c) Summary of mass balance - Gujarat Pollution Control...
Transcript of c) Summary of mass balance - Gujarat Pollution Control...
Rapid Environmental Impact Assessment Report Page : 51 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 4–Piperidone Hydrochloride is given in Table.
Summary of Mass Balance for – 4-Piperidone Hydrochloride
capacity of Finished Product MT/Month : 10.00
batch size kg : 20
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Piperidone Monohydrate Hydrochloric Acid
25 0.23 2.27
2 Acetone 15 0.14 1.36 Reactant
3 Toluene (Fresh) 15 0.14 1.36
4 Toluene (Recovered) 185 1.68 16.82 Solvent
Total 240 2.18 21.82
Output
1 4-Piperidone Hydrochloride 20 0.18 1.82 Finished Product
2 Rec Toluene 185 1.68 16.82 Recovered Solvent
3 Waste acetone 10 0.09 0.91
4 Waste Water 10 0.09 0.91 To ETP
5 Touene Loss 15 0.14 1.36 To Atm Total 240 2.18 21.82
Rapid Environmental Impact Assessment Report Page : 52 of 294 Chapter-2 Project Description
(A-13) Piperidone Mono Hydrate HCl
a) Material Balance Diagram:
Reaction Vessel
Liquid – Liquid Extraction
Distillation
N –Hexane (Fresh): 100 N –Hexane
(Recovered): 1400
Distilled mass
Heating followed by Cooling
Continue…….
Heating followed by Cooling Caustic Lye: 150
N-Carbethoxy-4-Piperidone: 200
Tri methyl ortho formate: 150
Methane sulfonic acid: 120 Methanol (Fresh): 300
Methanol (Recovered): 300
Aqueous Layer (Effluent): 1200
N –Hexane Recovered: 1400
Distillation Loss: 100 Distillation Residue: 10 Methanol Recovered:
600
N –Hexane & Methanol Recovery
Methanol (Fresh): 300 Methanol (Recovered):
300 Caustic Lye Solution:
100
Chloroform (Fresh): 100 Chloroform
(Recovered): 1100 Purified Water: 1400
Liquid – Liquid extraction & Layer
separation
Aqueous Layer (Effluent): 1000
CO2: 60
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Organic Layer Chloroform Recovery
Chloroform Recovered: 1100
Distillation Loss: 100 Distillation Residue: 10
High vaccum Distillation of
Crude 4-Piperidone
Distillation Loss:
Distillation Residue: 30
Reaction mass IPA: 450 HCl: 300
Cooling, Chilling & Centrifuge M/L as waste: 50
Piperidone Mono Hydrate HCl
(Finished Product)
IPA Recovered: 400
Rapid Environmental Impact Assessment Report Page : 54 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Chemical Formula
Chemical Name
N
O
COOEt
+ NaOH SolutionWater
Chloroform HCl N
H
O
HCl
+ C2H5OH CO2+
N-Carbethoxy 4-PIperidone 4-Piperidone Hydrochloride
Molecular Weight
171 40 135.5 46 44
c) Summary of mass balance
Summary of mass balance for Piperidone Mono Hydrate HCl is given in Table .
Summary of Mass Balance for – Piperidone Mono Hydrate HCl
capacity of Finished Product MT/Month : 10.00
batch size kg : 110
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Piperidone 200 1.82 18.18
2 Tri methyl ortho formate 150 1.36 13.64
3 Methane sulfonic acid 120 1.09 10.91
4 Caustic Lye 250 2.27 22.73
5 Water 1400 12.73 127.27
Reactant
6 Methanol (Fresh) 600 5.45 54.55
7 Methanol (Recovered) 600 5.45 54.55
8 N-Hexane (Fresh) 100 0.91 9.09
9 N-Hexane (Recovered) 1400 12.73 127.27
10 Chloroform (Fresh) 100 0.91 9.09
11 Chloroform (Recovered) 1100 10.00 100.00
12 Hydrochloric Acid 300 2.73 27.27
Solvent
Rapid Environmental Impact Assessment Report Page : 55 of 294 Chapter-2 Project Description
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/MonthRemarks
Input
13 Iso Propyl Alcohol (Fresh) 50 0.45 4.55
14 Iso Propyl Alcohol (Recovered)
400 3.64 36.36
Total 6770 61.55 615.45
Output
1 4-Piperidone Monohydrtae Hydrochloride
110 1.00 10.00 Finished Product
2 Effluent with ethanol & Methanol
2200 20.00 200.00 To ETP
3 Residue after distillation 50 0.45 4.55 To TSDF
4 Rec Methanol 600 5.45 54.55
5 Rec Iso Propyl Alcohol 400 3.64 36.36
6 Rec Chloroform 1100 10.00 100.00
7 Rec N-Hexane 1400 12.73 127.27
8 Carbon Di oxide 60 0.55 5.45
9 Iso Propyl Alcohol Loss 50 0.45 4.55
10 N-Hexane Loss 100 0.91 9.09
11 Chloroform Loss 100 0.91 9.09
12 Methanol Loss 600 5.45 54.55
Total 6770 61.55 615.45
Recovered Solvent
Rapid Environmental Impact Assessment Report Page : 56 of 294 Chapter-2 Project Description
(A-14) 4-Piperidone ethylene Ketal
a) Material Balance Diagram:
Reaction Vessel N-Carbethoxy-4-
Piperidone: 100 Para Toluene Sulphonic
acid: 110 Mono Ethylene Glycol:
200 Methane sulfonic acid: 90
Toluene (Fresh): 70 Toluene (Recovered): 450
Azeotropic Distillation
Organic Layer
Heating
Aqueous Layer (Effluent): 300
Cooling of Distilled mass & Layer
separation
Water: 200 Aqueous Layer (Effluent): 490
IPA: 240 KOH Soln in IPA: 95
Toluene Recovery: 450
IPA Recovery: 200
Layer separation of Reaction mass
Water: 95 Chloroform (Fresh): 100
Chloroform (Recovered): 500
Organic Layer Chloroform Recovery: 500
High Vaccum Distillation
Distillation Loss: 210
Distillation Residue: 40
4-Piperidone ethylene Ketal (Finished Product)
Rapid Environmental Impact Assessment Report Page : 57 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
Chemical Formula
Chemical Name
+N
OO
COOEtN -Carbethoxy 4-Piperidone N-Carbethoxy4-Piperidone Ethylene K
N
COOEt
O
OH OH
Mono ethylene glycol
+ H2O
Toluene
MSA
Molecular Weight
171 62 215 18
Stage –II
Chemical Formula
Chemical Name N
H
OO
N-Carbethoxy4-Piperidone Ethylene Ketal
+ C2H5OHN
OO
COOEt
IPA+ KOH
+ CO2
4- Piperidone Ethylene ketal
Molecular Weight
215 56 142 46 44
c) Summary of mass balance Summary of mass balance for 4-Piperidone ethylene Ketal is given in Table.
Summary of Mass Balance for – 4- Piperidone ethylene Ketal
capacity of Finished Product MT/Month : 10.00
batch size kg : 60
Working Days Per Month : 26
Rapid Environmental Impact Assessment Report Page : 58 of 294 Chapter-2 Project Description
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Piperidone 100 1.67 16.67
2 Para Toluene sulfonic acid 110 1.83 18.33
3 Methane sulfonic acid 90 1.50 15.00
4 Mono Ethylene glycol 200 3.33 33.33
Caustic Potash 95 1.58 15.83
Water 295 4.92 49.17
Reactant
5 Toluene (Fresh) 70 1.17 11.67
6 Toluene (Recovered) 450 7.50 75.00
8 Iso Propyl Alcohol (Fresh) 40 0.67 6.67
9 Iso Propyl Alcohol (Recovered) 200 3.33 33.33
10 Chloroform (Fresh) 100 1.67 16.67
11 Chloroform (Recovered) 500 8.33 83.33
Solvent
Total 2250 37.50 375.00
Output
1 4-Piperidone ethylene ketal 60 1.00 10.00 Finished Product
2 Effluent with ethanol & methanol
790 13.17 131.67 To ETP
3 Rec Toluene 450 7.50 75.00
4 Rec Iso Propyl Alcohol 200 3.33 33.33
5 Rec Chloroform 500 8.33 83.33
Recovered Solvent
6 Toluene Loss 70 1.17 11.67
7 Iso Propyl Alcohol Loss 40 0.67 6.67
8 Chloroform Loss 100 1.67 16.67 To Atm
9 Residue after diatilation 40 0.67 6.67 To TSDF Total 2250 37.50 375.00
Rapid Environmental Impact Assessment Report Page : 59 of 294 Chapter-2 Project Description
(A-15) N-Carbethoxy-4-Piperidone
a) Material Balance Diagram:
Reaction Vessel N-Methyl-4-Piperidone:
500 Ethyl chloroformate: 600
Toluene (Fresh): 100 Toluene (Recovered):
1500
Organic Layer
Layer separation Water: 400 Aqueous Layer (Effluent): 650
Toluene Recovery: 1500
High Vaccum Distillation
Distillation Loss: 100
Distillation Residue: 60
550 kg of N Carbethoxy- 4-Piperidone (Finished Product)
Crude N-Carbethoxy- 4-
Piperidone
Chloro methane: 240
Rapid Environmental Impact Assessment Report Page : 60 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
N OCH3 N O
O
C2H5
O+ ClCO2CH2CH3 + CH3Cl
Toluene
Water
N-Methyl 4-Piperidone Ethyl ChloroFormate N-Carbethoxy 4-Piperidone Methyl chlorid
MolecularWeight
113 108.5 171 50.5
Rapid Environmental Impact Assessment Report Page : 61 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for N-Carbethoxy-4-Piperidone is given in Table .
Summary of Mass Balance for – N-Carbethoxy-4- Piperidone
capacity of Finished Product MT/Month : 10.00
batch size kg : 500
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Methyl-4-Piperidone 500 1.00 10.00
2 Ethyl chloroformate 600 1.20 12.00
3 Water 350 0.70 7.00
Reactant
4 Toluene (Fresh) 100 0.20 2.00
5 Toluene (Recovered) 1500 3.00 30.00 Solvent
Total 3050 6.10 61.00
Output
1 N-Carbethoxy-4-Piperidone 500 1.00 10.00 Finished Product
2 Effluent 650 1.30 13.00 To ETP
3 Chloro methane 240 0.48 4.80
4 Residue after distillation 60 0.12 1.20 To TSDF
5 Rec Toluene 1500 3.00 30.00 Recovered Solvent
6 Toluene Loss 100 0.20 2.00 To Atm Total 3050 6.10 61.00
Rapid Environmental Impact Assessment Report Page : 62 of 294 Chapter-2 Project Description
(A-16) N-BOC- 4 Carbethoxy-4-Piperidone
a) Material Balance Diagram:
Reaction Vessel
Liquid – Liquid Extraction
Aqueous Layer
Chloroform (Fresh): 100 Chloroform
(Recovered): 500
Di BOC: 60
Organic Layer (Chloroform Recovery)
Chloroform Recovered: 500
Distillation Loss: 100 Distillation Residue: 30
Heating followed by Cooling
Reaction mass & Extraction
High Vaccum Distillation
Methanol Recovered: 40
Distillation Loss: 50 Distillation Residue: 25
Continue…….
N-Carbethoxy-4-Piperidone: 100
Caustic Lye: 125 Water: 600
Heating followed by Cooling
Methanol (Fresh): 50 Methanol (Recovered):
450 Aqueous Layer
(Effluent): 500
Methanol Recovery
Crude N-T-Boc-4-Piperidone
Hexane (Fresh): 50 Hexane (Recovered):
350
Rapid Environmental Impact Assessment Report Page : 63 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Chemical Formula
Chemical Name
+((CH3)3COC(O))2O
N-Boc 4-CarbethoxyPiperidine
+NH
COOEt
N
COOEt
O O CH3
CH3CH3
4 -Carbethoxy piperidine
(CH3)3COC(O)OH
Molecular Weight 157 218 257
ML: 240
90 kg of N-BOC-4-Carbethoxy-4-Piperidone
(Finished Product)
Cooling, chilling, Filtration
Rapid Environmental Impact Assessment Report Page : 64 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for N-Boc-4-Carbethoxy-Piperidone is given in Table.Summary of Mass Balance for – N-Boc-4-Carbethoxy- Piperidone
capacity of Finished Product MT/Month : 10.00
batch size kg : 90
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month
Remarks
Input
1 N-Carbethoxy-4-Piperidone 100 1.11 11.11 Reactant
2 Methanol (fresh) 50 0.56 5.56
3 Methanol(Recovered) 450 5.00 50.00 Solvent
4 DI BOC 60 0.67 6.67
5 Caustic Lye 125 1.39 13.89 Reactant
6 Chloroform (Fresh) 100 1.11 11.11
7 Chloroform (Recovered) 500 5.56 55.56
8 N-Hexane (Fresh) 50 0.56 5.56
9 N-Hexane (Recovered) 350 3.89 38.89
Solvent
10 Water 600 6.67 66.67 --- Total 2385 26.50 265.00
Output
1 N-Carbethoxy BOC Piperidone
90 1.00 10.00 Finished Product
2 Rec Methanol 450 5.00 50.00 Recovered Solvent
3 Waste water 740 8.22 82.22 To ETP
4 Rec Chloroform 500 5.56 55.56
5 Rec N-Hexane 350 3.89 38.89 Recovered
Solvent
6 Solid waste after distillation 55 0.61 6.11 To TSDF
7 N-Hexane Loss 50 0.56 5.56
8 Chloroform Loss 100 1.11 11.11
9 Methanol Loss 50 0.56 5.56 To Atm
Total 2385 26.50 265.00
Rapid Environmental Impact Assessment Report Page : 65 of 294 Chapter-2 Project Description
(B-1) N-Methyl-4-Hydroxy Piperidine
a) Material Balance Diagram:
14
14
Rapid Environmental Impact Assessment Report Page : 66 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
N OCH3 N OHCH3
N-Methyl 4-Piperidone
+ H2 gasMethanol
N-Methyl 4-HHydroxy Piperidine
MolecularWeight
113 2 115
Rapid Environmental Impact Assessment Report Page : 67 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for N-Methyl-4-Hydroxy Piperidine is given in Table.
Summary of Mass Balance for – N-Methyl-4-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 180
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Methyl-4-Pipridone 200 1.11 11.11 Reactant
2 Water 500 2.78 27.78 ----
3 Raney Nickel 2 0.01 0.11 Catalyst
4 Toluene(Fresh) 14 0.08 0.78
5 Toluene(Recovered) 230 1.28 12.78 Solvent
6 Hydrogen Gas 10 0.06 0.56 Reactant Total 956 5.31 53.11
Output
1 N-Methyl-4-Hydroxy Piperidine 180 1.00 10.00 Finished Product
2 Filtered Raney Nickel 2 0.01 0.11
3 Distilled water 442 2.46 24.56 Reuse
4 Rec Toluene 230 1.28 12.78 Recovered Solvent
5 Toluene Loss 14 0.08 0.78 To Atm
6 Residue after distillation 20 0.11 1.11 To TSDF
7 Water Vapors 40 0.22 2.22
8 Toluene Vapors 28 0.16 1.56 To Atm
Total 956 5.31 53.11
Rapid Environmental Impact Assessment Report Page : 68 of 294 Chapter-2 Project Description
(B-2) N-Methyl-4-Chloro Piperidine
a) Material Balance Diagram:
900
900
3632
Rapid Environmental Impact Assessment Report Page : 69 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
Chemical Formula
Chemical Name
N ClCH3N OHCH3 + SOCl2 + SO2 + HCl
N-Methyl 4-Hydroxy ThionylChloridePiperidine
N-Methyl 4-Chloro Piperidine
SulfurDioxide
Hydrochloriacid
MDC
MolecularWeight
115 119 133.5 64 36.5
Rapid Environmental Impact Assessment Report Page : 70 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for N-Methyl-4-Chloro Piperidine is given in Table.
Summary of Mass Balance for – N-Methyl-4-Chloro Piperidine -Processcapacity of Finished Product MT/Month : 10.00
batch size kg : 750
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Methyl-4-Hydroxy Piperidine 900.0 1.2 12.0 Reactant
2 Thionyl Chloride (Fresh) 875.0 1.2 11.7
3 Thionyl chloride (Recovered) 156.3 0.2 2.1
4 Methylene Di Chloride (Fresh) 62.5 0.1 0.8
5 Methylene Di Chloride (Recovered) 187.5 0.3 2.5
Solvent
6 DMF 18.8 0.0 0.3
7 Caustic Lye 900.0 1.2 12.0 Reactant
8 Water 2500.0 3.3 33.3 ----
9 N-Hexane(Fresh) 62.5 0.1 0.8
10 N-Hexane (recovered) 875.0 1.2 11.7 Solvent
Total 6538 8.72 87.17
Output
1 N-Methyl-4-Hydroxy Piperidine 750 1.0 10.0 Finished Product
2 Residue after distillation 63 0.1 0.8 To TSDF
3 Rec Methylene Di Chloride + Thionyl chloride 344 0.5 4.6 Reuse
4 SO2 gas 438 0.6 5.8
5 Hydrochloric Acid gas 313 0.4 4.2
ToScrubber
6 Effluent 3632 4.8 48.4 To ETP
7 Methylene Di Chloride Loss 63 0.1 0.8 To Atm
8 Rec N-Hexane 875 1.2 11.7 Recovered Loss
9 N-Hexane Loss 63 0.1 0.8 To Atm Total 6538 8.72 87.18
Rapid Environmental Impact Assessment Report Page : 71 of 294 Chapter-2 Project Description
Summary of Mass Balance N-Methyl-4-Chloro Piperidine - APCM
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 1166.7 44.9 448.7 Scrubbing Media
2 Hydrochloric Acid Gas 312.5 12.0 120.2 To Scrubber Total 1479.2 56.9 568.9
Water scrubber Output
1 Hydrochloric Acid (30 %)
1479.2 56.9 568.9 Sale as By Product
Total 1479.2 56.9 568.9
Alkali scrubber Input
1 Caustic 446.4 17.2 171.7
2 Water 3273.8 125.9 1259.2 Scrubbing
Media
3 SO2 Gas 437.5 16.8 168.3 To Scrubber
Total 4157.7 159.9 1599.1
Alkali scrubber Output
1 Sodium Hypo Sulphite 4157.7 159.9 1599.1 Sale as By Product
Total 4157.7 159.9 1599.1
Rapid Environmental Impact Assessment Report Page : 72 of 294 Chapter-2 Project Description
(B-3) 4-Hydroxy Piperidine
a) Material Balance Diagram:
b) Reaction Chemistry
75
20
20
75
Rapid Environmental Impact Assessment Report Page : 73 of 294 Chapter-2 Project Description
Stage –I
Chemical Formula
Chemical Name
N
OH
COOEt
N-Carbethoxy 4-Hydroxy Piperidine
+ NaOHWater
Chloroform NH
OH
4-Hydroxy Piperidine
+ C2H5OH + CO2
Ethanol CarbonDioxide
Sodium Hydroxide
MolecularWeight
173 40 101 46 44
c) Summary of mass balance Summary of mass balance for N-Hydroxy Piperidine is given in Table.
Summary of Mass Balance for – N-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 60
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Piperidone 200 3.33 33.33
2 Water 500 8.33 83.33 Reactant
3 Raney Nickel 2 0.03 0.33 Catalyst
4 Hydrogen Gas 12 0.20 2.00 Reactant
5 Toluene(Fresh) 30 0.50 5.00 Solvent
6 Caustic Lye 160 2.67 26.67 Neutralizing Agent
7 Chloroform(Fresh) 75 1.25 12.50
8 Acetone(Fresh) 20 0.33 3.33
9 Toluene(Recovered) 220 3.67 36.67
10 Chloroform(Recovered) 825 13.75 137.50
11 Acetone(Recovered) 160 2.67 26.67
Solvent
Total 2204 36.73 367.33
Output
1 4-Hydroxy Piperidine 60 1.00 10.00 Finished
Rapid Environmental Impact Assessment Report Page : 74 of 294 Chapter-2 Project Description
Product
2 Effluent with waste ethanol 677.5 11.29 112.92 To ETP
3 Raney Nickel 1.5 0.03 0.25 Reuse
4 Residue after distillation 30 0.50 5.00 To TSDF
5 Water Vapors 90 1.50 15.00 To Atm
6 Rec Toluene 220 3.67 36.67
7 Rec Acetone 160 2.67 26.67
8 Rec Chloroform 825 13.75 137.50
Recovered Solvent
9 Toluene Loss 30 0.50 5.00
10 Acetone Loss 20 0.33 3.33
11 Chloroform Loss 75 1.25 12.50
To Atm
12 Carbon Di Oxide 15 0.25 2.50 To Atm Total 2204 36.73 367.33
Rapid Environmental Impact Assessment Report Page : 75 of 294 Chapter-2 Project Description
(B-4) N-Carbethoxy-4-Hydroxy Piperidine
a) Material Balance Diagram:
25
25
1
1
Rapid Environmental Impact Assessment Report Page : 76 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
N
O
COOEt
+ H2 gas Water
N
OH
COOEt
N-Carbethoxy 4- Piperidone Hydrogen N-Carbethoxy 4-Hydroxy Piperidin
Molecular Weight
171 2 173
c) Summary of mass balance Summary of mass balance for N-Carbethoxy-4-Hydroxy Piperidine is given in
Table.
Summary of Mass Balance for – N-Carbethoxt-4-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 170
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input 1 N-Carbethoxy-4-Piperidone 200 1.18 11.76 Reactant 2 Water 500 2.94 29.41 --- 3 Raney Nickel rec. 2 0.01 0.12 4 Hydrogen Gas 12 0.07 0.71 Catalyst 5 Toluene(Fresh) 25 0.15 1.47 Reactant 6 Toluene(Recovered) 200 1.18 11.76 7 Raney Nickel fresh. 1 0.01 0.06
Solvent
Total 940 5.53 55.29
Output 1 N-Carbethoxy-4-Hydroxy
Piperidine 170 1.00 10.00 Finished Product
2 Rec Water 402 2.36 23.65 Reuse
Rapid Environmental Impact Assessment Report Page : 77 of 294 Chapter-2 Project Description
3 Raney Nickel 2 0.01 0.12 4 Residue after distillation 50 0.29 2.94 To TSDF 5 Water Vapors 90 0.53 5.29 To Atm 6 Rec Toluene 200 1.18 11.76 Recovered
Solvent7 Toluene Loss 25 0.15 1.47 8 Raney Nickel loss 1 0.01 0.06
To Atm
Total 940 5.53 55.29
(B-5) N-Carbethoxy-4-Chloro Piperidine a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 78 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
N
OH
COOEt
N-Carbethoxy 4-Hydroxy Piperidine
+ SOCl2
N
Cl
COOEt
4-Hydroxy Piperidine
+ ClH + SO2
HydroChloric SuphurDioxide
Thionyl Chloride
MDC
Water
Acid
Molecular Weight
173 119 191.5 36.5 64
c) Summary of mass balance Summary of mass balance for N-Carbethoxy-4-Chloro Piperidine is given in
Table.
Summary of Mass Balance for – N-Carbethoxt-4-Chloro Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 120
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Methyl-4-Chloro Piperidine 100 0.83 8.33
2 Ethyl chloro formate 110 0.92 9.17 Reactant
3 Toluene(Fresh) 100 0.83 8.33
4 Toluene(Recovered) 1900 15.83 158.33 Solvent
5 Water 400 3.33 33.33 --- Total 2610 21.75 217.50
Output
1 N-Carbethoxy-4-Chloro Piperidine
120 1.00 10.00 Finished Product
2 Effluent 430 3.58 35.83 To ETP
3 Rec Toluene 1900 15.83 158.33 Recovered
Rapid Environmental Impact Assessment Report Page : 79 of 294 Chapter-2 Project Description
Solvent
4 Toluene Loss 100 0.83 8.33 To Atm
5 Residue after distillation 60 0.50 5.00 To TSDF Total 2610 21.75 217.50
Rapid Environmental Impact Assessment Report Page : 80 of 294 Chapter-2 Project Description
(B-6) 4-Chloro Piperidine a) Material Balance Diagram:
b) Reaction Chemistry
Reaction Vessel (Hydrogenation)
Decantation
N-Methyl-4-Chloro Piperidine: 100
Ethyl Chloroformate: 110 Process water: 400 Ammonia Gas: 50
HCl : 500 Toluene(Fresh): 100
Toluene(Recovered): 1900
Layer separation
Crude 4-Chloro Piperidine
High Vaccum Distillation
Toluene Loss: 100
Heating followed by Cooling
Aqueous Layer (Effluent): 1056
Toluene recovered: 1900
Disti. 4- Chloro Piperidine
MDC (Fresh): 100 MDC (Recovered):
500
Cooling, Chilling & Filtration
Ethanol as waste: 27
Drying
30 kg of 4-Chloro Piperidine (Finished Product)
Distillation Residue: 25
MDC Loss: 100
MDC Recovered: 500
Carbon dioxide: 22
Rapid Environmental Impact Assessment Report Page : 81 of 294 Chapter-2 Project Description
Stage –I
ChemicalFormula
ChemicalName
N OH
O
O
CH3
N Cl
O
O
CH3
4 - CHLORO PIPERIDINE
NH Cl
Molecular Weight
160.190 178.63 132.61
Rapid Environmental Impact Assessment Report Page : 82 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for 4-Chloro Piperidine is given in Table.
Summary of Mass Balance for – 4-Chloro Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 30
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Methyl-4-Chloro Piperidine 100 3.33 33.33
2 Ethyl chloro formate 110 3.67 36.67 Reactant
3 Toluene(Fresh) 100 3.33 33.33
4 Toluene(Recovered) 1900 63.33 633.33 Solvent
5 Water 400 13.33 133.33 ----
6 Hydrochloric Acid 500 16.67 166.67 Reactant
7 Methylene Di Chloride(Fresh) 100 3.33 33.33
8 Methylene Di Chloride(Recovered)
500 16.67 166.67 Solvent
9 Ammonia Gas 50 1.67 16.67 Reactant Total 3760 125.33 1253.33
Output
1 4-Chloro Piperidine 30 1.00 10.00 Finished Product
2 Effluent 1056 35.20 352.00 To ETP
3 Rec Toluene 1900 63.33 633.33 Recovered Solvent
4 Residue after distillation 25 0.83 8.33 To TSDF
5 Rec Methylene Di Chloride 500 16.67 166.67 Recovered Solvent
6 Toluene Loss 100 3.33 33.33
7 Methylene Di Chloride Loss 100 3.33 33.33
8 Carbon di oxide 22 0.73 7.33 To Atm
9 Ethanol as waste 27 0.90 9.00 To ETP Total 3760 125.33 1253.33
Rapid Environmental Impact Assessment Report Page : 83 of 294 Chapter-2 Project Description
(B-7) 4-Amino N-Benzyl-Piperidine
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 84 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
Chemical Formula
Chemical Name
N
O
+ MeOH N
NH2
N-Benzyl 4-Piperidone
NH3+H2 Gas
N-Benzyl 4-Amino Piperidine
+ H2O
MolecularWeight
189 32 17 189 18
Rapid Environmental Impact Assessment Report Page : 85 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for 4-Amino N-Benzyl Piperidine is given in Table .
Summary of Mass Balance for – 4-Amino N-Benzyl Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 180
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
of Product
MT/Month Remarks
Input
1 N-Benzyl-4-Piperidone 200 1.11 11.11 Reactant
2 Methanol(Fresh) 40 0.22 2.22
3 Methanol(Recovered) 460 2.56 25.56 Solvent
4 Raney Nickel 5 0.03 0.28 Catalyst
5 Hydrogen Gas 12 0.07 0.67
6 Ammonia Gas 50 0.28 2.78 Reactant
Total 767 4.26 42.61
Output
1 N-Benzyl-4-Amino Piperidine 180 1.00 10.00 Finished Product
2 Rec Methanol 460 2.56 25.56 Recovered Solvent
3 Raney Nickel 5 0.03 0.28 Reuse
4 Residue after distillation 82 0.46 4.56 To TSDF
5 Methanol Loss 40 0.22 2.22 To Atm Total 767 4.26 42.61
Rapid Environmental Impact Assessment Report Page : 86 of 294 Chapter-2 Project Description
(B-8) 4-Hydroxy-N-Benzyl Piperidine a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 87 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
N O N OH+H2 GasMethanol
N-Benzyl 4-Piperidone N-Benzyl 4-HydroxyPiperidine
MolecularWeight
189 2 191
Rapid Environmental Impact Assessment Report Page : 88 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for 4-Hydroxy N-Benzyl Piperidine is given in Table.
Summary of Mass Balance for – 4-Hydroxy N-Benzyl Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 100
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Benzyl-4-Piperidone 125 1.25 12.50 Reactant
2 Methanol(Fresh) 100 1.00 10.00
3 Methanol(Recovered) 400 4.00 40.00 Solvent
4 Raney Nickel 2.5 0.03 0.25 Catalyst
5 Hydrogen Gas 5 0.05 0.50 Reactant Total 633 6.33 63.25
Output
1 N-Benzyl-4-Hydroxy Piperidine 100 1.00 10.00 Finished Product
2 Rec Methanol 400 4.00 40.00 Recovered Solvent
3 Raney Nickel 2.5 0.03 0.25 Reuse
4 Residue after distillation 30 0.30 3.00 To TSDF
5 Methanol Loss 100 1.00 10.00 To Atm Total 633 6.33 63.25
Rapid Environmental Impact Assessment Report Page : 89 of 294 Chapter-2 Project Description
(B-9) 4-Benzamido Piperidine
a) Material Balance Diagram:
Step-2
Chilling
Heating & TemperatureMaintaining
Purified Water:350 Reflux & Layer Seperation
Reaction Vessel Toluene:450
Sodium Carbonate:62.5 N-Carbethoxy-4-Amino
Pipridine:100
Benzoyl Chloride:110
Organic Layer
ML as Toluene
Aqueous Layer
Cooling & Centrifuge:
MethanolRecovery
RefluxMethanol(fresh):50
Methanol(Recoverd):350 Caustic Potash:75 Mass from step-1:
Purified Water:400 Cooling
Recovered Methanol:350
Drying
Step-1 Dry
Chloroform (Fresh): 125 Chloroform (Recovred): 500
Rapid Environmental Impact Assessment Report Page : 90 of 294 Chapter-2 Project Description
Step-3
Heating
Filtration
Cooling and Stirring
Iso Propyl Alkohol(fresh):50 Iso Propyl
Alkohol(Recoverd):350 A.Carbon:
Step 2:
Cooling, Centrifuging, IPA recovery, Drying
50 Kg, 4-Benzamido Piperidine Pure
Recovered IPA350 IPA Loss:50
Manthol loss:50 Chloroform Loss): 125
HeatingHCl:
Filteration Activated Carbon:
Hyflow & Activated Carbon:22.5
Cool, Centrifuge, Water Wash
DryingEffluent:800 Ethanol mixed effluent ;625
Rapid Environmental Impact Assessment Report Page : 91 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
Chemical Formula
Chemical Name
N
NH2
COOEt
O Cl
+N
NH
COOEt
O
N-Carbethoxy 4-amino PiperidineBenzoyl Chloride N-Carbethoxy 4-Benzamido Piperidine
Toluene+NaHCO3 +NaCl+ CO2+H2O
MolecularWeight
172 140.5 276 58.5 44 18
Stage –II
Chemical Formula
Chemical Name
N-Carbethoxy 4-Benzamido Piperidine
N
NH
COOEt
O
+ KOHIPA
NH
NH
O
4-Benzamido Piperidine
+ C2H5OH+CO2
.
MolecularWeight
276 56 203 46 44
c) Summary of mass balance Summary of mass balance for 4-Benzamido Piperidine is given in Table.
Summary of Mass Balance for – 4-Benzamido Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 50
Working Days Per Month : 26
Rapid Environmental Impact Assessment Report Page : 92 of 294 Chapter-2 Project Description
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Amino Piperidine
100 2.00 20.00
2 Benzoyl chloride 110 2.20 22.00
3 Toluene 450 9.00 90.00
4 Sodium Carbonate 62.5 1.25 12.50
Reactant
5 Methanol fresh 50 1.00 10.00
6 Methanol Rec 350 7.00 70.00 Solvent
7 Caustic Lye 75 1.50 15.00 Neutralizing Agent
8 Chloroform Rec. 500 10.00 100.00 Solvent 9 Water 750 15.00 150.00 -10 Iso Propyl Alcohol fresh 50 1.00 10.00
11 Iso Propyl Alcohol recov 350 7.00 70.00
12 Chloroform Fresh. 125 2.50 25.00 Solvent
Total 2973 59.45 594.50
Output
1 4-Benzamido Piperidine 50 1.00 10.00 Finished Product
2 Carbon Di Oxide 22.5 0.45 4.50 To Atm
3 Ethanol mixed effluent 750 15.00 150.00
4 Effluent 900 18.00 180.00 To ETP
5 Rec Iso Propyl Alcohol 350 7.00 70.00
6 Rec Methanol 350 7.00 70.00 Recovered
Solvent
7 Solid waste after centrifuge 50 1.00 10.00 To TSDF
8 Rec Chloroform 500 10.00 100.00 Recovered Solvent
9 Chloroform loss 125 2.50 25.00
10 Methanol loss 50 1.00 10.00
11 IPA Loss 50 1.00 10.00 To Atm
Total 2973 59.45 594.50
Rapid Environmental Impact Assessment Report Page : 93 of 294 Chapter-2 Project Description
(B-10) 4-Amino N-Carbethoxy Piperidine
a) Material Balance Diagram:
b) Reaction Chemistry
Chemical Formula
Chemical Name
+ MeOH
N-Carbethoxyl 4-Piperidone
NH3+H2 Gas
N-Carbethoxy 4-Amino Piperidin
+ H2O
N
O
COOEtN
NH2
COOEt
MolecularWeight
171 32 17 171 18
c) Summary of mass balance
Rapid Environmental Impact Assessment Report Page : 94 of 294 Chapter-2 Project Description
Summary of mass balance for 4-Amino N-Carbethoxy Piperidine is given in
Table.
Summary of Mass Balance for – 4-Amino N-Carbethoxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 180
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Piperidone 200 1.11 11.11
2 Ammonia Gas 40 0.22 2.22 Reactant
3 Methanol fresh 50 0.28 2.78
4 Methanol rec 450 2.50 25.00 Solvent
5 Raney Nickel 4 0.02 0.22 Catalyst
6 Hydrogen Gas 10 0.06 0.56 Reactant Total 754 4.19 41.89
Output
1 N-Carbethoxy-4-Amino Piperidine
180 1.00 10.00 Finished Product
2 Rec Methanol+ Ammonia 480 2.67 26.67
3 Raney Nickel recyclable 3.5 0.02 0.19 Reuse
4 Residue after distillation 90 0.50 5.00 To TSDF Total 754 4.19 41.86
Rapid Environmental Impact Assessment Report Page : 95 of 294 Chapter-2 Project Description
(B-11) 4-Amino N-Methyl Piperidine
a) Material Balance Diagram:
b) Reaction Chemistry ChemicalFormula
ChemicalName
NCH3 OMethanolic ammonia
HydrogenatorNCH3 NH2
MolecularWeight
126.18 127.21
C) Summary of mass balance Summary of mass balance for 4-Amino N-Methyl Piperidine is given in Table .
Summary of Mass Balance for – 4-Amino N-Methyl Piperidine
Rapid Environmental Impact Assessment Report Page : 96 of 294 Chapter-2 Project Description
capacity of Finished Product MT/Month : 10.00
batch size kg : 75
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Methyl-4-Piperidone 100 1.33 13.33 Reactant
2 Methanol Rec. 450 6.00 60.00 Solvent
3 Raney Nickel 5 0.07 0.67 Catalyst
4 Hydrogen Gas 12 0.16 1.60
5 Ammonia Gas 50 0.67 6.67 Reactant
6 Methanol Fresh 50 0.67 6.67 Solvent Total 667 8.89 88.93
Output
1 N-Benzyl-4-Amino Piperidine 75 1.00 10.00 Finished Product
2 Rec Methanol 450 6.00 60.00 Recovered Solvent
3 Raney Nickel 4 0.05 0.53 Reuse
4 Residue after distillation 38 0.51 5.07 To TSDF
5 Methanol Vapors 100 1.33 13.33 ReuseTotal 667 8.89 88.93
Rapid Environmental Impact Assessment Report Page : 97 of 294 Chapter-2 Project Description
(B-12) 4-T-BOC-Amino Piperidine
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 98 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
Chemical Formula
Chemical Name
N
NH2
COOEt
+ ((CH3)3COCO)2O
N
NH
COOEt
O
O CH3 CH3
CH3
N-Carbethoxy 4-Amino Piperidine Boc anhydride N-Carbethoxy 4-BocAmino Piperidine
MolecularWeight
172 218 272
Stage –II
Chemical Formula
Chemical Name N
H
NH O
O CH3 CH3
CH3
N-Carbethoxy 4-BocAmino Piperidine
N
NH
COOEt
O
O CH3 CH3
CH3
+ NaOH SolutionWater
Chloroform + C2H5OH CO2+
4-Tert Boc Amino Piperidine
MolecularWeight
272 40 200
c) Summary of mass balance Summary of mass balance for 4-T-Boc Amino Piperidine is given in Table.
Summary of Mass Balance for – 4-T-Boc-Amino Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 65
Working Days Per Month : 26
Rapid Environmental Impact Assessment Report Page : 99 of 294 Chapter-2 Project Description
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Amino Piperidine
100 1.33 13.33 Reactant
2 Methanol(Fresh) 100 1.33 13.33
3 Methanol(Recovered) 500 6.67 66.67 Solvent
4 Di BOC 80 1.07 10.67 Reactant
5 Water 800 10.67 106.67 ---
6 Caustic Lye 200 2.67 26.67 Neutralizing Agent
7 Chloroform(Fresh) 100 1.33 13.33
8 Chloroform(Recovered) 900 12.00 120.00
9 Acetone(Fresh) 100 1.33 13.33
10 Acetone(Recovered) 500 6.67 66.67
11 N-Hexane(Fresh) 100 1.33 13.33
12 N-Hexane(Recovered) 700 9.33 93.33
Solvent
Total 4180 55.73 557.33
Output
1 4-Amino-N-Boc-Piperidine 65 0.87 8.67 Finished Product
2 Rec Methanol 500 6.67 66.67 Recovered Solvent
3 Effluent with ethanol & methanol 1115 14.87 148.67 To ETP
4 Methanol Loss 100 1.33 13.33
5 Acetone Loss 100 1.33 13.33
6 Chloroform Loss 100 1.33 13.33
7 N-Hexane Loss 100 1.33 13.33
To Atm
8 Rec Acetone 500 6.67 66.67
9 Rec Chloroform 900 12.00 120.00
10 Rec N-Hexane 700 9.33 93.33
Recovered Solvent
Total 4180 55.73 557.33
Rapid Environmental Impact Assessment Report Page : 100 of 294 Chapter-2 Project Description
(B-13) N-Boc-4-Hydroxy Piperidine
a)Material Balance Diagram
Heating
Temperature & Pressure Maintaining
Raney Nickel Decantation
Crude N-Boc 4-Hydroxy Piperidine
50 Kg, N-Boc 4-Hydroxy Piperidine
Distilled N-Boc 4-Hydroxy Piperidine
HVD
Settled Raney Nickel:
Hydrogen Gas:4.2 Raney Nickel:4.2
N Haxane:
Heating, Stirring, Cooling, Centrifuge
Drying
ReactionMethanol:138.9
N-BOC 4, Piperidone:55.6
Methanol Recovered:125
Rapid Environmental Impact Assessment Report Page : 101 of 294 Chapter-2 Project Description
b)Reaction Chemistry
ChemicalFormula
Chemical Name
N
O
COOEt
+O OO
OO
CH3
CH3
CH3
CH3
CH3CH3
N
O
O O
CH3
CH3
CH3
N-Carbethoxy 4-Piperidone Boc anhydride N-Boc 4-Piperidone
c) Summary of mass balance
Summary of mass balance for N-Boc-4-Hydroxy Piperidine is given in Table.
Summary of Mass Balance for –N-Boc-4-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 50
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
of Product
MT/Month Remarks
Input
1 N-BOC-4-Piperidone 55.6 1.11 11.11 Reactant
2 Methanol(Fresh) 13.9 0.28 2.78
3 Methanol(Recovered) 125.0 2.50 25.00 Solvent
4 Raney Nickel 4.2 0.08 0.83 Catalyst
5 Hydrogen Gas 4.2 0.08 0.83 Reactant Total 203 4.06 40.56
Output
Rapid Environmental Impact Assessment Report Page : 102 of 294 Chapter-2 Project Description
1 N-BOC-4-Hydroxy Piperidine 50 1.00 10.00 Finished Product
2 Rec Methanol 125 2.50 25.00 Recovered Solvent
3 Methonol Loss 14 0.28 2.78 To Atm
4 Solid waste after distillation 14 0.28 2.78 To TSDF Total 203 4.06 40.56
(B-14) N-Boc-4-Amino Piperidine
a) Material Balance Diagram:
b) Reaction Chemistry
Rapid Environmental Impact Assessment Report Page : 103 of 294 Chapter-2 Project Description
Chemical Formula
N
O
O
CH3 O N O
O
OCH3
CH3
CH3
N NH2
O
OCH3
CH3
CH3
c) Summary of mass balance
Summary of mass balance for N-Boc-4-Amino Piperidine is given in Table.
Summary of Mass Balance for –N-Boc-4-Amino Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 35
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-BOC-4-Piperidone 50 1.43 14.29
2 Ammonia Gas 10 0.29 2.86 Reactant
3 Methanol 250 7.14 71.43 Solvent
4 Raney Nickel 2 0.06 0.57 Catalyst
5 Hydrogen Gas 2 0.06 0.57
6 Acetone 160 4.57 45.71 Reactant
Total 474 13.54 135.43
Output
1 4-Amino-N-Boc-Piperidine 35 1.00 10.00 Finished Product
2 Rec Methanol 250 7.14 71.43 Recovered Solvent
3 Raney Nickel 1 0.03 0.29
4 Acetone 120 3.43 34.29 Reuse
Rapid Environmental Impact Assessment Report Page : 104 of 294 Chapter-2 Project Description
5 Residue after distillation 25 0.71 7.14 To TSDF
6 Acetone Vapors 43 1.23 12.29 To Atm Total 474 13.54 135.43
(B-15) 4-Piperidino Piperidine
a) Material Balance Diagram:
Reaction vessel
Filteration
Piperidine:31.25 Toluene (Solvent)
Iso propyl Alcohol: N-Carbethoxy-4-Piperidone:41.67
5% Pd on carbon:4.17
Hysdrogen Gas:
IPA:208.33 Caustic Potash:
Solvent Recovery
Pd on carbon 5%
Hydrolysis IPA recovered
25Kg, Pure 4-Piperidino Piperidine
Cooling followed by Extraction
PurifiedWater:333
Toluene:
Organic LayerToluenerecovery
crude 4-Piperidino Piperidine
HVD
Rapid Environmental Impact Assessment Report Page : 105 of 294 Chapter-2 Project Description
b) Reaction Chemistry Step-1:
Chemical Formula
Chemical Name N
O
COOEt
+NH
+CH3OH
H2gasPd/C( 5%)
3 -4 kg Pressure 35-40 N
N
COOEt
Molecular Weight
171 85 32 240
Step-2: Chemical Formula
Chemical Name N
N
COOEt
+ KOHIPA
90 -95 °C
NH
N
Molecular Weight
240 56 168
Rapid Environmental Impact Assessment Report Page : 106 of 294 Chapter-2 Project Description
c)Summary of mass balance
Summary of mass balance for 4-Piperidino Piperidine is given in Table.
Summary of Mass Balance for –4- Piperidino Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 25
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Carbethoxy 4-Piperidone 41.67 1.67 16.67
2 Piperidine 31.25 1.25 12.50
3 Sodium Sulphate 8.33 0.33 3.33 4 Potassium Hydroxide 83.33 3.33 33.33
Reactant
5 Pd/C(5%) 4.17 0.17 1.67 Catalyst
6 IPA 208.33 8.33 83.33
7 Toluene 208.33 8.33 83.33
8 Chloroform(Fresh) 83.33 3.33 33.33
9 Chloroform(Recovered) 333.33 13.33 133.33
Solvent
10 Water 333.33 13.33 133.33 --- Total 1335 53.42 534.17
Output
1 4-Piperidino piperidine 25.00 1.00 10.00 Finished
Product 2 Pd/C(5%) 4.17 0.17 1.67 Reuse
3 Chloroform Loss 83.33 3.33 33.33 To Atm
4 Chloroform Recovered 333.33 13.33 133.33 Recovered
Solvent 5 Solid Waste 10.42 0.42 4.17 To TSDF
Total 456 18.25 182.50
Rapid Environmental Impact Assessment Report Page : 107 of 294 Chapter-2 Project Description
(B-16) 4-Chloro Piperidine HCl
a) Reaction Chemistry
Chemical Formula N OH
O
O
CH3
N Cl
O
O
CH3
NH ClNH Cl HC
b) Summary of mass balance
Summary of mass balance for 4-Chloro Piperidine HCl is given in Table.
Summary of Mass Balance for –4- Chloro Piperidine HCl
capacity of Finished Product MT/Month : 10.00
batch size kg : 40
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input 1 4-Chloro Piperidine 36 0.89 8.93
2 Toluene fresh 25 0.63 6.25 Reactant
3 Toluene rec 261 6.53 65.25
4 Hydrochloric Acid Gas 11 0.27 2.68
5 Acetone 100 2.50 25.00 Solvent
Total 432 10.81 108.11
Output
1 4-Chloro Piperidine Hydrochloric Acid
40 1.00 10.00 Finished Product
2 Rec Toluene 261 6.53 65.25
3 Waste Acetone 75 1.88 18.75 Recovered
Solvent
4 Mixed Toluene & Acetone 56 1.40 14.00 To Atm Total 432 10.80 108.00
Rapid Environmental Impact Assessment Report Page : 108 of 294 Chapter-2 Project Description
(B-17) 4-(-4-Chloro Phenyl )-4-Hydroxy Piperidine
a) Material Balance Diagram:
N-Carbethoxy-4-Piperidone:300
Rapid Environmental Impact Assessment Report Page : 109 of 294 Chapter-2 Project Description
Rapid Environmental Impact Assessment Report Page : 110 of 294 Chapter-2 Project Description
b) Reaction Chemistry Stage –I
Chemical Formula
Chemical Name
Br
Cl
+ Mg TuringsTHF
MgBr
Cl
P-Bromo Chloro Benzene Grignard Reagent Magnasium Metal
Molecular Weight
191.5 24 215.5
Stage –II
ChemicalFormula
ChemicalName
+
P-Bromo Chloro Benzene
MgBr
ClN
O
COOEt
Toluene
HCl Solution
N
OH
COOEt
Cl
+ MgBr(OH)
N-carbethoxy4-Piperidone
N-carbethoxy 4-Hydroxy4-(p-Chloro phenyl) Piperidine
MolecularWeight
215.5 171 283.5
Stage –III
Chemical Formula
Chemical Name OH
Cl
+ NaOH
Methanol Toluene
HCl l iOH
Cl
+ C2H5OH + CO2
MolecularWeight
283.5 40 211.5 46 44
Rapid Environmental Impact Assessment Report Page : 111 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 4-(-4-Chloro Phenyl )-4-Hydroxy Piperidine is given in
Table.
Summary of Mass Balance for –4-(-4-Chloro Phenyl )-4-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 500
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Carbethoxy-4-Piperidone 300 1.50 15.00
2 Hyflo 6 0.03 0.30
3 Hydrochloric Acid Gas 300 1.50 15.00
4 Acetone 150 0.75 7.50
5 Para Bromo chloro benzene 123 0.62 6.17
6 Hydrochloric Acid 494 2.47 24.69
Reactant
7 Tetra Hydro Furan(fresh) 360 1.80 18.00
8 Tetra Hydro Furan(Recovered) 720 3.60 36.00
9 Activated Carbon 12 0.06 0.60 Catalyst
10 Methanol 400 2.00 20.00
11 Toluene(Fresh) 200 1.00 10.00
12 Toluene(Recovered) 3000 15.00 150.00
13 Iso Propyl Alcohol(Fresh) 160 0.80 8.00
14 Iso Propyl Alcohol(Recovered) 1600 8.00 80.00
Solvent
15 Purified water 3000 15.00 150.00 ----
16 Caustic Potash 400 2.00 20.00
17 Caustic Lye 300 1.50 15.00 Neutralizing
Agent
Total 11525 57.63 576.26
Output 1 4-(-4-Chloro Phenyl )-4-Hydroxy
Piperidine 200 1.00 10.00 Finished
Product 2 Effluent 3436 17.18 171.80 To ETP
Rapid Environmental Impact Assessment Report Page : 112 of 294 Chapter-2 Project Description
3 Toluene loss 200 1.00 10.00 To Atm 4 Rec Iso Propyl Alcohol 1600 8.00 80.00
5 Iso Propyl Alcohol Rec 1600 8.00 80.00
6 Tetra Hydro Furan Rec 720 3.60 36.00
7 Toluene Rec 3000 15.00 150.00
Recovered Solvent
8 Solid Waste 50 0.25 2.50 To TSDF 9 IPA loss 160 0.80 8.00
10 Toluene Loss 200 1.00 10.00 To Atm
11 Tetra Hydro Furan loss 360 1.80 18.00 To TSDF Total 11526 57.63 576.30
Rapid Environmental Impact Assessment Report Page : 113 of 294 Chapter-2 Project Description
(B-18) 4-(-4- Bromo Phenyl )-4-Hydroxy Piperidine
a) Material Balance Diagram:
280
37
Tetra Hydro Furan rec 200
Rapid Environmental Impact Assessment Report Page : 114 of 294 Chapter-2 Project Description
80714
80
Rapid Environmental Impact Assessment Report Page : 115 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
Br
Br
+ Mg TuringsTHF
MgBr
Br
P-Di bromo Benzene Grignard Reagent Magnasium Metal
MolecularWeight
236 24 260
Stage –II
ChemicalFormula
ChemicalName
+
Gignard reagent
MgBr
BrN
O
COOEt
Toluene
HCl Solution
N
OH
COOEt
Br
+ MgBr(OH)
N-carbethoxy4-Piperidone
N-carbethoxy 4-Hydroxy4-(p-Bromo phenyl) Piperidine
Molecular
Weight
260 171 328
Stage –III
ChemicalFormula
ChemicalName N
OH
COOEt
Br
+ NaOH
Methanol Toluene
HCl solution
NH
OH
Br
+ C2H5OH + CO2
N-Carbethoxy 4-Hydroxy 4-(p-Bromo phenyl ) Piperidine
Sodium Hydroxide 4-Hydroxy 4-(p-Bromo phenyl )
Piperidine Ethanol Carbon
dioxide
Rapid Environmental Impact Assessment Report Page : 116 of 294 Chapter-2 Project Description
MolecularWeight
328 40 256 46 44
c) Summary of mass balance
Summary of mass balance for 4-(-4-Bromo Phenyl )-4-Hydroxy Piperidine is given in
Table.
Summary of Mass Balance for –4-(-4-Bromo Phenyl )-4-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 5
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Carbethoxy-4-Piperidone 71 1.43 14.29
2 Mg Turning 14 0.29 2.86
3 Tetra Hydro Furan Fresh 80 1.60 16.00
4 Para Di Bromo Benzene 114 2.29 22.86
5 Iodine 0 0.00 0.03
6 Hydrochloric Acid 107 2.14 21.43
Reactant
7 Toluene(Fresh) 286 5.71 57.14
8 Toluene(Recovered) 1143 22.86 228.57
9 Caustic Potash 86 1.71 17.14
10 Methanol 143 2.86 28.57
11 Activated Carbon 9 0.17 1.71
Solvent
12 Hyflo 6 0.11 1.14
13 Iso Propyl Alcohol(Fresh) 80 1.60 16.00 Catalyst
14 Iso Propyl Alcohol(Recovered) 714 14.29 142.86 ---
15 Purified water 2143 42.86 428.57
16 Caustic Lye 107 2.14 21.43 Neutralizing
Agent
17 Tetra Hydro Furan Rec 200 4.00 40.00 Solvent Total 5303 106.06 1060.60
Output
Rapid Environmental Impact Assessment Report Page : 117 of 294 Chapter-2 Project Description
1 4-(-4-Bromo Phenyl )-4-Hydroxy Piperidine
50 1.00 10.00 Finished Product
2 Effluent 2729 54.57 545.71 To ETP
3 Rec Toluene 1143 22.86 228.57
4 Rec Iso Propyl Alcohol 714 14.29 142.86 Recovered
Solvent
5 Toluene Loss 286 5.71 57.14
6 Iso Propyl Alcohol Loss 80 1.60 16.00 To Atm
7 Solid Waste 64 1.29 12.86
8 Waste Tetra Hydro Furan 37 0.74 7.40
9 Tetra Hydro Furan rec 200 4.00 40.00 To TSDF
Total 5303 106.05 1060.54
Rapid Environmental Impact Assessment Report Page : 118 of 294 Chapter-2 Project Description
(B-19) 4-Phenyl-4-Hydroxy Piperidine
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 119 of 294 Chapter-2 Project Description
Rapid Environmental Impact Assessment Report Page : 120 of 294 Chapter-2 Project Description
b) Reaction Chemistry
ChemicalFormula
Br MgBr
N
OH
EtOOCNH
OH
N
O
EtOOC
c) Summary of mass balance
Summary of mass balance for 4-Phenyl-4-Hydroxy Piperidine is given in Table.
Summary of Mass Balance for –4-(-4-Bromo Phenyl )-4-Hydroxy Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 5
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 N-Carbethoxy-4-Piperidone 8.33 1.67 16.67
2 Mg Turning 1.67 0.33 3.33
3 Bromo Benzene 2.78 0.56 5.56
4 Chloro Benzene 8.33 1.67 16.67
5 Iodine 0.01 0.00 0.01
6 Hydrochloric Acid 8.33 1.67 16.67
7 Hyflo 0.22 0.04 0.44
Reactant
Rapid Environmental Impact Assessment Report Page : 121 of 294 Chapter-2 Project Description
8 Toluene(Fresh) 16.67 3.33 33.33
9 Toluene(Recovered) 122.22 24.44 244.44
10 Methanol 13.33 2.67 26.67
11 Iso Propyl Alcohol(Fresh) 11.11 2.22 22.22
12 Iso Propyl Alcohol(Recovered) 55.56 11.11 111.11
Solvent
13 Tetra Hydro Furan 30.00 6.00 60.00
14 Activated Carbon 0.33 0.07 0.67 Catalyst
15 Purified water 166.67 33.33 333.33 ----
16 Caustic Potash 8.33 1.67 16.67
17 Caustic Lye 13.89 2.78 27.78 Neutralizing
Agent
Total 468 93.56 935.57
Output
1 4- Phenyl-4-Hydroxy Piperidine 5 1.00 10.00 Finished Product
2 Effluent 222.22 44.44 444.44 To ETP
3 Rec Toluene 122.22 24.44 244.44
4 Rec Iso Propyl Alcohol 55.56 11.11 111.11 Recovered
Solvent
5 Toluene loss 16.67 3.33 33.33
6 Iso Propyl Alcohol loss 11.11 2.22 22.22 To Atm
7 Solid Waste 1.67 0.33 3.33
8 Waste Tetra Hydro Furan 33.33 6.67 66.67 To TSDF
Total 468 93.56 935.56
Rapid Environmental Impact Assessment Report Page : 122 of 294 Chapter-2 Project Description
(B-20) 4-Phenyl Piperidine
a) Material Balance Diagram
Cooling
Layer Separation
MDC:
Water Layer
Stirring
Toluene Layer
5 Kg, 4 phenyl pepridine
Azeotrop
Crude Mass: Methanol:
Palladium on Carbon:1.25
Water:25
Aqueous Layer MDC Layer
Pd on Carbon: 1.25 Methanol:
Layer Separation
Heating & Pressure Maintaining
Cooling
Filtration
Cooling & Filtration
Rapid Environmental Impact Assessment Report Page : 123 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Chemical Formula
Chemical Name
NH
OH+ H2SO4
NH
Toluene
110-115 °C
Molecular Weight
177 98 159
c) Summary of mass balance
Summary of mass balance for 4-Phenyl Piperidine is given in Table.
Summary of Mass Balance -4-Phenyl Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 5
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 4-Phenyl 4-Hydroxy piperidine 12.5 2.50 25.00 Reactant
2 Toluene(Fresh) 25 5.00 50.00
3 Toluene(Recovered) 100 20.00 200.00 Solvent
4 Sulphuric acid 1.25 0.25 2.50 Reactant
5 Water 25 5.00 50.00 ---
6 Pd/C (5%) 1.25 0.25 2.50 Catalyst
7 Water 100 20.00 200.00 ---
8 Hyflow 1.25 0.25 2.50
9 Sodium sulphate 1.25 0.25 2.50 Reactant
Total 268 53.50 535.00
Output
Rapid Environmental Impact Assessment Report Page : 124 of 294 Chapter-2 Project Description
1 4-Phenyl Piperidine 5 1.00 10.00 Finished Product
2 Pd/C(5%) 1.25 0.25 2.50 Reuse
3 Toluene Loss 25 5.00 50.00 To Atm
4 Toluene Recovered 100 20.00 200.00 Recovered Solvent
5 Solid Waste 3.125 0.63 6.25 To TSDF
6 Water 134 26.80 268.00 To ETP
Total 268 53.68 536.75
(B-21) 1-Amino Piperidine
a) Material Balance Diagram:
190
30
Rapid Environmental Impact Assessment Report Page : 125 of 294 Chapter-2 Project Description
b) Reaction Chemistry
ChemicalFormula
ChemicalName
N
NH2
COOEt
N-Carbethoxy 4-Amino Piperidine
+ NaOH
NH
NH2
4-Amino Piperidine
+ C2H5OH + CO2
CarbonDioxide
Sodium Hydroxide
Water
Chloroform
Ethanol
MolecularWeight
171 40 99 46 44
c) Summary of mass balance
Summary of mass balance for 1-Amino Piperidine is given in Table.
Summary of Mass Balance -1-Amino Piperidine
capacity of Finished Product MT/Month : 10.00
batch size kg : 180
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material Kg/Batc
h
Kg/Kgof
Product MT/Month
Remarks
Input
1 N-Carbethoxy-4-Piperidone 200 1.11 11.11
2 Ammonia Gas 40 0.22 2.22
3 Methanol 500 2.78 27.78
Reactant
4 Raney Nickel 6 0.03 0.33 Catalyst
5 Hydrogen Gas 12 0.07 0.67
6 Caustic Lye 190 1.06 10.56 Reactant
7 Methylene Di Chloride(Fresh) 100 0.56 5.56
8 Methylene Di Chloride(Recovered)
900 5.00 50.00 Solvent
9 Water 600 3.33 33.33 --- Total 2548 14.16 141.56
Output
1 1-Amino Piperidine 180 1.00 10.00 Finished Product
Rapid Environmental Impact Assessment Report Page : 126 of 294 Chapter-2 Project Description
2 Rec Methanol+ Ammonia 480 2.67 26.67 Recovered Solvent
3 Raney Nickel recyclable 3.5 0.02 0.19 Reuse
4 Residue after distillation 30 0.17 1.67 To TSDF
5 Rec Methylene Di Chloride 900 5.00 50.00 Recovered Solvent
6 Methylene Di Chloride Loss 100 0.56 5.56
7 Carbon Di oxide 50 0.28 2.78 To Atm
8 Effluent with ethanol 804 4.47 44.67 To ETP
Total 2548 14.16 141.56 141.53
Rapid Environmental Impact Assessment Report Page : 127 of 294 Chapter-2 Project Description
(B-22) 1-Methyl-4-Piperidinyl Di Phenyl Hydroxy acetate
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 128 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
OH COOH
+ CH3OHH2SO4
OH COOCH3
Benzilic acid Methanol Benzilic acid methyl Ester
MolecularWeight
228 32 242
Stage –II
ChemicalFormula
ChemicalName
OH COOCH3
Benzilic acid methyl Ester
+N
OH
CH3
N -methyl 4 -Hydroxy Piperidine
O COOCH3
N
CH3
Toluene
Benzene Sodium Methoxide
methyl [(1-methylpiperidin-4-yl)oxy](diphenyl)acetate
MolecularWeight
242 115 339
Rapid Environmental Impact Assessment Report Page : 129 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 1-Methyl-4-Piperidinyl Di Phenyl Hydroxy acetate is
given in Table.
Summary of Mass Balance -1-Methyl-4-Piperidinyl Di Phenyl Hydroxy acetate
capacity of Finished Product MT/Month : 10.00
batch size kg : 115
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 N-Methyl-4-Hydroxy Piperidine 80 0.70 6.96 Reactant
2 Toluene 560 4.87 48.70
3 Benzene 345 3.00 30.00 Solvent
4 Benzillic acid 200 1.74 17.39
5 Methanol 500 4.35 43.48
6 Water 1000 8.70 86.96
7 Sodium Methoxide 80 0.70 6.96
Reactant
Total 2765 24.04 240.43
Output
1 1-Methyl-4-Piperidinyl Di Phenyl Hydroxy Acetate
115 1.00 10.00 Finished Product
2 Mixed Toluene & Benzene 1000 8.70 86.96 To ETP
3 Waste Methanol 450 3.91 39.13 To TSDF
4 Effluent 1200 10.43 104.35 To ETP
Total 2765 24.04 240.43
Rapid Environmental Impact Assessment Report Page : 130 of 294 Chapter-2 Project Description
(B-23) (1-Methyl-4-Piperidinyl)3-[2[(3-Chloro Phenyl)ethyl]-2-
Pyridinyl]Methanone
a) Reaction Chemistry
Stage –I
ChemicalFormula
ChemicalName
N
N
Cl
CH3
O
{3-[2-(3-chlorophenyl)ethyl]-2,3-dihydropyridin-2-yl}(1-methylpiperidin-4-yl)methanone
N
Cl
NC +N
MgCl
CH3
THF
Toluene
3-[2-(3-chlorophenyl)ethyl]pyridine-2-carbonitrile Gignard reagent
MolecularWeight
242.5 158 344.8
Rapid Environmental Impact Assessment Report Page : 131 of 294 Chapter-2 Project Description
b) Summary of mass balance
Summary of mass balance for (1-Methyl-4-Piperidinyl)3-[2[(3-Chloro Phenyl)ethyl]-2-
Pyridinyl]Methanone is given in Table.
Summary of Mass Balance - (1-Methyl-4-Piperidinyl)3-[2[(3-Chloro Phenyl)ethyl]-2-
Pyridinyl]Methanone
capacity of Finished Product MT/Month : 10.00
batch size kg : 150
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 3-(2-Chloro Phenyl )ethyl 2-cyano pyridine
125 0.83 8.33
2 N-Methyl-4-Chloro Piperidine 125 0.83 8.33
3 Magnesium Turning 30 0.20 2.00
Reactant
4 Tetra Hydro Furane 540 3.60 36.00 Catalyst
5 Iodine 0.1 0.00 0.01
6 Ethylene Bromide 3 0.02 0.20 Reactant
7 Water 1500 10.00 100.00 ----
8 Hydrochloric Acid 450 3.00 30.00
9 Tetra Hydro Furan 540 3.60 36.00 Reactant
10 Toluene 600 4.00 40.00 SolventTotal 3913 26.09 260.87
Output
1 Lorata-7 150 1.00 10.00 Finished Product
2 Rec Tetra Hydro Furan High M/C 600 4.00 40.00
3 Rec Toluene & Tetra Hydro Furan 800 5.33 53.33 To TSDF
4 Effluent 2313 15.42 154.20 To ETP
5 Solid waste 50 0.33 3.33 To TSDF
Total Total 3913 26.09 260.87
Rapid Environmental Impact Assessment Report Page : 132 of 294 Chapter-2 Project Description
(B-24) 1-Butanon-4-[4-(4-Chloro Phenyl)-4-Hydroxy-1-Piperidinyl-1-(-4-Fluoro Phenyl)
a) Summary of mass balance Summary of mass balance for 1-Butanon-4-[4-(4-Chloro Phenyl)-4-Hydroxy-1-
Piperidinyl-1-(-4-Fluoro Phenyl) is given in Table.
Summary of Mass Balance - 1-Butanon-4-[4-(4-Chloro Phenyl)-4-Hydroxy-1-
Piperidinyl-1-(-4-Fluoro Phenyl)
capacity of Finished Product MT/Month : 10.00
batch size kg : 50
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 4-Chloro p-Fluoro phenol 62.5 1.25 12.50
2 4-(p-chloro pheny)4-Hydroxy Piperidine
56.25 1.13 11.25 Reactant
3 Acetone(Fresh) 62.5 1.25 12.50
4 Acetone(Recovered) 250 5.00 50.00 Solvent
5 Potassium carbonate 31.25 0.63 6.25 Reactant
6 Water 125 2.50 25.00 ---
7 Methanol(Fresh) 125 2.50 25.00
8 Methanol(Recovered) 500 10.00 100.00 Solvent
9 Charcoal 6.25 0.13 1.25 Catalyst Total 1219 24.38 243.75
Output
1 Haloperidol(tech) 50 1.00 10.00 Finished Product
2 Acetone Loss 62.5 1.25 12.50 To Atm
3 Acetone Recovered 250 5.00 50.00 Re. Solvent
4 Methanol Loss 125 2.50 25.00 To Atm
5 Methanol Recovered 500 10.00 100.00 Re. Solvent
6 water 219 4.38 43.80 --
7 Solid Waste 12.5 0.25 2.50 To TSDF
Total Total 1219 24.38 243.80
Rapid Environmental Impact Assessment Report Page : 133 of 294 Chapter-2 Project Description
(C-1) 4-Amino 1,2,4 Triazole
a) Material Balance Diagram:
360
120
Rapid Environmental Impact Assessment Report Page : 134 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage –I
Chemical Formula
Chemical Name
H COOH + NH2NH2.H2O H
NH NH2
O
+
WaterFormic acid Hydrazine Hydrate Formyl Hydrazide
H2O
MolecularWeight
46 50 60 18
Stage –II
ChemicalFormula
ChemicalName
N N
N
NH2
4-Amino 1,2,4 Triazole
H
NH NH2
O
Formyl Hydrazide
2 + 2H2O
Water
MolecularWeight
120 84 36
Rapid Environmental Impact Assessment Report Page : 135 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 4-Amino 1,2,4 Triazole is given in Table.
Summary of Mass Balance – 4-Amino 1,2,4 Triazole
capacity of Finished Product MT/Month : 5.00
batch size kg : 1400
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Hydrazine Hydrate 2400 1.71 8.57
2 Formic acid 2100 1.50 7.50 Reactant
3 Iso Propyl Alcohol Rec 360 0.26 1.29 Solvent
4 Activated Carbon 8 0.01 0.03 Catalyst
5 Hyflo 4 0.00 0.01 Catalyst
6 Iso Propyl Alcohol Fresh 40 0.03 0.14 Reactant
Total 4912 3.51 17.54
Output
1 4-Amino 1,2,4 Triazole 1400
1.00 5.00 Finished Product
2 Distilled Water 3000 2.14 10.71 ---
3 Waste Activated Carbon + Hyflo 12 0.01 0.04 To TSDF
4 Iso Propyl Alcohol rec 360 0.26 1.29 Reuse
5 Water Vapors 100 0.07 0.36 To Atm
6 IPA Loss 40 0.03 0.14
Total 4912 3.51 17.54
Rapid Environmental Impact Assessment Report Page : 136 of 294 Chapter-2 Project Description
(C-2) 3-Amino 1,2,4 Triazole
a) Material Balance Diagram:
b) Reaction Chemistry
ChemicalFormula
ChemicalName
NH2 NH
NH2
NHH2CO3
+ H COOHIPA N
NNH
NH2
Guanidine carbonate Formic Acid 3-Amino 1,2,4 triazole
MolecularWeight
136 46 84
Condensation
Water Distillation Effluent: 512
Amino Guanidine bi carbonate:769.2
Formic acid :261.5
pH Adjustment
SolidWaste: 173 Filtration
Centrifugation & IPA wash
IPA(Recovered):3600 IPA Loss:92
3-Amino 1,2,4 Triazole (Finished Product):500
Charcoal:153.8
IPA(Recovered):3600 IPA(Fresh):92
Rapid Environmental Impact Assessment Report Page : 137 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 3-Amino 1,2,4 Triazole is given in Table.
Summary of Mass Balance – 3-Amino 1,2,4 Triazole
capacity of Finished Product MT/Month : 5.00
batch size kg : 500
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 AminoGuanidine bi carbonate 769 1.5 7.7
2 Formic acid 262 0.5 2.6
3 Iso Propyl Alcohol fresh 92 0.2 0.9
Reactant
4 Iso Propyl Alcohol rec 3600 7.2 36.0 solvent
5 Charcoal 154 0.3 1.5 Catalyst Total 4877 9.8 48.8
Output
1 3-Amino 1,2,4 Triazole 500.0 1.0 5.0 Finished Product
2 Iso Propyl Alcohol 3461.5 6.9 34.6
3 Effluent 684.6 1.4 6.8 To ETP
4 SolidWaste 173 0.3 1.7
5 Iso Propyl Alcohol loss 92 0.2 0.9 To TSDF
Total 4876.9 9.8 48.8
Rapid Environmental Impact Assessment Report Page : 138 of 294 Chapter-2 Project Description
(C-3) 1,2,4 Triazole
a) Material Balance Diagram:
Material balance Diagram - APCM
Condensation Hydrazine Hydrate: 222
Formic acid: 444 Ammonia: 178
Ethyl acetate (Recovered h): 756
Ethyl acetate (Fresh): 133
Centrifugation & IPA wash Waste Ethyl
Acetate: 133
Ammonia: 44
Drying
400 kg of 1,2,4 Triazole (Finished Product)
Dying loss: 400 EA (Re.) : 756
Water Scrubber NH3: 0.1 Water: 0.9
Byproduct NH3 (10 %): 1.00 (Sale)
Rapid Environmental Impact Assessment Report Page : 139 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage -I
Chemical Formula
Chemical Name
H COOH + NH3 H
O
NH2
+ H2O
Formic Acid Ammonia Formamide Water
MolecularWeight
46 17 45 18
Stage -II
Chemical Formula
Chemical Name
H
O
NH2
+ NH2NH2H2O
Formamide Hydrazine Hydrate
N
NN
H
+NH3+ H2O
(1H) 1,2,4 Triazole
MolecularWeight
45 50 69 17 18
Rapid Environmental Impact Assessment Report Page : 140 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for 1,2,4 Triazole is given in Table.Summary of Mass Balance –1,2,4 Triazole
capacity of Finished Product MT/Month : 5.00
batch size kg : 400
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 Formic Acid 444.4 1.11 5.56
2 Ammonia 177.8 0.44 2.22
3 Hydrazine Hydrate 222.2 0.56 2.78
Reactant
4 Ethyl acetate (Fresh) 755.6 1.89 9.44
5 Ethyl acetate (Recovered) 133.3 0.33 1.67 Solvent
Total 1733.3 4.33 21.67
Output
1 1,2,4 Triazole 400
1.00 5.00 Finished Product
2 Ammonia 44
0.11 0.55 To Scrubber
3 Ethyl acetate Waste 133 0.33 1.66 To TSDF
4 Ethyl acetate (Recovered) 756
1.89 9.45 Recovered Solvent
5 Drying Loss 400 1.00 5.00 To Atm
Total Total 1733 4.33 21.66
Summary of Mass Balance - 1,2,4 Triazole APCMQuantity
Sr. No. Name of Raw Material Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 400.00 1.0000 5.0000 Scrubbing Media
2 Ammonia Gas 44.44 0.1111 0.5556 To Scrubber Total 444.44 1.1111 5.5556
Water scrubber Output
1 Liq. Ammonia 444.44 1.1111 5.5556 Sale as By Product
Total 444.44 1.1111 5.5556
Rapid Environmental Impact Assessment Report Page : 141 of 294 Chapter-2 Project Description
(C-4) 1[(2,4 Di Fluoro Phenyl)-1-2-(1-H)1,2,4 Triazolyl Ethanone
a) Material Balance Diagram:
Material balance Diagram - APCM
Quenching
Layer Separation Effluent (Aqueous
Layer): 2171
Distillation
Cooling & temp maintaining
Recovered IPA: 4500
200 kg of 1[(2,4 Di Fluoro Phenyl)-1-2-(1-H)1,2,4 Triazolyl Ethanone
(Finished Product)
1,3 Di Fluoro Benzene: 125
MDC: 450 Chloro acetyl chloride:
105 Aluminium Chloride: 156
Ice: 800
MDC (Recovered): 400
Distillation loss: 50 Distillation residue:
25
Centrifugation & Drying
Chilling Sod. Nitrite Solution: 180 Hcl: 600
Ammonia Solution: 500
Centrifugation & Drying
lPA (Fresh): 500 lPA (Recovered): 4500 4 -Amino 1,2,4 Triazole:
165
Effluent (M/L): 4746 IPA Loss : 100
Waste sludge:100 HCL gas:60
Rapid Environmental Impact Assessment Report Page : 142 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage -I
Chemical Formula
Chemical Name
F
F
F
F
OCl
+ ClCH2COClMDC
+ HCl
1,3 Difluoro Benzene Chloro acetyl chloride 2-chloro-1-(2,4-difluorophenyl)ethanone
MolecularWeight
95 113 171.5
Stage -II
ChemicalFormula
ChemicalName
2-chloro-1-(2,4-difluorophenyl)ethanone
F
F
OCl
+N
N N
NH2
4-Amino 1,2,4 triazole
F
F
O
NN
N+NH2
HCl
QA salt
MolecularWeight
190.5 84 274.5
Stage -III
ChemicalFormula
ChemicalName
F
F
O
NN
N+NH2
HCl
QA salt
+ NaNO2Water
HCl solutionLiquor ammonia
F
F
O
NN
N
1-(2,4-difluorophenyl)-2-(1H-1,2,4-triazol-1-yl)ethanone
MolecularWeight
274.5 69 223
Water Scrubber HCl: 60 Water: 140
Byproduct HCl (30 %): 200 (Sale)
Rapid Environmental Impact Assessment Report Page : 143 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 1[(2,4 Di Fluoro Phenyl)-1-2-(1-H)1,2,4 Triazolyl
Ethanone is given in Table.
Summary of Mass Balance –1[(2,4 Di Fluoro Phenyl)-1-2-(1-H)1,2,4 Triazolyl Ethanone
capacity of Finished Product MT/Month : 5.00
batch size kg : 200
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
of Product
MT/Month Remarks
Input
1 1,3 DiFluoro Benzene 125 0.63 3.13
2 Chloro acetyl chloride 105 0.53 2.63 Reactant
3 Methylene Di Chloride(Fresh) 50 0.25 1.25
4 Methylene Di Chloride(Recovered) 400
2.00 10.00 Solvent
5 Aluminium chloride 156
0.78 3.90 Reactant
6 Ice 800 4.00 20.00
7 Water 2500 12.50 62.50 ----
8 Iso Propyl Alcohol(Fresh) 100 0.50 2.50
9 Iso Propyl Alcohol(Recovered) 4500 22.50 112.50 Solvent
10 4-Amino 1,2,4 Traizole 165 0.83 4.13
11 Hydrochloric Acid 600 3.00 15.00
12 Sodium Nitrite 180 0.90 4.50
13 Ammonia Solution 500 2.50 12.50
Reactant
Total 10181 50.91 254.53
Output
1 1-(2,4,Di Fluoro )1-H-1,2,4 Triazolyl Acetophenone 200 1.00 5.00 Finished
Product 2 Methylene Di Chloride Loss 50 0.25 1.25 To Atm
3 Rec Methylene Di Chloride 400 2.00 10.00
4 Iso Propyl Alcohol Loss 100 0.50 2.50
5 Rec Iso Propyl Alcohol 4500 22.50 112.50
Recovered Solvent
Rapid Environmental Impact Assessment Report Page : 144 of 294 Chapter-2 Project Description
6 Waste Sludge 100 0.50 2.50 To TSDF
7 Effluent 4746 23.73 118.65 To ETP
8 Residue after distillation 25 0.13 0.63 To TSDF
9 Hydrochloric Acid Gas 60 0.30 1.50 ToScrubber
Total 10181 50.91 254.53
Summary of Mass Balance -1[(2,4 Di Fluoro Phenyl)-1-2-(1-H)1,2,4 Triazolyl Ethanone
APCM
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 140 0.700 3.50 Scrubbing Media
2 Hydrochloric Acid Gas 60 0.300 1.50 To Scrubber Total 200 1.000 5.00
Water scrubber Output
1 Hydrochloric Acid (30 %) 200 1.000 5.00 Sale as By Product
Total 200 1.000 5.00
Rapid Environmental Impact Assessment Report Page : 145 of 294 Chapter-2 Project Description
(C-5) Epoxy Mesylate
a) Material Balance Diagram:
100
100
100
100
1900
100
250
1410
Rapid Environmental Impact Assessment Report Page : 146 of 294 Chapter-2 Project Description
b) Reaction Chemistry Stage -I
ChemicalFormula
ChemicalName
F
F
O
NN
N
+ CH3 S+
CH3
CH3 OI
EDC
NaOH solutionF
F
NN
N
O
1-(2,4-difluorophenyl)-2-(1H-1,2,4-triazol-1-yl)ethanone
1-{[2-(2,4-difluorophenyl)oxiran-2-yl]methyl}-1H-1,2,4-triazole
MolecularWeight
223 220 237
Stage -II
ChemicalFormula
ChemicalName
F
F
NN
N
O
1-{[2-(2,4-difluorophenyl)oxiran-2-yl]methyl}-1H-1,2,4-triazole
F
F
NN
N
O
+
CH3SO3H
AcetoneCH3 SO3H
Epoxy mesylate
MolecularWeight
237 96 333
Rapid Environmental Impact Assessment Report Page : 147 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for Epoxy Mesylate is given in Table.
Summary of Mass Balance –Epoxy Mesylate
capacity of Finished Product MT/Month : 5.00
batch size kg : 150
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
of Product
MT/Month Remarks
Input
1 DFTA 150 1.00 5.00 Reactant
2 Methylene Di Chloride(Fresh) 100 0.67 3.33
3 Methylene Di Chloride(Recovered) 1250 8.33 41.67
Solvent
4 Tri Methyl Silyl Iodide 250 1.67 8.33
5 Caustic Soda Lye 150 1.00 5.00 Reactant
6 Water 1200 8.00 40.00 ---
7 Acetone(Fresh) 100 0.67 3.33
8 Acetone(Recovered) 2000 13.33 66.67 Solvent
9 Methane Sulfonic acid 60 0.40 2.00 Reactant
Total 5260 35.07 175.33
Output
1 Epoxy mesylate 150 1.00 5.00 Finished Product
2 Methylene Di Chloride Loss 100 0.67 3.33 To Atm
3 Rec Methylene Di Chloride 1250 8.33 41.67 Recovered Solvent
4 Acetone Loss 100 0.67 3.33 To Atm
5 Rec Acetone 1900 12.67 63.33 Recovered Solvent
6 Acetone vapors in dryer 100 0.67 3.33 To Atm
7 Rec TMSI 250 1.67 8.33 Recovered Solvent
8 Effluent 1410 9.40 47.00 To ETP
Total 5260 35.07 175.33
Rapid Environmental Impact Assessment Report Page : 148 of 294 Chapter-2 Project Description
(D-1) Alfa Alfa Di Methyl Phenyl acetic acid methyl ester
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 149 of 294 Chapter-2 Project Description
b) Reaction Chemistry
ChemicalFormula
ChemicalName
COOH
CH3CH3
a,a Dimethyl phenyl acetic acid
+
.
Methanol COOMe
CH3CH3
a,a dimethyl Phenyl Acitic acid
+ H2O
.
+ HCl SolutionToluene
NaHCO3
Methyl ester
MolecularWeight
164 32 36.5 178 18
Rapid Environmental Impact Assessment Report Page : 150 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for Alfa Alfa Di Methyl Phenyl acetic acid methyl ester is
given in Table.
Summary of Mass Balance – Alfa Alfa Di Methyl Phenyl acetic acid methyl ester
capacity of Finished Product MT/Month : 3.00
batch size kg : 180
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Alfa Alfa Di methyl phenyl acetic acid 200 1.11 3.33
2 Methanol 600 3.33 10.00
3 Hydrochloric Acid 600 3.33 10.00
Reactant
4 Toluene(Fresh) 40 0.22 0.67
5 Toluene(Recovered) 560 3.11 9.33 Solvent
6 Purified water 500 2.78 8.33 ----
7 Sodium Carbonate 50 0.28 0.83 Reactant Total 2550 14.17 42.50
Output
1 Alfa Alfa Di methyl phenyl a. acid M Ester 180 1.00 3.00 Finished
Product 2 Effluent 1690 9.39 28.17 To ETP
3 Residue after toluene rec & prod.distln 80 0.44 1.33 To TSDF
4 Toluene Loss 40 0.22 0.67 To Atm
5 Rec Toluene 560 3.11 9.33 Recovered Solvent
Total 2550 14.17 42.50
Rapid Environmental Impact Assessment Report Page : 151 of 294 Chapter-2 Project Description
(D-2) Alfa Alfa Di Methyl Phenyl acetic acid
a) Material Balance Diagram:
165 kg of Alfa Alfa Di Methyl Phenyl acetic acid
(Finished Product)
Liquid – Liquid Extraction
Alluminum Chloride as by product:2000
Heating
Cooling & Chilling
Unreacted Benzene:600
Centrifugation & Drying
Process Water: 1200 Activated Carbon: 5
Hyflow: 5 Caustic Lye: 350
Chilling followed by stirring
Benzene: 200 Aluminum Chloride: 500
Methacrylic acid: 150 Process Water: 1600
HCL: 500
HCl: 250
Effluent (M/L): 1685
Rapid Environmental Impact Assessment Report Page : 152 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage -I
ChemicalFormula
ChemicalName
CN
Benzyl cyanide
+
.
CN
CH3CH3
a,a dimethyl Benzyl cynide
+ NaCl
.
MEG
KOH(CH3)2SO4
Dimethyl Sulphate
MolecularWeight
117 126 145 58.5
Stage -II
ChemicalFormula
ChemicalName
CN
CH3CH3
á,á Dimethyl Benzyl cyanide
+
.
NaOH LYE MEG
HCl +WaterCOOH
CH3CH3
a,a dimethyl Phenyl Acitic acid
MolecularWeight
145 40 164
Rapid Environmental Impact Assessment Report Page : 153 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for Alfa Alfa Di Methyl Phenyl acetic acid is given in
Table.
Summary of Mass Balance – Alfa Alfa Di Methyl Phenyl acetic acid
capacity of Finished Product MT/Month : 3.00
batch size kg : 165
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Benzyl Cyanide 100 0.61 1.82
2 Di Methyl Sulfate 150 0.91 2.73
3 Di methyl Sulfoxide 500 3.03 9.09
4 Caustic Potash 2600 15.76 47.27
Reactant
5 Purified water 250 1.52 4.55 ---
6 Toluene 250 1.52 4.55
7 Hydrochloric Acid 600 3.64 10.91 Reactant
Total 4450 26.97 80.91
Output
1 Alfa Alfa Di methyl phenyl acetic acid 165 1.00 3.00 Finished
Product 2 Effluent 1685 10.21 30.64 To ETP
3 Aluminium Chloride 2000 12.12 36.36
4 Benzene Rec. 600 3.64 10.91 To TSDF
Total 4450 26.97 80.91 80.91
Rapid Environmental Impact Assessment Report Page : 154 of 294 Chapter-2 Project Description
(D-3) Alfa Alfa Di Methyl Para Bromo Phenyl acetic acid
a) Material Balance Diagram:
Heating followed by cooling
Alfa Alfa Di methyl phenyl acetic acid :400
Clo. (Fresh) : 100 Clo. (Recovered) : 600
Iron Powder: 1.0 Liquid Bromine: 600
Sulfuric acid : 200 Water :1500
Layer separation Effluent (Aqueous
Layer): 1600
Cooling followed by centrifuge
Caustic Lye: 300 Effluent (M/L): 2526
Heptane Recovered: 1600
Heptane Loss: 100 Chloroform loss:100
Chloroform Recovered:600
Heptane Loss:100
170 kg of Alfa Alfa Di Methyl Para Bromo Phenyl acetic acid
(Finished Product)
Azeotrpic distillation of
Crude Product Heptane (fresh): 100
Heptane (Recovered): 1600
HBr gas: 305
Rapid Environmental Impact Assessment Report Page : 155 of 294 Chapter-2 Project Description
Mass Balance Diagram-APCM
Mass Balance Diagram-APCM
b) Reaction Chemistry
Chemical Formula
Chemical Name
COOH
CH3CH3
+ Br2CTC
COOH
CH3CH3
Br
a,a DiMethyl Phenyl acetic Acid a,a DiMethyl P-Bromo Phenyl acetic Acid
+ HBr
MolecularWeight
164 160 243 81
Hydrobromic Acid: 981 Water Scrubbing
Water: 676 HBr Gas: 305
Sodium Bromide: 2590 Water Scrubbing
Caustic: 8 Water: 56
HBr Gas: 2526
Rapid Environmental Impact Assessment Report Page : 156 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for Alfa Alfa Di Methyl Para Bromo Phenyl acetic acid is
given in Table.
Summary of Mass Balance – Alfa Alfa Di Methyl Para Btomo Phenyl acetic acid
capacity of Finished Product MT/Month : 3.00
batch size kg : 170
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Alfa Alfa Di methyl phenyl acetic acid 400 2.35 7.06 Reactant
2 Chloroform fresh 100 0.59 1.76
3 Chloroform rec 600 3.53 10.59 Solvent
4 Iron Powder 1.00 0.006 0.018
5 Liq Bromine 600 3.53 10.59
6 Sulfuric acid 200 1.18 3.53
Reactant
7 Caustic Lye 300 1.76 5.29 Neutralizing Agent
8 Water 1500 8.82 26.47 ---
9 Heptane(Fresh) 100 0.59 1.76
10 Heptane(Recovered) 1600 9.41 28.24 Solvent
Total 5401 31.77 95.31
Output
1 Alfa Alfa Di methyl P Bromo phenyl a. acid 170 1.00 3.00 Finished
Product 2 Effluent 2526 14.86 44.58 To ETP
3 HBr gas 305 1.79 5.38 To Scrubber
4 Rec Heptane 1600 9.41 28.24 Recovered Solvent
5 Heptane Loss 100 0.59 1.76
6 CTC Loss 100 0.59 1.76 To Atm
7 Rec CTC 600 3.53 10.59 Recovered Solvent
Total 5401 31.77 95.31
Rapid Environmental Impact Assessment Report Page : 157 of 294 Chapter-2 Project Description
Summary of Mass Balance - Alfa Alfa Di Methyl Para Bromo Phenyl acetic acid -
APCM
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 676 3.977 11.93 Scrubbing Media
2 HBr Gas 290 1.704 5.11 To Scrubber Total 966 5.681 17.04
Water scrubber Output
1 Hydrobromic Acid (30 %) 966 5.681 17.04 Sale as By
Product Total 966 5.681 17.04
Alkali scrubber Input
1 Caustic 8 0.05 0.14 To Scrubber
2 Water 56 0.33 0.99
3 HBr Gas 15 0.09 0.27 Scrubbing
Media
Total 79 0.47 1.40
Alkali scrubber Output
1 Sodium Bromide 79 0.47 1.40 Sale as By Product
Total 79 0.47 1.40
Rapid Environmental Impact Assessment Report Page : 158 of 294 Chapter-2 Project Description
(D-4) (A) 4-(-4-Chloro 1-Oxobutyl)2,2,di methyl phenyl a. acid
a) Material Balance Diagram:
250 Kg Alfa Alfa Di Methyl Phenyl acetic acid(FEX-2)
Chilling followed by Stirring
Benzene: 200 Aluminum Chloride: 500
Methacrylic acid: 150 Process Water: 1600
HCL: 500 Extraction Aluminum Chloride as by product
Heating Unreacted benzene
Cooling & Chilling HCl: 250
Centrifugation & Drying
Reaction Vessel
Heating & TemperatureMaintenance
Cooling
Methanol: HCl:
Fex-2:
Purified Water:
ExtractionAqueous Layer Toluene
Process Water: 1200 A. Carbon: 5
Hyflow: 5 Caustic Lye: 350
Effluent : 1000
Rapid Environmental Impact Assessment Report Page : 159 of 294 Chapter-2 Project Description
Organic Layer Recovered Toluene
Heating & TemperatureMaintenance
CoolingPurified Water:
HCl:
Extraction
Organic Layer
Aqueous Layer
Recovered Toluene
Chilling1,2 Di Methoxy ethane:
Aluminum Chloride: Sodium Borohudride:
Fex-3:
Toluene
Heating & Cooling
CoolingPurified Water:
Layer Separation
Organic Layer
Aqueous Layer
Reaction Vessel Fex-4:
Acetic Anhydride:
Sodium Carbonate
Solution
N-Haxane:
Stirring &Layer Separation
Aqueous Layer
Rapid Environmental Impact Assessment Report Page : 160 of 294 Chapter-2 Project Description
4-(-4-Chloro-1-Oxo Butyl)2,2 Di methyl Phenyl acetic
acid (D-4A) FEX-6
Organic Layer N-Haxane Recovered
Stirring & Chilling
Heating & Temperature Maintaining
Fex-5:
Chilling & Dumping of Mass
Stirring, Settling, Layer Separation & wash
aqueous Layer By MDC
Reaction Vessel Metylene Chloride: Aluminum Chloride:
HCl: Purified Water:
4-Cholo Butyryl Chloride:
Combine Organic Layer
MDC recovered
Aqueous Layer
Degassing
Rapid Environmental Impact Assessment Report Page : 161 of 294 Chapter-2 Project Description
Alfa Alfa Di methyl-4-(1-oxo-1-cyclo propyl)phenyl
acetic acid(D-4B) FEX-8
Extraction
Cooling & Temperaturemaintaining
D.N.S: Caustic Soda:
Fex-6: Toluene:
4-Cholo Butyryl Chloride:
Organic Layer Aqueous Layer
Toluene Recovery
Temperature maintaining
Stirring Caustic Lye Solution: Sodium Bi sulfite
Cooling and Stirring
Caustic Lye Solution: Fex-7:
Potassium Permanganate:
Extraction Toluene:
Organic Layer Aqueous Layer
Toluene Recovery
Rapid Environmental Impact Assessment Report Page : 162 of 294 Chapter-2 Project Description
4-(-4-Chloro-1-Oxo Butyl)2,2 Di methyl Phenyl acetic acid M
Ester (D-4C) FEX-9
Heating to reflux
U/VAC Methanol Recovery
Reaction Vessel Methanolic HCl: Fex-8:
CoolingPurified Water:
Stirring & Layer Separation
Aqueous Layer
Organic Layer
MIBK: Sodium Bi Carbonate:
Purified Water: Sodium chloride solution
Layer Separation
Aqueous Layer
Aqueous Layer
Organic Layer as Fex-9
Azacyclonol: Potassium Bi Carbonate:
Potassium Iodide:
Heat to reflux & Azeotrop to remove
water
Rapid Environmental Impact Assessment Report Page : 163 of 294 Chapter-2 Project Description
4-(-4-HYDROXY DI PHENYL METHYL )1-PIPERIDINYL-1-OXO BUTYL) ALFA ALFA DI
METHYL PHENYL ACETIC ACID METHYL ESTER (D-4D) FEX-10
Cooling & Neutsching salt
washing by MIBK
Filter & washing ML MIBK recovery
Cooling Water RecoveryWater Addition
Denatured Spirit: Purified water:
Stirring, Cooling, Chilling centrifuge
washing
Reaction Methanol: Fex-10:
Stir, Cooling,
Heating, & Temperature Maintaining
Caustic Lye: Sodium Borohydride 2nd
Lot
Rapid Environmental Impact Assessment Report Page : 164 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Cooling
CentrifugeWater wash HCl
Product: Purified Water
Heating, Stirring, Centrifuge, Hot
water wash
Benzene acetic acid, 4-(1-Hydroxy-4-[4-(Hydroxy Di Phenyl Methyl)-1-
Piperidinyl]Butyl]Alfa Alfa Di Methyl (D-4E) FEX-12
Heating, Stirring, Cooling, Centrifuge
DNS Wash
Fex-12
Mother Liqour
Fex-12 Pure
Mother Liqour
DNS Recovery
Rapid Environmental Impact Assessment Report Page : 165 of 294 Chapter-2 Project Description
Chemical Formula
Chemical Name
MolecularWeight
CN COOH
CH3CH3
COOMe
CH3CH3
CH2OH
CH3CH3CH3CH3
O CH3
O
CH3CH3O CH3
O
ClO
CH3CH3OH
ClO
COOH
CH3CH3
ClO
COOMe
CH3CH3
ClO FEX - 9 FEX -8
FEX -7FEX -6
FEX -5 FEX -4
FEX -3FEX -2FEX -1
Molecular Formula = C14H17ClO3
Formula Weight = 268.73598
Molecular Formula = C15H19ClO3
Formula Weight = 282.76256
Molecular Formula = C16H21ClO3
Formula Weight = 296.78914
Molecular Formula = C14H19ClO2
Formula Weight = 254.75246
Molecular Formula = C12H16O2
Formula Weight = 192.25424Molecular Formula = C10H14OFormula Weight = 150.21756
Molecular Formula = C11H14O2
Formula Weight = 178.22766Molecular Formula = C10H12O2
Formula Weight = 164.20108Molecular Formula = C8H7NFormula Weight = 117.14788
1. 14 1. 08
0.84
1.27
1.54
0.85
1.05
1.05
FEX -12
Rapid Environmental Impact Assessment Report Page : 166 of 294 Chapter-2 Project Description
ChemicalFormula
ChemicalName
MolecularWeight
COOMe
C H 3CH 3
C lO
COOMe
C H 3CH 3
O
NO H
COOMe
C H 3CH 3
O H
NO H
FEX -9
FEX -10
FEX -11
Molecular Formula = C33H41NO4
Formula Weight = 515.68294
Molecular Formula = C33H39NO4
Formula Weight = 513.66706
Molecular Formula = C15H19ClO3
Formula Weight = 282.76256
1.82
1.00
COOH
C H 3CH 3
O H
NO H
FEX -12
Molecular Formula = C32H39NO4
Formula Weight = 501.65636
COOMe
C H 3CH 3
O H
NO H
FEX -11
Rapid Environmental Impact Assessment Report Page : 167 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 4-(-4-Chloro-1-Oxo Butyl) 2,2 Di methyl Phenyl acetic
acid is given in Table.
Summary of Mass Balance – 4-(-4-Chloro-1-Oxo Butyl) 2,2 Di methyl Phenyl acetic
acid
capacity of Finished Product MT/Month : 3.00
batch size kg : 250
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/MonthRemarks
Input
1 4-(4-chloro-1-oxo butyl)alfa alfa di methyl phenyl acetic acid 250
1.00 3.00
2 Methanol fresh 350 1.40 4.20
3 Methanol rec. 250 1.00 3.00
Reactant
4 HCl 300 1.20 3.60
5 Methylene Di Chloride(Fresh) 50 0.20 0.60 Solvent
6 Sodium Bicarbonate 25 0.10 0.30 ---
7 Water 1000 4.00 12.00 Reactant
8 Methylene Di Chloride(Recovered) 500 2.00 6.00 Solvent Total 2725 10.90 32.70
Output
1 4-(-4-Chloro 1-Oxobutyl)2,2,di methyl phenyl a. acid 250 1.00 3.00 Finished
Product 2 Effluent 1675 6.70 20.10 To ETP
3 Methanol rec. 250 1.00 3.00
4 Rec Methylene Di Chloride 500 2.00 6.00 Recovered
Solvent
5 Methylene Di Chloride Loss 50 0.20 0.60 To Atm
Total 2725 10.9 32.7
Rapid Environmental Impact Assessment Report Page : 168 of 294 Chapter-2 Project Description
(D-5) [2-[(2,6, di chloro phenyl)Amino]phenyl acetoxy acetic acid a) Material Balance Diagram:
b) Reaction Chemistry
ChemicalFormula
CH3
CH3
OHCH3 +Cl
Cl
O
CH3
CH3
OCH3
Cl
O
OO
CH3CH
CH3
O
ONH
ClCl
OO
CH3CH3
CH3
O
ONH
ClCl
OOH
O
ONH
ClCl
S-81
2[(2,6 Di Chloro Phenyl) Amino] Phenyl acetoxy acetic acid
Chloro acetyl chloride: 418 Tertiary Butyl alcohol:300 N N Di Methyl aniline:490
Water:5000 Toluene:600
Sodium by Carbonate
Extraction &
HVD
Filtration
Filtration & Drying
Tetra butyl ammonium bromide:10
Diclofenac sodium:600 Methanol:600
Formic Acid:1080 Water:
Effluent Water: Recovered Toluene: Solid Waste after HVD:
Effluent Methanol Water:
Rapid Environmental Impact Assessment Report Page : 169 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for [2-[(2,6, di chloro phenyl)Amino]phenyl acetoxy
acetic acid is given in Table.
Summary of Mass Balance – [2-[(2,6, di chloro phenyl)Amino]phenyl acetoxy acetic
acid
capacity of Finished Product MT/Month : 3.00
batch size kg : 300
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
of Product
MT/Month Remarks
Input
1
2-Tert butoxy-2-oxo-ethyl (2-2,6 dichlorophenyl)amino)phenyl acetate
455 1.52 4.55
2 Formic acid 682 2.27 6.82
Reactant
3 Toluene(Fresh) 45 0.15 0.45
4 Toluene(Recovered) 318 1.06 3.18 Solvent
5 Water 909 3.03 9.09 --- Total 2409 8.03 24.09
Output
1 2-(2, 6 dichlorophenyl) Amino) phenyl acetoxy acetic acid 300 1.00 3.00 Finished
Product 2 Effluent 1745 5.82 17.45 To ETP
3 Toluene Recovered 318 1.06 3.18 Recovered Solvent
4 Toluene Loss 45 0.15 0.45 To Atm
Total 2409 8.03 24.09
Rapid Environmental Impact Assessment Report Page : 170 of 294 Chapter-2 Project Description
(D-6) 2-Tert Butoxy-2-oxo-ethyl{2-[2,6 di chloro phenyl)amino]phenyl acetate
a) Material Balance Diagram:
Heating
Cooling & filtration
Cooling
Effluent: 4.71Filtration
Drying
Water: 4.0
2-Chloroacetic acid t-butyl ester: 1.0
TBAB: 0.03 Diclofenec sodium: 1.50
Methanol (Fresh):1.20 Methanol (Recovered):
0.10
1.82 kg of 2-Tert Butoxy-2-oxo-ethyl{2-[2,6 di chloro
phenyl)amino]phenyl acetate (Finished Product)
Methanol Loss:1.20 Methanol
Recovered: 0.10
Rapid Environmental Impact Assessment Report Page : 171 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Chemical Formula
CH3
CH3
OHCH3 +Cl
Cl
O
CH3
CH3
OCH3
Cl
O
OO
CH3CH3
CH3
O
ONH
ClCl
OO
CH3CH3
CH3
O
ONH
ClCl
OOH
O
ONH
ClCl
S-81
Rapid Environmental Impact Assessment Report Page : 172 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 2-Tert Butoxy-2-oxo-ethyl{2-[2,6 di chloro
phenyl)amino]phenyl acetate is given in Table.
Summary of Mass Balance – 2-Tert Butoxy-2-oxo-ethyl{2-[2,6 di chloro
phenyl)amino]phenyl acetate
capacity of Finished Product MT/Month : 3.00
batch size kg : 250
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 2-Chloroacetic acid t-butyl ester 137 0.55 1.65
2 Diclofenec sodium 206 0.82 2.47
3 TBAB 3 0.01 0.04
Reactant
4 Methanol (Fresh) 165 0.66 1.98
5 Methanol(Recovered) 14 0.05 0.16 Solvent
6 Water 549 2.20 6.59 --- Total 1075 4.30 12.90
Output
1
2-Tert butoxy-2-oxo-ethyl (2-2,6 dichlorophenyl)amino)phenyl acetate
250 1.00 3.00 Finished Product
2 Effluent 646 2.58 7.75 To ETP
3 Methano Loss 165 0.66 1.98 To Atm
4 Methanol Recovered 14 0.05 0.16 Recovered Solvent
Total 1075 4.24 12.73
Rapid Environmental Impact Assessment Report Page : 173 of 294 Chapter-2 Project Description
(D-7) 2-Chloro acetic acid butyl ester
a) Material Balance Diagram:
b) Reaction Chemistry
Chemical Formula
Chemical Name
CH3
CH3
OHCH3 +Cl
Cl
O
CH3
CH3
OCH3
Cl
O
tert - butenol Chloroacetyl chloride tert-butyl chloroacetate
MolecularWeight
74 113 150.5
Layer separation Effluent: 4.47 Solid waste:0.40
High vaccum Distillation
N,N Di Methyl Aniline Losss: 0.13
Water: 3.0 Caustic Lye: 0.50
HCl: 0.10
Cooling Tert-Butyl alcohol: 1.0
Chloro Acetyl chloride: 1.40
N,N Di Methyl Aniline:1.63 Sodium Sulphate: 0.20
1.33 kg of 2-Chloro acetic acid butyl ester
(Finished Product)
Recovered N,N Di Methyl Aniline: 1.50
Rapid Environmental Impact Assessment Report Page : 174 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 2-Chloro acetic acid butyl ester is given in Table .
Summary of Mass Balance – 2-Chloro acetic acid butyl ester
capacity of Finished Product MT/Month : 3.00
batch size kg : 100
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Tert-Butyl alcohol 75.19 0.30 0.90
2 Chloro Acetyl chloride 105.26 0.42 1.26 Reactant
3 N,N Di Methyl Aniline 122.56 0.49 1.47 Solvent
4 Conc-Hydrochloric acid 7.52 0.03 0.09
5 Sodium sulphate 15.04 0.06 0.18 Reactant
6 Water 225.56 0.90 2.71 ---
7 Caustic lye 37.59 0.15 0.45 Neutralizing Agent
Total 588.72 2.35 7.06
Output
1 2-Chloroacetic acid t-butyl ester 100.00 0.40 1.20 Finished
Product
2 N,N Di Methyl Aniline (Recovered) 112.78 0.45 1.35 Recovered
Solvent 3 Effluent 336.09 1.34 4.03 To ETP
4 Solid Waste 30.08 0.12 0.36 To TSDF
5 N,N Di Methyl Aniline Loss 9.77 0.04 0.12 To Atm
Total 588.72 2.35 7.06
Rapid Environmental Impact Assessment Report Page : 175 of 294 Chapter-2 Project Description
(D-8) Di Benzo suberone
a) Material Balance Diagram:
100 kg of Di Benzo suberone (Finished Product)
Reaction vessel
Cooling & filtration
Autoclave
Aqueous Layer (Effluent): 500
Layer separation
Water: 4.0 Sodium Hydroxide: 0.20
Raney Ni: 25 Water:667
Phenyl acetic acid: 167 Pthalic anhydride: 167
Sodium acetate: 5 HCl: 33
Methanol (Fresh): 50 Methanol (Recovered):
283
Raney Ni (Recovered): 23
Methanol (Recovered): 283 Heating
Reaction vessel Phosphorus pentoxide:
70Phosphoric acid: 58
Xylene (Fresh): 33 Xylene (Recovered):
267
Cooling & Layer separation
Aqueous Layer (Effluent): 600
High Vaccum Distillation
Xylene(Recovered): 23
Methanol Loss: 50 Xylene Loss: 2
Rapid Environmental Impact Assessment Report Page : 176 of 294 Chapter-2 Project Description
b) Reaction Chemistry Stage -I
ChemicalFormula
ChemicalName
COOH
+ O
O
O
O
O
Phenyl acetic acid Phthalic anhydride (3Z)-3-benzylidene-2-benzofuran-1(3H)-one
MolecularWeight
136 148 222
Stage -II
ChemicalFormula
ChemicalName
(3Z)-3-benzylidene-2-benzofuran-1(3H)-one
O
O
OH
O
2-(2-phenylethyl)benzoic acid
+Raney NiNaOH solution
HCl solution
MolecularWeight
222 226
Stage -III
ChemicalFormula
ChemicalName
2-(2-phenylethyl)benzoic acid
OH
O
+ P2O5 + H3PO4
Xylene
O
Dibenzo suberone
MolecularWeight
226 142 208
c) Summary of mass balance Summary of mass balance for Di benzo Suberone is given in Table.
Rapid Environmental Impact Assessment Report Page : 177 of 294 Chapter-2 Project Description
Summary of Mass Balance – Di benzo Suberonecapacity of Finished Product MT/Month : 3.00
batch size kg : 100
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month
Remarks
Input
1 Phenyl acetic acid 167 1.67 5.00
2 Pthalic anhydride 167 1.67 5.00
3 Sodium acetate 5 0.05 0.15
Reactant
4 Methanol (fresh) 50 0.50 1.50
5 Methanol (Recovered) 283 2.83 8.50 Solvent
6 Raney Ni 23 0.23 0.69 Catalyst
7 Sodium Hydroxide 33 0.33 1.00
8 Hydrochloric acid 33 0.33 1.00
9 Phosphorus pentoxide 70 0.70 2.10
10 Phosphoric acid 58 0.58 1.75
Reactant
11 Xylene (fresh) 33 0.33 1.00
12 Xylene (Recovered) 267 2.67 8.00 Solvent
13 Water 667 6.67 20.00 --
14 Raney Ni (fresh) 2 0.02 0.06 Solvent Total 1858 18.58 55.75
Output
1 Dibenzo suberone 100 1.00 3.00 Finished Product
2 Effluent 1100 11.00 33.00 To ETP
3 Raney Ni 23 0.23 0.69 Reuse
4 Methanol (Recovered) 283 2.83 8.50 Recovered Solvent
5 Methanol Loss 50 0.50 1.50 To Atm
6 Rec. Xylene 267 2.67 8.00 Recovered Solvent
7 Xylene Loss 33 0.33 1.00 To Atm
8 Raney Ni (loss) 2 0.02 0.06
Total 1858 18.58 55.75
Rapid Environmental Impact Assessment Report Page : 178 of 294 Chapter-2 Project Description
(D-9) Di Benzo Suberenone a) Material Balance Diagram:
Reaction vessel
Cooling & filtration Effluent: 1.0
Autoclave
Layer separation
Water: 285.71 Sodium Hydroxide:
28.57
Phenyl acetic acid: 142.86
Pthalic anhydride: 142.86 Sodium acetate: 4.29
HCl: 28.57
Methanol (Fresh):42.86 Methanol (Recovered):
314.29
Heating
Reaction vessel Phosphorus pentoxide:
71.43 Phosphoric acid: 57.14
Xylene (Fresh): 28.57 Xylene (Recovered):400
Cooling & Layer separation
Aqueous Layer (Effluent): 661.43
High Vaccum Distillation
Xylene (Recovered): 400
100 kg of Di Benzo suberenone
(Finished Product)
Methanol Loss: 42.86 Xylene Loss:
28.57
Rapid Environmental Impact Assessment Report Page : 179 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage -I
Chemical Formula
Chemical Name
COOH
+ O
O
O
O
O
Phenyl acetic acid Phthalic anhydride (3Z)-3-benzylidene-2-benzofuran-1(3H)-one
MolecularWeight
136 148 222
Stage -II
Chemical Formula
Chemical Name
(3Z)-3-benzylidene-2-benzofuran-1(3H)-one
O
O
OH
O
NaOH solution
HCl solution
2-[(E)-2-phenylethenyl]benzoic acid
MolecularWeight
222 224
Stage -III
Chemical Formula
Chemical Name
2-(2-phenylethyl)benzoic acid
OH
O
+ P2O5 + H3PO4
Xylene
O
Dibenzo suberenone
MolecularWeight
224 206
Rapid Environmental Impact Assessment Report Page : 180 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for Di benzo Subererone is given in Table.
Summary of Mass Balance – Di benzo Subererone
capacity of Finished Product MT/Month : 3.00
batch size kg : 100
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Phenyl acetic acid 142.86 1.43 4.29
2 Pthalic anhydride 142.86 1.43 4.29
3 Sodium acetate 4.29 0.04 0.13
Reactant
4 Sodium Hydroxide 28.57 0.29 0.86 Solvent
5 Hydrochloric acid 28.57 0.29 0.86
6 Phosphorus pentoxide 71.43 0.71 2.14
7 Phosphoric acid 57.14 0.57 1.71
Reactant
8 Xylene (fresh) 28.57 0.29 0.86
9 Xylene (Recovered) 400.00 4.00 12.00 Solvent
10 Water 285.71 2.86 8.57 ---
11 Methanol (fresh) 42.86 0.43 1.29
12 Methanol (Recovered) 314.29 3.14 9.43 Solvent
Total 1547.14 15.47 46.41
Output
1 Dibenzo suberenone 100.00 1.00 3.00 Finished Product
2 Effluent 661.43 6.61 19.84 To ETP
3 Methanol (Recovered) 314.29 3.14 9.43 Recovered Solvent
4 Methanol Loss 42.86 0.43 1.29 To Atm
5 Rec. Xylene 400.00 4.00 12.00 Recovered Solvent
6 Xylene Loss 28.57 0.29 0.86 To Atm
Total 1547.14 15.47 46.41
Rapid Environmental Impact Assessment Report Page : 181 of 294 Chapter-2 Project Description
(D-10) Fex-10
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 182 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage -I
ChemicalFormula
ChemicalName
COOMe
CH3CH3
ClO
NHOH
+COOMe
CH3CH3
O
NOH
MIBK
DNS
methyl 2-[4-(4-chlorobutanoyl)phenyl]-2-methylpropanoate
Azacyclon
FEX -10
Molecular Weight
282.5 267 514
c) Summary of mass balance
Summary of mass balance for Fex-10 is given in Table.
Summary of Mass Balance – Fex-10
capacity of Finished Product MT/Month : 10.00
batch size kg : 200
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 4-(-4-Chloro 1-Oxobutyl)2,2, di methyl phenyl a. acid 180 1.00 10.00
2 Hydrochloric Acid 800 4.44 44.44
3 Methanol 640 3.56 35.56
4 Sodium Carbonate 15 0.08 0.83
Reactant
5 MIBK 1600 8.89 88.89 Solvent
6 Potassium Bi Carbonate 120 0.67 6.67
7 Potassium Iodide 1 0.01 0.06 Reactant
8 Retarter Solvent 1200 6.67 66.67 Solvent
9 Purified water 300 1.67 16.67 ----
10 Azacyclonol 160 0.89 8.89 Reactant Total 5016 27.87 278.67
Rapid Environmental Impact Assessment Report Page : 183 of 294 Chapter-2 Project Description
Output
1 Fex-10 200 1.11 11.11 Finished Product
2 Effluent 816 4.53 45.33 To ETP
3 Rec MIBK 1400 7.78 77.78 Recovered Solvent
4 Rec Retarter 1100 6.11 61.11 Reused
5 Solid waste 600 3.33 33.33 To TSDF
6 Ethanol as waste 300 1.67 16.67
7 Waste Hydrochloric Acid 600 3.33 33.33 To ETP
Total 5016 27.87 278.67
(E-1) 2-Amino Pyridine
a)Mass balance Diagram:
Reaction Vessel
Heating & TemperatureMaintenance
Cooling & Layer Separation
Toluene:1500 Pyridine:200
Sodium amide:60
Organic Layer
HVD
Toluene Layer:1400 Toluene Loss:100
190 kg of Pure 2 Amino Pyridine
Aq. Layer:20 Effluent:400
Water:400
Rapid Environmental Impact Assessment Report Page : 184 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Chemical Formula
Chemical Name
N
+NaNH2
Toluene
N NH2
Pyridine sodamide 2-Amino pyridine
Molecular Weight
79 39 94
c) Summary of mass balance Summary of mass balance for 2-Amino Pyridine is given in Table.
Summary of Mass Balance – 2-Amino Pyridine
capacity of Finished Product MT/Month : 2.00
batch size kg : 190
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Pyridine 200 1.05 2.11
2 Sodamide 60 0.32 0.63 Reactant
3 Toluene(Fresh) 100 0.53 1.05
4 Toluene(Recovered) 1400 7.37 14.74 Solvent
5 Water 400 2.11 4.21 --- Total 2160 11.37 22.74
Output
1 2-Amino Pyridine 190 1.00 2.00 Finished Product
2 Toluene Loss 100 0.53 1.05 To Atm
3 Rec Toluene 1400 7.37 14.74 Recovered Solvent
4 Effluent 420 2.21 4.42 To ETP
5 Solid waste after high vacuum distillation 50 0.26 0.53 To TSDF
Total 2160 11.37 22.74
Rapid Environmental Impact Assessment Report Page : 185 of 294 Chapter-2 Project Description
(E-2) 2-Bromo Pyridine
a) Material Balance Diagram
b) Reaction Chemistry
Step-1:
Chemical Formula
Chemical Name
N NH2
+NaNO2
N Br
HBrCuBr
2-Amino pyridine 2-Bromo Pyridine
Molecular Weight
94 158
Quenching
Stirring
Aqueous Layer
180 kg of 2-Bromo Pyridine
Recovered Chloroform:700
Chloroform Loss:100
Stirring2-Amino Pyridine:125 Acetic Acid:250
Liquid Bromine:200
Sodium carbonate:25
Chloroform:800 Water: 500
Extraction
Organic Layer
HVD
Efluent:880
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Step-2:
Chemical Formula
Chemical Name N
HNH
ToluenePd/C ( 5%)
40 -45 °C4-5 kg pressure
Molecular Weight
159 161
c) Summary of mass balance
Summary of mass balance for 2-Bromo Pyridine is given in Table.
Summary of Mass Balance – 2-Bromo Pyridine
capacity of Finished Product MT/Month : 2.00
batch size kg : 150
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 2-Amino Pyrdine 200 1.11 2.22
2 Liq Bromine 250 1.39 2.78
3 Acetic acid 500 2.78 5.56
Reactant
4 water 100 0.56 1.11 ---
5 Chloroform(Fresh) 700 3.89 7.78
6 Chloroform(Recovered) 25 0.14 0.28 Solvent
7 Sodium Nitrate 200 1.11 2.22 Reactant
Total 1900 10.56 21.11
Output
1 2-Bromo Pyridine 180 1.00 2.00 Finished Product
2 Effluent 880 4.89 9.78 To ETP
3 Rec Chloroform 700 3.89 7.78 Recovered Solvent
Rapid Environmental Impact Assessment Report Page : 187 of 294 Chapter-2 Project Description
4 Chloroform Loss 100 0.56 1.11 To Atm
5 residue after distillation 40 0.22 0.44 To TSDF
Total 1900 10.56 21.11
(E-3) 3[2(3-Chloro Phenyl) Ethyl]-2-Cyano Pyridine
a) Material Balance Diagram:
Chilling
Heat to reflux
Methanol (Recovered): 450
Methanol Loss: 150
Cooling Water: 1000
Sulfuric Acid: 900 Ice: 800
Methanol (Fresh):150 Methanol (Recovered): 450
Sodium Methoxide: 30 Methyl Nicotinate: 155
Meta chloro Benzyl cyanide: 150
Heating followed by cooling & Centrifuge
Effluent: 500
Ammonia solution: 450 Effluent (Aqueous Layer): 800
Ammonification & Layer separation
Reaction mass MEG (Fresh): 100 MEG (Recovered): 700 Hydrazine Hydrate: 60
Caustic Lye: 250
Toluene (Fresh): 100 Toluene (Recovered): 1100
Effluent (Aqueous Layer): 1000
Ammonification & Layer separation
Toluene (Recovered): 1100 Toluene Loss: 100
Rapid Environmental Impact Assessment Report Page : 188 of 294 Chapter-2 Project Description
High vaccum Distillation
120 kg of 3[2(3-Chloro Phenyl) Ethyl]-2-Cyano Pyridine (Finished Product)
MEG(Recovered):700 MEG Loss: 700
Heating Acetic Acid: 135
Hydrogen Peroxide: 156 Water: 1500
Cooling & Chilling Di Methyl Carbonyl
chloride: 130 Sodium Cyanide: 65
Chloroform (Recovered): 500
High vaccum distillation
Distillation residue:40
Chloroform (Fresh): 200 Chloroform (Recovered):
800
Liquid – Liquid extraction
Chloroform (Recovered): 1300
Chloroform Loss: 200
Heating
Aqueous Layer (Effluent):1000
Acetonitrile: 100
Liquid – Liquid extraction
High M/C Acetonitrile: 80
Aqueous Layer (Effluent): 1171
Water: 2000 IPA (Fresh): 70
IPA (Recovered): 480 Heating followed
by cooling & centrifuge
IPA (Fresh): 50
IPA (Recovered): 480 IPA Loss: 120
Centrifuge
Rapid Environmental Impact Assessment Report Page : 189 of 294 Chapter-2 Project Description
b) Reaction Chemistry
Stage -I
Chemical Formula
Chemical Name
CNCl
+N
MeOOC
CH3ONa
Methanol
N
CN OCl
m-Chloro benzyl Cyanide Methyl nicotinate 2-(3-chlorophenyl)-3-oxo-3-(pyridin-3-yl)propanenitrile
MolecularWeight
151.5 137 256.5
Stage -II
Chemical Formula
Chemical Name
N
CN OCl
+ H2SO4
N
OCl
2-(3-chlorophenyl)-3-oxo-3-(pyridin-3-yl)propanenitrile 2-(3-chlorophenyl)-1-(pyridin-3-yl)ethanone
MolecularWeight
256.5 98 231.5
Stage -III
Chemical Formula
Chemical Name
N
Cl
N
OCl
+ NH2NH2H2ONaOH Solution
2-(3-chlorophenyl)-1-(pyridin-3-yl)ethanone 3-[2-(3-chlorophenyl)ethyl]pyridine
MolecularWeight
231.5 50 217.5
Stage -IV
Chemical Formula
Chemical Name
N
Cl
3-[2-(3-chlorophenyl)ethyl]pyridine
N
Cl
3-[2-(3-chlorophenyl)ethyl]pyridine
Acetic acid
+ H2O2
O
N -Oxide
MolecularWeight
217.5 34 233.5
Stage -V
Rapid Environmental Impact Assessment Report Page : 190 of 294 Chapter-2 Project Description
Chemical Formula
Chemical Name
N
Cl
O
N
Cl
NCDMCC
NaCN+
3-[2-(3-chlorophenyl)ethyl]pyridineN -Oxide
3-(2-(3-Chlorophenyl)etyl )2-Cyano pyridine
MolecularWeight
233.5 49 258.5
c) Summary of mass balance
Summary of mass balance for 3[2(3-Chloro Phenyl) Ethyl]-2-Cyano Pyridine is given
in Table.
Summary of Mass Balance – 3[2(3-Chloro Phenyl) Ethyl]-2-Cyano Pyridine
capacity of Finished Product MT/Month : 2.00
batch size kg : 120
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/MonthRemarks
Input
1 Meta chloro Benzyl cyanide 150 1.25 2.50
2 Methyl Nicotinate 155 1.29 2.58 Reactant
3 Methanol (Fresh) 150 1.25 2.50
4 Methanol (Recovered) 450 3.75 7.50 Solvent
5 Sodium Methoxide 30 0.25 0.50 Reactant
6 Ice 800 6.67 13.33
7 Water 4500 37.50 75.00 ---
8 Sulfuric acid 900 7.50 15.00
9 Ammonia Solution 450 3.75 7.50 Reactant
10 Mono Ethyl Glycol (Fresh) 100 0.83 1.67
11 Mono Ethyl Glycol (Recovered) 700 5.83 11.67 Solvent
12 Caustic Lye 250 2.08 4.17 Neutralizing Agent
13 Hydrazien Hydrate 60 0.50 1.00 Reactant
14 Toluene (Fresh) 100 0.83 1.67 Solvent
Rapid Environmental Impact Assessment Report Page : 191 of 294 Chapter-2 Project Description
15 Toluene (Recovered) 1100 9.17 18.33
16 Hydrogen Peroxide 156 1.30 2.60
17 Acetic acid 135 1.13 2.25 Reactant
18 Chloroform (Fresh) 200 1.67 3.33
19 Chloroform (Recovered) 1300 10.83 21.67 Solvent
20 Acetonitrile 100 0.83 1.67
21 Di Methyl Carbonyl chloride 130 1.08 2.17
22 Sodium Cyanide 65 0.54 1.08
Reactant
23 Iso Propyl Alcohol (Fresh) 120 1.00 2.00
24 Iso Propyl Alcohol (Recovered) 480 4.00 8.00 Solvent
Total 12581 104.84 209.68
Output
1 3[2(3-Chloro Phenyl )Ethyl]-2-Cyano Pyridine 120 1.00 2.00 Finished
Product 2 Effluent 7041 58.68 117.35 To ETP
3 Rec Methanol 450 3.75 7.50 Recovered Solvent
4 Residue after solvent recovery 40 0.33 0.67 To TSDF
5 Rec Iso Propyl Alcohol 480 4.00 8.00
6 Rec Toluene 1100 9.17 18.33 Recovered
Solvent
7 High M/C Acetonitrile 80 0.67 1.33 Reused
8 Rec Mono Ethyl Glycol 700 5.83 11.67
9 Rec Chloroform 1300 10.83 21.67 Recovered
Solvent
10 Mono Ethyl Glycol Loss 700 5.83 11.67
11 Toluene Loss 100 0.83 1.67
12 Chloroform Loss 200 1.67 3.33
13 Iso Propyl Alcohol Loss 120 1.00 2.00
14 Methanol Loss 150 1.25 2.50
To Atm
Total 12581 104.84 209.69
Rapid Environmental Impact Assessment Report Page : 192 of 294 Chapter-2 Project Description
(E-4) 3[2(3-Chloro Phenyl )Ethyl]- Pyridine 2-Carboxylic acid
a) Material Balance Diagram:
b) Reaction Chemistry
ChemicalFormula
ChemicalName
N
Cl
NC N
Cl
HOOC
+ H2SO4
3-[2-(3-chlorophenyl)ethyl]pyridine-2-carbonitrile 3-[2-(3-chlorophenyl)ethyl]pyridine-2-carboxylic acid
MolecularWeight
242.5 98 261.5
Rapid Environmental Impact Assessment Report Page : 193 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 3[2(3-Chloro Phenyl )Ethyl]- Pyridine 2-Carboxylic acid
is given in Table.
Summary of Mass Balance – 3[2(3-Chloro Phenyl )Ethyl]- Pyridine 2-Carboxylic acid
capacity of Finished Product MT/Month : 2.00
batch size kg : 220
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 3-(2-Chloro Phenyl )ethyl 2-cyano pyridine 200 0.91 1.82
2 Sulfuric acid 450 2.05 4.09
Reactant
3 Ice 800 3.64 7.27
4 Water 500 2.27 4.55 ----
5 Caustic Lye 300 1.36 2.73 NeutralizingAgent
Total 2250 10.23 20.45
Output
1 3-(-2-Chloro Phenyl)ethyl Pyridine carboxylic acid 220 1.00 2.00 Finished
Product 2 Effluent 2030 9.23 18.45 To ETP
Total 2250 10.23 20.45
Rapid Environmental Impact Assessment Report Page : 194 of 294 Chapter-2 Project Description
(E-5) Iso Nicotinic acid
a) Material balance Diagram:
Heating
Stirring & Heating
Cooling & Centrifuge
Iso nicotinic acid crude
Process Water:500 Iso nicotinic acid crude
180 KG of Iso Nicotinic
Filtration
Heating to Dissolve
Drying
Acidic water as effluent:80
Effluent:1700
Centrifuge
Ammonia Liquid:500
ReactionSulfuric acid:400 Nitric acid:300
4-Methyl Pyridine:200
Rapid Environmental Impact Assessment Report Page : 195 of 294 Chapter-2 Project Description
b) Reaction Chemistry :
Chemical Formula
Chemical Name
N
CH3
+ HNO 3
N
COOH
4-Methyl Pyridine Iso nicotinic acid
Suphuric Acid
Nitric AcidMolecular
Weight 93 63 123
c) Summary of mass balance
Summary of mass balance for Iso Nicotinic Acid is given in Table.
Summary of Mass Balance – Iso Nicotinic Acid
capacity of Finished Product MT/Month : 2.00
batch size kg : 180
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 4-Methyl Pyridine 200 1.11 2.22
2 Nitric acid 300 1.67 3.33
3 Sulphuric acid 400 2.22 4.44
4 Liq. ammonia 560 3.11 6.22
Reactant
5 Water 500 2.78 5.56 --- Total 1960 10.89 21.78
Output
1 Isonicotinic acid 180 1.00 2.00 Finished Product
2 Effluent 1700 9.44 18.89
3 Acidic water as effluent 80 0.44 0.89 To ETP
Total 1960 10.89 21.78
Rapid Environmental Impact Assessment Report Page : 196 of 294 Chapter-2 Project Description
(E-6) 8-Chloro Azatidine
a) Material Balance Diagram:
Heating
Reflux
Cooling & TemperatureMaintaining
Cooling
Toluene: L5:
Layer Separation
Layer Separation
Cooling
Cooling & Centrifuge
Aqueous Layer
Organic Layer
THF:NMCP:
Water: Ammonia Solution:
Aqueous Layer
Reaction Ethylene Bromide:
THF:Iodine:
Mg Turning
CFML as Waste
Cooling Boric Acid:
Rapid Environmental Impact Assessment Report Page : 197 of 294 Chapter-2 Project Description
b) Reaction Chemistry :
Step-I
ChemicalFormula
Chemical Name
N
Cl
NC
+N
CH3
MgCl
THF
TolueneSulphuric acid
N
Cl
N
O
CH3
3-[2-(3-chlorophenyl)ethyl]pyridine-2-carbonitrile Gignard reagent{3-[2-(3-chlorophenyl)ethyl]pyridin-2-yl}(1-methylpiperidin-4-yl)methanone
Heating & TemperatureMaintaining
Cooling & Quenching
Stirring Ammonia:Toluene:
HeatingExtraction
TolueneDegassing
Aqueous Layer
Stirring, Cooling, Filtration, Drying
8-ChloroAzatrdine
Rapid Environmental Impact Assessment Report Page : 198 of 294 Chapter-2 Project Description
MolecularWeight
242.5 157.5 342.5
Step-II
Chemical Formula
Chemical Name {3-[2-(3-chlorophenyl)ethyl]pyridin-2-yl}(1-methylpiperidin-4-yl)methanone
N
Cl
N
O
CH3
Oleum
Sulphuric acidLiquor Ammonia
N
N
Cl
CH3
8-Chloro azatidine
MolecularWeight
342.5 324.5
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c) Summary of mass balance
Summary of mass balance for 8-Chloro Azatidine is given in Table.
Summary of Mass Balance – 8-Chloro Azatidine
capacity of Finished Product MT/Month : 2.00
batch size kg : 100
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 3-(2-Chloro Phenyl )ethyl 2-cyano pyridine 125.00 1.25 2.50
2 N-Methyl-4-Chloro Piperidine 125.00 1.25 2.50
3 Magnesium Turning 30.00 0.30 0.60
Reactant
4 Tetra Hydro Furane 540.00 5.40 10.80 Solvent
5 Iodine 0.10 0.00 0.00
6 Ethylene Bromide 3.00 0.03 0.06 Reactant
7 Water 1500.00 15.00 30.00 ---
8 Hydrochloric Acid 450.00 4.50 9.00
9 Oleum 900.00 9.00 18.00
10 Boric acid 200.00 2.00 4.00
11 Ammonia Solution 900.00 9.00 18.00
Reactant
12 Toluene(Fresh) 100.00 1.00 2.00
13 Toluene(Recovered) 1100.00 11.00 22.00
14 N-Hexane(Fresh) 100.00 1.00 2.00
15 N-Hexane (Recovered) 700.00 7.00 14.00
Solvent
Total 6773.1 67.73 135.46
Output
1 Methyl Loratadine 100 1.00 2.00 Finished Product
2 Effluent 4083 40.83 81.66 To ETP
3 Solid waste after distillation of solvents 50 0.50 1.00 To TSDF
4 Rec Toluene 1100 11.00 22.00 Recovered
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5 Rec N-Hexane 700 7.00 14.00 Solvent
6 Toluene Loss 100 1.00 2.00
7 N-Hexane Loss 100 1.00 2.00 To Atm
8 Waste Tetra Hydro Furan 500 5.00 10.00 To TSDF
9 THF Loss 40 0.40 0.80
Total 6773 67.73 135.46
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(E-7) Keto loratadine
a) Material Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 202 of 294 Chapter-2 Project Description
b) Reaction Chemistry:
Chemical Formula
Chemical Name
N
Cl
HOOC
+ SOCl2 + AlCl3
MDC N
O
Cl
3-[2-(3-chlorophenyl)ethyl]pyridine-2-carboxylic acid KetoLoratadine
MolecularWeight
261.5 119 243.5
c) Summary of mass balance
Summary of mass balance for Keto-Loratadine is given in Table.
Summary of Mass Balance – Keto-Loratadine
capacity of Finished Product MT/Month : 2.00
batch size kg : 50
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 3-(2-Chloro Phenyl )ethyl 2-cyano pyridine 100 2.00 4.00
2 Water 3000 60.00 120.00
3 Sulfuric acid 125 2.50 5.00
Reactant
4 Caustic Lye 250 5.00 10.00 Neutralizing Agent
5 Methylene Di Chloride (Fresh) 100 2.00 4.00
6 Methylene Di Chloride (Recovered) 2400 48.00 96.00 Solvent
7 Thionyl chloride 150 3.00 6.00
8 Aluminium chloride 80 1.60 3.20 Reactant
9 Ice 1200 24.00 48.00 ---
10 Ethyl acetate (Fresh) 100 2.00 4.00
11 Ethyl acetate (Recovered) 1400 28.00 56.00
Solvent
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12 Iso Propyl Alcohol (Fresh) 120 2.40 4.80
13 Iso Propyl Alcohol (Recovered) 880 17.60 35.20
14 A.Carbon 5 0.10 0.20 Catalyst
Total 9910 198.20 396.40
Output
1 Keto Loratadine 50 1.00 2.00 Finished Product
2 Effluent 4613 92.26 184.52 To ETP
3 Residue after solvent recovery 25 0.50 1.00 To TSDF
4 Hydrochloric Acid Gas 210 4.20 8.40 ToScrubber
5 Waste A.Carbon mixed Hyflo 12 0.24 0.48 To TSDF
6 Rec Ethyl acetate 1400 28.00 56.00
7 Rec Methylene Di Chloride 2400 48.00 96.00
8 Rec Iso Propyl Alcohol 880 17.60 35.20
Recovered Solvent
9 Loss Methylene Di Chloride 100 2.00 4.00
10 Loss Iso Propyl Alcohol 120 2.40 4.80
11 Loss Ethyl acetate 100 2.00 4.00
To Atm
Total 9910 198.20 396.40
Rapid Environmental Impact Assessment Report Page : 204 of 294 Chapter-2 Project Description
(F) 4-Chloro-4-Fluoro Butyrophenone
a) Material Balance Diagram:
Mass Balance Diagram- APCM
4 chloro butyryl chloride: 85.71
MDC(Fresh): 57.14
MDC(Recovered): 257.14 Aluminium Chloride:114.29
Fluoro benzene: 57.14
Quenching
Cooling and Layer Separation
Water: 514.29 Conc- HCl:
57.14
MDC LayerCharcoal: 5.7
Filteration
100 kg of 4-Chloro-4-Fluoro Butyrophenone
(Finished Product)
MDC(Recovered): 257.14 MDC Loss: 57.14
Solid Waste : 17.14
Effluent: 694.29 HCl: 22.86
Water ScrubbingWater: 0.90
HCl gas: 0.40 Hydrochloric Acid: 1.30
Rapid Environmental Impact Assessment Report Page : 205 of 294 Chapter-2 Project Description
b) Reaction Chemistry:
ChemicalFormula
ChemicalName
F + Cl
Cl
O AlCl3 FCl
O
Fluoro Benzene Chloro butryl chloride 4-Chloro 4-Fluoro butyrophenone
MolecularWeight
96 141 200.5
c) Summary of mass balance
Summary of mass balance for 4-Chloro-4-Fluoro Butyrophenone is given in Table.
Summary of Mass Balance – 4-Chloro-4-Fluoro Butyrophenone
capacity of Finished Product MT/Month : 2.00
batch size kg : 100
Working Days Per Month : 26
Quantity Sr. No.
Name of Raw Material Kg/Batch
Kg/Kgof
Product MT/Month
Remarks
Input
1 Fluoro benzene 57.14 0.57 1.14
2 4-Chloro butyryl chloride 85.71 0.86 1.71
3 Aluminium chloride 114.29 1.14 2.29
Reactant
4 Methylene Di Chloride(Fresh) 57.14 0.57 1.14
5 Methylene Di Chloride(Recovered) 257.14 2.57 5.14
Solvent
6 Water (Ice) 514.29 5.14 10.29 ---
7 Conc-Hydrochloric Acid 57.14 0.57 1.14 Reactant
8 Charcoal 5.71 0.06 0.11 Catalyst
Total 1148.57 11.49 22.97
Output
1 4-Chloro 4-Fluoro butyrophenone 100.00 1.00 2.00 Finished Product
Rapid Environmental Impact Assessment Report Page : 206 of 294 Chapter-2 Project Description
2 Effluent 694.29 6.94 13.89 To ETP
3 Methylene Di Chloride (Recovered) 257.14 2.57 5.14 Recovere
d Solvent 4 Methylene Di Chloride Loss 57.14 0.57 1.14 To Atm
5 Solid Waste 17.14 0.17 0.34 To TSDF
6 Hydrochloric Acid gas 22.86 0.23 0.46 ToScrubber
Total 1148.57 11.49 22.97
Summary of Mass Balance-4-Chloro-4-Fluoro Butyrophenone APCM
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 53.33 0.533 1.0667 Scrubbing Media
2 Hydrochloric Acid Gas 22.86 0.229 0.4571 To Scrubber
Total 76.19 1.524 3.0476
Water scrubber Output
1 Hydrochloric Acid (30 %) 76.19 0.762 1.5238 Sale as By Product
Total 76.19 0.762 1.5238
Rapid Environmental Impact Assessment Report Page : 207 of 294 Chapter-2 Project Description
(G-1) N-(2,6 Di methyl phenyl )-2-(Piperazinyl) acetamide
a) Mass Balance Diagram:
MDC Layer
Distillation Cyclohexane (Fresh): 12.5 Cyclohexane(Recovered):
112.5
Solid Waste: 6.3 Centrifuge and Drying under
vaccum
50 kg of N-(2,6 Di methyl phenyl )-2- (Piperazinyl) acetamide
(Finished Product)
MDC Recovery:390.6
Cyclohexane Recovery: 112.5
Water + IPA: 802.5
Dimer: 43.8
MDC Loss:100 Cyclohexane Loss:12.5
N-(2,6 Di methyl phenyl) 62.5 Chloro acetamide: 1.0
IPA: 350 MDC: 100
MDC Recovered: 390.6 Anhydrous Piperazine:
108.8 Water: 375
Sodium Sulphate: 6.3
Stirring Cooling followed by layer
separation
Rapid Environmental Impact Assessment Report Page : 208 of 294 Chapter-2 Project Description
b) Reaction Chemistry:
Step-I
Chemical Formula
Chemical Name
NH2
CH3
CH3
NH
CH3
CH3
ClO+
Cl
O
Cl
Toluene
K2CO3
2,6-dimethylaniline chloroacetyl chloride 2-chloro-N-(2,6-dimethylphenyl)acetamide
MolecularWeight
Step-II
Chemical Formula
Chemical Name
NH
CH3
CH3
ClO
2-chloro-N-(2,6-dimethylphenyl)acetamide
NH
CH3
CH3
O
NNH+
NH
NH
IPA
N-(2,6-dimethylphenyl)-2-(piperazin-1-yl)acetamide
PIperazine
MolecularWeight
Rapid Environmental Impact Assessment Report Page : 209 of 294 Chapter-2 Project Description
C) Summury of Mass Balance: capacity MT/month 1
batch size kg 50
Working Days 26
Quantity Sr. No.
Name of Raw Material
Kg/Batch Kg/Kg of Product
MT/Month
Input
1N-(2,6 Di methyl phenyl) 2-Chloro acetamide
62.5 1.3 1.3
2 Anhydrous Piperazine 108.8 2.2 2.2
3 Iso Propyl Alcohol 350.0 7.0 7.0
4 Methylene Di Chloride (Recovered) 390.6 7.8 7.8
5 Methylene Di Chloride (Fresh) 100.0 2.0 2.0
6 Water 375.0 7.5 7.5
7 Sodium sulphate 6.3 0.1 0.1
8 Cyclo Hexane (Fresh) 12.5 0.3 0.3
9 Cyclo Hexane (Recovered) 112.5 2.3 2.3
Total 1518.1 30.4 30.4
Output
1 N-(2,6 Di methyl phenyl) 2-(piperazinyl) acetamide 50.0
1.0 1.0
2 Dimer of N-(2,6 Di methyl phenyl )-2-(Piperazinyl) acetamide 43.8
0.9 0.9
3 Water+ Iso Propyl Alcohol 802.5 16.1 16.1
4 Methylene Di Chloride Loss 100.0 2.0 2.0
5 Solid waste 6.3 0.1 0.1
6 CycloHexane(Rec) 112.5 2.3 2.3
7 CycloHexane Loss 12.5 0.3 0.3
8 Methylene Di Chloride(Rec) 390.6 7.8 7.8
Total 1518.1 30.4 30.4
Rapid Environmental Impact Assessment Report Page : 210 of 294 Chapter-2 Project Description
(G-2) N-(2,6 Di methyl phenyl )-2-Chloro acetamide
c) Mass Balace Diagram:
86.2
d) Reaction Chemistry:
Chemical Formula
Chemical Name
NH2
CH3
CH3
NH
CH3
CH3
ClO+
Cl
O
Cl
Toluene
K2CO3
2,6-dimethylaniline chloroacetyl chloride 2-chloro-N-(2,6-dimethylphenyl)acetamide
MolecularWeight
121 113 197.5
e) Summury of Mass Balance:
Stirring
Centrifugeand Water washing
Toluene(Recovered):482.8
IPA(Recovered): 86.2
DryingToluene(Loss):17.2
IPA(Loss): 6.9 Solid Waste:34.5
Water:375 MDC(Fresh):100
MDC(Recovered): 390.6 Soda Carbonate: 29.7
2,6 dimethyl aniline: 34.5 Chloro acetyl Chloride: 38.6
IPA(Fresh): 6.9 IPA(Recovered): 86.2
Toluene:500
50 kg of N-(2,6 Di methyl phenyl )-2- Chloro acetamide
(Finished Product)
Rapid Environmental Impact Assessment Report Page : 211 of 294 Chapter-2 Project Description
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/Month Remarks
Input
1 2,6 dimthyl aniline 34.5 0.7 0.7
2 Chloro acetyl chloride 38.6 0.8 0.8
3 DM water 758.6 15.2 15.2
Reactant
4 Toluene (Fresh) 17.2 0.3 0.3
5 Toluene (Recovered) 482.8 9.7 9.7 Solvent
6 Soda carbonate 29.7 0.6 0.6 ---
7 Iso Propyl Alcohol (Fresh) 6.9 0.1 0.1 Solvent
8 Iso Propyl Alcohol (Recovered) 86.2 1.7 1.7 Reactant
Total 1454.5 29.1 29.1
Output
1 N-(2,6 Di methyl phenyl) 2-Chloro acetamide 50.00 1.0000 1.0000 Finished
Product 2 Effluent 776.9 15.5 15.5 To ETP
3 Toluene 482.8 9.7 9.7
4 Iso Propyl Alcohol 86.2 1.7 1.7 Recovered
Solvent
5 Solid waste 34.5 0.7 0.7 To TSDF
6 Toluene Loss 17.2 0.3 0.3 ---
7 Iso Propyl Alcohol Loss 6.9 0.1 0.1 --- Total 1454.5 29.1 29.1
Rapid Environmental Impact Assessment Report Page : 212 of 294 Chapter-2 Project Description
(H-1) 5 - Chloro 1-(-4-Piperidinyl)-2-Benzimidazolone
a) Mass Balance Diagram:
N-Carbethoxy-4-Amino Piperidine : 160
2,5 DiChloro Nitro Benzene: 160
Sodium Carbonate: 125 Potassium Iodide: 1.0
Water: 4000 Raney Nickel fresh:2
Heating followed by Cooling
Centrifuge Methanol(Fresh):600 Methanol(Recovered):
2400
Heating Reflux Raney Nickel: 8 Hydrazine Hydrate: 100
Nickel Filtration and Mass Transfer
R.Nickel Recovered : 8
Methanol Recovery followed by Chilling, Centrifuge and Drying
Recovered Methanol: 2400
Heating and Cooling
Urea: 120 Caustic Lye: 600
Water: 3000
A.Carbon : 20 HCl: 800 Hyflo: 15
Filtration followed by chilling and centrifuge
Effluent: 13721
Heating followed by filtration ,chilling and
centrifuge
Purified Water: 2000
A.Carbon: 10
A.Carbon mixed hyflo: 35
Methanol Loss: 600 Raney Nickel Loss:2
Rapid Environmental Impact Assessment Report Page : 213 of 294 Chapter-2 Project Description
Mass Balance Diagram-APCM:
Purified Water: 3000 IPA(Fresh):150
IPA(Recovered): 1450 Heating, centrifuge
and Drying IPA Recovered: 1450 IPA Loss: 150
A.Carbon: 10 Heating followed by filtration, Methanol Recovery, chilling,
Centrifuge and Drying
Ammonia Gas: 50 Carbon
dioxide:80 Waste: 100
115 kg of 5 - Chloro 1-(-4-Piperidinyl)-2-
Benzimidazolone (Finished Product)
Water for Scrubber: 450
Ammonia Gas: 50 Water Scrubbing Ammonia Solution:500
Rapid Environmental Impact Assessment Report Page : 214 of 294 Chapter-2 Project Description
b) Reaction Chemistry:
Step-I
Chemical Formula
Chemical Name
+
NO2
Cl
ClN
NH2
COOEt
NO2
NH
ClN
COOEt
K2CO3
NaI
4-Amino N-CarbethoxyPiperidine 2,4, DiChloro nitrobenzene Ethyl 4(4 -Chloro -2- nitrophenyl)amino) Piperidine -1 -Carboxylate
+ KCl
MolecularWeight
172 192 327.5 74.5
Step-II
Chemical Formula
Chemical Name
NO2
NH
ClN
COOEt
Ethyl 4(4 -Chloro -2- nitrophenyl)amino) Piperidine -1 -Carboxylate
+ NH2NH2H2OMethanol
Raney Ni
NH2
NH
ClN
COOEt
Ethyl 4(4 -Chloro -2- aminophenyl)amino) Piperidine -1 -CarboxylateHydrazine
Hydrate
MolecularWeight
327.5 50 297.5
Step-III
Chemical Formula
Chemical Name
NH2
NH
ClN
COOEt
Ethyl 4(4 -Chloro -2- aminophenyl)amino) Piperidine -1 -Carboxylate
+ NH2CONH 2
WaterCharcoal
NaOH SolutionHCl Solution
MethanolSoda ash
NH
N
ClNH
O
+C2H5OH CO2++ NH3
5-(Chloro -1- (4-Piperidinyl)-2-Benzimidizolone
MolecularWeight
297.5 60 250.5
Rapid Environmental Impact Assessment Report Page : 215 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 5-Chloro 1-(-4-Piperidinyl)-2-Benzimidazolone is given
in Table.
Summary of Mass Balance – 5 - Chloro 1-(-4-Piperidinyl)-2-Benzimidazolone
capacity of Finished Product MT/Month : 2.00
batch size kg : 115
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/BatchKg/Kg
ofProduct
MT/Month Remarks
Input
1 2,5 DiChloro Nitro Benzene 160 1.39 2.78
2 Potassium Iodide 1 0.01 0.02
3 Sodium Carbonate 125 1.09 2.17
Reactant
4 N-Carbethoxy-4-Amino Piperidine 160 1.39 2.78 Solvent
5 Water 12000 104.35 208.70 ---
6 Methanol(Fresh) 600 5.22 10.43
7 Methanol(Recovered) 2400 20.87 41.74 Solvent
8 Hydrazine Hydrate 100 0.87 1.74 Reactant
9 Raney Nickel 8 0.07 0.14 Catalyst
10 Urea 120 1.04 2.09 Reactant
11 Caustic Lye 600 5.22 10.43 Neutralizing Agent
12 A.Carbon 20 0.17 0.35 Catalyst
13 Hyflo 15 0.13 0.26 Reactant
14 Iso Propyl Alcohol(Fresh) 150 1.30 2.61
15 Iso Propyl Alcohol(Recovered) 1450 12.61 25.22 Solvent
16 Hydrochloric Acid 800 6.96 13.91 Reactant
17 Raney Nickel fresh 2 0.02 0.03
Total 18729 162.86 325.72
Output
1 5-Chloro-1-(-4-Piperidinyl)2,3di hydro 1H Benzimidazolone 115 1.00 2.00 Finished
Product
Rapid Environmental Impact Assessment Report Page : 216 of 294 Chapter-2 Project Description
2 Rec Methanol 2400 20.87 41.74
3 Rec Iso Propyl Alcohol 1450 12.61 25.22 Recovered
Solvent
4 Waste Carbon mixed hyflo 35 0.30 0.61 To TSDF
5 Effluent 13721 119.31 238.63 To ETP
6 Haz waste after distillation 100 0.87 1.74 To TSDF
7 Rec R.Nickel 8 0.07 0.14 Reuse
8 Ammonia Gas 50 0.43 0.87 ToScrubber
9 Carbon di oxide 80 0.70 1.39
10 Methanol Loss 600 5.22 10.43
11 Iso Propyl Alcohol Loss 150 1.30 2.61
12 Rec R.Nickel loss 2 0.02 0.03
To Atm
Total 18729 162.86 325.72
Rapid Environmental Impact Assessment Report Page : 217 of 294 Chapter-2 Project Description
Summary of Mass Balance-5-Chloro 1-(-4-Piperidinyl)-2-Benzimidazolone APCM
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 450.00 3.913 7.83 Scrubbing Media
2 Ammonia Gas 50.00 0.435 0.87 To Scrubber
Total 500.00 4.348 8.70
Water scrubber Output
1 Liq. Ammonia 500.00 4.348 8.70 Sale as By Product
Total 500.00 4.348 8.70
Rapid Environmental Impact Assessment Report Page : 218 of 294 Chapter-2 Project Description
(H-2) 3-(3-Chloro Propyl )-2,3 Di hydo1-H-Benzimidazolone
a) Mass Balance Diagram:
Rapid Environmental Impact Assessment Report Page : 219 of 294 Chapter-2 Project Description
b) Reaction Chemistry:
Step-I
ChemicalFormula
Chemical Name
NH2
NH2
+ CH3 OCH3
O O
NH
NO
CH3
CH2
o-Phenelene diamine Methyl acetoacetate 1-(prop-1-en-2-yl)-1,3-dihydro-2H-benzimidazol-2-one
Xylene+ H2O
MolecularWeight
108 116 174 18
Step-II
ChemicalFormula
ChemicalName
XyleneNH
NO
CH3
CH2
+Cl BrN
NH
O
Cl
1-(prop-1-en-2-yl)-1,3-dihydro-2H-benzimidazol-2-one
Bromo Chloro propane
1-(3-chloropropyl)-1,3-dihydro-2H-benzimidazol-2-one
MolecularWeight
174 157.5 210.5
Rapid Environmental Impact Assessment Report Page : 220 of 294 Chapter-2 Project Description
c) Summary of mass balance
Summary of mass balance for 3-(3-Chloro Propyl )-2,3 Di hydo1-H-Benzimidazoloneis given in Table.Summary of Mass Balance – 3-(3-Chloro Propyl )-2,3 Di hydo1-H-
Benzimidazolone
capacity of Finished Product MT/Month : 2.00
batch size kg : 160
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material Kg/
Batch Kg/Kg of Product
MT /Month
Remarks
Input
1 Xylene(Fresh) 50 0.31 0.63
2 Xylene(Recovered) 750 4.69 9.38 Solvent
3 Methyl aceto acetate 155 0.97 1.94
4 Ortho Phenylene Di Amine 180 1.13 2.25 Reactant
5 Caustic Lye 250 1.56 3.13 Neutralizing Agent
6 Water 1900 11.88 23.75 ----
7 Hydrochloric Acid 250 1.56 3.13 Reactant
8 A./Carbon 5 0.03 0.06 Catalyst
9 1,3 Dromo Chloro Propane 135 0.84 1.69
10 Tetra Butyl ammonium bromide 3 0.02 0.04 Reactant
Total 3678 22.99 45.98
Output
1 3(3-Chloro Propyl)2,3 Di Hydro 1H Benzimidazolone 160 1.00 2.00 Finished
Product 2 Effluent 2658 16.61 33.23 To ETP
3 Solid waste after distillation 50 0.31 0.63
4 Waste A.Carbon mixed Hyflo 10 0.06 0.13 To TSDF
5 Rec Xylene 750 4.69 9.38 Recovered Solvent
6 Xylene Loss 50 0.31 0.63 To Atm Total 3678 22.99 45.98
Rapid Environmental Impact Assessment Report Page : 221 of 294 Chapter-2 Project Description
(I-1) 1,3,5 Tri Methoxy Benzene
a) Mass Balance Diagram:
Mass Balance Diagram-APCM
Aniline: D.M. Water
Conc. HCBromine: Acetic Acid:
Methanol(Fresh): Methanol(Recovered):
Filtration followed by Drying
Water: Hydrogen Bromide gas: Nitrogen:
Sulphuric Acid: Sodium Nitrite: Drying
Separation DMF(Fresh):
DMF(Recovered): Sodium Methoxide:
Cupric Chloride:
Methanol(Recovered: DMF (Recovered): Methanol Loss: DMF Loss:
Reaction Mass MDC(Fresh): MDC(Recovered):
Water:
Distillation Water
1,3,5 Tri Methoxy Benzene (Finished Product)
MDC(Recovered): MDC Loss:
Solid waste:
Water for Scrubber: 2.0 HBr Gas: 0.90
Water Scrubbing Hydrobromic Acid: 2.90
Rapid Environmental Impact Assessment Report Page : 222 of 294 Chapter-2 Project Description
Mass Balance Diagram-APCM
Reaction Chemistry:
Step-I
Chemical Formula
Chemical Name
NH2
Br
Br
Br
NH2
+ 3 Br2
Acetic acid
Water + 3 HBr
Aniline Bromine 2,4,6 Tri bromo aniline Hydrogen Bromide
MolecularWeight
93 480 330 243
Step-II
Chemical Formula
Chemical Name
NH2
Br
Br
Br
+
2,4,6 Tri bromo aniline Sodium Nitrite
NaNO2
MetthanolBenzene
Sulphuric Acid
Br
Br
Br
1,3,5 Tri bromo benzene
+N2 Na2SO4 + H2O+
MolecularWeight
330 69 315
Step-III
ChemicalFormula
Chemical Name
Br
Br
Br
+
2,4,6 Tri bromo aniline Sodium Methoxide
CH3ONa
OCH3
OCH3
H3CO
1,3,5 Tri Methoxy benzene
+ NaBr3
DMFMethanol
Cupric chloride
Sodium Bromid
Water for Scrubber: 0.17
HBr Gas: 0.05 Caustic: 0.02
Water Scrubbing Sodium Bromide: 0.23
Rapid Environmental Impact Assessment Report Page : 223 of 294 Chapter-2 Project Description
MolecularWeight
315 54 168 309
c) Summary of mass balance
Summary of mass balance for 1,3,5 Tri Methoxy Benzene is given in Table.
Summary of Mass Balance – 1,3,5 Tri Methoxy Benzene
capacity of Finished Product MT/Month : 2.00
batch size kg : 50
Working Days Per Month : 26
Quantity Sr. No.
Name of Raw Material Kg/Batch
Kg/Kg of Product MT/Month
Remarks
Input
1 Aniline 45.5 0.9 1.8
2 Bromine 236.4 4.7 9.5
3 Acetic Acid 77.3 1.5 3.1
4 Sodium Nitrite 63.6 1.3 2.5
Reactant
5 Methanol (Fresh) 136.4 2.7 5.5
6 Methanol (Recovered) 954.5 19.1 38.2 Solvent
7 Sulphuric Acid 63.6 1.3 2.5
8 Cupric chloride 13.6 0.3 0.5 Reactant
9 DMF (Fresh) 90.9 1.8 3.6
10 DMF (Recovered) 318.2 6.4 12.7 Solvent
11 Sodium Methoxide 131.8 2.6 5.3
12 Conc-Hydrochloric Acid 45.5 0.9 1.8 Reactant
13 Water 2045.5 40.9 81.8 ----
14 Methylene Di Chloride (Fresh) 136.4 2.7 5.5
15 Methylene Di Chloride (Recovered) 1272.7 25.5 50.9
Solvent
Total 5631.8 112.6 225.3
Output
1 1,3,5 Tri methoxy benzene 50.0 1.0 2.0 Finished Product
2 Water 2045.5 40.9 81.8 To TSDF
3 Methanol(Recovered) 954.5 19.1 38.2
Rapid Environmental Impact Assessment Report Page : 224 of 294 Chapter-2 Project Description
4 DMF(Recovered) 318.2 6.4 12.7 Recovered Solvent
5 Hydrogen bromide (gas) 40.9 0.8 1.6 ToScrubber
6 Nitrogen 563.6 11.3 22.5 To Atm
7 Methylene Di Chloride(Recovered) 1272.7 25.5 50.9 Recovere
d Solvent 8 Solid Waste 22.7 0.5 0.9 To TSDF
9 Methanol Loss 136.4 2.7 5.5
10 DMF Loss 90.9 1.8 3.6
11 Methylene Di Chloride Loss 136.4 2.7 5.5 Total 5631.8 112.6 225.3
Summary of Mass Balance - 1,3,5 Tri Methoxy Benzene APCM
(I-2) 1,3 Di bromo aniline
a) Reaction Chemistry:
Step-I
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month Remarks
Water scrubber Input
1 Water 90.68 1.814 3.63 Scrubbing Media
2 HBr Gas 40.91 0.818 1.64 To Scrubber
Total 131.59 2.632 5.26 Water scrubber Output
1 Hydrobromic Acid (30 %) 131.59 2.632 5.26 Sale as By Product
Total 131.59 2.632 5.26 Alkali scrubber Input
1 Caustic 1.03 0.0009 0.0687 To Scrubber
2 Water 7.56 0.0063 0.5039
3 HBr Gas 2.05 0.0017 0.1364 Scrubbing
Media
Total 10.63 0.0089 0.7090 Alkali scrubber Output
1 Sodium Bromide 10.63 0.0089 0.7090 Sale as By Product
Total 10.63 0.0089 0.7090
Rapid Environmental Impact Assessment Report Page : 225 of 294 Chapter-2 Project Description
ChemicalFormula
Chemical Name
NH2
SO2NH2
NH2
SO2NH2
BrBr
HBrH2O2+ +Water
4-aminobenzenesulfonamide 4-amino-3,5-dibromobenzenesulfonamide
MolecularWeight
172 34 81 330
Step-II
Chemical Formula
Chemical Name
NH2
BrBr
4-amino-3,5-dibromobenzenesulfonamide
NH2
SO2NH2
BrBr
+H2SO4 Steam Distilation
2,6 Dibromo aniline
MolecularWeight
330 98 251
Rapid Environmental Impact Assessment Report Page : 226 of 294 Chapter-2 Project Description
b) Summary of mass balance
Summary of mass balance for 2,6 Di Bromo Aniline is given in Table.
Summary of Mass Balance – 1,3 Di Bromo Aniline
capacity of Finished Product MT/Month : 2.00
batch size kg : 25
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Sulphanilamide 29.4 1.2 2.4
2 Hydrogen peroxide 23.5 0.9 1.9
3 Conc-Hydrobromic acid 70.6 2.8 5.6
Reactant
4 Water 1470.6 58.8 117.6 ---
5 Caustic Flakes 29.4 1.2 2.4 Neutralizing Agent
6 Conc –Hydrochloric acid 58.8 2.4 4.7
7 Sulphuric acid 29.4 1.2 2.4 Reactant
8 Cyclohexane Fresh 14.7 0.6 1.2
9 Cyclohexane Recovered 161.8 6.5 12.9 Solvent
Total 1888.2 75.5 151.1
Output
1 1,3 dibromo aniline 25.0 1.0 2.0 Finished Product
2 Effluent 1686.8 67.5 134.9 To ETP
3 Rec Cyclo hexane 161.8 6.5 12.9 Recovered Solvent
4 Cyclo hexane Loss 14.7 0.6 1.2 To Atm
Total 1888.2 75.5 151.1
Rapid Environmental Impact Assessment Report Page : 227 of 294 Chapter-2 Project Description
(I-3) Selenic Ahnydride a) Material balance Diagram
Heating
U/VAC Methanol Recovery
Reaction Vessel Tetra Hydro Furane
IodineMg Turning
Dumping of mass
Aqueous LayerOrganic Layer
THF Recovery
Cooling
Recovered THF:591.3
Centrifuged mass Dioxane
Bromo Benzene
Stirring THF
Selenium
Stirring & Layer Separation
Methanol
MethanolDi methyl Sulfoxide
Chilling
Filtration
Rapid Environmental Impact Assessment Report Page : 228 of 294 Chapter-2 Project Description
Hydrogen Peroxide Cooling
Stirring
Centrifuge
Mother Liquor
Benzene selannic anhydride
Unloading
Azeotrop
Cooling
Filtration Mother Liquor
Drying
Rapid Environmental Impact Assessment Report Page : 229 of 294 Chapter-2 Project Description
b) Reaction Chemistry:
Step-I
ChemicalFormula
Chemical Name
Mg Br
+ Se2
Se Se
DiPhenyl diselanideGrignard reagent Sealinium
MolecularWeight
362 79 312
Step-II
ChemicalFormula
Chemical Name
Se Se
DiPhenyl diselanide
SeO
O
2
Benzene selenic anhydrid
MolecularWeight
312 372
Rapid Environmental Impact Assessment Report Page : 230 of 294 Chapter-2 Project Description
c) Summary of mass balance Summary of mass balance for Selenic Anhydride is given in Table.
Summary of Mass Balance – Selenic Anhdride
capacity of Finished Product MT/Month : 2.00
batch size kg : 40
Working Days Per Month : 26
Quantity Sr. No. Name of Raw Material
Kg/Batch Kg/Kg of Product MT/Month
Remarks
Input
1 Bromo benzene 173.9 4.3 8.7 Reactant
2 Tetra Hydro Furan (Fresh) 121.7 3.0 6.1 3 Tetra Hydro Furan (Recovered) 591.3 14.8 29.6
Solvent
4 Iodine 8.7 0.2 0.4
5 Mg Turnigs 27.8 0.7 1.4
6 Selanium 60.9 1.5 3.0
7 Conc-Hydrochloric acid 208.7 5.2 10.4
8 Ice 347.8 8.7 17.4
9 DMSO 34.8 0.9 1.7
Reactant
10 Methanol (Fresh) 20.0 0.5 1.0
11 Methanol (Recovered) 156.5 3.9 7.8 Solvent
12 Dioxane 87.0 2.2 4.3
13 Hydrogen peroxide 34.8 0.9 1.7 Reactant
14 Toluene (Fresh) 17.4 0.4 0.9
15 Toluene (Recovered) 69.6 1.7 3.5 Solvent
Total 1960.9 49.0 98.0
Output 1 Selenic anhydride
40.0 1.0 2.0 FP
2 Tetra Hydro Furan 591.3 14.8 29.6 To TSDF
3 Effluent 1066.1 26.7 53.3 To ETP
4 Toluene (Recovered) 69.6 1.7 3.5
5 Methanol (Recovered) 156.5 3.9 7.8 Recovered
Solvent
6 Toluene Loss 17.4 0.4 0.9
7 Methanol Loss 20.0 0.5 1.0 To Atm
Total 1960.9 49.0 98.0
Rapid Environmental Impact Assessment Report Page : 231 of 294 Chapter-2 Project Description
(I-4) 2- Nitro Ethanol
a) Mass Balance Diagram:
b) Reaction Chemistry:
Chemical Formula
Chemical Name
CH3 NO2 + (HCHO)nOH
O2N
Nitro methane Paraformaldehyde 2-Nitro Ethanol
Molecular Weight
61 30 91
Nitro Methane : 1771.9 Para formaldehyde: 78.1
Methanolic KOH: 9.4 N-Hexane(Fresh): 25.0
N-Hexane (Recovered): 125.0
Reaction Vessel
Distillation Di phenyl ether(Fresh): 10.0 Di phenyl ether(Recovered): 125.0
Stirring followed by filtration
100 kg of 2-Nitro Ethanol (Finished Product)
Effluent: 1662.5 N-Hexane(Rec):125
N-Hexane(Loss): 25 Solid Waste: 100
Sulphuric Acid: 3.1
Di phenyl ether(Recovered):125
Di phenyl ether Loss: 10
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c) Summary of mass balance
Summary of mass balance for 2-Nitro Ethanol is given in Table.
Summary of Mass Balance – 2-Nitro Ethanol
capacity of Finished Product MT/Month : 2.00
batch size kg : 100
Working Days Per Month : 26
QuantitySr. No. Name of Raw Material
Kg/Batch Kg/Kg
ofProduct
MT/Month Remarks
Input
1 Nitro methane 1771.9 17.7 35.4
2 Para formaldehyde 78.1 0.8 1.6
3 Sulphuric acid 3.1 0.0 0.1
4 Methanolic KOH (3N) 9.4 0.1 0.2
Reactant
5 Di phenyl ether (Fresh) 10.0 0.1 0.2
6 Di phenyl ether (Recovered) 125.0 1.3 2.5
7 N-Hexane (Fresh) 25.0 0.3 0.5
8 N-Hexane (Recovered) 125.0 1.3 2.5
Solvent
Total 2147.5 21.5 43.0
Output
1 2-Nitro ethanol 100.0 1.0 2.0 Finished Product
2 Di phenyl ether(Recovered) 125.0 1.3 2.5
3 N-Hexane(Recovered) 125.0 1.3 2.5 Recovered
Solvent
4 N-Hexane Loss 25.0 0.3 0.5
5 Di phenyl ether Loss 10.0 0.1 0.2 To Atm
6 Solid waste 100.0 1.0 2.0 To TSDF
7 Effluent 1662.5 16.6 33.3 To ETP
Total 2147.5 21.5 43.0
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2.7 SOLVENT RECOVERY SYSTEM
The industry is engaged in the manufacturing of synthetic organic chemicals,
which require solvents during various unit processes. Presently the unit uses
various solvents viz. Methanol, chloroform, Toluene, Benzene, Methylene Di
Chloride, N-Hexane, thionyl chloride, Iso Propyl Alcohol, Ethyl Acetate and after
proposed expansion few more solvents like, Acetone, Heptanes, Cyclo Hexane,
Carbon Tetra Chloride, Mono Ethyl Glycol, Tetra Hydro Furane, and Xylene will
be used.
The spent solvent generated during the manufacturing process will be
recovered by way of distillation and will be reused in the process. The process of
the solvent recovery system is described hereunder;
After completion of the reaction, the whole mass in the reactor will be
pumped to re-boiler through candle filter and then subjected to the
distillation to separate finished product and recover solvent.
Firstly, the mass will be distilled at required temperature where pure solvent
will be distilled out depending on their boiler points and it will be collected in
the recovered solvent storage tank and reused in the process.
The recovered solvent will be reused in the process and residue will be sent
to TSDF site for the disposal by incineration.
Vaccum will also be applied as per requirement during distillation.
The overall requirements and mass balance for the solvent based on mass
balance of each product and summary has been worked out which is given
in Table-2.6 & Table-2.7 respectively. The schematic diagram of the solvent
recovery system is shown in the Drawing- 2.1.
Measures for achieving maximum solvent recovery:
The entire manufacturing activities & distillation process will be carried out
in totally closed system.
Regular maintenance of the pipeline and valves & fittings will be carried
out regularly to avoid any leakages.
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Distillation column will be connected with two numbers of condensers
where cooling water and chilled water will be used as media and also
equipped with vaccum system.
The condenser will be provided with the sufficient HTA and residence time
to achieve more than 80% recovery.
During the manufacturing activity as well as during distillation process 11 - 25%
of the total solvent will be lost; approx. 75 - 89% of solvent will be recovered
during the process. The fresh solvent requirement will depend on solvent loss
during distillation as well as manufacturing activity.
Table –2.6: Solvent Consumption & Mass BalanceSolvent requirement,
MT/Month Solvent requirement,% Group
Codeof
ProductSolvent
Fresh Recover Total Fresh Recover Total
Total Spent
Solvent
Methanol 0.18 3.38 3.56 5.00 95.00 100.0 A-1
Chloroform 6.67 121.60 128.27 5.20 94.80 100.0 124.98
Methanol 2.22 4.44 6.67 33.33 66.67 100.0 Toluene 3.33 63.33 66.67 5.00 95.00 100.0 A-2Chloroform 3.33 63.33 66.67 5.00 95.00 100.0
131.11
A-3 Chloroform 13.64 122.73 136.36 10.00 90.00 100.0 122.73 Methanol 2.00 8.67 10.67 18.75 81.25 100.0
A-4Chloroform 3.67 33.33 37.00 9.91 90.09 100.0
42.00
Methanol 2.50 14.00 16.50 15.15 84.85 100.0 A-5
Chloroform 3.00 62.00 65.00 4.62 95.38 100.0 76.00
Methanol 2.00 8.67 10.67 18.75 81.25 100.0 A-6
Chloroform 2.67 73.33 76.00 3.51 96.49 100.0 82.00
Methanol 0.89 2.67 3.56 25.00 75.00 100.0 A-7
Chloroform 6.67 121.60 128.27 5.20 94.80 100.0 124.27
Toluene 28.57 142.86 171.43 16.67 83.33 100.0 A-8
Chloroform 14.29 114.29 128.57 11.11 88.89 100.0 257.14
A-9 N-Hexane 3.33 30.00 33.33 10.00 90.00 100.0 30.00 Chloroform 9.09 127.27 136.36 6.67 93.33 100.0
A-10N-Hexane 9.09 127.27 136.36 6.67 93.33 100.0
254.55
N-Hexane 9.09 127.27 136.36 6.67 93.33 100.0 A-11
Chloroform 9.09 100.00 109.09 8.33 91.67 100.0 227.27
A-12 Toluene 1.36 16.82 18.18 7.50 92.50 100.0 16.82 A-13 N-Hexane 9.09 127.27 136.36 6.67 93.33 100.0 263.64
A
A-13 Chloroform 9.09 100.00 109.09 8.33 91.67 100.0
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Solvent requirement, MT/Month Solvent requirement,%
Group Code
of Product
Solvent Fresh Recover Total Fresh Recover Total
Total Spent
Solvent
IPA 4.55 36.36 40.91 11.11 88.89 100.0 Toluene 11.67 75.00 86.67 13.46 86.54 100.0 IPA 6.67 33.33 40.00 16.67 83.33 100.0 A-14 Chloroform 16.67 83.33 100.00 16.67 83.33 100.0
191.67
A-15 Toluene 2.00 30.00 32.00 6.25 93.75 100.0 30.00 Methanol 5.56 50.00 55.56 10.00 90.00 100.0 Chloroform 11.11 55.56 66.67 16.67 83.33 100.0 A-16 N-Hexane 5.56 38.89 44.44 12.50 87.50 100.0
144.44
Max Methanol 5.56 50.00 55.56 10.00 90.00 100.0
Max Toluene 28.57 142.86 171.43 16.67 83.33 100.0 Max Chloroform 16.67 127.27 136.36 12.22 93.33 105.6 Max N-Hexane 9.09 127.27 136.36 6.67 93.33 100.0
Max IPA 6.67 36.36 40.91 16.30 88.89 105.1
263.64
B-1 Toluene 0.78 12.78 13.56 5.74 94.26 100.0 12.78
MDC 0.83 2.50 3.33 25.00 75.00 100.0 N-Hexane 0.83 11.67 12.50 6.67 93.33 100.0 B-2Thyonil chloride 11.67 2.08 13.75 84.85 15.15 100.0
16.25
Toluene 5.00 36.67 41.67 12.00 88.00 100.0 Chloroform 12.50 137.50 150.00 8.33 91.67 100.0 B-3Acetone 3.33 26.67 30.00 11.11 88.89 100.0
200.83
B-4 Toluene 1.47 11.76 13.24 11.11 88.89 100.0 11.76 B-5 Toluene 8.33 158.33 166.67 5.00 95.00 100.0 158.33
Toluene 33.33 633.33 666.67 5.00 95.00 100.0 B-6
MDC 33.33 166.67 200.00 16.67 83.33 100.0 800.00
B-7 Methanol 2.22 25.56 27.78 8.00 92.00 100.0 25.56 B-8 Methanol 10.00 40.00 50.00 20.00 80.00 100.0 40.00
Chloroform 25.00 100.00 125.00 20.00 80.00 100.0 Methanol 10.00 70.00 80.00 12.50 87.50 100.0 B-9IPA 10.00 70.00 80.00 12.50 87.50 100.0
240.00
B-10 Methanol 2.78 25.00 27.78 10.00 90.00 100.0 25.00 B-11 Methanol 6.67 60.00 66.67 10.00 90.00 100.0 60.00
Methanol 13.33 66.67 80.00 16.67 83.33 100.0 Chloroform 13.33 120.00 133.33 10.00 90.00 100.0 Acetone 13.33 66.67 80.00 16.67 83.33 100.0
B-12
N-Hexane 13.33 93.33 106.67 12.50 87.50 100.0
346.67
B
B-13 Methanol 2.78 25.00 27.78 10.00 90.00 100.0 25.00
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Solvent requirement, MT/Month Solvent requirement,%
Group Code
of Product
Solvent Fresh Recover Total Fresh Recover Total
Total Spent
Solvent
B-14 Acetone 11.43 34.29 45.71 25.00 75.00 100.0 34.29 B-15 Chloroform 33.33 133.33 166.67 20.00 80.00 100.0 133.33 B-16 Toluene 6.25 65.25 71.50 8.74 91.26 100.0 65.25
Toluene 10.00 150.00 160.00 6.25 93.75 100.0 IPA 8.00 80.00 88.00 9.09 90.91 100.0 B-17Tetra Hydro Furan 18.00 36.00 54.00 33.33 66.67 100.0
266.00
Toluene 57.14 228.57 285.71 20.00 80.00 100.0 IPA 16.00 142.86 158.86 10.07 89.93 100.0 B-18Tetra Hydro Furan 16.00 40.00 56.00 28.57 71.43 100.0
411.43
Toluene 33.33 244.44 277.78 12.00 88.00 100.0 B-19 Iso propyl
Alcohol 22.22 111.11 133.33 16.67 83.33 100.0 355.56
B-20 Toluene 50.00 200.00 250.00 20.00 80.00 100.0 200.00 B-21 MDC 5.56 50.00 55.56 10.00 90.00 100.0 50.00
Toluene 22.67 17.33 40.00 56.67 43.33 100.0 B-23 Tetra Hydro
Furan 36.00 36.00 72.00 50.00 50.00 100.0 53.33
Acetone 12.50 50.00 62.50 20.00 80.00 100.0 B-24
Methanol 25.00 100.00 125.00 20.00 80.00 100.0 150.00
Max Toluene 57.14 633.33 690.48 8.28 91.72 100.0
Max Methylene Dichloride 33.33 166.67 200.00 16.67 83.33 100.0 Max N-Hexane 13.33 93.33 106.67 12.50 87.50 100.0
Max Chloroform 33.33 137.50 170.83 19.51 80.49 100.0 Max Acetone 13.33 66.67 80.00 16.67 83.33 100.0
Max Methanol 25.00 100.00 125.00 20.00 80.00 100.0 Max Iso propyl Alcohol 22.22 142.86 158.86 13.99 89.93 103.9
Max THF 36.00 40.00 72.00 50.00 55.56 105.5 Max Thyonil Chloride 11.67 2.08 13.75 84.85 15.15 100.0
800.00
C-1 IPA 0.14 1.29 1.43 10.00 90.00 100.0 1.29 C-2 IPA 0.92 36.00 36.92 2.49 97.51 100.0 36.00
C-3 Ethyle acetate 1.67 9.44 11.11 15.00 85.00 100.0 9.44
MDC 1.25 10.00 11.25 11.11 88.89 100.0 C-4
IPA 2.50 112.50 115.00 2.17 97.83 100.0 122.50
MDC 3.33 41.67 45.00 7.41 92.59 100.0
C
C-5Acetone 3.33 66.67 70.00 4.76 95.24 100.0
108.33
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Solvent requirement, MT/Month Solvent requirement,%
Group Code
of Product
Solvent Fresh Recover Total Fresh Recover Total
Total Spent
Solvent
Max of Methylene Dichloride 3.33 41.67 45.00 7.41 92.59 100.0 Max of Iso propyl Alcohol 2.50 112.50 115.00 2.17 97.83 100.0
Max of Acetone 3.33 66.67 70.00 4.76 95.24 100.0 Max of Ethyle Acetate 1.67 9.44 11.11 15.00 85.00 100.0
122.50
D-1 Toluene 0.67 9.33 10.00 6.67 93.33 100.0 9.33 D-2 Benzene 1.82 10.91 12.73 14.29 85.71 100.0 10.91
Chloroform 1.76 10.59 12.35 14.29 85.71 100.0 D-3
Heptane 1.76 28.24 30.00 5.88 94.12 100.0 38.82
Methanol 4.20 3.00 7.20 58.33 41.67 100.0 D-4
MDC 0.60 6.00 6.60 9.09 90.91 100.0 9.00
D-5 Toluene 0.45 1.73 2.19 20.70 79.30 100.0 1.73 D-6 Methanol 1.98 0.16 2.14 92.31 7.69 100.0 0.16
Xylene 1.00 8.00 9.00 11.11 88.89 100.0 D-8
Methanol 1.50 8.50 10.00 15.00 85.00 100.0 16.50
Xylene 0.86 12.00 12.86 6.67 93.33 100.0 D-9
Methanol 1.29 9.43 10.71 12.00 88.00 100.0 21.43
MIBK 11.11 77.78 88.89 12.50 87.50 100.0
D
D-10 Retarter Solvent 5.56 61.11 66.67 8.33 91.67 100.0
138.89
Max of Toluene 0.67 9.33 10.00 6.67 93.33 100.0
Max of Heptane 1.76 28.24 30.00 5.88 94.12 100.0 Max of MDC 0.60 6.00 6.60 9.09 90.91 100.0
Max of Methanol 4.20 9.43 10.71 39.20 88.00 127.2 Max of Xylene 1.00 12.00 12.86 7.78 93.33 101.1
Max of MIBK 11.11 77.78 88.89 12.50 87.50 100.0 Max of Retarter 5.56 61.11 66.67 8.33 91.67 100.0
Max of chloroform 1.76 10.59 12.35 14.29 85.71 100.0 Max of benzene 1.82 10.91 12.73 14.29 85.71 100.0
138.89
E-1 Toluene 1.05 14.74 15.79 6.67 93.33 100.0 14.74 E-2 Chloroform 1.11 7.78 8.89 12.50 87.50 100.0 7.78
Methanol 2.50 7.50 10.00 25.00 75.00 100.0 MEG 1.67 11.67 13.33 12.50 87.50 100.0 Toluene 1.67 18.33 20.00 8.33 91.67 100.0 Chloroform 3.33 21.67 25.00 13.33 86.67 100.0
E-3
IPA 2.00 8.00 10.00 20.00 80.00 100.0
67.17
E
E-6 Toluene 2.00 22.00 24.00 8.33 91.67 100.0 46.00
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Solvent requirement, MT/Month Solvent requirement,%
Group Code
of Product
Solvent Fresh Recover Total Fresh Recover Total
Total Spent
Solvent
N-Hexane 2.00 14.00 16.00 12.50 87.50 100.0 THF 0.80 10.00 10.80 MDC 4.00 96.00 100.00 4.00 96.00 100.0 Ethyl Acetate 4.00 56.00 60.00 6.67 93.33 100.0 E-7
IPA 4.80 35.20 40.00 12.00 88.00 100.0
187.20
Max of Toluene 2.00 22.00 24.00 8.33 91.67 100.0
Max of Chloroform 3.33 21.67 25.00 13.33 86.67 100.0 Max of Methanol 2.50 7.50 10.00 25.00 75.00 100.0
Max of Mono Ethyl Glycol 1.67 11.67 13.33 12.50 87.50 100.0 Max of IPA 4.80 35.20 40.00 12.00 88.00 100.0
Max of N-Hexane 2.00 14.00 16.00 12.50 87.50 100.0 Max of MDC 4.00 96.00 100.00 4.00 96.00 100.0
Max of Ethyl Acetate 4.00 56.00 60.00 6.67 93.33 100.0 Max of THF 0.80 10.00 10.80 7.41 92.59 100.0
187.20
F F-1 MDC 1.14 5.14 6.29 18.18 81.82 100.0 5.14
Max of MDC 1.14 5.14 6.29 18.18 81.82 100.0 5.14
Toluene 0.34 9.66 10.00 3.45 96.55 100.0
G-1 IPA 0.14 1.72 1.86 7.41 92.59 100.0
11.38
MDC 2.00 7.81 9.81 20.38 79.62 100.0 GG-2 Cyclo
Hexane 0.25 2.25 2.50 10.00 90.00 100.0 10.06
Max of Toluene 0.34 9.66 10.00 3.45 96.55 100.0
Max of IPA 0.14 1.72 1.86 7.41 92.59 100.0 Max of MDC 2.00 7.81 9.81 20.38 79.62 100.0
Max of Cyclo Hexane 0.25 2.25 2.50 10.00 90.00 100.0
11.38
Methanol 10.43 41.74 52.17 20.00 80.00 100.0
H-1 Iso propyl Alcohol 2.61 25.22 27.83 9.38 90.63 100.0
80.00 H
H-2 Xylene 0.63 9.38 10.00 6.25 93.75 100.0 9.38
Max of Methanol 10.43 41.74 52.17 20.00 80.00 100.0 Max of IPA 2.61 25.22 27.83 9.38 90.63 100.0
Max of Xylene 0.63 9.38 10.00 6.25 93.75 100.0 80.00
Rapid Environmental Impact Assessment Report Page : 239 of 294 Chapter-2 Project Description
Solvent requirement, MT/Month Solvent requirement,%
Group Code
of Product
Solvent Fresh Recover Total Fresh Recover Total
Total Spent
Solvent
Methanol 5.45 38.18 43.64 12.50 87.50 100.0 DMF 3.64 12.73 16.36 22.22 77.78 100.0 I-1 MDC 5.45 50.91 56.36 9.68 90.32 100.0
101.82
I-2 Cyclo Hexane 1.18 12.94 14.12 8.33 91.67 100.0 12.94
THF 6.09 29.57 35.65 17.07 82.93 100.0 Methanol 1.00 7.83 8.83 11.33 88.67 100.0 I-3 Toluene 0.87 3.48 4.35 20.00 80.00 100.0
40.87
Di phenyl ether 0.20 2.50 2.70 7.41 92.59 100.0
I
I-4 N-Hexane 0.50 2.50 3.00 16.67 83.33 100.0
5.00
Max of Methanol 5.45 38.18 43.64 12.50 87.50 100.0 Max of DMF 3.64 12.73 16.36 22.22 77.78 100.0
Max of MDC 5.45 50.91 56.36 9.68 90.32 100.0 Max of Cyclo Hexane 1.18 12.94 14.12 8.33 91.67 100.0
Max of Tetra Hydro Furan 6.09 29.57 35.65 17.07 82.93 100.0 Max of Toluene 0.87 3.48 4.35 20.00 80.00 100.0
Max of Di phenyl ether 0.20 2.50 2.70 7.41 92.59 100.0 Max of N-Hexane 0.50 2.50 3.00 16.67 83.33 100.0
101.82
Total Spent Solvent 1710.57
Table-2.7: Detailed summary of Total solvent requirement
Solvent Requirement, MT/Month Solvent Requirement, % Solvent
Fresh Recovered Total Fresh Recovered Total Methanol 54.94 246.85 297.08 18.49 83.09 101.59
Toluene 89.60 820.66 910.25 9.84 90.16 100.00 Chloroform 55.10 286.44 332.20 16.59 86.23 102.81 N-Hexane 24.92 237.11 262.03 9.51 90.49 100.00
IPA 38.94 353.86 384.45 10.13 92.04 102.17 MDC 48.98 376.77 426.89 11.47 88.26 99.73
Acetone 16.67 133.33 150.00 11.11 88.89 100.00 Ethyl Acetate 5.67 56.00 60.00 9.44 93.33 102.78
Heptane 1.76 28.24 30.00 5.88 94.12 100.00 Xylene 1.62 21.38 22.86 7.11 93.52 100.62
Cyclo Hexane 1.43 15.19 16.62 8.58 91.42 100.00 Benzene 1.82 12.73 16.36 11.11 77.78 88.89
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Solvent Requirement, MT/Month Solvent Requirement, % Solvent
Fresh Recovered Total Fresh Recovered Total Tetra Hydro Furan 22.89 29.57 35.65 64.20 82.93 147.12
Thyonil chloride 11.67 2.08 13.75 84.85 15.15 100.00
MIBK 11.11 77.78 88.89 12.50 87.50 100.00 Di phenyl ether 0.20 2.50 2.70 7.41 92.59 100.00
Retarter 5.56 61.11 66.67 8.33 91.67 100.00
DMF 3.64 12.73 16.36 22.22 77.78 100.00 Mono Ethyle Glycol 1.67 11.67 13.33 12.50 87.50 100.00
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Drawing-2.1: Schematic Diagram of the Solvent Recovery System
Specification of Distillation Column
Diameter & Height : 0.3 m dia & 3.0 m. ht
MOC : 316 L
Specification of Condenser
Nos. : 2
Cooling Media: : Cooling water/ Chilled Water
Heat Transfer Area : 4 & 2 Sq. m.
Residence Time : 1 hr
Vacuum : 752 mm of Hg
VACUUM =752 mm of Hg
RE-BOILER
C/W OUT
CONDENSER - 1
REFLUX
C/W IN
DIS
TILL
ATI
ON
CO
LUM
N
STEAM
Recovered Solvent
CONDENSER -2CHILLEDWATER IN
CHILLED WATER OUT
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2.8 MATERIAL REQUIREMENTS, HANDLING, STORAGE AND TRANSPORTATION
2.8.1 RAW MATERIAL REQUIREMENT
Details of product wise raw material consumption for the proposed project are
given in Table - 2.8.
Table-2.8: Details of Product wise Raw Material Requirement
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
1,3 DiFluoro Benzene C-4 0.63 3.13 3.13 1,3 Dromo Chloro Propane H-2 0.84 1.69 1.69 2,5 DiChloro Nitro Benzene H-1 1.39 2.78 2.78 2,6 dimthyl aniline G-2 0.69 0.69 0.69 2-Amino Pyrdine E-3 0.69 1.39 1.39 2-Chloroacetic acid t-butyl ester D-6 0.55 1.65 1.65 2-Tert butoxy-2-oxo-ethyl (2-2,6 dichlorophenyl)amino)phenyl acetate D-5 1.51 4.54 4.54
B- 24 0.83 8.33 E-5 0.91 E-7 1.25
2.50 3-(2-Chloro Phenyl )ethyl 2-cyano pyridine
F-1 2.00 4.00
14.83
4-(4-chloro-1-oxo butyl)alfa alfa di methyl phenyl acetic acid D-4 1.00 3.00 3.00
4-(-4-Chloro 1-Oxobutyl)2,2,di methyl phenyl a. acid D-10 1.00 10.00 10.00
4-(p-chloro pheny)4-Hydroxy Piperidine B- 25 1.13 11.25 11.25 4-Amino 1,2,4 Traizole C-4 0.83 4.13 4.13 4-Chloro p-Fluoro phenol B- 25 1.25 12.50 12.50
B- 16 0.89 4-Chloro Piperidine
B- 17 1.50 15.00 15.00
4-Methyl Pyridine E-6 1.11 2.22 2.22 4-Phenyl 4-Hydroxy piperidine B- 20 2.50 25.00 25.00 Activated Carbon F-1 0.10 0.20 0.20
A-9 1.17 11.667 E-3 1.39 E-4 1.13
2.78 Acetic acid
I-1 1.55 3.09
17.54
Acetic Anhydride A-9 1.00 10.000 10.00
A-12 0.14 A-8 4.29
42.86
B- 12 1.33 Acetone
B- 14 3.43 34.29
80.48
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Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kgof
productGroup
maximum Total
B- 16 2.50 B- 17 0.75 AcetoneB- 25 1.25 B- 3 0.33
AcetoneC-5 0.67 3.33
Acetonitrile E-4 0.83 1.67 1.67 B- 17 0.06 B- 18 0.17 B- 19 0.07
1.71
C-1 0.01 0.03 H-1 0.17
Activated Carbon
H-2 0.03 0.35
2.09
D-1 1.11 Alfa Alfa Di methyl phenyl acetic acid
D-3 2.35 7.06 7.06
C-4 0.78 3.90 Aluminium chloride
F-1 1.60 3.20 7.10
AminoGuanidine bi carbonate C-2 1.54 7.69 7.69 C-3 0.44 C-4 2.50
12.50
B- 10 0.22 B- 11 0.67 B- 14 0.29 B- 22 0.22 B- 6 1.67
Ammonia Gas
B- 7 0.28
16.67 29.17
E-4 3.75 Ammonia Solution
E-7 9.00 18.00 18.00
Anhydrous Piperazine G-1 2.18 2.18 2.18 Aniline I-1 0.91 1.82 1.82 Azacyclonol D-10 0.89 8.89 8.89 Benzene B- 23 3.00 30.00 30.00 Benzillic acid B- 23 1.74 17.39 17.39 Benzoyl chloride B- 9 2.20 22.00 22.00 Benzyl Amine A-2 0.83 8.33 8.33 Benzyl Cyanide D-2 0.61 1.82 1.82 Beta- Phenyl Ethyl Amine A-7 0.44 4.44 4.44 Boric acid E-7 2.00 4.00 4.00
Bromine I-1 4.73 9.45 9.45
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Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
B- 19 0.56 5.56 Bromo Benzene
I-3 4.35 8.70 14.25
Caustic Flakes I-2 1.18 2.35 2.35 A-10 2.36 A-11 2.27 A-13 2.27 A-16 1.39 A-2 1.33 A-4 2.67 A-5 2.00 A-6 0.67 A-7 0.89 A-8 4.29
42.86
B- 12 2.67 B- 17 1.50 B- 18 2.14 B- 19 2.78 B- 2 1.20 B- 21 1.06 B- 3 2.67 B- 9 1.50
27.78
D-3 1.76 D-7 0.15
5.29
E-4 2.08 E-5 1.36
4.17
F-1 5.00 10.00 H-1 5.22
Caustic Lye
H-2 1.56 10.43
100.53
A-14 1.58 15.83 B- 17 2.00 B- 18 1.71 B- 19 1.67
20.00 Caustic Potash
D-2 15.76 47.27
83.11
C-5 1.00 5.00 Caustic Soda Lye D-4 1.20 3.60
8.60
B- 25 0.13 1.25 Charcoal
C-2 0.31 1.54 2.79
C-4 0.53 2.63 Chloro Acetyl chloride D-7 0.42 1.26
4.66
Rapid Environmental Impact Assessment Report Page : 245 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kgof
productGroup
maximum Total
G-2 0.77 0.77 Chloro Benzene B- 19 1.67 16.67 16.67
B- 12 1.33 B- 15 3.33 B- 3 1.25 B- 9 2.50
33.33
A-1 0.67 A-10 0.91 A-11 0.91 A-13 0.91 A-14 1.67 A-16 1.11 A-2 0.33 A-3 1.36 A-4 0.37 A-5 0.30 A-6 0.27 A-7 0.67 A-8 1.43
16.67
E-3 0.56 E-4 1.67
3.33
Chloroform
D-3 0.59 1.76
55.10
I-2 2.35 I-1 0.91 I-2 2.82 I-3 5.22
10.43 Conc –Hydrochloric acid
D-7 0.03 0.09
10.53
CTC D-3 0.59 1.76 1.76 Cupric chloride I-1 0.27 0.55 0.55
G-1 0.25 0.25 Cyclo Hexane
I-2 0.59 1.18 1.43
DFTA C-5 1.00 5.00 5.00 A-10 1.09 A-16 0.67
10.91 Di BOC
B- 12 1.07 10.67 21.58
Di Methyl Carbonyl chloride E-4 1.08 2.17 2.17 Di Methyl Sulfate D-2 0.91 2.73 2.73 Di methyl Sulfoxide D-2 3.03 9.09 9.09 Di phenyl ether I-4 0.10 0.20 0.20
Rapid Environmental Impact Assessment Report Page : 246 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
Diclofenec sodium D-6 0.82 2.47 2.47 Dioxane I-3 2.17 4.35 4.35 DM water G-2 15.17 15.17 15.17
B- 2 0.03 0.25 DMF
I-1 1.82 3.64 3.89
DMSO I-3 0.87 1.74 1.74 C-3 0.33 1.67
Ethyl acetateF-1 2.00 4.00
5.67
B- 5 0.92 B- 6 3.67
36.67 Ethyl chloro formate
A-15 1.20 12.00 48.67
B- 24 0.02 0.20 Ethylene Bromide
E-7 0.03 0.06 0.26
C-1 1.50 C-2 0.52 C-3 1.11
7.50 Formic acid
D-5 2.27 6.82
14.32
Heptane D-3 0.59 1.76 1.76 E-4 0.50 1.00 C-1 1.71 C-3 0.56
8.57 Hydrazien Hydrate
H-1 0.87 1.74
11.31
A-10 3.64 A-13 2.73 A-2 0.89 A-4 3.00 A-5 2.50 A-6 3.33 A-7 1.00 A-8 7.86
78.57
B- 17 2.47 B- 18 2.14 B- 19 1.67 B- 24 3.00 B- 6 16.67
166.67
C-4 3.00 15.00 D-1 3.33
D-10 4.44
Hydrochloric Acid
D-2 3.64
44.44
78.57
Rapid Environmental Impact Assessment Report Page : 247 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kgof
productGroup
maximum Total
D-4 1.20 D-8 0.33 D-9 0.29 E-7 4.50 9.00 H-1 6.96
Hydrochloric Acid
H-2 1.56 13.91
B- 16 0.27 Hydrochloric Acid Gas
B- 17 1.50 15.00 15.00
B- 1 0.06 B- 10 0.06 B- 11 0.16 B- 13 0.08 B- 14 0.06 B- 22 0.07 B- 3 0.20 B- 4 0.07 B- 7 0.07
Hydrogen Gas
B- 8 0.05
2.00 2.00
E-4 1.30 2.60 I-2 0.94 Hydrogen Peroxide I-3 0.87
1.88 4.48
B- 17 0.03 B- 18 0.11 B- 19 0.04 B- 20 0.25
2.50
C-1 0.00 0.01
Hyflo
H-1 0.13 0.26
2.78
Industrial solvent D-4 1.40 4.20 4.20 B- 17 0.001 B- 18 0.003 B- 24 0.001
0.03 Iodine
I-3 0.22 0.43
0.46
Iron Powder D-3 0.01 0.02 0.02 Iso Butyl amine A-6 1.00 10.00 10.00
B- 17 0.80 B- 18 1.60 B- 19 2.22 B- 9 1.00
22.22
Iso Propyl Alcohol
C-1 0.03 2.50
47.80
Rapid Environmental Impact Assessment Report Page : 248 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
C-2 0.18 C-4 0.50 G-1 7.00 G-2 0.14
7.00
H-1 1.30 2.61 A-13 0.45 A-14 0.67
6.67
E-4 1.00 2.00
Iso Propyl Alcohol
F-1 2.40 4.80 Iso Propyl amine A-5 1.00 10.00 10.00
D-3 3.53 10.59 Liq Bromine
E-3 1.11 2.22 12.81
Liq. ammonia E-6 3.11 6.22 6.22 B- 24 0.20 2.00
Magnesium Turning E-7 0.30 0.60
2.60
Meta chloro Benzyl cyanide E-4 1.25 2.50 2.50 A-11 1.09 A-13 1.09 A-14 1.50
15.00 Methane sulfonic acid
C-5 0.40 2.00
17.00
B- 10 0.28 B- 11 0.67 B- 12 1.33 B- 13 0.28 B- 14 7.14 B- 15 0.67 B- 17 2.00 B- 18 2.86 B- 19 2.67 B- 22 2.78 B- 23 4.35 B- 25 2.50 B- 7 0.22 B- 8 1.00 B- 9 1.00
71.43
D-1 3.33 D-4 1.40
D-10 3.56
Methanol
D-6 0.66
35.56
179.92
Rapid Environmental Impact Assessment Report Page : 249 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kgof
productGroup
maximum Total
D-8 0.50 D-9 0.43 H-1 5.22 10.43 A-1 0.02 A-11 3.18 A-13 5.45 A-16 0.56 A-2 0.22 A-4 0.20 A-5 0.25 A-6 0.20 A-7 0.09 A-8 0.21
54.545
E-4 1.25 2.50 I-1 2.73
Methanol
I-3 0.50 5.45
Methanolic KOH (3N) I-4 0.09 0.19 0.19 Methyl aceto acetate H-2 0.97 1.94 1.94
A-1 2.40 A-2 1.83 A-3 2.27 A-4 2.00 A-5 3.00 A-6 2.67 A-7 2.40
Methyl acrylate
A-8 5.71
57.14 57.14
Methyl Amine A-1 0.44 4.444 4.44 Methyl methacrylate A-8 2.86 28.571 28.57 Methyl Nicotinate E-4 1.29 2.58 2.58
C-4 0.25 C-5 0.67
3.33
D-4 0.20 0.60 B- 2 0.08 B- 22 0.56 B- 6 3.33
33.33
E-7 2.00 4.00 F-1 2.00 4.00 G-1 2.00
Methylene Di Chloride
G-2 2.00 2.00
52.72
Rapid Environmental Impact Assessment Report Page : 250 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
I-1 2.73 5.45
I-3 0.70 1.39 B- 18 0.29 Mg Turnigs B- 19 0.33
3.33 4.72
MIBK D-10 1.11 11.11 11.11 A-3 0.91
MMA Solution A-8 2.86
28.57 28.57
Mono ethyl amine solution A-3 0.91 9.09 9.09 Mono Ethyl Glycol E-4 0.83 1.67
A-14 3.33 33.33 35.00
N-(2,6 Di methyl phenyl) 2-Chloro acetamide G-1 1.25 1.25 1.25
N,N Di Methyl Aniline D-7 0.49 1.47 1.47 B- 7 1.11
N-Benzyl-4-Piperidone B- 8 1.25
12.50 12.50
B- 13 1.11 N-BOC-4-Piperidone
B- 14 1.43 14.29 14.29
B-17 N-Carbethoxy 4-Piperidone
B- 15 0.83 8.33 8.33 B- 12 1.33 B- 9 2.00
20.00 N-Carbethoxy-4-Amino Piperidine
H-1 1.39 2.78 22.78
A-10 1.82 A-11 1.82 A-13 1.82 A-14 1.67 A-16 1.11
18.18
B- 10 1.11 B- 18 1.43 B- 19 1.67 B- 22 1.11 B- 3 3.33
N-Carbethoxy-4-Piperidone
B- 4 1.18
33.33
51.52
A-10 0.91 A-11 0.91 A-13 0.91 A-16 0.56
N-Hexane
A-9 0.33
9.09
24.92
Rapid Environmental Impact Assessment Report Page : 251 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kgof
productGroup
maximum Total
B- 12 1.33 B- 2 0.08
13.33
E-7 1.00 2.00 N-Hexane I-4 0.25 0.50 Nitric acid E-6 1.67 3.33 3.33 Nitro methane I-4 17.72 35.44 35.44
B- 24 0.83 B- 5 0.83 B- 6 3.33 B- 23 0.70 B- 2 1.20
33.33 N-Methyl-4-Chloro Piperidine
E-7 1.25 2.50
35.83
N-Methyl-4-Hydroxy Piperidine B-2 1.20 12.00 12.00 A-15 1.00 10.00 B- 1 1.11 N-Methyl-4-Piperidone B- 11 1.33
13.33 23.33
n-Propyl amine A-4 0.67 6.667 6.67 Oleum E-7 9.00 18.00 18.00 Ortho Phenylene Di Amine H-2 1.13 2.25 2.25 Para Bromo chloro benzene B- 17 0.62 6.17 6.17 Para Di Bromo Benzene B- 18 2.29 22.86 22.86 Para formaldehyde I-4 0.78 1.56 1.56 Para Toluene sulfonic acid A-14 1.83 18.33 18.33
B- 15 0.17 Pd/C (5%)
B- 20 0.25 2.50 2.50
D-8 1.67 Phenyl acetic acid
D-9 1.43 5.00 5.00
D-8 0.58 Phosphoric acid
D-9 0.57 1.75 1.75
D-8 0.70 Phosphorus pentoxide
D-9 0.71 2.14 2.14
Piperidine B- 15 0.83 8.33 8.33 Piperidone Base A-9 0.83 8.333 8.33 Piperidone Monohydrate Hydrochloric Acid A-12 0.23 2.27 2.27
Potassium Bi Carbonate D-10 0.67 6.67 6.67 Potassium carbonate B- 25 0.63 6.25 6.25 Potassium Hydroxide B- 15 0.33 3.33 3.33
D-10 0.01 0.06 Potassium Iodide
H-1 0.01 0.02 0.07
Rapid Environmental Impact Assessment Report Page : 252 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
Potassium permanganate D-4 2.00 6.00 6.00 D-8 1.67
Pthalic anhydride D-9 1.43
5.00 5.00
Pyridine E-2 1.05 2.11 2.11 D-8 0.23 0.69 B- 1 0.01 B- 10 0.02 B- 11 0.07 B- 13 0.08 B- 14 0.06 B- 22 0.03 B- 3 0.03 B- 4 0.01 B- 7 0.03 B- 8 0.03
0.83 Raney Nickel
H-1 0.07 0.14
1.66
Retarter Solvent D-10 0.56 5.56 5.56 Selanium I-3 1.52 3.04 3.04
A-10 2.27 22.73 Soda ash
G-2 0.59 0.59 23.32
Sodamide E-2 0.32 0.63 0.63 D-8 0.05
Sodium acetate D-9 0.04
0.15 0.15
Sodium Bicarbonate D-4 0.10 0.30 0.30 B- 9 1.25 12.50 D-1 0.28
D-10 0.08 0.83
E-3 0.14 0.28 Sodium Carbonate
H-1 1.09 2.17
15.79
Sodium Cyanide E-4 0.54 1.08 1.08 D-8 0.33 1.00
Sodium Hydroxide D-9 0.29
1.00
A-1 0.83 A-2 0.67 A-3 0.91 A-4 0.67 A-5 1.00 A-6 0.75
Sodium Methoxide
A-7 0.83
10.00
22.73
Rapid Environmental Impact Assessment Report Page : 253 of 294 Chapter-2 Project Description
Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kgof
productGroup
maximum Total
B- 23 0.70 6.96 E-4 0.25 0.50
I-1 2.64 5.27
C-4 0.90 4.50 Sodium Nitrite
I-1 1.27 2.55 7.05
B- 15 0.17 B- 20 0.25
2.50
D-7 0.06 0.18 Sodium Sulphate
G-1 0.13 0.13
2.81
D-3 1.18 3.53 E-4 7.50 E-5 2.05
15.00 Sulfuric acid
F-1 2.50 5.00
23.53
Sulphanilamide I-2 1.18 2.35 2.35 B- 20 0.25 2.50 E-6 2.22 4.44 I-1 1.27 I-2 1.18
Sulphuric acid
I-4 0.03 2.55
9.49
TBAB D-6 0.01 0.04 0.04 Tert-Butyl alcohol D-7 0.30 0.90 0.90 Tetra Butyl ammonium bromide H-2 0.02 0.04 0.04
B- 17 1.80 B- 18 1.60 B- 19 6.00 B- 24 3.60 B- 24 3.60
60.00
I-3 3.04 6.09
Tetra Hydro Furan
E-7 5.00 10.00
76.09
F-1 3.00 6.00 Thionyl chloride
B- 2 1.17 11.67 17.67
B- 1 0.08 B- 16 0.63 B- 17 1.00 B- 18 5.71 B- 19 3.33 B- 20 5.00 B- 23 4.87
Toluene
B- 24 4.00
90.00 126.33
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Quantity, MT/Month Name of Raw Material Code of
Product
Kg/Kg of
product Group
maximum Total
B- 3 0.50 B- 4 0.15 B- 5 0.83 B- 6 3.33 B- 9 9.00 D-1 0.22 D-2 1.52 D-4 0.20 D-5 0.15
4.55
A-12 0.14 A-14 1.17 A-15 0.20 A-2 0.33 A-8 2.86
28.57
E-2 0.53 E-4 0.83 E-7 1.00
2.00
G-2 0.34 0.34
Toluene
I-3 0.43 0.87 A-11 1.36
Tri methyl ortho formate A-13 1.36
13.64
Tri Methyl Silyl Iodide C-5 1.67 8.33 8.33 Urea H-1 1.04 2.09 2.09
H-2 0.31 0.63 D-8 0.33 Xylene D-9 0.29
1.00 1.62
, Di methyl4-(1-oxobutyl)phenyl ethyl acetate D-4 1.00 3.00 3.00
Rapid Environmental Impact Assessment Report Page : 255 of 294 Chapter-2 Project Description
2.8.2. HANDLING
All the raw materials, by products and finished products are handled as per the
standard practice and same practice will be continued after proposed
expansion. Also, all the pipes and equipment will be kept cleaned to avoid any
blockage and deposits. Pressure tests of the reactors will be carried out before
every start–up of the process to find out any leakage. All the process and
storage equipment used for the handling of chemicals will be maintained
properly to avoid any leakage or spillage of the chemical. All protective and
safety precautions will be taken while cleaning up spills. Also all storage tanks,
transfer lines, valves, fittings and every joint are inspected by third party
periodically. For handling of liquid chemicals pumping system will be used
which is very safe and simple to operate. Drum trolley will be used for safe
handling and transfer of hazardous chemicals as well as hazardous waste from
one place to another place in the plant area.
2.8.3. STORAGE
Industry has already provided adequate storage area of 48 m2 and proper
storage facilities for all the finished products which will be adequate for the
proposed expansion. Separate storage area of 1463 m2 has provided to store
different types of hazardous raw materials and it will be expanded upto 1795 m2
after proposed expansion. Hazardous solid waste is stored at a distance place
from the other plant activities with storage area of 47.50 m2 which will be
continued after proposed expansion. The unit has also provided separate
storage area of 41 m2 for fuels used in the plant. The storage yard of chemicals is
isolated from other plant activities and it has equipped with necessary safety
provisions and suitable control measures. The storage area is properly
ventilated. Fire extinguishers and safety showers will be provided in tank farms.
Spark proof equipment will be used during handling and storage. The details of
storage capacity, source and mode of transportation of Raw Material, Product
and By-Products are given in Table- 2.9.
Rapid Environmental Impact Assessment Report Page : 256 of 294 Chapter-2 Project Description
2.8.4. TRANSPORTATION
The vehicles for transportation of raw material, products and by-product will be
parked at specified loading facilities where fire extinguishers along with the
safety gazettes will be provided. Spark arresters will be fitted on all the tankers
entering inside factory. All the raw materials required for proposed expansion
and all the products will be transported through tanks or trucks by roadway. All
the necessary precautions will be taken while carrying out transport of the
above materials as per the Hazardous Rules of transportation, Central Motor
Vehicle Act-1988 & 1989.
Table-2.9 Details of Products, By-Products and Raw Material Storage, Source and mode of Transportation
Sr. No. Name of chemical
Type of Packing/ Storage
Physical Form
Packing Size Kg /
Nos. & Size of Storage
Tanks
Maximum Storage
Capacity, MT
Market/Source
Products
1 Derivatives of Piperidones Solid 25 kg Export/
Local
2 Derivatives of Piperidines Solid 25 kg
10Export/ Local
3 Derivatives of Triazoles Solid 25 kg 5 Export/ Local
4 Fexofinadine Intermediates Solid 25 kg 3 Export/
Local
5 Loratadine intermediates & others Solid 25 kg 2 Export/
Local
6 Haloperidol Intermediate Solid 25 kg 2 Export/
Local
7 Ranozaline Intermediates Solid 25 kg 1 Export/
Local
8 Domperidone Intermediates Solid 25 kg 2 Export/
Local
9Other bulk drug intermediate & chemicals
Fiber/ HDPEDrum
Solid 25 kg 2 Export/ Local
Rapid Environmental Impact Assessment Report Page : 257 of 294 Chapter-2 Project Description
Sr. No. Name of chemical
Type of Packing/ Storage
Physical Form
Packing Size Kg /
Nos. & Size of Storage
Tanks
Maximum Storage
Capacity, MT
Market/ Source
By Products
1 Hydrochloric Acid (30 %) Liquid 200 Lit Local
2 Hydrobromic Acid (30 %) Liquid 200 Lit Local
3 Sodium Hypo Sulphite Liquid 200 Lit Local4 Liq. Ammonia Liquid 200 Lit Local5 Sodium Bromide Liquid 200 Lit Local
6
Dimer of N-(2,6 Di methyl phenyl )-2-(Piperazinyl) acetamide
HDPE Drum
Liquid 200 Lit
25
Local
Raw Materials
1 Methyl acrylate MSDrum Liquid 180 Lit 36.0 Import/
India
2 Sodium Methoxide MSDrum Powder 100 kg 15.0 Import/
India 3 Caustic Soda Lye Tank Liquid 15000 Lit 15.0 GIDC
4 Chloroform MSDrum Liquid 300 Lit 30.0 Import/
India 5 Methanol Tank Liquid 12000 Lit 15.0 GIDC 6 Toluene Tank Liquid 12000 Lit 15.0 GIDC
7 Mono Methyl anine solution Tank Liquid 10000 Lit 15.0 Out of
Gujarat
8 Mono Methyl amine Gas Cylinder Gas 400 kg 1.2 Out of
Gujarat
9 Raney Nickel HDPE Carboy Solid 10 kg 0.2 Out of
Gujarat 10 Hydrogen Gas Cylinder Gas 1kg 6 11 Nitrogen Gas Cylinder Gas 2 kg 6 12 Ammonia Gas Cylinder Gas 50 kg 1.5 13 Hydrochloric Acid Tanker Liquid 10000 Lit 20.0 14 Benzaldehyde MS Drum Liquid 210 Lit 15.0 15 Thionyl chloride GI Drums Liquid 300 Lit 9.0
Within Gujarat
16 Di Methyl Formamide MS Drum Liquid 200 Lit 1.0 Out of Gujarat
17 N-Hexane MS Drum Liquid 200 Ltr 5.0 Out of Gujarat
18 Ethyl chloro fomate MSPE Drum Liquid 200 Lit 5.0 Out of
Gujarat
19 Mg Turning Bags Solid 30 kg 0.5 Out of Gujarat
20 Tetra Hydro Furan MS Drum Liquid 180 Lit 5.4 Out of Gujarat
Rapid Environmental Impact Assessment Report Page : 258 of 294 Chapter-2 Project Description
Sr. No. Name of chemical
Type of Packing/ Storage
Physical Form
Packing Size Kg /
Nos. & Size of Storage
Tanks
Maximum Storage
Capacity, MT
Market/Source
21 Para Bromo chloro Benzene Bags Solid 50 kg 1.0 Out of
Gujarat
22 Para Di Chloro Benzene
HDPECarboy Solid 50 kg 2.0 Out of
Gujarat 23 Iodine Bags Solid 5 kg 0.01 GIDC 24 Caustic Potash Bags Solid 50 kg 5.0 GIDC
25 Activated Carbon Bags Solid 20 kg 1.0 Out of Gujarat
26 Hyflo Bags Solid 16.8 kg 0.5 Out of Gujarat
27 Hydrazine Hydrate HDPECarboy Liquid 200 Lit 25.0 Import/
India
28 Formic acid HDPECarboy Liquid 35 Lit 15.0 GIDC
29 Benzyl Cyanide MS Drum Liquid 200 Lit 5.0 Out of Gujarat
30 Denatured spirit MS Drum Liquid 250 Lit 15.0 Out of Gujarat
31 Di Methyl Sulfoxide HDPECarboy Liquid 210 Lit 12.0 Out of
Gujarat
32 Mono ethylene glycol MS Drum Liquid 200 Lit 8.0 Out of Gujarat
33 Mono Glyme MS Drum Liquid 200 Lit 8.0 GIDC 34 Aluminium chloride Bags Solid 50 kg 5.0 GIDC
35 Acetic Anhydride HDPECarboy Liquid 35 Lit 5.0 GIDC
36 4 Chloro Butyryl chloride
HDPECarboy Liquid 50 Lit 2.0 GIDC
37 Mix solvent MS Drum Liquid 200 Ltr 5.0 GIDC
38 Potassium Permanganate Bags Powder 50 kg 5.0 Out of
Gujarat 39 Sodium Bi Sulfite Bags Powder 50 kg 1.0 GIDC
40 Methylene Di chloride HDPEDrums Liquid 250 Lit 12.0 GIDC
41 Carbon tetra chloride HDPEDrums Liquid 300 Lit 2.0 GIDC
42 Heptane MS Drum Liquid 200 Ltr 5.0 GIDC
43 Cyclo Hexane MS Drum Liquid 200 Ltr 5.0 Out of Gujarat
44 Methyl Iso Butyl Ketone MS Drum Liquid 160 lit 5.0 Out of Gujarat
45 Azacyclonol Fibre Drum Solid 50 kg 5.0 Out of
Gujarat
46 Potassium Iodide Bags Solid 10 kg 0.2 Out of Gujarat
47 Sodium Bi Carbonate Bags Solid 50 kg 5.0 GIDC
Rapid Environmental Impact Assessment Report Page : 259 of 294 Chapter-2 Project Description
Sr. No. Name of chemical
Type of Packing/ Storage
Physical Form
Packing Size Kg /
Nos. & Size of Storage
Tanks
Maximum Storage
Capacity, MT
Market/ Source
48 Potasium Bi Carbonate Bags Solid 50 kg 5.0 GIDC 49 Sodium Carbonate Bags Solid 50 kg 5.0 GIDC
50 2,5 Di Chloro Nitro Benzene Bags Solid 50 kg 3.0 Out of
Gujarat
51 Meta chloro Benzyl cyanide
MSPE Drum Liquid 100 lit 2.0 Out of
Gujarat
52 Methyl Nicotinate Bag Solid 50 kg 2.0 Out of Gujarat
53 Sulfuric acid Bottle Liquid 60 lit 6.0 GIDC 54 Liq Ammonia Bottle Liquid 50 lit 6.0 GIDC 55 Hydrogen Peroxide Bottle Liquid 50 lit 5.0 GIDC 56 Acetic acid Bottle Liquid 35 lit 5.0 GIDC 57 Sodium Cyanide MS Drum Liquid 50 lit 2.0 GIDC 58 Boric acid Bags Solid 50 kg 1.0 GIDC 59 Oleum Tank Liquid 12000 lit 12.0 GIDC
60 1,3,Di Fluoro Benzene MS Drum Liquid 200 lit 0.5 Out of Gujarat
61 Chloro acetyl chloride MSPE Drum Liquid 200 lit 1.0 Out of
Gujarat
62 Tri Methyl chloro silane MSPE Drum Liquid 170 lit 1.0 Out of
Gujarat
63 Tri Methyl Sulfoxonium Iodide
HDPE Carboy Powder 25 lit 2.0 GIDC
64 Sodium Nitrite Bags Solid 50 kg 2.0 GIDC 65 Acetone Tank Liquid 12000 lit 12.0 GIDC 66 Iso Propyl Alcohol Tank Liquid 12000 lit 12.0 GIDC
67 Para Di Bromo Benzene Bags Solid 50 kg 0.5 Out of
Gujarat
68 Ortho Phenylene Di Amine Bags Solid 50 kg 2.0 Out of
Gujarat
69 Methyl aceto acetate HDPE Carboy Liquid 35 lit 2.0 Out of
Gujarat
70 Tetra Butyl ammonium Bromide
HDPE Carboy Powder 10 kg 0.5 Out of
Gujarat
71 Xylene MS Drum Liquid 200 Ltr 5.0 Out of Gujarat
72 Fluoro benzene MS Drum Liquid 200 lit 2.0 Out of Gujarat
73 Pyridine MS Drum Liquid 200 lit 2.0 Out of Gujarat
74 Nitric acid HDPE Carboy Liquid 50 lit 5.0 GIDC
75 Liquid Bromine Bottles Liquid 3 lit 5.0 GIDC
76 Iron Powder Pakcet Powder 1 kg 0.05 GIDC
Rapid Environmental Impact Assessment Report Page : 260 of 294 Chapter-2 Project Description
Sr. No. Name of chemical
Type of Packing/ Storage
Physical Form
Packing Size Kg /
Nos. & Size of Storage
Tanks
Maximum Storage
Capacity, MT
Market/Source
77 Hydro bromic acid HDPEDrums Liquid 200 lit 5.0 GIDC
78 Chloro Benzene MS Drum Liquid 250 lit 2.0 Out of Gujarat
79 Bromo Benzene MS Drum Liquid 50 lit 2.0 Out of Gujarat
80 Para Toluene Sulfonic acid Bags Solid 50 kg 1.0 GIDC
81 Acetonitrile MS Drum Liquid 160 lit 2.0 GIDC
82 ammonium chloride Bags Solid 50 kg 0.5 Out of Gujarat
83 Ethylene Di Chloro Tetra acetic acid
HDPECarboy Solid 10 kg 0.1 Out of
Gujarat 84 Urea Bags Solid 50 kg 1.0 GIDC
85 Mono ethyl amine Tank Liquid 170 lit 2.00 Out of Gujarat
86 Di Boc MSPE Lined Drum
Liquid 50 lit 1.0 Import
87 Benzoyl chloride MS Drum Liquid 200 lit 1.0 Out of Gujarat
88 Common salt Bags Powder 50 kg 3.0 GIDC 89 Methane sulfonic acid Bags Solid 50 kg 1.0 GIDC
90 Tri methyl ortho formate MS Drum Liquid 200 lit 1.0 Out of
Gujarat 91 Benzyl amine MS Drum Liquid 200 lit 5.0 Import
92 Nitro Methane HDPEDrum Liquid 50 lit 0.5 Out of
Gujarat
93 Diclofenac sodium O/T
MSPE Drum
Powder 50 kg 2.0 Out of Gujarat
94 Ethyl acetate MS Drum Liquid 160 lit 2.0. Out of Gujarat
2.9 INFRASTRUCTURAL FACILITIES
2.9.1 LAND
The unit is located at survey no. 47, Hadmtala Industrial Area, Rajkot Gondal
Highway, Taluka Kotda Sangani, Dist. Rajkot, Gujarat. At present the unit is
having land admeasuring 21,138 m2, which is adequate to accommodate the
proposed expansion. Thus, there will not be any need of additional land. Out of
total land available, the unit has developed green belt area of 1,935.07 m2
Rapid Environmental Impact Assessment Report Page : 261 of 294 Chapter-2 Project Description
which will be increased up to @ 4,483 m2 area for the betterment of the
environment. The detail break up of area is shown in Table-2.10. Moreover, key
plan and plan Layout is shown in Drawing – 2.2 & 2.3 respectively.
Table- 2.10: Break-up of Area
Area (Sqmt) Sr. No. Particular
Existing Proposed Total % of Total
Land
1 Process Plant 1,780 1,470 3,250 15.37
2 Product Storage 48 0 1463 6.92
3 Utility 257 143 400 1.89
4 Storage of Hazardous Chemicals 1,463 332 1,795 1.79
5 Storage of Fuel 41 0 41 0.19
6 Hazardous Waste Storage area 48 0 48 0.22
7 Effluent Treatment Plant 332 204 535 2.53
8 Green Belt 1,935 2,548 4,483 21.21 9 Roads 6,408 1,530 7,938 37.55 10 Parking Area 86 0 86 0.41
11 Administrative Area 341 0 341 1.61
12 Rain Water Harvesting Area 0 245 245 1.16
13 Undeveloped 8,401 -6471 1,930 9.13
Total 21,138 0.0 21,138 100.00
2.9.2 Details of Equipments/Vessels/Reactor and Utilities
As the proposed expansion will be carried out in the existing premises, existing
infrastructure facilities will be utilized with the addition of some new machinery
after proposed expansion. The lists of existing plant machineries as well as after
proposed expansion are given in Table-2.11.
Rapid Environmental Impact Assessment Report Page : 262 of 294 Chapter-2 Project Description
Table-2.11: Details of plant machinery for the existing and after Proposed Expansion
Sr.No.
Reactors/Vessel/Equipments MoC Process/
Activity Qty. Size/ Capacity
Existing1 Reaction Vessel MS Reaction 2 5.0 KL 2 Reaction Vessel SS 316 Reaction 3 5.0 KL 3 Reaction Vessel SS 316 Reaction 2 4.0 KL 4 Reaction Vessel SS 316 Reaction 2 3.0 KL 5 Reaction Vessel SS 316 Reaction 4 2.0 KL 6 Reaction Vessel SS 316 Reaction 1 1.0 KL 7 Reaction Vessel SS 316 Reaction 4 0.75 KL 8 Reaction Vessel SS 316 Reaction 4 0.50 KL 9 Reaction Vessel SS 304 Reaction 1 2.0 KL
10 Reaction Vessel SS 304 Reaction 1 3.0 KL 11 Reaction Vessel Glass Lined Reaction 1 6.3 KL 12 Reaction Vessel Glass Lined Reaction 1 5.0 KL 13 Reaction Vessel Glass Lined Reaction 3 3.0 KL 14 Reaction Vessel Glass Lined Reaction 2 1.0 KL 15 Crystallizer SS 304 Crystallization 1 2.0 KL 16 PP/FRP Vessel PP/FRP Quenching 1 3.0 KL 17 Centrifuge SS 316 Filtration 4 36” 18 Tray Dryer SS 304 Drying 2 48 Trays 19 Sparkler Filter SS 316 Filtration 1 18” 20 Catalyst Filter SS 316 Filtration 1 14”
21 HVD Unit SS 316 High Vac Distn 2 0.30 KL
22 Vacuum Tray Dryer SS 304 Drying 1 22 Trays
23 Vacuum Tray Dryer SS 316 Drying 1 20 Trays
24 SS Pumps SS 316 RM Handling 6 12.00 KL/Hour
Proposed
1 Solvent Recovery Plant SS 316 Solv.
recovery 1 0.5 KL/Hour
2 Reaction Vessel SS 316 Reaction 3 2.0 KL 3 Reaction Vessel SS 316 Reaction 3 3.0 KL 4 Reaction Vessel SS 316 Reaction 4 5.0 KL 5 Sparkler Filter SS 316 Filtration 2 24” 6 Fluid Bed Dryer SS 316 Drying 2 125 KG 7 Cooling Tower FRP Cooling 3 200 TR 8 Neutsch Filter SS 316 Filtration 6 0.50 KL 9 Press Filter SS 316 Filtration 4 0.10 KL
Rapid Environmental Impact Assessment Report Page : 263 of 294 Chapter-2 Project Description
Sr.No.
Reactors/Vessel/Equipments MoC Process/
Activity Qty. Size/ Capacity
10 Reactor SS 316 Reaction 2 6.5 KL 11 Reactor SS 316 Reaction 2 5.0 KL 12 Reactor SS 316 Reaction 1 4.0 KL 13 Reactor SS 316 Reaction 1 3.0 KL 14 Reactor SS 316 Reaction 5 2.0 KL 15 Reactor Glass Lined Reaction 3 3.0 KL 16 Reactor MSGL Reaction 1 3.0 KL 17 Reactor MSGL Reaction 1 1.0 KL 18 Centrifuge SS 316 Filtration 3 200.0 KG 19 Reactor MSGL Reaction 1 6.3 KL
Details of Utility
21 Steam Boiler MS/ CI/CS SteamGeneration 1 3000 Kg per
hour
22 Water jet Vacuum Pumps SS 316 Vacuum
Generation 12 3000 LPM
23 Water jet Vacuum Pumps PP/Teflon Vacuum
Generation 6 2000 LPM
24 Cooling Tower FRP Cooling water 2 250 TR
25 Refrigeration Plant MS/ CI/CS/ Copper
Brine for process 1 -30 Deg C
10 TR
26 Refrigeration Plant MS/CI/CS/Copper Brine for process 1 -10 Deg C
20 TR
27 Solvent Recovery Plant SS 316 Solvent
Recovery 1 5 KL
Rapid Environmental Impact Assessment Report Page : 264 of 294 Chapter-2 Project Description
Drawing-2.2: Key Plan
Rap
id E
nviro
nmen
tal I
mpa
ct A
sses
smen
t Rep
ort
P
age
: 265
of 2
94
Cha
pter
-2 P
roje
ct D
escr
iptio
n
Draw
ing-
2.3:
Pla
nt la
yout
Rapid Environmental Impact Assessment Report Page : 266 of 294 Chapter-2 Project Description
2.10 RESOURCE CONSUMPTION
2.10.1 WATER
Presently the entire water requirement of M/s. Sam Fine Chem Ltd. is met
through own bore well and same source will be utilized after proposed
expansion.
The total fresh water requirement for existing unit is 23.4 KL/day for domestic,
gardening and Industrial purpose. After proposed expansion, it will be increased
up to 61.4 KL/day. Thus, the additional water requirement for proposed
expansion will be 38.0 KL/day. Domestic water requirement will be increase
from 2.0 KL/day to 6.5 KL/day after proposed expansion.
As per Guidelines issued by Central Ground Water Authority, Ministry of Water
Resources, New Delhi vide Letter No. 21-4/Guidelines/CGWA/2009-832, Dated
14/10/2009, the unit falls under Semi critical zone and Ground water
development in the region is 70-100 %.
The total water requirement of the plant is 61.4 KL/day, which does not exceed
the limit of 100 KL/day as per CGWA guidelines. Thus, it is not mandatory for the
unit to obtain permission from CGWA for the abstraction of ground water.
2.10.2. FUEL REQUIREMENT
Presently, the unit has installed one steam boiler (1.0 TPH) and thermic fluid
heater (6.0 Lac Kcal/hr). Earlier, Furnace Oil was used as fuel; now, the unit has
switched over to agricultural waste.
During proposed expansion, the unit will install new steam boiler (2.0 TPH) which
will be kept working and thus the existing steam boiler (1.0 TPH) will remain as
stand by. Existing thermic fluid heater will also keep working.
The unit has also provided one stand by D.G.set (500 KVA), where HSD is used as
fuel. D.G. set will be used in case of main power failure only. The detail of
existing and proposed fuel consumption is given in Table-2.12.
Rapid Environmental Impact Assessment Report Page : 267 of 294 Chapter-2 Project Description
Table- 2.12: Details of Fuel Consumption for the existing and Proposed Expansion:
Status Daily Fuel ConsumptionSr.
No. Fuel Used In Existing Proposed Existing Total after
expansion
1 Steam Boiler – 1.0 TPH Working Stand by
2 Steam Boiler – 2.0 TPH NA Working
3
Agricultural Waste
Thermic Fluid Heater – 6.0 Lac Kcal/ hr
Working Working
2.4 MT/DAY
12.0 MT/DAY
4 HSD D. G. set – 500 KVA
Standby Stand by 100 lit 400 lit
2.10.3 ELECTRICITY REQUIREMENT
At present the total connected load of power is about 350 KVA and which is
expected to be increased up to about 750 KVA after proposed expansion. Thus,
the additional power requirement for the proposed expansion will be 400 KVA,
which will be procured from Paschim Gujarat vij Company Ltd. (PGVCL)
subsidiary of Gujarat Electricity Board (GEB).
2.10.4 MANPOWER REQUIREMENT
The manpower is one of the main resource requirements for the operation and
maintenance of the plant in a better and efficient way. At present, total 109
numbers of staff is required which will increase up to 168 after proposed
expansion. Thus, there will be additional 59 nos. of manpower will be required
for the proposed expansion. The details of Manpower requirement for existing
unit as well as for proposed expansion are given in Table- 2.13.
Rapid Environmental Impact Assessment Report Page : 268 of 294 Chapter-2 Project Description
Table – 2.13: Details of Manpower requirement
Man
agem
ent
Staf
f*
Supe
rviso
ry
Staf
f*
Cle
rks*
Wor
kers
*
Tota
l*
Descriptions
E P T E P T E P T E P T E P T
Administration 2 1 3 2 1 3 3 1 4 7 7 14 14 10 24
Plant (Production & other services
personnel) 7 4 11 30 12 42 1 2 3 40 21 61 78 39 117
Stores & Dispatch 1 1 3 4 4 8 - - - 12 5 17 17 10 27
Total 10 6 17 36 17 53 4 3 7 59 33 92 109 59 168 *E-Existing, P-Proposed, T-Total after proposed expansion
2.11 ENVIRONMENTAL POLLUTION AND CONTROL MEASURES
2.11.1 WATER POLLUTION
A) DETAILS OF WATER CONSUMPTION & WASTEWATER GENERATION
M/s. Sam Finechem Ltd. is the existing unit and proposes to increase the
production capacity by manufacturing new products of same category. Water
is mainly required for manufacturing process, APCE and steam boiler to make
up the losses, besides it is also require for the cooling tower makeup and
washing. Based on the material balance and technical experience of the unit,
the water consumption and wastewater generation for various categories have
been calculated. The entire water requirement of the proposed unit will be met
through own bore well. Presently, total fresh Industrial water consumption is 21.0
KLD including process, APCE, boiler, cooling and washing, which will increased
up to 39.5 KLD. Water required for domestic and gardening purpose is 2.0 KLD
which will be increased up to 6.5 KLD after proposed project.
The product wise water consumption & waste water generation is given in Table
– 2.14 and category wise water consumption and waste water generation is
given in Table – 2.15 & Table – 2.16. The water balance diagram for existing and
after proposed expansion is given in Drawing-2.4 & Drawing-2.5 respectively.
Rapid Environmental Impact Assessment Report Page : 269 of 294 Chapter-2 Project Description
Table – 2.14: Product wise Water Consumption & Wastewater Generation after proposed expansion
Water Consumption, Liter Wastewater Generation, Liter Sr. No. Stream
Per Batch Per Kg Per Day Per Batch Per Kg Per Day
A-1 PROCESS 10500.0 11.7 4487.2 10990.0 12.2 4696.6 A-2 PROCESS 0.0 0.0 0.0 3800.0 4.2 1623.9 A-3 PROCESS 1000.0 9.1 3496.5 1065.0 9.7 3723.8 A-4 PROCESS 4390.0 14.6 5628.2 6430.0 21.4 8243.6 A-5 PROCESS 3100.0 15.5 5961.5 4570.0 22.9 8788.5 A-6 PROCESS 2000.0 6.7 2564.1 3905.0 13.0 5006.4 A-7 PROCESS 5000.0 5.6 2136.8 8680.0 9.6 3709.4 A-8 PROCESS 40.0 1.1 439.6 900.0 25.7 9890.1 A-9 PROCESS 50.0 1.7 641.0 85.0 2.8 1089.7
A-10 PROCESS 800.0 7.3 2797.2 1800.0 16.4 6293.7 A-11 PROCESS 1400.0 12.7 4895.1 1950.0 17.7 6818.2 A-12 PROCESS 0.0 0.0 0.0 10.0 0.5 192.3 A-13 PROCESS 1400.0 12.7 4895.1 2200.0 20.0 7692.3 A-14 PROCESS 295.0 4.9 1891.0 790.0 13.2 5064.1 A-15 PROCESS 350.0 0.7 269.2 650.0 1.3 500.0 A-16 PROCESS 600.0 6.7 2564.1 740.0 8.2 3162.4 MAX of A-Process 10500.0 15.5 5961.5 10990.0 25.7 9890.1 B-1 PROCESS 500.0 2.8 1068.4 0.0 0.0 0.0
PROCESS 2500.0 3.3 1282.1 3632.0 4.8 1862.6 B-2
APCE 3212.8 4.3 1647.6 1479.2 2.0 758.5 B-3 PROCESS 500.0 8.3 3205.1 677.5 11.3 4342.9 B-4 PROCESS 500.0 2.9 1131.2 402.0 2.4 909.5 B-5 PROCESS 400.0 3.3 1282.1 430.0 3.6 1378.2 B-6 PROCESS 400.0 13.3 5128.2 1056.0 35.2 13538.5 B-7 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-8 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-9 PROCESS 750.0 15.0 5769.2 1425.0 28.5 10961.5 B-10 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-11 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-12 PROCESS 800.0 12.3 4733.7 1115.0 17.2 6597.6 B-13 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-14 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-15 PROCESS 20.8 0.8 320.5 0.0 0.0 0.0 B-16 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 B-17 PROCESS 3000.0 15.0 5769.2 3436.0 17.2 6607.7 B-18 PROCESS 2142.9 42.9 16483.5 2728.6 54.6 20989.0 B-19 PROCESS 1666.7 33.3 12820.5 2222.2 44.4 17094.0 B-20 PROCESS 25.0 5.0 1923.1 134.0 26.8 10307.7 B-21 PROCESS 600.0 3.3 1282.1 804.0 4.5 1717.9
Rapid Environmental Impact Assessment Report Page : 270 of 294 Chapter-2 Project Description
Water Consumption, Liter Wastewater Generation, Liter Sr. No. Stream
Per Batch Per Kg Per Day Per Batch Per Kg Per Day
B-22 PROCESS 1000.0 8.7 3344.5 1200.0 10.4 4013.4
B-23 PROCESS 1500.0 10.0 3846.2 2313.0 15.4 5930.8
B-24 PROCESS 125.0 2.5 961.5 219.0 4.4 1684.6
MAX of B- Process 3000 42.9 16483.5 3632.0 54.6 20989.0
MAX of B- APCE 3212.8 4.3 1647.6 1479.2 2.0 758.5
C-1 PROCESS 0.0 0.0 0.0 0.0 0.0 0.0
C-2 PROCESS 0.0 0.0 0.0 512.0 1.0 196.9
PROCESS 0.0 0.0 0.0 0.0 0.0 0.0 C-3
APCE 396.0 1.0 190.4 440.0 1.1 211.5
PROCESS 2500.0 12.5 2403.8 4746.0 23.7 4563.5 C-4
APCE 140.0 0.7 134.6 200.0 1.0 192.3
C-5 PROCESS 1200.0 8.0 1538.5 1410.0 9.4 1807.7
MAX of C-Process 2500.0 12.5 2403.8 4746.0 23.7 4563.5
MAX of C- APCE 396.0 1.0 190.4 440.0 1.1 211.5 D-1 PROCESS 500.0 2.8 320.5 1690.0 9.4 1083.3 D-2 PROCESS 2600.0 15.8 1818.2 1685.0 10.2 1178.3
PROCESS 1500.0 8.8 1018.1 2526.0 14.9 1714.5 D-3 APCE 676.1 4.0 458.9 1045.1 6.1 709.4 D-4 PROCESS 1000.0 4.0 461.5 1675.0 6.7 773.1 D-5 PROCESS 1667.0 3.0 349.7 3250.0 5.9 681.8 D-6 PROCESS 549.5 2.2 253.6 646.0 2.6 298.2 D-7 PROCESS 225.6 2.3 260.3 336.1 3.4 387.8 D-8 PROCESS 666.7 6.7 769.2 1100.0 11.0 1269.2 D-9 PROCESS 285.7 2.9 329.7 661.4 6.6 763.2 D-10 PROCESS 300.0 1.5 173.1 1416.0 7.1 816.9 MAX of D-Process 2600.0 15.8 1818.2 3250.0 14.9 1714.5
MAX of D -APCE 676.1 4.0 458.9 1045.1 6.1 709.4 E-1 PROCESS 400.0 2.1 161.9 450.0 2.4 182.2 E-2 PROCESS 500.0 2.8 213.7 880.0 4.9 376.1
E-3 PROCESS 4500.0 37.5 2884.6 7041.0 58.7 4513.5
E-4 PROCESS 500.0 2.3 174.8 2030.0 9.2 709.8
E-5 PROCESS 500.0 2.8 213.7 1700.0 9.4 726.5 E-6 PROCESS 1500.0 15.0 1153.8 4083.0 40.8 3140.8
PROCESS 3000.0 60.0 4615.4 4613.0 92.3 7096.9 E-7 APCE 490.0 9.8 753.8 700.0 14.0 1076.9
Rapid Environmental Impact Assessment Report Page : 271 of 294 Chapter-2 Project Description
Water Consumption, Liter Wastewater Generation, Liter Sr. No. Stream
Per Batch Per Kg Per Day Per Batch Per Kg Per Day
MAX of E- Process 4500.0 60.0 4615.4 7041.0 92.3 7096.9
MAX of E- APCE 490.0 9.8 753.8 700.0 14.0 1076.9
PROCESS 514.3 5.1 395.6 694.3 6.9 534.1 F-1
APCE 53.3 0.5 41.0 76.2 0.8 58.6
MAX of F -Process 514.3 5.1 395.6 694.3 6.9 534.1
MAX of F - APCE 53.3 0.5 41.0 76.2 0.8 58.6
G-1 PROCESS 758.6 15.2 583.6 776.9 15.5 597.6
G-2 PROCESS 375.0 7.5 288.5 802.5 16.1 617.3
MAX of G-Process 758.6 15.2 583.6 802.5 16.1 617.3
PROCESS 12000.0 104.3 8026.8 13721.0 119.3 9177.9 H-1
APCE 450.0 3.9 301.0 500.0 4.3 334.4
H-2 PROCESS 1900.0 11.9 913.5 2658.0 16.6 1277.9
MAX of H-Process 12000.0 104.3 8026.8 13721.0 119.3 9177.9
MAX of H -APCE 450.0 3.9 301.0 500.0 4.3 334.4
PROCESS 2045.5 40.9 3146.9 0.0 0.0 0.0 I-1
APCE 98.2 2.0 151.1 142.2 2.8 218.8
I-2 PROCESS 1470.6 58.8 4524.9 1686.8 67.5 5190.0
I-3 PROCESS 0.0 0.0 0.0 1066.1 26.7 2050.2
I-4 PROCESS 0.0 0.0 0.0 1662.5 16.6 1278.8
MAX of I -Process 2045.5 58.8 4524.9 1686.8 67.5 5190.0
MAX of I - APCE 98.2 2.0 151.1 142.2 2.8 218.8
Total - Process 44813.3 -- -- 59773.3
Total - APCE 3543.9 -- -- 3368.2
Rapid Environmental Impact Assessment Report Page : 272 of 294 Chapter-2 Project Description
Table – 2.15: Category wise Water Consumption
Water Consumption, m3/day Sr.No. Category E* P* T* 1 Domestic 2.0 4.5 6.5 2. Gardening 0.4 15.0 15.4 3. Industrial
a. Process Fresh 2.0 11.9 13.9
Reuse 3.0 28.6 31.6 b. APCE 1.0 2.6 3.6 c. Boiler Fresh 11.0 -11.0 0.0 Reuse 1.0 21.0 22.0 d. Cooling 6.0 12.0 18.0 e. Washing 1.0 3.0 4.0
Total Industrial (Fresh + Reuse) 25.0 68.1 93.1
Industrial Reuse 4.0 49.6 53.6 Total Industrial (Fresh) 21.0 18.5 39.5
Total (Domestic + Gardening + Industrial) 23.4 38.0 61.4
Table – 2.16: Category wise Wastewater Generation
Wastewater Generation, m3/daySr.No. Category
E* P* T* 1 Domestic 2.0 4.0 6.0 2. Gardening Nil Nil Nil 3. Industrial a. Process 4.0 57.0 61.0 b. APCE 1.3 3.5 4.8 c. Boiler 0.0 2.0 2.0 d. Cooling 0.0 0.0 0.0 e. Washing 1.0 3.0 4.0 Total Industrial (Generation) 6.3 65.5 71.8
E-Existing, P: Proposed, T: Total after proposed expansion
Rapid Environmental Impact Assessment Report Page : 273 of 294 Chapter-2 Project Description
Drawing – 2.4: Water Balance Diagram (Existing)
Note: All quantities are expressed In KL / Day.
To soak pit via septic tank system
Loss(11.0)Loss(1.0)
Fresh Water (23.4)
Fresh Industrial (21.0)
Domestic(2.0)
Gardening(0.4)
Boiler(Make up)
(11.0)
(Nil)
Cooling(Make up)
(6.0)
(Nil)
Washing
(1.0)
(1.0)
APCE
(1.0)
(4.0)
Process
(2.0)
To ETP, Evaporator & TFD
Zero Industrial Effluent Discharge
Reuse (3.0)
Reuse(1.0)
(6.3)
Solid waste from Dryer (1.0)
(1.3)
Evaporation Loss (1.3)
Rapid Environmental Impact Assessment Report Page : 274 of 294 Chapter-2 Project Description
Drawing – 2.5: Water Balance Diagram (After proposed expansion)
Cooling (Make up)
To soak pit via septic tank system
Domestic (6.5)
Note: All quantities are expressed In KL / Day.
Loss(18.0) Loss(20.0)
Fresh Water (61.4)
FreshIndustrial
(39.5)
Gardening (15.4)
Boiler(Make up)
(Nil)
(2.0)
(18.0)
(Nil)
Washing
(4.0)
(4.0)
APCE
(3.6)
(4.8)
Process
(13.9)
To ETP, MEE & TFD
Zero Industrial Effluent Discharge
Reuse(31.6) Reuse
(22.0)
(71.8)
Solid waste from Dryer (13.4)
(61.0)
Evaporation Loss (4.8)
Rapid Environmental Impact Assessment Report Page : 275 of 294 Chapter-2 Project Description
B) WASTEWATER MANAGEMENT SYSTEM
At present industrial effluent generation @ 5.0 KL/day is taken to own effluent
treatment plant comprising of primary treatment units where waste water is
treated by physico chemical treatment. The treated waste water is further
passed through Multiple Effect Evaporator followed by Thin Film Dryer. After
evaporation and condensation, water is reused as boiler feed water & in
process. The solid waste generated is disposed to the Gujarat Enviro Protection
Infrastructure Ltd. (GEPIL) TSDF site. Thus, the unit maintains "Zero Effluent
Discharge."
After proposed expansion the waste water generation will be @ 71.8 KL/day.
New effluent treatment plant having total capacity of 75 KL/Day with the same
treatment scheme will be installed along with the additional multiple effect
evaporators & thin film dryer. Then the treated water will be reused as boiler
feed water & in process. Thus, there will be a Zero Effluent Discharge from the
proposed expansion also.
Domestic effluent is discharged into soak pit through septic tank and same
practice will be continued after the proposed expansion.
The detail of existing & proposed effluent treatment plant is given hereunder in
Table-2.17 (A) & (B) and schematic flow diagram of proposed ETP is given in
Drawing - 2.6.
Table-2.17 (A) : Detail of effluent treatment plant (Existing)
Sr.No. Units N
os.
Leng
th, m
Wid
th,
m
Liqui
dDe
pth,
m
Liqui
dVo
lum
e,
m3
1. Oil & Grease Trap 3 1.50 1.20 2.0 10.8
2. Neutralization cum Treatment Tank 2 10.0 3.0 2.0 120.0
3. Settling Tank 1 3.0 3.0 2.0 18.0
4. Sludge Drying Bed 3 5.0 2.0 1.0 30.0
Rapid Environmental Impact Assessment Report Page : 276 of 294 Chapter-2 Project Description
Table-2.17 (B) : Detail of effluent treatment plant (Proposed)
Treatment Scheme:
(1) Oil Grease trap:
The wastewater generating from various manufacturing activities is first
passed through oil & Grease chamber where emulsified oil, grease and
other floating matter is removed or skimmed off manually.
(2) Neutralization cum collection tank:
The raw effluent generated due to manufacturing activities will be
collected in neutralization cum collection tank where it will be neutralize by
chemical dosing.
(3) Chemical Dosing Tanks (Lime, Alum and Polyelectrolyte Dosing Tank):
The chemical dosing tanks will be provided for the preparation of chemical
solution required for the primary treatment such as hydrated lime and
alum.
(4) Primary Settling tank/Primary Clarifier:
Presently, effluent from collection tank is led to Primary settling tank where
the effluent is retained for the certain period in a relatively quiescent state.
Sr. No. Units N
os.
Leng
th, m
Wid
th,
m
Liqui
dDe
pth,
m
Liqui
dVo
lum
e, m
3
1. Oil & Grease Trap 3 1.50 1.20 2.0 10.8
2. Neutralization cum Treatment Tank 2 10.0 3.0 2.0 120.0
3. Chemical Dosing Tank 2 1.0 1.0 1.2 2.4
4. Primary Clarifier 1 4.0 3.0 37.70
5. Treated water collection Tank 1 4.0 3.0 3.0 36.0
6. Filter Press 1 24'' X 24"X 35 Plates
7. Sludge collection Tank 1 3.0 3.0 3.0 27.0
Rapid Environmental Impact Assessment Report Page : 277 of 294 Chapter-2 Project Description
Thus, chemical flocs having higher specific gravity then the liquid are tends
to settle to the tank bottom.
During proposed expansion, the effluent from collection tank will be led to
Primary clarifier where with same phenomenon; chemical flocs will be
settled to the tank bottom. The clear supernatant effluent from tank
overflow will be taken to the treated water collection tank.
(5) Sludge drying bed/Filter Press
Presently, settled sludge from the bottom of Primary settling tank is drained
into Sludge drying bed. Here free water from the sludge is filter through bed
and filtrate is taken back to the neutralization tank. The sludge after drying
is removed, collected and stored in to hazardous waste storage area.
During proposed expansion, the settled sludge at the bottom of the clarifier
will be collected in sludge collection tank from where it will be taken to
filter press through mud pump. The filtered sludge will be removed,
collected and stored in to hazardous waste storage area.
(6) Treated water collection tank
A treated effluent from primary settling tank/clarifier will be collected here.
The whole wastewater will be then passed through Multi Effect Evaporator
and thin film dryer.
Multi Effect Evaporator System/Thin Film Dryer:
Multi effect evaporator is used to evaporate entire quantity of effluent. Thin Film
Dryers is used for continuous drying of heat sensitive products with total solvent
recovery. Finally evaporated and condensed water is reused for manufacturing
process. Concentrated Sludge generated during the MEE system is transferred
to Sludge drying bed. The dried sludge is packed and stored in solid waste
storage site and finally sent to TSDF site of Gujarat Enviro Protection
Infrastructure Ltd. (GEPIL) for final disposal.
During the study period composite sampling of the effluent, treated in the ETP
has been carried twice in a month and the details of analysis of the samples
taken form inlet of MEE is given in Table – 2.18.
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Table – 2.18: Sampling analysis of effluent at inlet of the MEE
Sr.No.
Date of Sampling pH TDS TSS COD BOD O&G Cl- SO4-2 NH3-
N1 12/10/10 7.38 1408 120 60 21 0.8 985 40 1.8 2 26/10/09 7.12 1468 116 72 26 0.9 897 52 1.7 3 18/11/10 7.25 1554 64 118 30 1.2 410 74 1.7 4 28/11/10 7.34 1612 61 98 32 0.8 435 70 1.6 5 09/12/10 7.26 1880 75 103 28 0.9 765 56 1.5 6 20/12/10 7.15 1798 83 88 23 1.0 694 50 1.8
GPCB Norms 6.5-8.5 2100 100 100 30 10 600 1000 50
Drawing- 2.6: Flow Diagram of Effluent Treatment Plant
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The details of Technical Specification and operating parameters for existing
Multiple (Triple) Effect Evaporator and Thin Film Dryer (TFD) are given in Table-
2.19 & Table-2.20 respectively along with the Drawing-2.7.
Table 2.19: Technical Specification of MEE
EQUIPMENT MULTIPLE EFFECT EVAPORATOR (2FF+1FC)
TYPE TRIPLE EFFECT EVAPORATOR WITH TVR
CAPACITY 1,186 kg/h WATER EVAPORATION
MOC TUBES SS 316 VAPOUR CONTACT PARTS SS 304
OPERATING PARAMETERS Unit Value
Feed rate (kg/h) 1,482
Feed temperature OC 30 Initial solids (%) 8.0
Total suspended solids PPM < 500
Specific gravity of feed Kg/m3 1.04
Solids in concentrate (%) 40
Concentrate output (kg/h) 296
Water evaporation (kg/h) 1,186
SERVICES/UTILITIES REQUIRED
Dry saturated steam Requirement at 8 kg/cm2-g
(kg/h) 285
Steam economy (kg of water evaporation / kg of steam)
-- 4.17
Cooling water circulation Rate at 30°c
(m3/h) 18
Power installed (excluding cooling tower and cooling water pump)
(kW) 20
Power consumed (kWH/H) 16
Compressed air requirement at 6 kg/cm2-gpressure
(nm3/h) 4
Cooling water inlet temp. (°C) 30 – 32
Cooling water outlet temp. (°C) 38 – 40
Tolerance:All performance figure within +5%All consumption figure within +10%
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Table-2.20: Technical specification of TFD
EQUIPMENT Thin Film Dryer
CAPACITY 124 evaporation kg/h water
Parameters Unit Value
Feed rate kg/h 220
Initial feed solid content % 40
Final moisture in dry baggable
product % 8 - 10
Water evaporation kg/h 124
Solid output in baggable form at 8% -10% moisture content
kg/h 96
Dry saturated steam requirement at 7 kg/cm2-g pressure
kg/h 161
Electrical load (excluding cooling tower and Cooling water pump)
kW 18
Normal consumption kWH/hr 15
Cooling water circulation Rate at 30°c – 32°c
m3/h 12
Cooling water inlet temp. °C 30 – 32
Cooling water outlet temp. °C 38 – 40
Tolerance:
All performance figure within + 5%
All consumption figure within +10%
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2.11.2 AIR POLLUTION
As unit proposes to expand production capacity of existing products with the
introduction of some new products of the same category, the source of air
pollution will remain same after proposed expansion. Only quantity of gaseous
pollutants will increase as mentioned below. There will be also chances of
fugitive emission due to manufacturing activities and raw material handing and
transportation.
(A) Process Gas Emissions
The various process gases viz, HCl, HBr, Ammonia and SO2 will be generated
from the manufacturing of various products. The details of gaseous pollutants
emission due to existing as well as proposed manufacturing activities are given
in Table – 2.21 & Table – 2.22 respectively.
Adequate scrubbing system is provided for the control of process gas emission.
The details of process gas stacks and scrubbing system (existing & proposed)
are given hereunder in Table-2.23 and Table-2.24 respectively. The schematic
diagram of air pollution control measure is given as Drawing – 2.8 & 2.9.
Table – 2.21: Details of existing Air Pollution Measures for Process Gas Emission
Air Pollution Control Equipment Sr. No.
Scrubberattached to
ReactorAir Pollutant
1st Stage 2nd Stage
1. APCM-1 HCl and SO2, HBr, HCl Water Scrubber –A
Caustic Scrubber-B
Table – 2.22: Details of proposed Air Pollution Measures for Process Gas Emission
Air Pollution Control Equipment Sr. No.
Scrubberattached to
Reactor Air Pollutant
1st Stage 2nd Stage1. APCM-2 HCl and HBr Scrubber –C Scrubber-D
2. APCM-3 NH3 Scrubber –E --
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Table – 2.23: Details of Process Gas Stack
Sr.No. Stack attached to Height
(m) Dia.(m)
Temp(°C)
PolluantConcentration
mg/NM3
1. APCM-1 15 0.05 40
2. APCM -2 15 0.05 40
HCl < 20 mg/Nm3
SO2 < 40 mg/Nm3
HBr < 30 mg/Nm3
3. APCM -3 12 0.025 40 NH3 < 175 mg/Nm3
Table – 2.24: Details of Scrubbing System
Sr.No.
Size of Scrubber, meter
(Ht. & Dia.)
Scrubbing Media
Capacity of Scrubbing Tank, KL
PumpCapacity
M3/Hr Output
Existing
A 6.0 x 0.30 Water 1.0 7.5 HCl (30 %), HBr (24.45), Liquor
NH3 (10%)
B 4.5 x 0.30 Caustic 1.0 18.0 To ETP
Proposed
C 6.0 x 0.30 Water 1.0 7.5 HCl (30 %), HBr (24.45), Liquor
NH3 (10%)
D 4.5 x 0.30 Caustic 1.0 18.0 To ETP
E 6.0 x 0.30 Water 1.0 7.5 Liquor NH3 (10%)
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Drawing–2.8 – Schematic Diagram of Air Pollution Control Equipment (2 nos.)–HCl, HBr /SO2
Caustic Solution
HCl, HBr /SO2 gas
Caustic Solution Storage
Tank
SMF
Circulation Pump
Circulation Pump
Water Tank
By Product (HCl / HBr)
Outlet Gas
Blower
By Product (NaBr/NaHSO3)
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Drawing –2.9 – Schematic Diagram of Air Pollution Control Equipment – NH3
B) FLUE GAS EMISSION
Presently, the unit has installed one steam boiler (1.0 TPH - Working) and thermic
fluid heater (6 Lac Kcal/hr – stand by) where FO was used as fuel. Now, the unit
has switched over to agricultural waste to be use as fuel. Unit will install new
steam boiler (2.0 TPH) during proposed expansion. Thus, existing steam boiler
(1.0 TPH) will be kept stand by. Existing Thermic fluid heater will be kept working.
There will be common stack attached to existing/proposed steam boiler and
thermic fluid heater, thus there is no need of any additional flue gas stack after
proposed expansion. However, fuel consumption and hence flue gas volume
NH3 gas
Blower
Water tank
SMF
Liq. NH3
(sold as by product)
Circulation Pump
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will be increased after proposed expansion. Since, agricultural waste is used as
fuel in the steam boiler and thermic fluid heater; the unit has provided separate
Cyclone Separator attached to the each as an APCM, which will be adequate
after proposed expansion.
Adequate stack height of 31 m is provided for proper dispersion of pollutant to
the common stack of boiler & thermic fluid heater. The unit has also provided
one D. G. set (500 KVA) where HSD is used as fuel. D.G. Set will be used in case
of main power failure only. The flue gas emission will be well within gaseous
emission norms described by the GPCB. The details of flue gas are given
hereunder in Table-2.25.
Table – 2.25: Details of Flue Gas Stack
Status* Sr. No.
Stack Attach to E P
Ht. m
Dia.m Type of Fuel Concentration
of Polluants
AirPollution Control
Measures Steam
Boiler-1 TPH W S Cyclone Separator
Steam Boiler-2 TPH NA W Cyclone
Separator 1Thermic
Fluid Heater-6 Lac Kcal/
hr
W W
31 0.45 Agricultural waste
Cyclone Separator
2 D.G. set-500 KVA S S 31 0.1 HSD
PM < 150 mg/Nm3
SO2 < 100 ppm NOx < 50 ppm
Not Required
*E-Exiting, P-Proposed expansion, W-Working, S-Stand by NA-Not Applicable
STACK HEIGHT CALCULATION & VERIFICATION:
As per the GPCB/CPCB guidelines, the evaluation of height for the stack
proposed by the unit has been worked out considering capacity of fuel
consumption and is explained in Table-2.26.
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Table – 2.26: Stack height calculation
Stack Height Parameter Unit Value
Stack ID -- 1Stack Attached to -- Steam Boiler Fuel name -- Agricultural Waste
Working Hours Nos. 20 MT/Day 12.00 Fuel Consumption MT/Hour 0.60
Based on Sulfur ContentSulfur Content % 0.08 Total Sulfur Load Kg/hr 0.48000 Sulfur Removed by limestone Dosing % 0.00 Sulfur Capture by limestone Dosing Kg/hr 0.00 Sulfur Emission into Flue gas Kg/hr 0.480
Kg/hr 0.96 SO2 emission into flue Gas gm/sec 0.2667 Stack Height required Meter 13.83 Based on Ash Content Ash Content % 19.40 Total Ash Load MT/hr 0.1164
% 60Bottom Ash Removal MT/hr 0.0698 Ash Load to APCE MT/hr 0.0466
Ash Removed by Air pollution Equipment % 80
Ash removed by APCE MT/hr 0.0372 MT/hr 0.0093 PM Emission into Flue Gas gm/sec 2.587
Stack Height required Meter 20.94 Final Stack Height required Meter 20.94 Stack Height Proposed Meter 31.0
Thus the maximum height required is 20.94 m, whereas the proposed stack height is 31 meter which will be adequate for proper dispersion of the flue gas.
During the study period monitoring of the common stack attached to the
existing/proposed steam boiler & thermic fluid heater as well as process gas
stack attached to and scrubber has been carried out monthly and the details
of stacks gas emissions are given in Table – 2.27. Copy of Monthly analysis report
by third party is attached as Annexure-XVI.
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Table – 2.27: Analysis of Gas StackCommon stack attached to boiler & thermic fluid heater Stack attached to Scrubber
Sr.No.
SamplingDate PM,
mg/Nm3SOX,ppm
NOX,ppm
HClMg/Nm3
HBr,Mg/Nm3
SO2Mg/Nm3
1 12/10/10 77 6.8 0.72 10.8 - 12.8 2 26/10/09 96 7.1 0.64 8.7 - 10.7 3 18/11/10 104 5.4 0.45 4.9 - 15.2 4 28/11/10 112 6.3 0.54 - 1.8 19.4 5 09/12/10 82 5.4 0.40 - 2.0 12.6 6 20/12/10 114 5.7 0.45 5.6 - 10.9
GPCB Norms 150 100 50 20 5 40
C) FUGITIVE EMISSIONS:
There are chances of fugitive emission due to storage & handling and loading
unloading of Raw materials, product and by-product, manufacturing activity,
transportation of vehicles and scrubbing system. The unit will take adequate
precaution for the control of fugitive emission.
An action plan to control and monitor secondary fugitive emissions from all the
sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E)
dated 30th May, 2008
G.S.R 414(E) dated 30th May is related to Sponge iron Plant (Rotary Kiln),
whereas ours is a Bulk drug and drug intermediate manufacturing unit and
therefore an action plan to control and monitor secondary fugitive emissions
from all the sources as per the latest permissible limits issued by the Ministry vide
G.S.R. 414(E) dated 30th May, 2008 is not applicable to our unit. Copy of the
G.S.R. 414(E) is attached as Annexure-III for reference.
However, Unit has taken following control measures for fugitive emission and
same will be followed after proposed expansion.
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Control Measures For Fugitive Emission during material handling and process:
The entire manufacturing activities are carried out in the closed reactors
and regular checking and maintenance of reactors and distillation
column is carried out to avoid any leakages.
All the motors of pumps for the handling of hazardous chemicals are
flame proof and provided with suitable mechanical seal with stand by
arrangement.
Vacuum distillation with double condenser system is adopted.
The Control of all parameters on a continuous basis is done by adequate
control valves, pressure release valves and safety valves etc.
All the flange joints of the pipe lines are covered with flange guards.
All the raw materials are stored in isolated storage area and containers
are tightly closed.
Precautionary measures are also being taken while handling various
hazardous chemicals.
There is also provision of adequate ventilation system in process plant and
hazardous chemical storage area.
A regular preventive maintenance will be planned to replace or rectify all
gaskets, joints etc.
The unit has also developed green belt within the factory premises to
control the fugitive emission from spreading in to surrounding
environment.
Control measures for Fugitive Emission during Transportation Activity
The project site is located in the Industrial area, which is well connected to the
National Highway No. 8B. Hence there is an easy and fast accessibility within the
Industrial area. The area has good road network within and all roads are pucca
and asphalted. Hence there is almost no chance of particulate matter got
airborne due to the vehicular movement. Incremental traffic due to the
proposed expansion of M/s. Sam Finechem Ltd. will be very less and hence
there will be very less chance of air pollution due to the vehicular emission from
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the proposed project. However, the unit proposes to adopt following measures
to reduce the air pollution due to the transportation activity.
All the internal roads within premises will be asphalted or concreted to
avoid dust formation caused by movement of vehicles.
Adequate parking space for trucks within the premises will be provided.
Transporter will be instructed to cover the trucks, entering in to the
premises for transportation of raw materials and products, by tarpaulin
sheets.
The PUC of the vehicles entering the industrial premises will be checked
regularly.
The owned vehicles will be serviced at a regular interval of time.
2.11.3 HAZARDOUS / SOLID WASTE GENERATION
The main sources of hazardous waste generation from proposed manufacturing
activity will be Process Waste viz. Spent Solvent, Spent Carbon, Spent Catalyst
and Distillation Residue and Dried sludge generated from effluent treatment
plant. The ancillary source of hazardous waste generation will be discarded
bags/bottles/drums/Carboys/Containers from storage and handling of raw
materials and spent oil generation from plant machinery. The details of
hazardous waste generation and handling / Management are given in Table-
2.28.
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Table-2.28: Detail of Hazardous Waste Generation and management
Quantity per Annum Source Type of waste Cat.
E P T
Physical- Chemical
Form
Method of Disposal
Spent Solvent 20.2 2.16 KL
1710.57 KL
@1712.73 KL/Annum
Liquid- Organic
Collection, Storage,
recovery & reuse within the
process
Distillation Residue 36.2 7.2
MT 275.0
MT 282.2
MT Semisolid inorganic
Collection, Storage,
Transportation, Disposal by
incineration at near by CHWIF.
Spent Catalyst 35.2 0.05 MT
0.1MT 0.15 MT
Collection, Storage & reuse
within the process or sold to registered reprocessors
Spent Carbon 28.2 0.6MT 14.0 MT 14.6 MT
Used Ion Exchange
Resin 34.2 0.05
MT 0.1MT
0.15 MT
Semisolid organic
Process
Solid waste from
Centrifuge 36.1 8.5
MT 375.0
MT 382.5 MT Solid Inorganic
EMS ETP Waste 34.3 14.4 MT 12.0 MT 26.4 MT Solid-
organic
Collection, Storage,
Transportation & disposal at
TSDF site
Raw Material
Storage & Handling
Discarded Container
bags/bottles/ drums/Carboys
33.3 3.6MT 32.4 MT 36.0 MT Solid-
Inorganic
Send back to vendor for reuse OR
Decontaminate and sell
Plant and Machineries Used Oil 5.1 0.09
KL 2.0KL 2.09 KL Liquid-
Organic
Reused as lubricant within
premises
Calorific value of the organic waste is given in Table -2.29.
Sr. No Particular Calorific Value
1. ETP Sludge < 300 K.cal/Kg
2. Distillation Residue 1000-1500 K.cal/Kg
The unit has provided designated storage area of 1,463 sq. m for the hazardous
waste storage within premises having impervious floor and roof cover system
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and leachate collection system which will be expanded upto 1,795 sq. m during
proposed expansion.
The unit has already obtain membership of the nearest TSDF/CHWIF site of
Gujarat Enviro Protection Infrastructure Ltd. (GEPIL) for disposal of resins, spent
carbon, distillation residue & ETP waste. As no incineration will be carried out on
site thus, no need to provide design details of the Incinerator.
The unit will developed proper procedure for handling of ETP and other
hazardous waste.
1. The ETP sludge generated will be collected in the HDPE bags/MS drums
after complete sun drying.
2. The bags will be sealed or tightly closed.
3. The tightly closed HDPE bags will be labled as “ETP Sludge/Hazardous
waste”.
4. After that the bag will transferred through the trolley to the designated
storage area.
5. The bags will be sent to nearest TSDF/CHWIF site at a regular interval of
time for final disposal.
6. Proper log book and record of the waste generated, disposed at TSDF site
or sold data will be maintained.
Discarded container/Barrels/Bottles/Bags/drums will be sent back to vendor or it
will be reused again in the plant after decontamination. The unit will also
develop proper procedure for decontamination of discarded
container/barrel/Bottles/Bags/drums which is given below.
1. Empty container/barrel/Bottles/Bags/drums will be sent to
decontamination area after ensuring that it is completely empty and the
lids are tightly closed.
2. Treated wastewater of the existing ETP will be used to clean the
containers/Barrels/Liners.
3. 20 to 30 lit of water will charged and lid will be closed properly.
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4. Container/Barrels/Liners/drums will be rolled on the ground for 2 to 3
minute and than will be emptied. The procedure will be repeated for 2 to
3 times. The water from cleaning will be sent to propose Effluent
Treatment Plant.
5. The second wash will be carried out by 10% solution of either acid or
alkali. Then final wash will be carried out with treated water.
6. The label “DECONTAMINATED” will be sticked on washed containers
/Barrels/Liners/drums and it will be transfer to decontaminated storage
area.
7. From the storage area containers/Barrels/Liners/drums will be reuse or sell
to scrap vendor.
The unit will also keep the records of the empty container generated and
disposed in the register.
2.11.4 NOISE POLLUTION
Noise is an unwanted sound and excessive noise is harmful to health and
diminishes the quality of life. Thus, noise is considered as one of the potential
pollutant. Management of noise includes the monitoring and controlling of
noise levels, at source, the transmission paths and the surrounding environment.
There will not be any major source of noise generation due to proposed project.
The only source of noise generation is the vibrating noise from the operation of
plant and machineries from the proposed manufacturing activity. One of the
auxiliary sources of noise generation would be from transportation within and
out side the premises. However, for the abatement of noise pollution, following
precautions will be taken by the unit;
Latest low noise D.G. Sets are in place with acoustic enclosure to reduce
the noise generation.
Proper and timely oiling, lubrication and preventive maintenance will be
carried out for the machineries and equipments to reduce noise
generation.
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The noise generation will be mitigated by installing noise barriers/absorbers
around stationery noise sources. Adequate noise control measures such as
anti vibration pad for equipment with high vibration will be provided.
All the vibrating parts will be checked periodically and serviced to reduce
the noise generation. The equipment, which generates excessive noise, will
be provided with enclosures etc.
To minimize the adverse effect on the health, Ear muffs/ earplugs will be
provided to the workers working under high noise area.
To reduce the noise generation during the transportation activities; the
transport contractor will be instructed kept vehicle periodically serviced
and maintain as per the requirement of latest trend in automobile industry.
Only those vehicles with PUC’s will be allowed for the transportation.
The transport contractor will be informed to avoid unnecessary speeding of
vehicles inside the premises.
Noise monitoring will be done regularly at different parts of the plant.
Green belt area will be developed to prevent the noise pollution outside
the factory premises.