

Proper earthing will be provided to all the electrical equipment and the joints / connections

wherever solvent handling is done.

Reactor and solvent handling pump will have mechanical seals to prevent leakage.

Reactor will be connected to chilled brine condenser system. Condensers will be provided

with sufficient Heat Transfer Area (HTA) and residence time so as to achieve maximum

recovery

Chilled brine circulation will be c arried out to condensate the solvent vapor and t o the

receivers of the solvent vapors which ensures the maximum recovery.

The industry will take measures for reduction of fugitive emissions and f urther reduction

industry will be provided vent condensers to the tanks.

Solvent vapours from the Centrifuge and Catch pots will be connect to vent condensers.

The height of the solvent receiver tank vent is above production block roof level and the

diameter is 20 mm.

Flame proof fitting / equipments / pumps / lighting will continue to be us ed wherever solvents are used. The solvent storage tanks will be provided with breather valve to prevent losses.

Solvent Input

Solvent consumption

in Process

Solvent Loss in Effluent

Solvent Loss in

Org. residue

Solvent Loss

(Handling)

Solvent Recovery

Solvent Recovery

(KLD) (KLD) (KLD) (KLD) KLD / (%) (KLD) (%) 151 1.3 1.2 1.6 7.8 / (5.1%) 139.1 92.1


20

6.8.3 Emissions–Utilities

Boilers and DG sets are the two main sources contributing to emissions from the plant.

Proposed coal fired boilers of 10, 5 & 3 TPH and 2 n os. of 4 Lac K.Cal/hr Thermic Fluid Heater in

addition to the existing 3 TPH boiler.

Diesel about 478 lit / hr will be used at full operation load in the Proposed DG sets of 530

KVA, 2 x 630 KVA and existing DG sets of 600 KVA. These will be used as standby during power

failure.The emissions from the utilities are given in Table 13.

Table 13: Stack Emission Details – Proposed

Source Stack Height

(m)

Diameter (m)

Temperature ( oC)

Flue Gas Flow rate

(m3/hr)

Exit Gas Velocity (m/sec)

PM SO2 NOx

kg/hr

Coal Fired Boilers 10 TPH 40 0.8 150 21960 12.14 1.494 14.94 10.44 5 TPH 30 0.6 150 13100 12.88 0.747 7.47 5.22 3 TPH 30 0.5 150 8820 12.50 0.448 4.482 3.132

Coal Fired Thermic Fluid Heater (TFH)

4 Lac K. cal/hr 30 0.15 150 530 8.32 0.104 1.045 0.730

Diesel Generator (DG) sets 530 KVA 9 0.1 150 2990 11.76 0.033 0.663 0.711 630 KVA 9 0.1 150 3560 13.98 0.039 0.788 0.845

The various measures proposed to minimize the pollution from the boiler are as follows:

Multi-cyclone separator followed by Bag filter will be installed to control the particulate (PM)

emissions within statutory limit of 115 mg/Nm3. To facilitate wider dispersion of pollutants,

30m height stack each will be installed.

The NOx emissions from the boilers will be controlled by controlling combustion measures,

which will be approached by way of low NOx burners or by air stagging in boiler. The NOx

emissions will be restricted to below 500 mg/Nm3.

Stacks will be provided to proposed D.G sets as per CPCB / SPCB Guidelines.

Fugitive dust will be controlled by adopting dust extraction and dust suppression measures

and development of greenbelt along the periphery of the proposed Boiler area.

6.8.4 Noise Environment

• Compressors, Boilers and DG sets will be the major noise generating units in the plant.

• The noise levels of the DG sets will be well within the limits as these will be installed with

acoustic enclosures. Workers will always be provided with ear muffs.


21

• All the equipment in the plant would be designed to have a total noise level not exceeding

85-90 dB(A) as per the requirement of OSHA (Occupational Safety and Health

Administration) standards.

6.9 Hazardous / Solid Waste Management

• Solid waste mainly segregated into process organic residues, inorganic salts, boiler ash

spent mixed unrecoverable solvents and spent carbon.

• The organic residues, Spent carbon & Spent mixed unrecoverable solvents can be

disposed off to Cement plants as recommended by CPCB for use as alternate fuels either

in the solid or liquid form.

• Boiler ash will be sold to brick manufacturers.

• Inorganic salts are to be sent for landfill at HWMP – TSDF.

Solid waste will be segregated, stored and disposed as mentioned in the Table 8.

6.10 Power Requirement & Supply / Source

The proposed power requirement of the plant is 4000 KVA including existing 1500 KVA.

Proposed DG sets of 530 KVA, 2 x 630 KVA in addition to the existing DG sets of 600 KVA will be

used as alternate arrangement in case of power failure.

7.0 Rehabilitation and Resettlement (R&R) Plan

The proposed additional land is plain land and is in possession of project proponent.

Therefore Rehabilitation and Resettlement plan is not applicable to this expansion project site.

8.0 Project Schedule & Cost Estimates

8.1 Time Schedule for the project construction

The timelines for commencement of proposed construction activity will be from June 2016

as it is expected that the expansion project will be in a position to obtain Environmental Clearance

& Consent for Establishment for the project. In 2016-17 the commercial production is expected to

be commenced.

8.2 Estimated Project Cost

Overall estimated cost involved in the total project (existing and p roposed) like land,

building, plant & machinery is Rs. 155.5 Crores. Total capital cost allocated towards environmental

pollution control measures is Rs. 20 Crores and the Recurring cost will be about Rs. 26.1 Crores

per annum.


22

9.0 Analysis of proposal (Final Recommendations)

• The proposed expansion project will result in growth of surrounding area by generating direct

and indirect employment to local people. Around 550 members will be benefitted due to the

expansion project (incl. existing 200 nos.).

• Under the Corporate Social Responsibility the Industry will continue to develop a pol icy of

developing the villages in the vicinity by identifying the requirements.

• No adverse effect on environment is envisaged as proper mitigation measures will be taken

up.

• Industry will strengthen the existing Safety, Health & Environment Department and also

continue to engage recognized laboratories to carry out all necessary monitoring parameters

for its activities.

• The segregated (HTDS / LTDS) wastewater will regularly analyzed before and a fter

treatment in ETP-ZLD.

• Qualified staff will continue to be appointed for the purpose of Operation and Maintenance of

the pollution control facilities.

• Stand-by facilities will be provided to all the pumps so as to ensure fail proof treatment,

handling and disposal.

9.1 Budgetary allocation for Pollution Control Measures

The management will set aside adequate funds in its budget to fully meet the stated

objectives of the environmental policy. The proposed and existing capital equipment for

environmental management include up-gradation of effluent treatment plants, pipelines and

channels for wastewater discharge, greenbelt development and the environment laboratory. The

break-up of budgetary allocation for various control measures is presented in Table 14.


23

Table 14: Budgetary allocation for Pollution Control Measures

• Recurring cost includes manpower, consumables, energy charges per annum

S. No.

Description Existing cost (in Lakhs)

Proposed cost (in Lakhs)

Capital *Recurring Capital *Recurring Air Pollution Control 1. Multi cyclone & Bag filter with Stacks 35

5 150

13 2. Scrubbers 10 80 3. Vent condensers 15 60 Water Pollution Control

4. ETP Civil works, Steam stripper, MEE, ATFD, R.O. and mechanical equipment

75 14 750 1340

Noise Pollution Control 5. Silencers / acoustic enclosures 5 1 30 2 Hazardous / Solid Waste

Management

6. Covered Platform with leachate collection system 10 4 40 1200

7. Greenbelt Development 10

26

20

55

8. Occupational Health and Safety 50 120 9. Fire Management 75 150

10. Dyke walls and Storm water drains 30 40 11. Environmental Laboratory 10 60 12. Miscellaneous 50 125

Total 375 50 1625 2610

ANNEXURES

Annexure-I

24

Annexure-I

25

Annexure-I

26

Annexure-I

27

Annexure-I

28

Annexure-I

29

Annexure-II

30

manu

Text Box

Annexure-II

31

Annexure-II

32

Annexure-II

33

Annexure-II

34

Annexure-II

35

Annexure-III

36

Annexure-III

37

Annexure-III

38

Annexure-III

39

Annexure-III

40

Annexure-III

41

Annexure-III

42

Annexure-III

43

Project Site

General Location Map

Telangana State

Jinnaram Mandal, Medak District

Annexure-IV

44

Dargulla

Air Force Academy Dundigal

Vivimed Labs Limited

Project Site Village

Air Force Academy

Specific Location (Route Map) Annexure-V

45

Sl. No. Latitude Longitude Sl.

No. Latitude Longitude

1 17°40'5"N 78°22'21"E 9 17°40'0"N 78°22'33"E 2 17°40'3"N 78°22'28"E 10 17°40'0"N 78°22'29"E 3 17°40'5"N 78°22'29"E 11 17°40'0"N 78°22'29"E 4 17°40'5"N 78°22'30"E 12 17°39'58"N 78°22'27"E 5 17°40'5"N 78°22'36"E 13 17°39'58N 78°22'24"E 6 17°40'2"N 78°22'36"E 14 17°40'0"N 78°22'24"E 7 17°40'0"N 78°22'36"E 15 17°40'0"N 78°22'21"E

8 17°39'59"N 78°22'33"E

Google Map showing the Project Coordinates Annexure-VI

46

Annexure-VII

47

Flow Chart

Para tert-Butyl benzoic acidMethanol Sol.RecoverySulfuric acid Evaporation LossToluene EffluentSodium Carbonate Inorganic ResidueSodium Sulfate Process EmissionsWater

Stage-1 in Toluene (155+535) Sol.RecoveryAcetyl anisole Evaporation LossSodium amide EffluentHydrochloric acid (35%) Organic ResidueMethanol Process EmissionsWater

Sol.RecoveryEvaporation Loss

Methanol Organic ResidueCarbon Spent Carbon

PRODUCT : Avobenzone (AVIS)

Description :

Avobenzone (Tech) with Methanol (162.5+40)

Avobenzone (AVIS)

Stage-1 : Para tert-Butyl benzoic acid is esterified with Methanol in presence of Catalytic quantity of Sulfuric acid to get PTBBA-Methyl ester. The excess Methanol used is distilled out and reused. The UnreactedPTBBA is washed away by aqueous Soda Ash, and recovered by neutralizing it by HCl.

Stage-2 : The Toluene Layer Containing PTBBA-Methyl Ester is reacted with Acetyl anisole in presence ofSodium amide followed by neutralization with HCl – to get Avis. The Toluene layer is washed with water andtoluene recovered by distillation. The residue treated with Methanol and Avobenzone (Tech) Centrifuged.

Stage-3 : Avobenzone Technical is purified by charcolising in Methanol followed by cooling and centrifugingto obtain pure Avobenzone (Pure)

Stage I

Stage II

Stage III

Annexure-VIII

48

Flow Chart

EpichlorchydrinSulfuric acid ProductSodium HydroxideWater

P-ChlorophenolSodium HydroxideMonochlorohydrin mass Sol.RecoveryToluene Evaporation LossHydrochloric acid (35%) Organic ResidueCarbon Spent CarbonHyflowWater

Chlorphenesin (Tech) Sol.RecoveryMethanol Evaporation LossCarbon Organic ResidueHyflow Spent Carbonn-Hexane Process Emissions

PRODUCT : Chlorphenesin (Cosvat)

Chlorphenesin (Cosvat)

Stage-1 : Epichlorhydrine is hydrolysed with water in presence of catalytic quantity of Sulfuric acid tomonochlorohydrine.

Stage-2 : Para chloro phenol is converted to it’s sodium salt by adding aqueous sodium hydroxide and thenreacted with mono chlorohydrin to give chlorphenesin as an organic layer which is seperated.The aqueous layer containing sodium chloride is sent for evaporation.

Stage-3 : The Technical Chlorphenesin is charcolised in methanol and after removal of methanol bydistillation, added hexane to precipitate it out.The pure Chlorphenesin is isolated by filtration.

Description :

Stage I

Stage II

Stage III

Annexure-VIII

49

Flow Chart

ResorcinolTolueneZinc Chloride Sol.RecoveryButyric acid Evaporation Loss

EffluentOrganic Residue

Hydrochloric acid (35%) Process EmissionsSodium CarbonateHexaneWater

Stage-1Toluene Sol.RecoveryIsopropyl Alcohol Evaporation LossHydrochloric acid (35%) EffluentZinc Organic ResidueWater Process EmissionsHexane

PRODUCT : 4-n-Butylresorcinol (Vivinol)

Tetrabutyl ammonium bromide

4-n-Butylresorcinol (Vivinol)

Stage-1 : Resorcinol on reaction with n-butyric acid in presence of Zinc chloride in toluene producesResbutyrophenone. To the reaction mass in toluene dilute HCl washings are given to remove traces of Zincchloride.Then Resbutyrophenone is extracted into aqueous Soda ash solution which on neutralization givespure Resbutyrophenone.Stage-2 : Resbutyrophenone is reduced to 4-n-Butyl resorcinol with Zinc and HCl in toluene and IPA mixture.Toluene is recovered by distillation.The aqueous layer sent for evaporation.The residue obtained bydistillation of toluene is subjected to high vacuum fractional distillation.The pot residue is sent forinceneration.

Description :

Stage I

Stage II

Annexure-VIII

50

Flow Chart

Para Nitrobenzoic acid2-Ethylhexanol Sol.RecoveryPerchloroethylene Evaporation LossSulfuric acid EffluentSodium Carbonate Process EmissionsAcetic acidWater

Stage-1Hydrogen Sol.RecoveryFormaldehyde (37%) Evaporation LossPalladium Carbon EffluentMethanol Organic ResidueHexane Spent CarbonSodium Sulfate Process EmissionsSodium ChlorideWater

2-Ethylhexyl 4-(dimethylamino) benzoate (Padimate-O)

Stage-1 : Para Nitrobenzoic acid is esterified with 2-Ethyl hexanol in presence of catalytic quantity ofSulfuric acid in Perchloroethylene to give Stage-1 Compound.The small quantity of unreacted PABA isremoved by treating the reaction mass with aqueous soda ash solution.The Perchloroethylene recovered bydistillation.

Stage-2 : Stage-1 Compound is subjected to reductive alkylation in presence of hydrogen, palladium oncharcoal and formaldehyde in methanol. Palladium is filtered and methanol is recovered by distillation. ThenHexane is added to the residue and washed with water. On recovering Hexane by distillation the crudePadimate-O is obtained.All the aqueous layers are sent for evaporations.The crude Padimate-O is purifiedby high vacuum fractional distillation.The pot residue is sent for incineration.

Description :

PRODUCT : 2-Ethylhexyl 4-(dimethylamino) benzoate (Padimate-O)

Stage I

Stage II

Annexure-VIII

51

Flow Chart

Ascorbic acidPyridinePhosphorous Oxychloride Sol.RecoveryPotassium Carbonte Evaporation LossPotassium Hydroxide Effluent

Inorgainc Solid WasteProcess Emissions

Calcium ChlorideWater

Stage-1Resin+ Sol.RecoverySodium Hydroxide Evaporation LossCarbon Organic ResidueMethanol Spent CarbonWater

Spent Resin CalciumHydrochloric acid (35%) EffluentWater

Stage-2 : Calcium ascorbyl phosphate is treated with cationic ion exchange residue where Calcium isexchanged to give 2-Ascorbyl phosphate that is free from all salts, to which aqueous Sodium hydroxide isadded to produce trisodium ascorbyl phosphate on adding Methanol Trisodium ascorbyl phosphate isexpelled which is centrifuged.Stage-3 : The spent resine containing Calcium is regenerated.

Magnesium Chloride Hexahydrate

Trisodium ascorbyl-2-Phosphate (C-Vite)

PRODUCT : Trisodium ascorbyl-2-Phosphate (C-Vite)

Description :Stage-1 : Ascorbic acid is reacted with Phosphorous oxy chloride in presence of Pyridine, PotassiumCarbonte and Potassium Hydroxide in water to get 2-ascorbyl phosphate trisodium salt. To removePosphoric acid thus formed by decomposition of excess Phosphorous Oxychloride, Magnesium Chloride isadded. The Phosphoric acid which is converted to KMgPO4is removed by filtration.Pyridine is distilled andreused.2-Ascorbyl phosphate trisodium salt is reacted with Calcium chloride to obtain Calcium ascorbylphosphate, which is isolated by filtration.

Stage I

Stage II

Stage III

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Description :

Flow Chart

Diethylene GlycolPhosphorous OxychlorideSodium HydroxideWater

4-Octyl PhenolStage-1 Sol.RecoverySodium Hydroxide Evaporation LossToluene EffluentWater Organic Residue

Stage-2 Sol.RecoveryDimethylamine (40%) Evaporation LossEthyl Acetate EffluentWater Organic Residue

Stage-3 Sol.RecoveryToluene Evaporation LossCarbon Organic ResidueBenzyl Chloride Spent Carbon

Benzethonium Chloride (BZC)

PRODUCT : Benzethonium Chloride (BZC)

Stage-1 : Diethylene Glycol reacts with Phosphorous Oxychloride in presence of Sodium Hydroxide in aqueousmedium to get Stage-1 Compound.

Stage-2 : 4-Octyl Phenol on reaction with Stage-1 Compound in presence of Sodium Hydroxide in Toluenesolvent medium to form Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate reacts with Dimethylamine in presence of Ethyl Acetate as solvent medium to giveStage-3 Compound.

Stage-4 : Stage-3 Compound on reaction with Benzyl Chloride in presence of Toluene as solvent medium andgets purified with Carbon to obtain Benzethonium Chloride (BZC).

EffluentStage I

Stage II

Stage III

Stage IV

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Description :

Flow Chart

o-PhenylenediamineSulfuric acidMethanolWater

Stage-1BenzaldehydeSodium Hydroxide (48%) EffluentSodium Metabisulfate Spent CarbonAcetic acid Process EmissionsCarbonWater

PRODUCT : Phenylbenzimidazole Sulfonic acid (PBSA)

Stage-1 : o -Phenylenediamine on reaction with hot Sulfuric acid in presence of Methanol medium to form Stage-1Compound.

Stage-2 : Stage-1 Compound on neutralisation with Sodium Hydroxide and reaction with Benzaldehyde inpresence of Acetic acid and Sodium Metabisulfate in aqueous medium and gets purified with Carbon to obtainPhenylbenzimidazole Sulfonic acid (PBSA).

Effluent

Phenylbenzimidazole Sulfonic acid (PBSA)

Stage I

Stage II

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54

Flow Chart

P-Nitrobenzoic acid2-Ethylhexanol Sol.RecoveryPerchloroethylene Evaporation LossSulfuric acid EffluentSodium Carbonate Process EmissionsWater

Stage-1Palladium CarbonMethanol Sol.RecoveryHydrogen Evaporation LossPerchloroethylene EffluentHexane Spent CarbonCarbonFuller's earthWater

Stage-2Xylene Sol.RecoveryCyanuric Chloride Evaporation LossAmmonia (25%) Sol. EffluentCarbon Organic ResidueFuller's earth Spent CarbonAcetonitrile Process EmissionsWater

PRODUCT : 1,3,5-Para Amino-2-ethylhexylbenzoate-2,4,6-triazine (Etone)

1,3,5-Para Amino-2-ethylhexylbenzoate-2,4,6-triazine (Etone)

Stage-1 : PNBA (P-Nitrobenzoic acid) is esterified with 2-Ethylhexanol in presence of catalytic quantity ofSulfuric acid to get PN2EHB (Para nitro 2-ethyl hexyl benzoate). The Sulfuric acid is neutralized with Sodaash and the Unreacted PNBA is extracted with aqueous Soda ash solution which on neutralization givesrecovery PNBA.Stage-2 : PN2HB is reduced to PA2EHB (Para amino 2-ethyl hexyl benzoate) in presence of Pd/C-H2 inmethanol. Pd/C is filtered and reused. Methanol distilled and sent for column distillation. To the residueHexane is added to expel the product and centrifuged.Stage-3 : PA2EHB is reacted with Cyanuric chloride in Xylene to get Etone. To the reaction mass water isadded and PH is adjusted with ammonia. Aqueous layer seperated and sent for evaporation. The Xylenelayer taken for Xylene distillation (recovery). To residue Acetonitrile is added and charcolised – cooled andEtone is filtered.

Description :

Stage I

Stage II

Stage III

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Stage-4 : Cyclised product (Stage-3) reacts with Hydroxylamine hydrochloride and Sodium carbonate diluted withsolvent, filtered and washed the bed with solvent. Finally organic layer was washed with water and distilled thesolvent completely to afford Stage-4 compound.

Stage-5 : The Stage-4 is diluted with Ethyl acetate, added Monoethanolamine, warms the material, cooled andfiltered the solid, washed with solvent, dried the material to afford Piroctone olamine.

PRODUCT : Piroctone Olamine (Dandoff)

Description :

Stage-1 : 3,3-Dimethyl acrylic acid is converted to methyl ester in presence of p-Toluenesulfonic acid,Hydroquinone and Methanol at reflux temperature, followed by water addition and extraction of the product inMethylene Dichloride which is subsequently washed with Sodium bicarbonate followed by water and brinesolution. Dry the Methylene Dichloride layer with Sodium sulfate to afford Stage-1 compound.

Stage-2 : 3,3-Dimethyl methyl acrylate is taken in Methylene Dichloride and added 3,5,5-Timethyl hexanoylchloride in presence of Sodium bicarbonate and Aluminum Chloride at low temperature. After completion of thereaction, mass is quenching into ice and HCl, separated Methylene Dichloride layer, extracted the aqueous layerwith Methylene Dichloride, washed with Sodium bicarbonate followed by water, brine solution. Dried theMethylene Dichloride layer with Sodium sulfate to afford Stage-2 compound.

Stage-3 : To Condensed product (Stage-2) in Methylene Dichloride added Sodium methoxide powder slowly atlow temperature, after completion of the reaction, neutralized the reaction mass with Hydrochloric acid. Thereaction mass is washed with water and dried, distilled the solvent completely to afford Stage-3 compound.

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Flow Chart

3,3-Dimethyl acrylic acidMethanol Sol.RecoveryMethylene Dichloride Evaporation LossHydroquinone Effluentp-Toluenesulfonic acid Organic ResidueSodium Bicarbonate Inorgainc Solid WasteSodium Chloride Process EmissionsSodium SulfateWater

Stage-1Methylene Dichloride Sol.Recovery3,5,5-Trimethyl hexanoyl chloride Evaporation LossAluminium Chloride EffluentHydrochloric acid (35%) Organic ResidueSodium Bicarbonate Inorgainc Solid WasteSodium Chloride Process EmissionsSodium SulfateWater

Stage-2 Sol.RecoveryMethylene Dichloride Evaporation LossSodium Methoxide EffluentHydrochloric acid (35%) Organic ResidueWater Inorgainc Solid Waste

Stage-3 Sol.RecoveryMethylene Dichloride Evaporation LossSodium Carbonate EffluentHydroxylamine Hdyrochloride Organic ResidueWater Inorgainc Solid Waste

Process Emissions

Stage-4 Sol.RecoveryEthyl Acetate Evaporation LossMonoethanolamine Organic Residue

PRODUCT : Piroctone Olamine (Dandoff)

Piroctone Olamine (Dandoff)

Stage I

Stage II

Stage III

Stage IV

Stage V

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Flow Chart

2-ChloropyridineHydrogen Peroxide (50%)Acetic acidHexane Sol.RecoverySodium Hydroxide Evaporation LossSodium Sulfide (50%) EffluentSodium Bicarbonate Organic ResidueHydrochloric acid (35%) Spent CarbonCarbon Process EmissionsZinc Sulfate HeptahydrateWaterDimethyl HydentionCMCDespersol

Stage-1 : 2-Chloropyridine in presence of acetic acid, water and hydrogen peroxide undergoes N-Oxidationto give 2-chloropyridene N-oxide. The unreacted 2-chloropyridine is removed by Hexane washings. Hexaneand 2-chloropyridine are recovered. The acetic acid is neutralized to Sodium acetate with NaOH. 2-Chloropyridine-N-oxide is then reacted with Sodium hydro sulphide (NaSH) which is prepared in situ byadding Sodium bicarbonate and Sodium Sulphide to obtain N-oxy-2-pyridine thiol sodium salt. To N-oxy-2-pyridine thiol is added Zinc sulphate to produce Zinc pyrithione (ZPTO) which is isolated by centrifugalfiltration.

Zinc Pyrithione (Dantuff-Z)

PRODUCT : Zinc Pyrithione (Dantuff-Z)

Description :

Stage I

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Flow Chart

Fugitive LossSodium Hydroxide Organic ResidueGuar gum Inorganic Solid WasteCitric acidWater

2-Hydroxy propyl-3-trimethylammonium chloride Guar (Star Cat)

Stage-1 : 3-Chloro-2-hydroxypropyl trimethylammonium Chloride (70%) is treated with aqueous Sodium Hydroxide and the resulting solution is filtered to separate sodium chloride and added to Guar dal flour in a RRM. The mixture is then sent to Drier and from there to a sieve.The dry sieved Starcat is packed. The sieve residue is unwanted lumpy Starcat, which is sent for incineration.

Description :

PRODUCT : 2-Hydroxy propyl-3-trimethylammonium chloride Guar (Star Cat)

3-Chloro -2-hydroxypropyl trimethylammonium Chloride (70%)

Stage I

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Flow Chart

Silver OxideWater

Silver Oxide - DTPA Complex (Viv Ag)

Stage-1 : Silver Oxide forms complex instantaneously with Diethylene triamine pentaacetic acid in presence ofaqueous medium.

PRODUCT : Silver Oxide - DTPA Complex (Viv Ag)

Description :

Diethylene triamine pentaacetic acid (40%) ProductStage I

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Description :

Flow Chart

p-Nitrobenzoic acid Sol.RecoveryToluene Evaporation LossDimethylformamide Organic ResidueThionyl Chloride Process Emissions

Stage-1 in Toluene (350 + 700)Toluene Sol.Recoverytert-Butylamine Evaporation LossTriethylamine EffluentWater Organic Residue

Stage-2 Sol.RecoveryMethanol Evaporation LossPalladium Carbon EffluentHydrogen Organic ResidueToluene Process Emissions

Stage-3 Sol.RecoveryCyanuric Chloride Evaporation LossAcetonitrile EffluentPotassium Carbonate Organic ResidueWater Process Emissions

Stage-42-Ethylhexyl 4-Aminobenzoate Sol.RecoveryAmmonia (25%) solution Evaporation LossToluene EffluentHexane Organic ResidueWater

Vivtroze-H

Stage-4 : Stage-3 Compound on reaction with Cyanuric Chloride in presence of Potassium Carbonate usingAcetonitrile as solvent medium to get Stage-4 Intermediate.

Stage-5 : Stage-4 Intermediate reacts with 2-Ethylhexyl 4-Aminobenzoate in presence of Ammonia in Toluene andHexane solvent media to obtain Vivtroze-H.

PRODUCT : Vivtroze-H

Stage-1 : p -Nitrobenzoic acid is reacted with Thionyl Chloride in the presence of Dimethylformamide and Toluenesolvent media to get Stage-1 Compound.

Stage-2 : Stage-1 Compound on treatment with tert-Butylamine in presence of Triethylamine using Toluene assolvent medium to form Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate on hydrogenation with Hydrogen in presence of Palladium Carbon catalyst inMethanol and Toluene solvent media gives Stage-3 Compound.

Stage I

Stage II

Stage III

Stage IV

Stage V

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Flow Chart

o-NitroanilineHydrochloric acid (35%)Sodium NitriteSulfamic acid Sol.Recovery4-tert-Octylphenol Evaporation LossSodium Hydroxide EffluentMethanol Organic ResidueAcetic acidTolueneWater

Stage-1 in Toluene (1277+4570)Zinc Powder Sol.RecoverySodium Hydroxide Evaporation LossIsopropyl Alcohol EffluentHydrochloric acid (35%) Organic ResidueMethanol Process EmissionsWater

Stage-2ParaformaldehydeDiethylamine Sol.RecoverySodium Ethoxide Evaporation LossEthanol EffluentXylene Organic ResidueWater

Tinosorb-M (Vivzole-M)

Stage-1 : o -Nitroaniline is diazotized and coupled with 4-tert-Octylphenol in presence of Sodium Nitrite, Sulfamicacid, Hydrochloric acid, Sodium Hydroxide and Acetic acid using Methanol as solvent medium to form Stage-1Compound.

Stage-2 : Stage-1 Compound in Toluene is further reacted with Zinc in presence of Hydrochloric acid and SodiumHydroxide using Isopropyl Alcohol and Methanol as solvent media to get Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate is reacted with Paraformaldehyde in presence of Diethylamine and Sodium Ethoxideusing Xylene and Ethanol as solvent media for generating intermediate which is finally condensed to obtain Tinosorb-M.

PRODUCT : Tinosorb-M (Vivzole-M)

Description :

Stage I

Stage II

Stage III

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Flow Chart

4-BromoanisoleTetrahydrofuranMagnesium Sol.RecoveryIodine Evaporation LossVitride (70%) in Toluene EffluentCyanuric Chloride Organic ResidueToluene Spent CarbonCarbon Process EmissionsHexaneWater

Stage-1Ethylene Dichloride Sol.RecoveryAluminium Chloride Evaporation LossResorcinol EffluentIsopropyl Alcohol Organic ResidueWater Process Emissions

Stage-2Dimethylformamide Sol.RecoverySodium Carbonate Evaporation Loss2-Ethylhexyl Bromide EffluentToluene Organic ResidueCarbon Spent Carbonn-Butanol Process EmissionsWater

Tinosarb-S (Vivitraz-S)

Stage-1 : 4-Bromoanisole is reacted with Magnesium metal in Tetrahydrofuran medium to form correspondingGrignard intermediate which is selectively reacted with Cyanuric Chloride to form Stage-1 Compound in Toluenemedium, produt thus formed is isolated using Hexane and gets purified with Carbon.

Stage-2 : Stage-1 Compound is reacted with Resorcinol in presence of Aluminium Chloride using EthyleneDichloride and Isopropyl Alcohol as solvent media to get Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate reacts with 2-Ethylhexyl Bromide in presence of Sodium Carbonate using n-Butanol, Toluene and Dimethylformamide as solvent media and gets purified with Carbon to obtain Tinosarb-S.

PRODUCT : Tinosarb-S (Vivtraz-S)

Description :

Stage I

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Stage III

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Description :

PRODUCT : Pyrrolidinyl diamino pyrimidine-N-oxide (Vividine)

Stage-1 : Ethyl cyanoacetate on reaction with Guanidine Hydrochloride in presence of Sodium methoxide inMethanol followed by neutralization gives 2,6-Diamino-4-hydroxy pyrimidine. Methanol recovered and reused.The reaction mass diluted with water and charcolised at 900C on cooling product precipitates out which iscentrifuged.Stage-2 : 2,6-Diamino-4-hydroxy pyrimidine is reacted with Phosphorous oxychloride and then quenched intoAmmonia water to get 2,6-Diamino-4-chloro pyrimidine which is extracted into Ethyl acetate.

Stage-3 : Phthalic anhydride is treated with Hydrogen peroxide and Magnesium Oxide in Ethyl acetate to giveMMPP which is centrifuged.

Stage-4 : 2,6-Diamino-4-choro pyrimidine is subjected to N-oxidation with MMPP in Methanol to give 2,6-Diamino-1-oxy-4-chloro pyrimidine which is centrifuged. The wet cake of 2,6-Diamino-1-oxy-4-chloro pyrimidineis treated with hot water to remove Magnesium phthalate.

Stage-5 : 2,6-Diamino-1-oxy-4-chloro pyrimidine is reacted with pyrrolidine to give tech VIVIDINE (2,6-Diamino-1-oxy-4-pyrrolidino Pyrimidine) which along with pyrrolidine hydrochloride is centrifuged. ML’S sent for pyrrolidinerecovery. The Tech VIVIDINE is purified from Methanol and water to get pure VIVIDINE.

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Flow Chart

Ethyl cyanoacetateGuanidine HydrochlorideMethanol Sol.RecoverySodium Methoxide Evaporation LossWater EffluentHydrochloric acid (35%) Spent CarbonAmmonia (25%) solutionCarbonHyflow

Stage-1Phosphorus Oxychloride Sol.RecoveryWater Evaporation LossAmmonia gas EffluentHexane Process EmissionsEthyl acetate

Phthalic anhydride Sol.RecoveryEthyl acetate Evaporation LossMagnesium oxide EffluentHydrogen peroxide( 50%) Organic Residue

Process Emissions

Stage-2 Sol.RecoveryMethanol Evaporation LossStage-3 EffluentWater Organic Residue

Process Emissions

Stage-4Pyrrolidine Sol.RecoveryHexane Evaporation LossMethanol EffluentWater Organic ResidueHyflow Spent CarbonCarbon

Pyrrolidinyl diamino pyrimidine-N-oxide (Vividine)


Stage I

Stage II

Stage III

Stage IV

Stage V

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Description :

Flow Chart

Thiosalicylic acid4-Bromobenzoic acidSodium Hydroxide EffluentCopper Powder Inorganic Solid WasteCarbon Spent CarbonWater

Stage-1 Sol.RecoveryPolyphosphoric acid Evaporation LossToluene EffluentWater Organic Residue

Stage-2 Sol.RecoveryToluene Evaporation LossThionyl Chloride Organic ResidueEthanol Process Emissions


Toluene Organic ResidueCarbon Spent Carbon

Stage-4 : Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (Crude) in presence of Toluene solvent medium and getspurified with Carbon to obtain Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (Pure).

Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (Crude)

Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (9-OXO)

Stage-3 : Stage-2 Intermediate reacts with Thionyl Chloride in presence of Toluene and Ethanol solvent media togive Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (Crude).

PRODUCT : Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (9-OXO)

Stage-1 : Thiosalicylic acid on reaction with 4-Bromobenzoic acid in presence of Sodium Hydroxide and CopperPowder in aqueous medium and gets purified with Carbon to form Stage-1 Compound.

Stage-2 : Stage-1 Compound on treatment with Polyphosphoric acid in presence of Toluene as solvent medium toget Stage-2 Intermediate.

Stage I

Stage II

Stage III

Stage IV

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Flow Chart

3,4-DimethoxyphenylacetoneTitanium Tetrachloride Sol.RecoveryZinc Evaporation Loss1,4-Dioxane EffluentHydrochloric acid (35%) Organic ResidueCarbon Tetrachloride Inorgainc Solid WasteMethanol Process EmissionsWater

Stage-1 Sol.RecoveryHydrogen Evaporation LossMethanol Organic ResiduePalladium Carbon Process Emissions

Stage-2Hydrobromic acid (48%) EffluentWater

Vintox (Crude) Sol.RecoveryAcetic acid Evaporation LossCarbon EffluentAcetonitrile Organic ResidueWater Spent Carbon

Stage-3 : Stage-2 Intermediate is demethylated with Hydrobromic acid in aqueous medium to give the crude formof Vintox.

Stage-4 : The Crude Vintox in presence of Acetic acid and Acetonitrile as solvent media and gets purified withCarbon to obtain Pure form of Vintox.

Vintox

PRODUCT : Vintox

Description :

Stage-1 : 3,4-Dimethoxyphenylacetone on reaction with Titanium Tetrachloride in presence of Hydrochloric acidand Zinc using 1,4-Dioxane, Carbon Tetrachloride and Methanol as solvent media ot get Stage-1 Compound.

Stage-2 : Stage-1 Compound on reduction with Hydrogen in presence of Palladium Carbon as catalyst usingMethanol as solvent medium to form Stage-2 Intermediate.

Stage I

Stage II

Stage III

Stage IV

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Flow Chart

L-MentholLactic acidSodium BisulfateToluene


Sodium Hydroxide (50%) EffluentWater Organic Residue

Stage-2 : During the process of esterification Menthyl Lactate gets further esterified with Lactic acid to giveMLL and MLLL which are unwanted and are to be converted back to Menthyl Lactate by mild hydrolysis. Finallythe crude Menthyl Lactate is purified by HVD and dispersed in Water to obtain a free flowing powder.

Menthyl Lactate (Vivfresh)

PRODUCT : Menthyl Lactate (Vivfresh)

Description :

Stage-1 : L-Menthol is esterified with Lactic acid in presence of Sodium Bisulfate in Toluene medium to giveMenthyl Lactate Mass.

Product Mass

Menthyl Lactate (Vivfresh) Mass

Stage I

Stage II

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Description :

Flow Chart

Salicylic acidNitric acidSulfuric acidWater

Stage-1 Sol.RecoveryEthanol Evaporation LossCarbon EffluentAmmonium Hydroxide (25%) Organic Residue

Spent Carbon

Ammonium Dinitrosalicylic acid (ADNSA)

PRODUCT : Ammonium Dinitrosalicylic acid (ADNSA)

Stage-1 : Salicylic acid on treatment with fuming Nitric acid in presence of Sulfuric acid in aqueous medium toform Stage-1 Compound.

Stage-2 : Stage-1 Compound on reaction with aqueous Ammonium Hydroxide in presence of Ethanol as solventmedium and gets purified with Carbon to obtain Ammonium Dinitrosalicylic acid.

EffluentStage I

Stage II

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Flow Chart

2,6-Di-tert-butylphenolFormaldehyde (40%) Sol.RecoveryButanol Evaporation LossPotassium Carbonate EffluentAluminium Oxide Organic ResidueSodium Chloride Inorgainc Solid WasteSodium Sulfate Spent CarbonHexane Process EmissionsWater

PRODUCT : 2,6-Di-tert-butyl-5-hydroxybenzyl alcohol (DTBTBA)

Description :

Stage-1 : 2,6-Di-tert-butylphenol reacts with Formaldehyde in presence of Potassium Carbonate, AluminiumOxide, Sodium Chloride and Sodium Sulfate using Butanol and Hexane as solvent media to obtain 2,6-Di-tert-butyl-5-hydroxy benzyl alcohol (DTBTBA).

2,6-Di-tert-butyl-5-hydroxybenzyl alcohol (DTBTBA)

Stage I

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Flow Chart

4-Amino-2-ethylhexy benzoateToluene Sol.RecoveryCyanuric Chloride Evaporation LossSodium Bicarbonate EffluentHyflo Organic ResidueIsopropyl Alcohol Inorgainc Solid WasteWater Process Emissions

PRODUCT : Suntech

Description :

Stage-1 : 4-Amino-2-ethylhexy benzoate on reaction with Cyanuric Chloride in presence of Sodium Bicarbonateusing Toluene and Isopropyl Alcohol as solvent media to form Suntech.

Suntech

Stage I

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Flow Chart

P-ChloroanilineSol.Recovery

Evaporation LossToluene EffluentMethanolWater

Trichlorocarbanilide (Vivilide)

Stage-1 : P-Chloroaniline (PCA) reacts with 3,4-dichloro phenyl isocyanate (3,4-DCPI) in toluene to giveTCC (Trichlorocarbanilide). Toluene is recovered by distillation and water is added and centrifused. To thecentrifuged puoduct methanol washing is given.

PRODUCT : Trichlorocarbanilide (Vivilide)

Description :

3,4-Dichlorophenyl Isocyanate

Stage I

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Flow Chart

4-Amino-3-nitrophenol Sol.Recovery2-Chloroethyl chloroformate Evaporation LossEthyldioxitol EffluentCalcium Carbonate Process EmissionsWater

Stage-1Potassium Hydroxide EffluentHydrochloric acid (35%) Process EmissionsOxygenWater

EffluentCarbon Spent CarbonWater

3-Nitro-4-(2-hydroxyethyl) amino phenol (NHEAP)

3-Nitro-4-(2-hydroxyethyl) amino phenol (Tech)

Stage-3 :The technical 3-Nitro-4-(2-hydroxyethyl) amino phenol (NHEAP) is purified from water.

PRODUCT : 3-Nitro-4-(2-hydroxyethyl) amino phenol (NHEAP)

Description :Stage-1 : 4-Amino-3-nitrophenol is reacted with 2-Chloroethyl chloroformate in presence of CalciumCarbonate in Ethyldioxitol to give 4-Amino-3-nitrophenol carbamate. On quenching the above reaction massinto water the carbamate precipitates out, which is isolated by filtration.Stage-2 : 4-Amino-3-nitrophenol carbamate is hydrolised to 3-Nitro-4-(2-hydroxyethyl) amino phenol(NHEAP) Tech by treating it with aqueous Potassium Hydroxide followed by neutralization with Hydrochloricacid. The technical 3-Nitro-4-(2-hydroxyethyl) amino phenol (NHEAP) is filtered.

Stage I

Stage II

Stage III

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Flow Chart

Sodium Nitrite EffluentHydrochloric acid (35%)Sodium HydroxideWater

Stage-1 Sol.RecoveryEthanol Evaporation LossPalladium Carbon EffluentHydrogen Spent CarbonSulfuric acid Process EmissionsWater


Ethanol EffluentCarbon Spent CarbonWater

PRODUCT : 4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (BHP)

Description :

4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (BHP)

Stage-1 : 4-Amino N,N-Bis 2-hydroxyethyl aniline is nitrosated withSsodium Nitrite in presence ofHydrochloric Acid and Water. On neutralization of the mass with aqueous Sodium Hydroxide, the nitrosoNHA precipitates out which is then isolated by filtration.

Stage-2 : The nitroso NHA is hydrogenated in presence of Palladium Carbon in Ethanol to obtain thecorresponding amine which after separating from Pd/C treated with Sulfuric acid to give 4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (BHP)-(Tech).The BHP Tech is isolated from the mass by filtration.

Stage-3 : The 4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (BHP) Technical is purified from Water +Ethanol by dissolving it, followed by carbon treatment and then isolating by filtration.

4-Amino N,N-Bis 2-hydroxyethyl aniline

4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (Tech)

Stage I

Stage II

Stage III

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Flow Chart

1,4-D-Violet Sol.RecoverySodium Carbonate Evaporation Lossn-Butanol EffluentDiethylsulfate Organic ResidueCarbon Spent CarbonHydrochloric acid (31.3 %) Process EmissionsWater


Methanol Organic Residue

PRODUCT : Nitroblue (Blue12)

Nitroblue with n-Butanol (Tech) (330+81)

Nitroblue (Blue 12)

Stage-1 : 1,4-D-Violet is ethylated with diethyl sulphate in presence of sodium carbonate in water and n-butanol to get Nitroblue (Tech). The aqueous layer is separated and sent for evaporation. To the Butanol layer HCl is added to get Nitro blue (HCl salt) Tech which is isolated by filtration.

Stage-2 : The Technical Nitroblue is purified from methanol to give Nitroblue (Pure).

Description :

Stage I

Stage II

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Stage : 1Material Balance:

Kg OUTPUT KgProduct

2,6-Dichlorobenzaldehyde = 15 Stage-1 = 332,6-Dimethylaniline = 21 Effluent = 264.7Sulfuric acid = 18 Sodium Sulfate 26.08Sodium Hydroxide = 14.7 2,6-Dimethylanline 0.26Water = 229 Organic Compound 1.2

gen.water 8.16Water 229

Total Input = 297.7 Total Output = 297.7


Kg OUTPUT KgProduct

Stage-1 = 33 Satge-2 = 33Ethanol = 136 RecoveryChloranil = 20.35 Ethanol = 125Sodium Hydroxide = 15.6 Ethanol Loss = 8Water = 1563 Effluent = 1601.9

Sodium Hydroxide 8.98Ethanol 3Organic Compound 1.28gen.water 2.98Water 1561.51Process Emissions = 0.05Ammonia 0.05


PRODUCT : 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Jade Blue/ Blue15)

INPUT

INPUT

Disodium Salt of Tetrachlorohydroquinone 24.15

Annexure-VIII

76


Kg OUTPUT KgProduct

Stage-2 = 33Ethanol = 399Carbon = 0.35Kiesulgar = 0.5Phosphoric acid (85%) = 19.8 Recovery =Water = 79 Ethanol = 367

Ethanol Loss = 24Effluent = 111.8Phosphoric acid 8.8Ammonium Phosphate 0.28Ethanol 8Organic Compound 11.36gen.water 1.39Water from Phosphoric acid 2.97Water 79Spent Carbon = 0.85Carnon 0.35Kiesulgar 0.5


Stage : 4 (Purification)Material Balance:

Kg OUTPUT KgProduct

Ethanol = 400 Recovery =Water = 200 Ethanol = 368

Ethanol Loss = 24Effluent = 216Ethanol 8Organic Compound 8Water 200

Total Input = 628 Total Output = 628

INPUT

1-(3,5-Dimethyl-4-amino phenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Tech)

= 28

1-(3,5-Dimethyl-4-amino phenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Pure)

= 20

PRODUCT : 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Jade Blue/Blue15)

INPUT


= 28

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77

Stage-4 : The Technical 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl)methane Phosphate is purified by Ethanol to get 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethyliminophenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Pure).

Stage-3 : The Carbinol derivative is treated with H3PO4 85% (Phosphoric acid) to give Technical 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (JadeBlue).

PRODUCT : 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Jade Blue/Blue15)

Description :Stage-1 : 2,6-Dichloro benzaldehyde reacts with 2,6-Dimethyl aniline in presence of Sulfuric acid and waterto give Triphenyl methane derivative which is isolated by centrifuging. Stage-2 : Triphenyl methane derivative on reaction on reaction with para chloronil in ethanol yields carbinolderivative which is centrifuged and washed with aqueous Sodium Hydroxide solution. The aqueous ML’Ssent for evaporation.

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78

Flow Chart

2,6-Dichlorobenzaldehyde2,6-DimethylanilineSulfuric acid EffluentSodium HydroxideWater

Stage-1 Sol.RecoveryEthanol Evaporation LossChloranil EffluentSodium Hydroxide Process EmissionsWater

Stage-2Ethanol Sol.RecoveryCarbon Evaporation LossKiesulgar EffluentPhosphoric acid (85%) Spent CarbonWater


EffluentEthanolWater


PRODUCT : 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Jade Blue/ Blue15)

1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane Phosphate (Jade Blue/Blue15)

Stage I

Stage II

Stage III

Stage IV

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Flow Chart

ToluleneN-Methylpyrrolidone Sol.RecoveryDimethyl Sulfoxide Evaporation LossSodium Acetate EffluentCuprous Acetate Organic Residue

Inorgainc Solid Waste

Isopropyl AlcoholWater

Stage-1N-Methylpyrrolidone Sol.RecoveryTributylamine Evaporation Loss1-Bromopropane Organic ResidueIsopropyl Alcohol Spent CarbonCarbon


n-Butanol Organic ResidueWater

Methylamino dimethylamino Propylamino Propylbromide anthraquinone (BQB/Blue16)

4-Bromo-1-Methylamino anthraquinone (Impure)

3-( Dimethylamino ) -1-Propylamine

Methylamino dimethylamino Propylamino Propylbromide anthraquinone (Tech)

PRODUCT : Methylamino dimethylamino Propylamino Propylbromide anthraquinone (BQB/ Blue16)

Stage-1 : The impure 4-Bromo-1-(Methylamino anthraquinone is purified from a mixture of solventsToluene and NMP.The ML’S containing toluene and NMP are sent for column distillation for the recovery ofsolvents.Thus purified BMA is reacted with 3 DMPA (3-Dimethyl amino propyl amine) in presence of sodium acetate, cuprous acetate in DMSO to give BQ – Inter. Then the product is expelled from the mass byadding IPA and water and filtered.

Stage-2 : The BQ – Inter is treated with 1- Bromo propane in presence of N-TBA in NMP to giveMethylamino dimethylamino Propylamino Propylbromide anthraquinone (BQB) Tech, which on addition ofIPA precipitates out and filtered.

Stage-3 : The Technical Methylamino dimethylamino Propylamino Propylbromide anthraquinone (BQB) isrecrystallised from n-Butanol to give Methylamino dimethylamino Propylamino Propylbromideanthraquinone (Pure).

Description :

Stage I

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Stage III

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Description :

Flow Chart

Monoethanolamine EffluentCelite Inorganic Solid WasteMagnesium OxideWater


Methanol Organic ResidueCarbon Spent Carbon

2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2)

PRODUCT : 2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2)

Stage-1 : N,N-Bis-(Hydroxyethyl)-4-Fluoro-3-Nitroaniline is treated with Monoethanolamine in presence ofMagnesium Oxide and gets filtrated with Celite in aqueous medium to form 2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2 Crude) .

Stage-2 : 2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2 Crude) gets purified with Carbonin presence of Methanol solvent medium to obtain 2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol(Blue-2 Pure).

N,N-Bis-(Hydroxyethyl)-4-Fluoro-3-Nitroaniline

2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2 Crude)

Stage I

Stage II

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Flow Chart

2,4-Dinitrochlorobenzene Sol.RecoveryMomoethylene glycol Evaporation LossSodium Carbonate EffluentWater Process Emissions

Stage-1 (Crude) Sol.RecoveryMethanol Evaporation LossCarbon EffluentHyflo Spent CarbonWater

Stage-2 Sol.RecoveryEthanol Evaporation LossPalladium Carbon EffluentHydrogen Organic ResidueHydrogen Chloride

Sol.RecoveryEthanol Evaporation LossCarbon EffluentHyflo Spent CarbonWater

Stage-4 : 2,4-Diamino Phenoxyethanol sulfate (DPE – Sulfate) Tech is recrystallised from Ethanol watermixture.

2,4-Diamino phenoxyethanol Dihydrochloride (Tech)

2,4-Diamino phenoxyethanol Dihydrochloride (DPE HCl)

PRODUCT : 2,4-Diamino phenoxyethanol Dihydrochloride (DPE HCl)

Description :Stage-1 : 2,4-DNCB (2,4-Dinitro Chloro benzene) is reacted with Momoethylene glycol (MEG) in presence ofSodium carbonate, to give 2,4-Dinitro phenoxy ethanol. The reaction mass is quenched in to water to expelthe product 2,4-Dinitro phenoxy ethanol centrifuged.

Stage-2 : 2,4-Dinitro phenoxy ethanol contains traces of dimer impurity to remove this impurity it needs to berecrystallised from methanol.

Stage-3 : 2,4-Dinitro phenoxy ethanol is reduced to 2,4-diamino phenoxy ethanol in presence of Palladiumon Charcoal in ethanol. Pd/C filtered and the filtrate treated with H2SO4 and the precipitated 2,4-DiaminoPhenoxyethanol sulfate (DPE-Sulfate) tech centrifuged.

Stage I

Stage II

Stage III

Stage IV

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Flow Chart

Meta Nitro para ToluidineEthyldioxitol Sol.RecoveryCalcium Carbonate Evaporation Loss2-Chloroethyl Chloroformate EffluentPotassium Hydroxide Inorganic ResidueHydrochloric acid (35%) Process EmissionsWater

EffluentHydrochloric acid (35%)Water

PRODUCT : 4-Hydroxyethylamino-3-nitro toluene (HNT)

4-Hydroxyethylamino-3-nitro toluene (HNT)

Stage-1 : MNPT (Meta Nitro para Toluidine) is reacted with 2-Chloroethyl Chloroformate in presence ofCalcium Carbonate in Ethyldioxitol followed by hydrolysis with aqueous Potassium Hydroxide to give 4-Hydroxyethylamino-3-nitro toluene (HNT) Tech.

Stage-2 : Technical 4-Hydroxyethylamine-3-nitro toluene (HNT) is purified by recrystallisation from diluteHydrochloric acid to get pure 4-Hydroxyethylamino-3-nitro toluene (HNT).

4-Hydroxyethylamine-3-nitro toluene (Tech) wet

Description :

Stage I

Stage II

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83

Flow Chart

2,4-Dinitrochlorobenzene Sol.RecoveryMomoethylene glycol Evaporation LossSodium Carbonate EffluentWater Process Emissions

Stage-1 (Crude) Sol.RecoveryMethanol Evaporation LossCarbon EffluentHyflo Spent CarbonWater

Stage-2 Sol.RecoveryEthanol Evaporation LossPalladium Carbon EffluentHydrogen Organic ResidueSulfuric acid

Sol.RecoveryEthanol Evaporation LossCarbon EffluentHyflo Spent CarbonWater

2,4-Diamino Phenoxyethanol sulfate (Tech)

Stage-4 : 2,4-Diamino Phenoxyethanol sulfate (DPE – Sulfate) Tech is recrystallised from Ethanol watermixture.

2,4-Diamino phenoxyethanol Sulfate (DPE Sulfate)

Stage-3 : 2,4-Dinitro phenoxy ethanol is reduced to 2,4-diamino phenoxy ethanol in presence of Palladiumon Charcoal in ethanol. Pd/C filtered and the filtrate treated with H2SO4 and the precipitated 2,4-DiaminoPhenoxyethanol sulfate (DPE-Sulfate) tech centrifuged.

PRODUCT : 2,4-Diamino phenoxyethanol Sulfate (DPE Sulfate)

Description :Stage-1 : 2,4-DNCB (2,4-Dinitro Chloro benzene) is reacted with Momoethylene glycol (MEG) in presenceof Sodium carbonate, to give 2,4-Dinitro phenoxy ethanol. The reaction mass is quenched in to water toexpel the product 2,4-Dinitro phenoxy ethanol centrifuged.

Stage-2 : 2,4-Dinitro phenoxy ethanol contains traces of dimer impurity to remove this impurity it needs tobe recrystallised from methanol.

Stage I

Stage II

Stage III

Stage IV

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Description :

Flow Chart

Guanidine Hydrochloride Sol.RecoveryMalononitrile Evaporation LossSodium Methoxide Organic ResidueMethanol Inorganic Solid Waste

Stage-1Acetic acid Sol.RecoverySodium Nitrate Evaporation LossMethanol EffluentWater

Stage-2Zinc dustHydrochloric acid (35%) EffluentCarbon Spent CarbonSulfuric acid Process EmissionsWater

2,4,5,6-Tetraaminopyrimidine Sulfate (TAPS)

PRODUCT : 2,4,5,6-Tetraaminopyrimidine Sulfate (TAPS)

Stage-1 : Guanidine Hydrochloride is reacted with Malononitrile in presence of Sodium Methoxide using Methanolas solvent medium to get Stage-1 Compound.

Stage-2 : Stage-1 Compound undergoes nitration reaction with Sodium Nitrate in presence of Acetic acid inMethanol solvent medium to form Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate is reacted with Zinc in presence of Hydrochloric acid to get 2,4,5,6-Tetraaminopyrimidine, which on further reaction with Sulfuric acid and gets purified with Carbon in aqueous medium to obtain2,4,5,6-Tetraaminopyrimidine Sulfate as final product.

Stage I

Stage II

Stage III

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Description :

Flow Chart

o-NitrofluorobenzeneMonoethanolamineMagnesium Oxide EffluentCelite Inorganic Solid WasteWater

PRODUCT : Yellow-2

Stage-1 : o -Nitrofluorobenzene on treatment with Monoethanolamine in presence of Magnesium Oxide and getsfiltrated with Celite in aqueous medium to form Yellow-2.

Yellow-2

Stage I

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86

Description :

Flow Chart

m-Amino AcetanilideManesium OxideDimethyl SulfateHydrochloric acid (35%) Inorganic Solid WasteSodium Hydroxide (25%) Spent CarbonCarbonWater

Stage-1 ML'sSodium CarbonateHydrochloric acid (35%)Sodium Nitrite Effluent1-Phenyl-3-methylpyrazolone Spent CarbonCarbon Process EmissionsSodium ChlorideWater

Stage-2 : Stage-1 compound is diazotized with Sodium Nitrite in presence of Hydrochloric acid and coupled with1-Phenyl-3-methylpyrazolone in presence of Sodium Carbonate and Sodium Chloride in aqueous medium andgets purified with Carbon to obtain Straw Yellow.

Straw Yellow

PRODUCT : Straw Yellow

Stage-1 : m -Amino Acetanilide is trilethylated with Dimethyl Sulfate in presence of Manesium Oxide to get acetylcompound, which is then hydrolysed with Sodium Hydroxide in presence of Hydrochloric acid in aqueous mediumand gets purified with Carbon to form Stage-1 compound.

Stage I

Stage II

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87

Description :

Flow Chart

α-Naphthol Sol.RecoveryEthanol Evaporation LossFormaldehyde (37%) EffluentPiperidine Organic Residue

Stage-1 (Crude) Sol.RecoveryToluene Evaporation LossMethanol Organic Residue

Stage-2 (Pure)Acetic anhydrideKieselguhr Sol.RecoveryEthanol Evaporation LossPalladium Carbon EffluentHydrogen Organic ResidueCarbon Spent CarbonWater

1-Acetoxy-2-methyl naphthalene (AMN)

Stage-1 : α-Naphthol on reaction with Formaldehyde and Piperidine in ethanol gives Stage-1 (Crude).

Stage-2 : The Stage-1 (Crude) is purified from toluene + methanol to geive Stage-2 (Pure).

Stage-3 : Stage-2 (Pure) is reacted with acetic anhydride and then subjected to hydrogenation in presenceof Pd/C-H2 in ethanol to give 1-Acetoxy-2-methyl naphthalene (AMN). Pd/C filtered and reused. To thefiltrate DM Water is added to expel the product and centrifuged.

PRODUCT : 1-Acetoxy-2-methyl naphthalene (AMN)

Stage I

Stage II

Stage III

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PRODUCT : 2-Methoxymethyl-1,4-benzenediamine (MBB)

Stage-4 : Stage-3 Compound on reduction with Hydrogen in presence of Palladium Carbon as catalyst andSodium Sulfite using Methanol and Ethyl Acetate as solvent media and gets purified with Carbon to obtain 2-Methoxymethyl-1,4-benzenediamine (MBB).

Description :

Stage-1 : 2-Chlorobenzyl Chloride is subjected to nitration with Nitric acid in presence of Sulfuric acid, SodiumBicarbonate and Sodium Sulfate using Toluene as solvent medium to form Stage-1 Compound.

Stage-2 : Stage-1 Compound on reaction with Sodium Methoxide in presence of Methanol as solvent mediumto get Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate gets reacted with Benzylamine in presence of Tetrabutylammonium bromideand Hydrochloric acid using Toluene and Methanol as solvent media to give Stage-3 Compound.

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89

Flow Chart

2-Chlorobenzyl ChlorideSulfuric acid Sol.RecoveryNitric acid Evaporation LossToluene EffluentSodium Bicarbonate Organic ResidueSodium Sulfate Process EmissionsWater

Stage-1 Sol.RecoveryEvaporation LossOrganic Residue

Methanol Inorgainc Solid Waste

Stage-2BenzylamineTetrabutylammonium bromide Sol.RecoveryToluene Evaporation LossHydrochloric acid (35%) EffluentMethanol Organic ResidueWater

Stage-3Methanol Sol.RecoveryPalladium Carbon Evaporation LossHydrogen EffluentCarbon Organic ResidueSodium Sulfite Spent CarbonEthyl Acetate Process Emissions

2-Methoxymethyl-1,4-benzenediamine (MBB)


Sodium Methoxide (30%) in Methanol

Stage I

Stage II

Stage III

Stage IV

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90

Flow Chart

2,7-Dihydroxy NaphthaleneAmmonium Hydroxide (25%)Sodium Metabisulfite (21%)Water

Stage-1 (Crude)Methyl Isobutyl Ketone Sol.RecoveryHydrochloric acid (35%) Evaporation LossSodium Hydroxide (47%) EffluentWater

Stage-2 (Pure)Dimethyl SulfideHydrochloric acid (35%)Water

Stage-3 ML'so-AnisidineSodium Nitrite Sol.RecoveryHydrochloric acid (35%) Evaporation LossSodium Hydroxide (50%) EffluentAcetic acid Process EmissionsWater

Stage-3 : Stage-2 Intermediate on reaction with Dimethyl Sulfide in presence of Hydrochloric acid in aqueousmedium to give Stage-3 ML's.

Stage-4 : Stage-3 Compound on reaction with o-Anisidine in presence of Sodium Nitrite, Hydrochloric acid,Sodium Hydroxide and Acetic acid in aqueous medium to obtain Madder Red.

Madder Red

Product ML's

Effluent

PRODUCT : Madder Red

Description :

Stage-1 : 2,7-Dihydroxy Naphthalene on reaction with Ammonium Hydroxide in presence of Sodium Metabisulfitein aqueous medium to give Crude form of Stage-1 Compound.

Stage-2 : Crude Stage-1 Compound gets purified in presence of Hydrochloric acid and Sodium Hydroxide usingMethyl Isobutyl Ketone as solvent medium to yield Pure form of Stage-2 Intermediate.

Stage I

Stage II

Stage III

Stage IV

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Flow Chart

4-Amino-3-nitrophenolDioxitol Sol.RecoveryCalcium Carbonate Evaporation Loss3-Chloropropyl Chloroformate EffluentWater Process Emissions

Stage-1Potassium Hydroxide EffluentHydrochloric acid (35%) Process EmissionsWater

EffluentCarbon Spent CarbonWater

PRODUCT : 3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN)

3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN) (Tech)

3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN)

Description :

Stage-1 : 4-Amino-3-nitrophenol is reacted with 3-Chloropropyl Chloroformate in presence of Calcium Carbonateusing Dioxitol as solvent medium and the reaction mass is quenched into water to expel to form Stage-1Compound and then filtered. The aqueous ML’S containing water and Dioxitol are sent for column distillation.

Stage-2 : Stage-1 Compound is hydrolysed to Tech RED BN by treating it with aqueous Potassium Hydroxidefollowed by neutralization with Hydrochloric acid in aqueous medium. The Tech 3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN) is isolated by filtration. The aqueous ML’S containing water and Potassium Chloride aresent for evaporation.Stage-3 : The Tech 3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN) is charcolised in water andrecrystallised and filtered to get pure 3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN) (Tech). The aqueousML’S containing water are sent for evaporation.

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Description :

Flow Chart

4-Nitro-o-phenylenediamineFormic acidHydrochloric acid (35%)Sodium Nitrite EffluentSodium Hydroxide (48%) Organic ResidueSodium Hypochlorite (15%) Spent CarbonSulfuric acid Process EmissionsSodium CarbonateCarbonWater

PRODUCT : 5-Nitrobenzimidazole (5NBI)

Stage-1 : 4-Nitro-o-phenylenediamine is treated with Formic acid at higher temperatures in presence ofHydrochloric acid, Sodium Hydroxide, Sodium Hypochlorite and Sodium Carbonate in aqueous medium to get 5-Nitrobenzimidazole crude. The crude is then converted into its Nitric acid salt with Sodium Nitrate and isolated. TheNitric acid salt of 5-Nitrobenzimidazole is treated with Sulfuric acid and isolated as free 5-Nitrobenzimidazole.

5-Nitrobenzimidazole (5NBI)

Stage I

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93

Flow Chart

Phenyl hydrazineToluene Sol.RecoverySodium methoxide Evaporation LossMethyl acrylate EffluentHydrochloric acid (35%) Organic ResidueWater

1-Phenyl-3-Pyrazolidone (PHN)

PRODUCT : 1-Phenyl-3-Pyrazolidone (PHN)

Description :Stage-1 : Phenyl hydrazine is reacted with Methyl acrylate in presence of Sodium methoxide in Toluenefollowed by neutralization with Hydrochloric acid and dilution with water. Aqueous layer separated and sentfor evaporation. Methanol and Methyl acrylate which come out during reaction are sent for columndistillation.The product 1-Phenyl-3-Pyrazolidone is centrifuged.

Stage I

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94

Flow Chart

Phenyl hydrazineToluene Sol.RecoverySodium methoxide Evaporation LossMethyl methacrylate EffluentHydrochloric acid (35%) Organic ResidueWater

1-Phenyl-4-methyl-3-pyrazolidone (MPP)

Stage-1 : Phenyl hydrazine is reacted with Methyl methacrylate in presence of Sodium methoxide intoluene followed by neutralization with Hydrochloric acid and dilution with water. Aqueous layer separatedand sent for evaporation.Methanol and Methyl acrylate which come out during reaction are sent for columndistillation.

PRODUCT : 1-Phenyl-4-methyl-3-pyrazolidone (MPP)

Description :

Stage I

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95

Flow Chart

Phenyl hydrazine

MethanolSulfuric Acid Sol.RecoveryToluene Evaporation Loss

Effluent

Hydrochloric acid (35%) Water

Stage-1 Sol.RecoveryToluene Evaporation LossAmberlyst EffluentWater Organic Residue

Inorganic Solid Waste

Description :

PRODUCT : 4-(Hydroxymethyl)-4-methyl-1-phenyl pyrazolidin-3-one (HMP)

2,2- Dihydroxymethyl Propionic acid

Sodium Methoxide (30%) in Methanol

4-(Hydroxymethyl)-4-methyl-1-phenyl pyrazolidin-3-one (HMP)

Stage-1 : DMPA (2,2-Dihydroxy methyl propionic acid) is treated with methanol in presence of catalytic quantity of H2SO4 to get it’s methyl ester. Methanol + water + toluene is distilled out. To the residue 30% SMO in methanol is added followed by phenyl hydrazine to obtain HMP-Hydrazide. Methanol is distilled out and sent for column rectification. The mass is then diluted with water and neutralized with HCl. The HMP-Hydrazide thus precipitated out is centrifuged.

Stage-2 : HMP-Hydrazide is cyclised to 4-(Hydroxymethyl)-4-methyl-1-phenyl pyrazolidin-3-one (HMP) inpresence of Amberlyst catalyst in toluene.

Stage I

Stage II

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Flow Chart

Phenyl hydrazine

Sol.RecoveryMethanol Evaporation Loss

Effluent

Hydrochloric acid (34.26%)Water

Stage-1 Sol.RecoveryToluene Evaporation LossAmberlyst Organic ResidueWater Inorganic Solid Waste

4,4-Dimethyl-1-phenyl pyrazolidin-3-one (DPP)

Stage-1 : Phenyl Hydrazine on reaction with Hydroxy Pivalinic Acid Methyl Ester in presence of Methanoland Sodium Hydroxide, followed by acidification with HCl gives DPP-Hydrazide which is isolated byCentrifugation.

Stage-2 : DPP-Hydrazide under goes cyclisation to give DPP in pressure of cationic resine in Toluene atreflux temp.The Water formed in the reaction is removed through azeotrope.The resine is removed byfiltration and the product which is isolated by Centrifuging.

PRODUCT : 4,4-Dimethyl-1-phenyl pyrazolidin-3-one (DPP)

Description :

Hydroxypivalic acid methyl ester

Sodium methoxide (30%) in Methanol

Stage I

Stage II

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Flow Chart

2-Methyl-5-amino phenol2-Chloroethyl Chloroformate EffluentTrisodium Citrate (54.4%) Process EmissionsWater

Stage-1Sodium Hydroxide EffluentAcetic acid Organic ResidueCarbon Spent CarbonHydrose Process EmissionsSodiumbisulfiteWater

Carbon EffluentHydrose Spent CarbonSodium BisulfiteWater

2-Methyl-5-hydroxyethyl amino phenol (Tech)

PRODUCT : 2-Methyl-5-hydroxyethylamino phenol (2M5HEAP)

Description :

2-Methyl-5-hydroxyethylamino phenol (2M5HEAP)

Stage-1 : 2M5AP (2-Methyl-5-amino phenol) is reacted with 2-Chloroethyl Chloroformate in presence ofTrisodium citrate in water to give the corresponding carbamate, which is isolated by filtration.

Stage-2 : 2M5AP Carbamate is treated with aqueous NaOH followed by carbon treatment and neutralizationwith acetic acid to produce impure 2M5HEAP.

Stage-3 : The impure 2M5HEAP is purified by recrystallisation from water.

Stage I

Stage II

Stage III

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Flow Chart

p-BenzoquinoneAcetic Anhydride Sol.RecoverySulfonic acid Evaporation LossVanisperse EffluentWater

Stage-1 Sol.RecoveryAcetic acid Evaporation LossCarbon EffluentToluene Organic ResidueWater Spent Carbon

Sol.RecoveryEthyl Acetate Evaporation LossToluene Organic Residue

1,2,4-Trihydroxybenzene (1,2,4 THB)

PRODUCT : 1,2,4-Trihydroxybenzene (1,2,4 THB)

Description :

Stage-1 : p -Benzoquinone on reaction with Acetic Anhydride in presence of Sulfonic acid and Vanisperse inaqueous medium to form Stage-1 Compound.

Stage-2 : Stage-1 Compound is hydrolysed in presence of Acetic acid and Toluene as solvent media and getspurified with Carbon to get Crude form of 1,2,4-Trihydroxybenzene.

1,2,4-Trihydroxybenzene (Crude)

Stage-3 : The Crude 1,2,4-Trihydroxybenzene gets purified in presence of Ethyl Acetate and Toluene as solventmedia to obtain Pure 1,2,4-Trihydroxybenzene.

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PRODUCT : Platinum Gray

Description :Stage-1 : Anisyl Dihydronaphthol (ADHN) is reacted with N-Bromo succinamide in presence of DimethylSulfate followed by water and Methanolic Potassium Hydroxide to give Anisyl epoxy naphthol which iscentrifuged.

Stage-2 : The Anisyl epoxy naphthol is converted to Anisyl keto naphthol by treatment with Clay in Toluene.The Clay is filtered. To the filtrate Methanol is added and the Anisyl keto naphthol is centrifuged.

Stage-7 : 4,41-Dihydroxy Benzophenone is reacted with 2-Bromo propane in presence of KOH in DMSO togive 4,41-Diisopropoxy Benzophenone. The reaction mass is quenched into water and IPA to expel theproduct and centrifuge it.

Stage-4 : The unsaturated ester undergoes hydrolysis in presence of aqueous NaOH and ethanol to yieldunsaturated acid. The reaction mass is washed with toluene to remove unhydrolysed unsaturated ester.This toluene layer sent for toluene recovery. The aqueous layer is further diluted with water and neutralizedwith HCl to expel the unsaturated acid and centrifuge it.

Stage-5 : The unsaturated acid is reacted with acetic anhydride in presence of Sodium acetate followed bywater addition to give Acetyl RCP Naphthol which is centrifuged.

Stage-6 : Acetyl RCP Naphthol is hydrolyzed in Acetic acid HCl and water to get RCP Naphthol which iscentrifuged.

Stage-3 : Anisyl keto naphthol is reacted with TEPA (Triethyl phosphono acetate) in presence of Sodiumhydride in THF followed by decomposition with 35% NaCl aqueous solution to give unsaturated ester.The aqueous layer is seperated and sent for evaporation. To the organic layer Ethanol is added to expel theproduct and centrifuge.

Stage-8 : 4,41-Diisopropoxy Benzophenone is reacted with TMSA (Trimethyl Silyl Acetylene) in presence ofn-Hexyl Lithium in THF, followed by decomposition with 35% aqueous NaCl solution. The aqueous layer sentfor evaporation. The organic layer treated with methanolic KOH and Acetic acid to obtain 4,41-DiisopropoxyPPA as a precipitate and centrifuged.

Stage-9 : RCP Naphthol (Stage – VI) and 4,41-Diisopropoxy PPA (Stage – VIII) are reacted in presence ofacetic acid in toluene. To the reaction mass Methanol is added to expel Tech Platinum Grey and centrifuged.

Stage-10 : Technical Platinum Grey is purified from Tetrahydrofuran and Methanol.

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Flow Chart

Anisyl DihydronaphtholDimethyl Sulfoxide Sol.RecoveryN-Bromosuccinimide Evaporation LossPotassium Hydroxide EffluentMethanolWater

Stage-1 Sol.RecoveryToluene Evaporation LossClay Organic ResidueMethanol Inorganic Solid Waste

Stage-2Tetrahydrofuran Sol.RecoveryTriethyl Phosphonoacetate Evaporation Loss


Sodium Chloride (35%) Soln Process EmissionsEthanol

Stage-3Sodium Hydroxide Sol.RecoveryEthanol Evaporation LossToluene EffluentHydrochloric acid (35%) Organic ResidueWater

Stage-4Sodium Acetate EffluentAcetic AnhydrideWater

Stage-5Acetic acidHydrochloric acid (35%) EffluentWater

Sodium Hydride (60%) in paraffin Oil


Stage I

Stage II

Stage III

Stage IV

Stage V

Stage VI

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101

4,4-DihydroxybenzophenoneDimethyl SulfoxidePotassium Hydroxide Sol.Recovery2-Bromopropane Evaporation LossPotassium Iodide EffluentIsopropyl AlcoholWater

Stage-7TetrahydrofuranTrimethylsilyacetylene Sol.RecoveryHexyllithium (33%) in Hexane Evaporation LossSodium Chloride (35%) EffluentMethanol Organic ResiduePotassium Hydroxide Inorganic Solid WasteAcetic acidTolueneWater

Stage-6Stage-8 Sol.RecoveryAcetic acid Evaporation LossToluene Organic ResidueMethanol

Platinum Gray (Tech) Sol.RecoveryTetrahydrofuran Evaporation LossCarbon Organic ResidueMethanol Spent carbon


Platinum Gray

Stage VII

Stage VIII

Stage IX

Stage X

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Description :

PRODUCT : Volcanic Gray

Stage-1 : 4,41-Dimethoxy benzophenone is reacted with Dimethyl succinate in presence of Potassium tertiary butoxide in t-Butanol. To the reaction mass toluene and water added and neutralized with HCl. The organic layer cooled to expel the product DMBP-Stobbe and centrifuged.

Stage-2 : DMBP-Stobbe on reaction with Acetic anhydride in presence of Sodium acetate gives DMBP-BLANC. To the reaction mass water is added and cooled to expel the product and centrifuged.

Stage-3 : DMBP-BLANC is reacted with Vitride in Tetrahydrofuran to get DMBP-Hydroxy methyl naphthol. After the reaction is over Ethyl acetate is added and neutralized with Hydrochloric acid. The reaction mass quenched into water and Toluene. The Toluene + Ethyl acetate + THF layer is cooled and DMBP- Hydroxy methyl naphthol is centrifuged.

Stage-4 : DMBP-Hydroxy methyl naphthol is reduced to DMBP-methyl naphthol in presence of Palladium carbon with Hydrogen gas in Isopropyl alcohol media. Palladium carbon filtered and reused. The Isopropyl alcohol product filtrate is cooled and the product is centrifuged.

Stage-5 : 4,4'-Difluoro benzophenone is reacted with Piperidine in presence of Calcium carbonate in DMSO to get 4,4'-Dipiperidino Benzophenone. The reaction mass is filtered and quenched into water and the product centrifuged.

Stage-6 : 4,4'-Dipiperidino Benzophenone is reacted with Trimethyl silyl acetylene in presence of n-Hexyl lithium in THF followed by decomposition with aqueous ammonium chloride and hydrolysis with methanolic Potassium hydroxide and neutralization by Acetic acid to give Dipiperidino PPA. The Dipiperidino PPA is centrifuged.

Stage-7 : DMBP-Methyl naphthol (Stage-IV) and 4,4'-Dipiperidino PPA (Stage-VI) are reacted in presence of basic alumina in Toluene to give Volcanic grey. Basic Alumina is filtered and reused. To the filtrate Methanol is added to expel the product and centrifuged.

Stage-8 : Technical Volcanic grey is purified from Toluene and Methanol mixture to get pure Volcanic grey.

Annexure-VIII

103

Flow Chart

4,4'-Dimethoxy Benzophenone Dimethyl Succinate Sol.Recoveryt-Butanol Evaporation LossPotassium t-butoxide EffluentToluene Organic ResidueWaterHydrochloric acid (36%)

Stage-1Acetic AnhydrideSodium Acetate EffluentVanisperse Water

Stage-2Tetrahydrofuran Sol.RecoveryEthyl Acetate Evaporation LossHydrochloric acid (35%) EffluentWater Process EmissionsTolueneVitride in Toluene (70%)

Stage-3 Sol.RecoveryIsopropyl Alcohol Evaporation LossPalladium on carbon Organic ResidueHydrogen


Stage I

Stage II

Stage III

Stage IV

Annexure-VIII

104

4,4'-Difluoro benzo phenone Sol.RecoveryPiperidine Evaporation LossCalcium Carbonate EffluentDimethyl Sulfoxide Inorganic Solid WasteWater Process Emissions

Stage-5TetrahydrofuranButyl Lithium in Hexane Sol.RecoveryTrimethylsilyl acetylene Evaporation LossAmmonium Chloride (35%) EffluentAcetic Acid Organic Residue

Process Emissions

Stage-4Stage-6 Sol.RecoveryAlumina Evaporation LossToluene Organic ResidueMethanol

Volcanic Grey (Tech) Sol.RecoveryToluene Evaporation LossCarbon Organic ResidueMethanol Spent Carbon

Volcanic Gray


Potassium hydroxide in Methanol (5%)

Stage V

Stage VI

Stag VII

StageVIII

Annexure-VIII

105

PRODUCT : Fountain Blue

Description :

Stage-1 : 2,4-Dihydroxy benzaldehyde is reacted with Dimethyl succinate in presence in presence of Sodiummethoxide in methanol. The reaction mass is neutralized with HCl and diluted with water to expel STOBBE andcentrifuge it.Stage-2 : STOBBE is reacted with Acetic anhydride in presence of Sodium acetate to get BLANC. To the reactionmass water is added to expel the product and centrifuge it.

Stage-3 : BLANC is reacted with Vitride in THF followed by decomposition with 35% Ammonium chloride andneutralization with HCl. The aqueous layer is seperated and sent for evaporation. To the organic layer toluene isadded and cooled to expel the product CBP – 2 and centrifuged.Stage-4 : CBP – 2 is reduced to CBP – 3 in presence of Pd/C – H2 in IPA. Pd/C is filtered and reused. The filtrateis diluted with water to expel CBP – 3 and centrifuged it.Stage-5 : 4-Fluoro benzoic acid is reacted with Anisole in presence of Polyphosphoric acid to give 4-Fluoro-41–methoxy Benzophenone. The reaction mass is quenched in water to expel the product and centrifuge it.4-Fluoro-41-methoxy benzophenone is recrystallised from Methanol.Stage-6 :4 -Fluoro-41-Methoxy Benzophenone is reacted with Dimethyl amine in presence of Pural Mg – 70 inDMSO. Pural – Mg – 70 is filtered. The filtrate quenched into water to expel 4-NN1-Dimethyl amino - 41-methoxybenzophenone and centrifuge it.

Stage-7 : 4-NN1-Dimethyl amino - 41-methoxy benzophenone is reacted with TMSA (Trimethyl Silyl Acetylene) inpresence of n-Hexyl Lithium in THF followed by addition of Methanolic KOH and 35% aqueous NaCl.

Stage-8 : CBP-3 (Stage – III) and 4-NN1-Dimethyl amino - 41-methoxy PPA (Stage – VI) are reacted in presenceof Pural Mg – 30 in toluene. Pural Mg – 30 is filtered. The filtrate is passed through a Chromatographic column andwashed with Toluene and Ethyl acetate mixture. To the eluent Methanol is added to expel the product. The productFountain Blue Tech is isolated by centrifuge.

Stage-9 : Fountain Blue is purified from the mixture solvents THF and Methanol.

Annexure-VIII

106

Flow Chart

2,4 Dimethoxy benzaldehydeMethanolDimethyl succinate Sol.RecoverySodium methoxide Evaporation LossHydrochloric acid (35%) EffluentWater

Stage-1Sodium acetateAcetic AnhydrideWater

Stage-2Tetrahydrofuran Sol.RecoveryVitride in Toluene (70%) Evaporation LossAmmonium chloride (35%) EffluentHydrochloric acid (35%) Organic ResidueToluene Process EmissionsWater

Stage-3Isopropyl Alcohol Sol.RecoveryHydrogen Evaporation LossWater EffluentPalladium Carbon Process Emissions

4-Fluoro Benzoic acid Anisole Sol.RecoveryPolyphosphoric acid Evaporation LossWater EffluentMethanol Organic ResidueCarbon Spent CarbonKieselguhr


Effluent

Stage I

Stage II

Stage III

Stage IV

Stage V

Annexure-VIII

107

Stage-5Dimethylamine (40%) Sol.RecoveryDimethyl Sulfoxide Evaporation LossPural Mg-70 EffluentIsopropyl Alcohol Inorganic Solid WasteWater

Stage-6TetrahydrofuranTrimethylsilyl acetylene Sol.RecoveryButyl lithium (33%) in Hexane Evaporation LossMethanol EffluentPotassium hydroxide Organic ResidueEthyl Acetate Process EmissionsSodium chloride (35%) solution

Stage-4Stage-7 Sol.RecoveryToluene Evaporation LossEthyl Acetate Organic ResidueMethanolPural Mg-30

Fountain Blue (Tech)Tetrahydrofuran Sol.RecoveryCarbon Evaporation LossKieselguhr Organic ResidueMethanol Spent Carbon

Fountain Blue


Stage VI

Stage VII

StageVIII

Stage IX

Annexure-VIII

108

Description :

Flow Chart

4-Aminopyridine1-Octanal Sol.RecoveryIsopropyl Alcohol Evaporation LossHexane EffluentHydrogen Organic ResiduePd/C Catalyst Process Emissions

1,10-Decanediol Sol.RecoveryThionyl Chloride Evaporation Loss


Process Emissions

Stage-1 Sol.RecoveryStage-2 Evaporation LossAcetone EffluentWater Organic Residue

Octenidine Dihydrochloride (Viv OCT)

PRODUCT : Octenidine Dihydrochloride (Viv OCT)

Stage-1 : 4-Aminopyridine is treated with 1-Octanal in presence of Hydrogen in Pd/C Catalyst using Hexane andIsopropyl Alcohol solvent media to form Stage-1 Compound.

Stage-2 : 1,10-Decanediol on chlorination with Thionyl Chloride to give Stage-2 Intermediate.

Stage-3 : Stage-1 Compound reacts with Stage-2 Intermediate in presence of Acetone solvent medium to obtainOctenidine Dihydrochloride.

Stage I

Stage II

Stage III

Annexure-VIII

109

Raw Material

Consumption of Raw Material /

Batch of Product

Daily Consumption of

Raw Material

Kg KgAcetyl anisole = 144 2477.42Carbon = 4 68.82Hydrochloric acid (35%) = 200.55 3450.32Methanol = 907 15604.30Para tert-Butyl benzoic acid = 178 3062.37Sodium amide = 75 1290.32Sodium Carbonate = 19.7 338.92Sodium Sulfate = 13.35 229.68Sulfuric acid = 17.8 306.24Toluene = 535 9204.30

Raw Material


Batch of Product


Raw Material

Kg KgCarbon = 33.5 13.67Epichlorchydrin = 422 172.24Hydrochloric acid (35%) = 52 21.22Hyflow = 39 15.92Methanol = 2460 1004.08Monochlorohydrin mass = 1796 733.06n-Hexane = 1875 765.31P-Chlorophenol = 500 204.08Sodium Hydroxide = 252 102.86Sulfuric acid = 4 1.80Toluene = 1830 746.94

Raw Material


Batch of Product


Raw Material

Kg KgButyric acid = 210 6.18Hexane = 2200 64.71Hydrochloric acid (35%) = 2958 87Isopropyl Alcohol = 164 4.82Resorcinol = 200 5.88Sodium Carbonate = 438 12.88Tetrabutyl ammonium bromide = 2.72 0.08Toluene = 2755 81.03Zinc = 498 14.65Zinc Chloride = 320 9.41

PRODUCT : Avobenzone (AVIS)LIST OF RAW MATERIALS

PRODUCT : Chlorphenesin (Cosvat)LIST OF RAW MATERIALS

PRODUCT : 4-n-Butylresorcinol (Vivinol)LIST OF RAW MATERIALS

ANNEXURE - IX

110

Raw Material


Batch of Product


Raw Material

Kg Kg2-Ethylhexanol = 360 161.19Acetic acid = 1 0.45Formaldehyde (37%) = 480 214.93Hexane = 2400 1074.63Hydrogen = 26.9 12.04Methanol = 3900 1746.27Palladium Carbon = 48.9 21.90Para Nitrobenzoic acid = 450 201.49Perchloroethylene = 1575 705.22Sodium Carbonate = 40 17.91Sodium Chloride = 350 156.72Sodium Sulfate = 14 6.27Sulfuric acid = 9 4.03

Raw Material


Batch of Product


Raw Material

Kg KgAscorbic acid = 100 8.26Calcium Chloride = 111 9.17Carbon = 20 1.65Hydrochloric acid (35%) = 300 24.79Magnesium Chloride Hexahydrate = 173.7 14.36Methanol = 800 66.12Phosphorous Oxychloride = 200 16.53Potassium Carbonte = 415 34.30Potassium Hydroxide = 130 10.74Pyridine = 90 7.44Resin+ = 2420 200Sodium Hydroxide = 54.5 4.50

PRODUCT : 2-Ethylhexyl 4-(dimethylamino) benzoate (Padimate-O)

LIST OF RAW MATERIALS

PRODUCT : Trisodium ascorbyl-2-Phosphate (C-Vite)


ANNEXURE - IX

111

Raw Material


Batch of Product


Raw Material

Kg Kg4-Octyl Phenol = 185 61.67Benzyl Chloride = 100 33.33Carbon = 17 5.67Diethylene Glycol = 106 35.33Dimethylamine (40%) = 296 98.67Ethyl Acetate = 1400 466.67Phosphorous Oxychloride = 124 41.33Sodium Hydroxide = 153 51Toluene = 2645 881.67

PRODUCT : Benzethonium Chloride (BZC)LIST OF RAW MATERIALS

ANNEXURE - IX

112

Raw Material


Batch of Product


Raw Material

Kg KgAcetic acid = 82 54.67Benzaldehyde = 125 83.33Carbon = 40 26.67Methanol = 30 20o -Phenylenediamine = 145 96.67Sodium Hydroxide (48%) = 267 178Sodium Metabisulfate = 354 236Sulfuric acid = 290 193.33

Raw Material


Batch of Product


Raw Material

Kg Kg2-Ethylhexanol = 286 442.72Acetonitrile = 2040 3157.89Ammonia (25%) Sol. = 20 30.96Carbon = 54 83.59Cyanuric Chloride = 83 128.48Fuller's earth = 74 114.55Hexane = 1900 2941.18Hydrogen = 10.9 16.87Methanol = 2375 3676.47Palladium Carbon = 47.5 73.53Perchloroethylene = 3170 4907.12P-Nitrobenzoic acid = 334 517.03Sodium Carbonate = 20 30.96Sulfuric acid = 18.5 28.64Xylene = 1360 2105.26

PRODUCT : Phenylbenzimidazole Sulfonic acid (PBSA)


PRODUCT : 1,3,5-Para Amino-2-ethylhexyl benzoate-2,4,6-triazine (Etone)


ANNEXURE - IX

113

Raw Material


Batch of Product


Raw Material

Kg Kg3,3-Dimethyl acrylic acid = 200 476.193,5,5-Trimethyl hexanoyl chloride = 394 938.10Aluminium Chloride = 50 119.05Ethyl Acetate = 950 2261.90Hydrochloric acid (35%) = 230 547.62Hydroquinone = 5 11.90Hydroxylamine Hdyrochloride = 125 297.62Methanol = 416 990.48Methylene Dichloride = 5060 12047.62Monoethanolamine = 87 207.14p-Toluenesulfonic acid = 15 35.71Sodium Bicarbonate = 288 685.71Sodium Carbonate = 100 238.10Sodium Chloride = 15 35.71Sodium Methoxide = 100 238.10Sodium Sulfate = 94 223.81

Raw Material


Batch of Product


Raw Material

Kg Kg2-Chloropyridine = 400 10618.42Acetic acid = 424 11255.52Carbon = 20 530.92CMC = 1.6 42.47Despersol = 8.8 233.61Dimethyl Hydention = 2.6 69.02Hexane = 800 21236.83Hydrochloric acid (35%) = 103.66 2751.76Hydrogen Peroxide (50%) = 448 11892.63Sodium Bicarbonate = 83.49 2216.33Sodium Hydroxide = 309.17 8207.24Sodium Sulfide (50%) = 310.12 8232.46Zinc Sulfate Heptahydrate = 340 9025.65

PRODUCT : Piroctone Olamine (Dandoff)LIST OF RAW MATERIALS

PRODUCT : Zinc Pyrithione (Dantuff-Z)LIST OF RAW MATERIALS

ANNEXURE - IX

114

Raw Material


Batch of Product


Raw Material

Kg Kg3-Chloro -2-hydroxypropyl trimethylammonium Chloride (70%) = 81 225

Citric acid = 7.74 21.5Guar gum = 240.8 668.89Sodium Hydroxide = 16.9 46.94

Raw Material


Batch of Product


Raw Material

Kg KgDiethylene triamine pentaacetic acid (40%) = 1018 6786.67

Silver Oxide = 122 813.33

PRODUCT : 2-Hydroxy propyl-3-trimethyl ammonium chloride Guar (Star Cat)


PRODUCT : Silver Oxide - DTPA Complex (Viv Ag)LIST OF RAW MATERIALS

ANNEXURE - IX

115

Raw Material


Batch of Product


Raw Material

Kg Kg2-Ethylhexyl 4-Aminobenzoate = 740 246.67Acetonitrile = 1880 626.67Ammonia (25%) solution = 300 100Cyanuric Chloride = 310 103.33Dimethylformamide = 4 1.33Hexane = 4000 1333.33Hydrogen = 15 5Methanol = 3100 1033.33Palladium Carbon = 13 4.33p -Nitrobenzoic acid = 350 116.67Potassium Carbonate = 138 46tert-Butylamine = 204 68Thionyl Chloride = 560 186.67Toluene = 8950 2983.33Triethylamine = 238 79.33

Raw Material


Batch of Product


Raw Material

Kg Kg4-tert-Octylphenol = 883 883Acetic acid = 343 343Diethylamine = 23 23Ethanol = 3720 3720Hydrochloric acid (35%) = 3329 3329Isopropyl Alcohol = 600 600Methanol = 9850 9850o -Nitroaniline = 587 587Paraformaldehyde = 52 52Sodium Ethoxide = 41 41Sodium Hydroxide = 678 678Sodium Nitrite = 312 312Sulfamic acid = 23 23Toluene = 4570 4570Xylene = 3130 3130Zinc Powder = 527 527

PRODUCT : Vivtroze-HLIST OF RAW MATERIALS

PRODUCT : Tinosorb-M (Vivzole –M)LIST OF RAW MATERIALS

ANNEXURE - IX

116

Raw Material


Batch of Product


Raw Material

Kg Kg2-Ethylhexyl Bromide = 720 4804-Bromoanisole = 400 266.67Aluminium Chloride = 620 413.33Carbon = 147 98Cyanuric Chloride = 395 263.33Dimethylformamide = 2930 1953.33Ethylene Dichloride = 3620 2413.33Hexane = 840 560Iodine = 2 1.33Isopropyl Alcohol = 5170 3446.67Magnesium = 70 46.67n-Butanol = 3660 2440Resorcinol = 445 296.67Sodium Carbonate = 750 500Tetrahydrofuran = 2000 1333.33Toluene = 8940 5960Vitride (70%) in Toluene = 2 1.33

Raw Material


Batch of Product


Raw Material

Kg KgAmmonia (25%) solution = 13 0.72Ammonia gas = 400 22.22Carbon = 10 0.56Ethyl acetate = 5695 316.39Ethyl cyanoacetate = 134 7.44Guanidine Hydrochloride = 110 6.11Hexane = 424 23.56Hydrochloric acid (35%) = 150 8.33Hydrogen peroxide(50%) = 99.4 5.52Hyflow = 4 0.22Magnesium oxide = 38.6 2.14Methanol = 3083 171.28Phosphorus Oxychloride = 1058 58.78Phthalic anhydride = 276 15.33Pyrrolidine = 700 38.89Sodium Methoxide = 129.5 7.19

PRODUCT : Tinosarb-S (Vivtriaz-S)LIST OF RAW MATERIALS



ANNEXURE - IX

117

Raw Material


Batch of Product


Raw Material

Kg Kg4-Bromobenzoic acid = 141 47Carbon = 22 7.33Copper Powder = 5 1.67Ethanol = 262 87.33Polyphosphoric acid = 110 36.67Sodium Hydroxide = 30 10Thionyl Chloride = 340 113.33Thiosalicylic acid = 108 36Toluene = 1850 616.67

Raw Material


Batch of Product


Raw Material

Kg Kg1,4-Dioxane = 230 463,4-Dimethoxyphenylacetone = 542 108.4Acetic acid = 1530 306Acetonitrile = 420 84Carbon = 22 4.4Carbon Tetrachloride 5420 1084Hydrobromic acid (48%) = 1208 241.6Hydrogen = 2 0.4Methanol = 4940 988Palladium Carbon = 32 6.4Titanium Tetrachloride = 314 62.8Zinc = 237 47.4

PRODUCT : Ethyl-9-oxo-9H-thioxanthene-2-carboxylate (9-OXO)


PRODUCT : VintoxLIST OF RAW MATERIALS

ANNEXURE - IX

118

Raw Material


Batch of Product


Raw Material

Kg KgLactic acid = 4160 1386.67L-Menthol = 2893 964.33Sodium Bisulfate = 79 26.33Sodium Hydroxide (50%) = 2158 719.33Toluene = 3950 1316.67

Raw Material


Batch of Product


Raw Material

Kg KgAmmonium Hydroxide (25%) = 60 10Carbon = 7 1.17Ethanol = 500 83.33Nitric acid = 65 10.83Salicylic acid = 70 11.67Sulfuric acid = 130 21.67

PRODUCT : Menthyl Lactate (Vivfresh)LIST OF RAW MATERIALS

PRODUCT : Ammonium Dinitrosalicylic acid (ADNSA)


ANNEXURE - IX

119

Raw Material


Batch of Product


Raw Material

Kg Kg2,6-Di-tert-butylphenol = 104 13.87Aluminium Oxide = 3 0.4Butanol = 780 104Formaldehyde (40%) = 40 5.33Hexane = 520 69.33Potassium Carbonate = 14 1.87Sodium Chloride = 20 2.67Sodium Sulfate = 21 2.8

Raw Material


Batch of Product


Raw Material

Kg Kg4-Amino-2-ethylhexy benzoate = 110 36.67Cyanuric Chloride = 28 9.33Hyflo = 6 2Isopropyl Alcohol = 350 116.67Sodium Bicarbonate = 40 13.33Toluene = 1100 366.67

PRODUCT : 2,6-Di-tert-butyl-5-hydroxybenzyl alcohol (DTBTBA)


PRODUCT : SuntechLIST OF RAW MATERIALS

ANNEXURE - IX

120

Raw Material


Batch of Product


Raw Material

Kg Kg3,4-Dichlorophenyl Isocyanate = 250 205.76Methanol = 300 246.91P-Chloroaniline = 170 139.92Toluene = 1500 1234.57

Raw Material


Batch of Product


Raw Material

Kg Kg2-Chloroethyl chloroformate = 109.1 8.664-Amino-3-nitrophenol = 100 7.94Calcium Carbonate = 54 4.29Carbon = 20 1.59Ethyldioxitol = 575 45.63Hydrochloric acid (35%) = 344.5 27.34Methanol = 2 0.16Oxygen = 0.24 0.02Potassium Hydroxide = 220 17.46

PRODUCT : Trichlorocarbanilide (Vivilide)LIST OF RAW MATERIALS

PRODUCT : 3-Nitro-4-(2-hydroxyethyl) amino phenol (NHEAP)


ANNEXURE - IX

121

Raw Material


Batch of Product


Raw Material

Kg Kg4-Amino N,N-Bis 2-hydroxyethyl aniline = 462 133.91Carbon = 10 2.90Ethanol = 2310 669.57Hydrochloric acid (35%) = 627.5 181.88Hydrogen = 8.7 2.52Palladium Carbon = 15.5 4.49Sodium Hydroxide = 138.6 40.17Sodium Nitrite = 176.2 51.07Sulfuric acid = 133.4 38.67

Raw Material


Batch of Product


Raw Material

Kg Kg1,4-D-Violet = 300 10.42Carbon = 21 0.73Diethylsulfate = 367.5 12.76Hydrochloric acid (31.3 %) = 126 4.38Methanol = 860 29.86n-Butanol = 4746 164.79Sodium Carbonate = 200 6.94

PRODUCT : 4-Amino N,N-Bis (2-hydroxyethyl) aniline sulfate (BHP)


PRODUCT : Nitroblue (Blue 12)LIST OF RAW MATERIALS

ANNEXURE - IX

122

Raw Material


Batch of Product


Raw Material

Kg Kg2,6-Dichlorobenzaldehyde = 15 1.252,6-Dimethylaniline = 21 1.75Carbon = 0.35 0.03Chloranil = 20.35 1.70Ethanol = 935 77.92Kiesulgar = 0.5 0.04Phosphoric acid (85%) = 19.8 1.65Sodium Hydroxide = 30.3 2.53Sulfuric acid = 18 1.5

Raw Material


Batch of Product


Raw Material

Kg Kg1-Bromopropane = 48 7.623-( Dimethylamino ) -1-Propylamine = 42.6 6.764-Bromo-1-Methylamino anthraquinone (Impure) = 50 7.94

Carbon = 2 0.32Cuprous Acetate = 2.16 0.34Dimethyl Sulfoxide = 150 23.81Isopropyl Alcohol = 245 38.89n-Butanol = 467 74.13N-Methylpyrrolidone = 287 45.56Sodium Acetate = 20.6 3.27Tolulene = 225 35.71Tributylamine = 6.7 1.06

PRODUCT : 1-(3,5-Dimethyl-4-aminophenyl)-1-(3,5-dimethylimino phenyl)-1-(2,6-dichlorophenyl) methane

Phosphate (Jade Blue/Blue 15)LIST OF RAW MATERIALS

PRODUCT : Methylamino dimethylamino Propylamino Propylbromide anthraquinone (BQB/ Blue 16)


ANNEXURE - IX

123

Raw Material


Batch of Product


Raw Material

Kg KgCarbon = 9 1.5Celite = 7 1.17Magnesium Oxide = 11 1.83Methanol = 1070 178.33Monoethanolamine = 35 5.83N,N-Bis-(Hydroxyethyl)-4-Fluoro-3-Nitroaniline = 110 18.33

Raw Material


Batch of Product


Raw Material

Kg Kg2,4-Dinitrochlorobenzene = 200 37.04Carbon = 19 3.52Ethanol = 3810 705.56Hydrogen = 10.26 1.9Hydrogen Chloride = 69 12.78Hyflo = 6 1.11Methanol = 820 151.85Momoethylene glycol = 1332 246.67Palladium Carbon = 27.4 5.07Sodium Carbonate = 71 13.15

PRODUCT : 2,2'-[[4-[(2-Hydroxyethyl)amino]-3-nitrophenyl]imino] bisethanol (Blue-2)


PRODUCT : 2,4-Diamino phenoxyethanol Dihydrochloride (DPE HCl)


ANNEXURE - IX

124

Raw Material


Batch of Product


Raw Material

Kg Kg2-Chloroethyl Chloroformate = 155.6 6.48Calcium Carbonate = 57.83 2.41Ethyldioxitol = 675 28.13Hydrochloric acid (35%) = 458.22 19.09Meta Nitro para Toluidine = 100 4.17Potassium Hydroxide = 227 9.46

Raw Material


Batch of Product


Raw Material

Kg Kg2,4-Dinitrochlorobenzene = 200 16.67Carbon = 19 1.58Ethanol = 2510 209.17Hydrogen = 10.26 0.86Hyflo = 6 0.5Methanol = 820 68.33Momoethylene glycol = 1332 111Palladium Carbon = 27.4 2.28Sodium Carbonate = 71 5.92Sulfuric acid = 83.82 6.99

PRODUCT : 4-Hydroxyethylamino-3-nitro toluene (HNT)


PRODUCT : 2,4-Diamino phenoxyethanol Sulfate (DPE Sulfate)


ANNEXURE - IX

125

Raw Material


Batch of Product


Raw Material

Kg KgAcetic acid = 9 1.5Carbon = 2 0.33Guanidine Hydrochloride = 16 2.67Hydrochloric acid (35%) = 62 10.33Malononitrile = 12 2Methanol = 130 21.67Sodium Methoxide = 10 1.67Sodium Nitrate = 9 1.5Sulfuric acid = 12 2Zinc dust = 19 3.17

Raw Material


Batch of Product


Raw Material

Kg KgCelite = 2 0.33Magnesium Oxide = 3 0.5Monoethanolamine = 11 1.83o -Nitrofluorobenzene = 17 2.83

PRODUCT : 2,4,5,6-Tetraaminopyrimidine Sulfate (TAPS)


PRODUCT : Yellow-2LIST OF RAW MATERIALS

ANNEXURE - IX

126

Raw Material


Batch of Product


Raw Material

Kg Kg1-Phenyl-3-methylpyrazolone = 22 3.67Carbon = 9 1.5Dimethyl Sulfate = 37 6.17Hydrochloric acid (35%) = 128 21.33m -Amino Acetanilide = 22 3.67Manesium Oxide = 25 4.17Sodium Carbonate = 26 4.33Sodium Chloride = 140 23.33Sodium Hydroxide (25%) = 47 7.83Sodium Nitrite = 9 1.5

Raw Material


Batch of Product


Raw Material

Kg KgAcetic anhydride = 27 10Carbon = 0.5 0.19Ethanol = 191 70.74Formaldehyde (37%) = 8.9 3.30Hydrogen = 0.09 0.03Kieselguhr = 0.25 0.09Methanol = 18 6.67Palladium Carbon = 1.8 0.67Piperidine = 9.3 3.44Toluene = 22 8.15α-Naphthol = 15 5.56

PRODUCT : Straw YellowLIST OF RAW MATERIALS

PRODUCT : 1-Acetoxy-2-methyl naphthalene (AMN)LIST OF RAW MATERIALS

ANNEXURE - IX

127

Raw Material


Batch of Product


Raw Material

Kg Kg2-Chlorobenzyl Chloride = 908 302.67Benzylamine = 854 284.67Carbon = 15 5Ethyl Acetate = 2320 773.33Hydrochloric acid (35%) = 145 48.33Hydrogen = 25 8.33Methanol = 13860 4620Nitric acid = 400 133.33Palladium Carbon = 15 5Sodium Bicarbonate = 136 45.33Sodium Methoxide (30%) in Methanol = 1029 343Sodium Sulfate = 182 60.67Sodium Sulfite = 16 5.33Sulfuric acid = 400 133.33Tetrabutylammonium bromide = 120 40Toluene = 14530 4843.33

Raw Material


Batch of Product


Raw Material

Kg Kg2,7-Dihydroxy Naphthalene = 84 14Acetic acid = 96 16Ammonium Hydroxide (25%) = 84 14Dimethyl Sulfide = 251 41.83Hydrochloric acid (35%) = 185 30.83Methyl Isobutyl Ketone = 460 76.67o -Anisidine = 51 8.5Sodium Hydroxide (47%) = 40 6.67Sodium Hydroxide (50%) = 255 42.5Sodium Metabisulfite (21%) = 214 35.67Sodium Nitrite = 29 4.83



PRODUCT : Madder RedLIST OF RAW MATERIALS

ANNEXURE - IX

128

Raw Material


Batch of Product


Raw Material

Kg Kg3-Chloropropyl Chloroformate = 133 22.174-Amino-3-nitrophenol = 111 18.5Calcium Carbonate = 60 10Carbon = 22 3.67Dioxitol = 640 106.67Hydrochloric acid (35%) = 377 62.83Potassium Hydroxide = 240 40

PRODUCT : 3-Nitro-N-(2-hydroxypropyl)-4-aminophenol (RED BN)


ANNEXURE - IX

129

Raw Material


Batch of Product


Raw Material

Kg Kg4-Nitro-o -phenylenediamine = 50 20.83Carbon = 9 3.75Formic acid = 87 36.25Hydrochloric acid (35%) = 65 27.08Sodium Carbonate = 10 4.17Sodium Hydroxide (48%) = 49 20.42Sodium Hypochlorite (15%) = 10 4.17Sodium Nitrite = 28 11.67Sulfuric acid = 25 10.42

Raw Material


Batch of Product


Raw Material

Kg KgHydrochloric acid (35%) = 550.4 58.24Methyl acrylate = 458 48.47Phenyl hydrazine = 500 52.91Sodium methoxide = 285 30.16Toluene = 4070 430.69

PRODUCT : 5-Nitrobenzimidazole (5-NBI)LIST OF RAW MATERIALS

PRODUCT : 1-Phenyl-3-Pyrazolidone (PHN)LIST OF RAW MATERIALS

ANNEXURE - IX

130

Raw Material


Batch of Product


Raw Material

Kg KgHydrochloric acid (35%) = 656.6 55.62Methyl methacrylate = 612 51.84Phenyl hydrazine = 600 50.83Sodium methoxide = 340 28.80Toluene = 4500 381.19

Raw Material


Batch of Product


Raw Material

Kg Kg2,2- Dihydroxymethyl Propionic acid = 162 71.05Amberlyst = 33.5 14.69Hydrochloric acid (35%) = 138.75 60.86Methanol = 216 94.74Phenyl hydrazine = 125 54.82Sodium Methoxide (30%) in Methanol = 239.5 105.04Sulfuric Acid = 1.25 0.55Toluene = 2058 902.63

PRODUCT : 1-Phenyl-4-methyl-3-pyrazolidone (MPP)


PRODUCT : 4-(Hydroxymethyl)-4-methyl-1-phenyl pyrazolidin-3-one (HMP)


ANNEXURE - IX

131

Raw Material


Batch of Product


Raw Material

Kg KgAmberlyst = 510 17Hydrochloric acid (34.26%) = 525 17.5Hydroxypivalic acid methyl ester = 1000 33.33Methanol = 530 17.67Phenyl hydrazine = 503 16.77Sodium methoxide (30%) in Methanol = 887 29.57Toluene = 3300 110

Raw Material


Batch of Product


Raw Material

Kg Kg2-Chloroethyl Chloroformate = 290 24.172-Methyl-5-amino phenol = 227 18.92Acetic acid = 563.32 46.94Carbon = 40 3.33Hydrose = 2.2 0.18Methanol = 2 0.17Sodium Bisulfite = 5.5 0.46Sodium Hydroxide = 446.65 37.22Sodiumbisulfite = 15 1.25Trisodium Citrate (54.4%) = 453.8 37.82

PRODUCT : 4,4-Dimethyl-1-phenyl pyrazolidin-3-one (DPP)


PRODUCT : 2-Methyl-5-hydroxyethylamino phenol (2M5HEAP)


ANNEXURE - IX

132

Raw Material


Batch of Product


Raw Material

Kg KgAcetic acid = 172 34.4Acetic Anhydride = 432 86.4Carbon = 14 2.8Ethyl Acetate = 850 170p -Benzoquinone = 72 14.4Sulfonic acid = 14 2.8Toluene = 2230 446Vanisperse = 1 0.2

PRODUCT : 1,2,4-Trihydroxybenzene (1,2,4-THB)LIST OF RAW MATERIALS

ANNEXURE - IX

133

Raw Material


Batch of Product


Raw Material

Kg Kg2-Bromopropane = 70 3.054,4-Dihydroxybenzophenone = 35 1.53Acetic acid = 472.5 20.59Acetic Anhydride = 232 10.11Anisyl Dihydronaphthol = 100 4.36Carbon = 2 0.09Clay = 20 0.87Dimethyl Sulfoxide = 1200 52.29Ethanol = 660 28.76Hexyllithium (33%) in Hexane = 48.36 2.11Hydrochloric acid (35%) = 73.46 3.20Isopropyl Alcohol = 140 6.10Methanol = 3290 143.36N-Bromosuccinimide = 83 3.62Potassium Hydroxide = 96 4.18Potassium Iodide = 8.75 0.38Sodium Acetate = 14.87 0.65Sodium Chloride (35%) = 228.5 9.96Sodium Hydride (60%) in paraffin Oil = 9.26 0.40Sodium Hydroxide = 16.76 0.73Tetrahydrofuran = 955 41.61Toluene = 1360 59.26Triethyl Phosphonoacetate = 54 2.35Trimethylsilyacetylene = 20 0.87

PRODUCT : Platinum GrayLIST OF RAW MATERIALS

ANNEXURE - IX

134

Raw Material


Batch of Product


Raw Material

Kg Kg4,4'-Difluoro benzo phenone = 78 3.064,4'-Dimethoxy Benzophenone = 200 7.84Acetic Acid = 9 0.35Acetic Anhydride = 575 22.55Alumina = 138 5.41Ammonium Chloride (35%) = 50 1.96Butyl Lithium in Hexane = 120 4.71Calcium Carbonate = 35.77 1.40Carbon = 10 0.39Dimethyl Succinate = 363 14.24Dimethyl Sulfoxide = 345 13.53Ethyl Acetate = 1425 55.88Hydrochloric acid (35%) = 565 22.16Hydrogen = 0.64 0.03Isopropyl Alcohol = 665 26.08Methanol = 6486 254.35Palladium on carbon = 2.58 0.10Piperidine = 178 6.98Potassium hydroxide in Methanol (5%) = 63 2.47Potassium t-butoxide = 208 8.16Sodium Acetate = 74 2.90t-Butanol = 1000 39.22Tetrahydrofuran = 1032 40.47Toluene = 5230 205.10Trimethylsilyl acetylene = 30 1.18Vanisperse = 0.22 0.01Vitride in Toluene (70%) = 344 13.49

PRODUCT : Volcanic GrayLIST OF RAW MATERIALS

ANNEXURE - IX

135

Raw Material


Batch of Product


Raw Material

Kg Kg2,4 Dimethoxy benzaldehyde = 100 4.964-Fluoro Benzoic acid = 82 4.07Acetic Anhydride = 550 27.28Ammonium chloride (35%) = 620 30.75Anisole = 68 3.37Butyl lithium (33%) in Hexane = 100 4.96Carbon = 12 0.60Dimethyl succinate = 110 5.46Dimethyl Sulfoxide = 600 29.76Dimethylamine (40%) = 200 9.92Ethyl Acetate = 700 34.72Hydrochloric acid (35%) = 317.9 15.77Hydrogen = 0.39 0.02Isopropyl Alcohol = 830 41.17Kieselguhr = 11 0.55Methanol = 3700 183.53Palladium Carbon = 4.5 0.22Polyphosphoric acid = 792 39.29Potassium hydroxide = 15 0.74Pural Mg-30 = 100 4.96Pural Mg-70 = 50 2.48Sodium acetate = 35 1.74Sodium chloride (35%) solution = 200 9.92Sodium methoxide = 83 4.12Tetrahydrofuran = 1200 59.52Toluene = 5220 258.93Trimethylsilyl acetylene = 40 1.98Vitride in Toluene (70%) = 390 19.35

PRODUCT : Fountain BlueLIST OF RAW MATERIALS

ANNEXURE - IX

136

Raw Material


Batch of Product


Raw Material

Kg Kg1,10-Decanediol = 56 9.331-Octanal = 55 9.174-Aminopyridine = 40 6.67Acetone = 190 31.67Hexane = 400 66.67Hydrogen = 1 0.17Isopropyl Alcohol = 560 93.33Pd/C Catalyst = 4 0.67Thionyl Chloride = 230 38.33

PRODUCT : Octenidine Dihydrochloride (Viv OCT)LIST OF RAW MATERIALS

ANNEXURE - IX

137

LIST OF HAZARDOUS RAW MATERIALS

Porposed Products S.No.

Raw Material S.No. Raw Material

1 1,4-Dioxane 44 Sulfuric acid 2 2,6-Dimethylaniline 45 tert-Butylamine 3 2-Chloroethyl Chloroformate 46 Tetrahydrofuran 4 2-Ethylhexanol 47 Thionyl Chloride 5 4-Aminopyridine 48 Toluene 6 Acetic acid 49 Triethylamine 7 Acetic Anhydride 50 Xylene 8 Acetone 9 Acetonitrile 10 Ammonia (25%) solution 11 Ammonia gas 12 Benzyl Chloride 13 Carbon Tetrachloride 14 Diethylamine 15 Diethylene Glycol 16 Dimethylamine (40%) 17 Epichlorchydrin 18 Ethanol 19 Ethyl Acetate 20 Ethylene Dichloride 21 Formaldehyde (37%) 22 Formic acid 23 Hexane 24 Hydrobromic acid (48%) 25 Hydrochloric acid (35%) 26 Hydrogen 27 Hydrogen Chloride 28 Hydroquinone 29 Isopropyl Alcohol 30 Malononitrile 31 Methanol 32 Methyl Isobutyl Ketone 33 Methyl methacrylate 34 Methylene Dichloride 35 Momoethylene glycol 36 o-Phenylenediamine 37 p-Benzoquinone 38 P-Chloroaniline 39 Perchloroethylene 40 Phosphorous Oxychloride 41 Phthalic anhydride 42 Piperidine 43 Pyridine

ANNEXURE - X

138

Annexure-XI

139

Collection cum Equalization

Tank

Solvents for Recovery / PCB Auth. Party (with moisture) Condenser

Holding Tank

Neutrali-zation

Aeration Tank

Storage Tank

Dual media filter

Stea

m S

trip

per

ATFD

Pre aeration tank

Cond

ense

r R.O. System Product water to

Utilities

ACF

HTDS / HCOD Effluent inlet

Storage Tank

MEE

Sys

tem

Condensate

Condensate Pre

aera

tion

tank

Filtr

ate

Sludge Decanter/ SDBS and dried sludge to TSDF Sludge Decanter/

SDBS and dried sludge to TSDF

Filtr

ate

Concentrate

RO / Used to Cooling Tower

Salts to TSDF

LTDS / LCOD & Domestic Effluent

inlet

Rejects

Forc

ed

Evap

orat

ion

Condensate to Utilities Salts to TSDF

Scrubber Effluent inlet

Sludge recycle

Effluent Treatment Flow Scheme Annexure-XII

140

manu

Text Box

Schematic flow Sheet for EIA Procedure

Time schedule for obtaining the EC from MOEF

Submission of application by proponent (Form 1, Pre-feasilibility report and Draft Terms of Reference)

Scrutiny by EAC

Scoping an communication of Terms of Reference for EIA Studies to the Proponent for EIA preparation

Submission of proceedings of the public hearing by the SPCB / PCC to EAC

Conducting public hearing by SPCB / PCC or any other public Agency / authority engaged by regulatory authority

Submission of Draft EIA / Summary EIA / Application for Public consultation

Appraisal by EAC

Submission of final EIA by the proponent after improving EIA / EMP

Decision of MoEF

Decision of MoEF

Specific Concerns

Yes NO Rejection

Issuing clearance to project proponent

60 days

45 days

60 days

Scop

ing

Publ

ic C

onsu

ltanc

y De

cisio

n M

akin

g Ap

prai

sal

Reservation on the proposal conveyed to EAC

EAC views on reservations sent to MoEF

45 days

60 days

30 days

Category A Project

Preparation of FORM I Application & Prefeasibility report

30 days on obtaining information from industry

as per check list

Preparation of Draft EIA report 120 days minimum other than monsoon period of 120 days

30 days for preparation of Final REIA Maximum

Annexure-XIII

141

Environmental Baseline Monitoring (To Establish quality of the

Environment)

Application of Impact Prediction Tools (Quantitative Significance Analysis)

Identification of Likely Impacts (Quantitative Significance Analysis

(Ref: Impact Matrix)

EIA Team

Social Impact Assessment

Risk Assessment

Project Features (Pre-feasibility Report,

Form1)

Valued Environment Components

Mitigation Measures

Environmental Management Plan

Reporting

Approach of EIA Study – 4 months other than monsoon period after obtaining TOR copy from MOEF

Annexure-XIII

142

Annexure-XIV

143

Annexure-XV

144

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