M/S. Jayveer Pharma Chem. -...
Transcript of M/S. Jayveer Pharma Chem. -...
PRE FEASIBILITY REPORT
OF
M/S. Jayveer Pharma Chem.
Survey No. : 621, Jagudan – Kochva Road, Village: Jagudan,
Taluka & District: Mehsana.
Mr. Ritesh R. Chaudhary
(M) 09825095477
E-mail: [email protected]
Prepared By:
T. R. ASSOCIATES
C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,
S. G. Highway, Ahmedabad.
Mo. No.: 98253 71099
Email ID: [email protected];
May 2015
1. Executive summary
M/s. Jayveer Pharma Chem is proposing to manufacture Pharmaceutical Drugs
& their Intermediates at Survey No. : 621, Jagudan – Kochva Road, Village:
Jagudan, Taluka & District: Mehsana. Proposed unit will manufacture
Pharmaceutical Drugs for sell purpose.
The total land area of company is 6779 m2 out of which 2873 Sq. Mt. land will be
used for greenbelt area development. The estimated cost of the Resin project is
11.0 Crores. Total budget allocation towards Environmental Management
Facilities will be Rs. 75 Lacs. Total 12 persons will be employed including skilled
persons, unskilled persons and office staff.
M/s. T. R. Associates is carried out EIA/EMP studies for Environmental Clearance.
Production details are given below:
Sr. No. Name of Product Quantity
1 N - Methyl 4 Piperidone 7.5 MT/M
2 N – Methyl 4 Chloro Piperidine (NMCP) 2 MT/M
3 5 Chloro 1 (4 Piperidyl) 2 Benzimidazolonone
(D-7) 5 MT/M
4 1 – (3 – Chloropropyl) -1- Dihydro – 2 –H –
Benzimidazolone (D-2) 4 MT/M
5
Dompiridone 5 – Chloro – 1 – (1 – (3 – (2 – Oxo
– 1 – Benzimidazolinyl) Propyl) – 4 –
Piperidyl) – 2- Benzimidaz
5 MT/M
6 Chlorzoxazone (5 – Chloro – 3 – H Benzooxa-
zolonone) OR 5 – Chloro – 2 – Benzoxazolione 10 MT/M
7 4 CAP (4 Chloro 2 Amino Phenol) 25 MT/M
8 Peraphenylene Diamine 50 MT/M
9 2.5 Dichloro Peraphenylene Diamine 10 MT/M
Salient Features with in 10 km radius surroundings area as follows:
S.No Important Features Description
1 Location Survey No. : 621, Jagudan – Kochva Road,
Village: Jagudan, Taluka & District: Mehsana
2 Topomap F43A7
3 Longitude 72°24'32"E
4 Latitude 23°30'40"N
5 MSL 127 m
6. Nearest power station UGVCL (Uttar Gujarat Vij Company Ltd.)
7 Proponent Name Mr. Ritesh R. Chaudhary
8 Corporate office address Jayveer Pharma Chem, Near Sarvajanik
Vidhyalaya, Panch Limdi, Mehsana – 384001.
9 Temperature range 140 C to 430 C
10 Annual Rain fall 900 mm
11 Nearest Road SH 41 (0.75 Km)
12 Nearest Railway station Jagudan Railway Station– 0.68 Km
13 Nearest city Mehsana – 8.5 Km
14 Nearest village Jagudan – 0.5 Km
15 National HW NO NH 8 (43 Km)
16 State HW No SH 41 (0.75 Km)
17 Seismic Zone Zone-III (Less Active)
18 National Parks / Sanctuary None within 10 Km radius.
2. Project back ground.
Pharmaceutical Drugs & their Intermediates used in treating different diseases
and health issues. For e.g: Domperidone is used to relieve symptoms of feeling sick
(nausea) and sickness (vomiting). The proposed product have good market
demand.
Export Possibility.
There is good possibility for export. But currently we are focused to local sale
market for distribution.
Employment Generation (Direct and Indirect) due to the project.
This project will provide direct employment to 12 people whereas it will provide
employment to many others indirectly.
3. Project Description
(i) Type of project including interlinked and interdependent projects.
Pharmaceutical Drugs & their Intermediates used in treating different
diseases and health issues. It is sometimes dependent on units producing
Intermediate products.
(ii) Location
Longitude: 72°24'32"E
Latitude : 23°30'40"N
(iii) Project description with process details
MANUFACTURING PROCESS
1. N-METHYL – 4- PIPERIDONE (NMP)
Take 630 Kg Methyl Acrylate in dry reactor at 25 – 30 °C.
Charge 30% Mono Methyl Amine solution of 360 Kg (108 kg MMA in 252 kg
Methanol) in reactor at 20 ° C for 3 hrs. Keep stirring.
Maintain 20-25 °C temp for 6 to 8 hrs.
Check sample. If G.C. is ok than maintain temperature 30-35 °C for 2-4 hrs
Send sample for G.C. if G.C. is ok than cool reaction mass to 0°C.
Now charge weight wise Sodium Methoxide powder 200 Kg at temp 0-10 ° C in
8 hrs.
After completion of addition, heat the reaction mass to 40 °C.
Maintain 40 °C for 6 hrs and check T.L.C.
After this charge 1500 Lit of D.M. Water & 1500 L Chloroform. Slowly temperature
rises up to 55-60 °C. Maintain temperature for 2 hrs.
Send sample for T.L.C., if T.L.C. is ok than cool up to 35-40 °C.
Reaction mass extract with chloroform at 40-45 °C.
Total 1500 Lit chloroform extract (5x300 Lit).
Collect total chloroform extract in other distillation reactor.
Distilled out total chloroform.
Cool up to 25-30 °C. Transfer the materials in vacuum distillation reactor.
Start vacuum distillation and collect materials at temperature 90-120 °C.
Finally get product N-METHYL – 4- PIPERIDONE up to 250 Kg.
Mass Balance Table:
Input per batch Output per batch
Methyl Acrylate 630 NMP 250
MMA 30% 110 Effluent 2125
(Methanol) 252 Chloroform 1500
Sodium Methoxide 200 Methanol 252
D.M Water 1500 Waste Residue 65
Chloroform 1500
TOTAL 4192 4192
PROCESS FLOW DIAGRAM OF N-METHYL – 4 - PIPERIDONE
S.S. Reactor 630 Kg Methyl Acrylate
360 Kg 30% MMA soln
(108 kg MMA in 252 Kg methanol)
200 Kg Sodium Methoxide powder
1500 Lit D.M Water
1500 Lit Cloroform
1500 Lit Chloroform
250 Kg Methanol for reused
250 kg Methanol
1500 lit Chloroform
315 Crude
250 Kgs Finished NMP
Vaccum Distillation
1500 lit wastewater
(2125 Kgs)
65 Kg Waste Residue
2 N-METHYL – 4- CHLORO – PIPERIDINE (NMCP)
Charge N- Methyl 4- Piperidone 500 Kg (Aqueous Solution of 500 KG NMP and
500 Kg D. M. Water in hydrogenator at 25 – 30 °C) in hydrogenator. Then charge
Ranny Nickle catalyst of 20 Kg and close the main hole.
Purge N2 gas for removal of O2 gas and purge H2 gas for removal of O2 & N2 gas.
Pass & purge hydrogen gas at 4-6 Kg pressure.
Start hydrogenator and pass H2 gas up to consumption of H2 should be nil.
Check sample for G.C. & T.L.C. if ok than filter the materials and collect catalyst.
Collect mother liquor in vacuum distillation reactor.
Start vacuum distillation up to 110 °C. Recovered 500 Lit of water and reused.
500 Kg of N- Methyl – 4- Hydroxy Piperidine (NMHP) is obtained.
Take 150 Lit of toluene and 500 Kg NMHP and mix it.
Charge 800 Kg of Thionoyl Chloride in glass line reactor with 2000 L toluene at
25-30 °C.
Start charging of mixture of toluene and NMHP in glass line reactor at below 60 °C
for 5-6 hrs.
Raise the temperature up to 60-65 °C for 1 hr and maintain it for 6 hrs. Now cool it
at 20-25 °C.
Charge slowly D. M. Water of 700 Lit at 25-30 °C and stir for 1 hr.
Settle and separate product (aqueous) layer. Now take this aqueous layer in
another reactor.
Slowly add 600 Lit of soda solution 25 % (150 Kg soda ash in 500 Lit water) for 3-
4 hrs.
Add 200 Kg of caustic lye up to 50° C for 1-2 hr and add 1050 Lit chloroform for
extraction.
Collect extract chloroform in distillation reactor and distil out chloroform up to
110°C. Cool up to 30-35 °C.
Now start high vacuum distillation and collect final product NMCP at 80-110 °C.
Final output 450 Kg of NMCP is obtained.
Liquid Effluent 1300 lit. is also obtained.
Mass Balance Table:
Input per batch Output per batch
NMP 500 NMCP 450
DM Water 1700 Spent Catalyst 20
R. Nickle 20 Distilled Water 500
Thionyl chloride 800 Toluene 2150
Toluene 2150 Effluent 2350
Soda 150 Chloroform 1050
Caustic Lye 200 Residue 50
Chloroform 1050 NMCP 450
TOTAL 6570 TOTAL 6570
PROCESS FLOW DIAGRAM OF N-METHYL – 4- CHLORO PIPERIDINE
Hydrogenetor 500 Kg NMP
500 Kg DM water
20 Kgs Ranny Nickle
H2 Gas
N2 Gas
Reactor
Glass Lined Reactor 800 Kg Thionyl Chloride in
2150 litres Toluene
700 Lit D.M water
20 Kg Spent Catalyst for resell
500 Litres Distilled Water
Vaccum Distillation
NMCP 450 Kg
1050 Litre Chloroform
distilled and reused
1300 Litre Effluent
(2350 Kg)
Distillation reactor
Separation of Aqueous
Layer
2150 litre Toluene distilled for reuse
50 Kg Residue
Vaccum Distillation
Final Product NMHP
500 Kg
25% 600 Litres Soda Soln
(150 Kgs in 500 litres water)
200 Kg Caustic Lye
1050 litre Chloroform
Distillation
O2 Gas
N2 Gas
3 D-7 (5- CHLORO – 1 (4 – PIPERIDYL) 2 - BENZIMIDAZOLONONE
Stage 1 – D3 N-CARBETOXY 4-PIPERIDONE (NCP)
Charge 1500 Lit toluene and 300 Kg Ethyl chloroformate (ECF) & 30 kg
Caustic lye in reactor at 25-30 °C .
Raise the temperature up to 40-45 °C.
Start addition of mixture of 250 Kg (N-METHYL -4-PIPERIDONE) and 200 lit
Toluene at 40-45 °C within 8 hrs. Maintain temperature up to 50-55 °C for 6
hrs.
Check T.L.C. if ok than add 250 Lit D. M. Water & 30 kg caustic Lye. Settle and
separate the aqueous layer in other distillation reactor.
Start distillation up to 110-125 °C for toluene recovery. Also start vacuum
distillation to recover solvent traces.
Cool it and transfer vacuum distillation reactor. Start vacuum distillation up to
100-125 °C.
Collect 250 kg product NCP (N-CARBETHOXY 4-PIPERIDONE). Also collect
water effluent up to 250 Lit.
Mass Balance Table:
Input per batch Output per batch
Toluene 1700
Carbethoxy
Piperidine 250
ECF 300 Effluent 530
NMP 250 Toluene 1700
D.M. Water 250 Waste residue 50
Caustic Lye 30
TOTAL 2530 2530
PROCESS FLOW DIAGRAM OF D-3 (NCP)
S. S. Reactor
1700 Lit Toluene
300 Kg Ethyl chloroformate
250 Kg NMP
250 Lit D. M. Water
30 Kg Caustic Lye
Extraction /
Separation
Distillation
250 Kg N-CARBETHOXY
PIPEDINE
250 Lit 7.0 pH water effluent
(530 Kgs)
1650 Lit Toluene Reuse
10 Kgs residue Solid
waste
Stage -2 - D-4, 4 –AMINO-NCP
Charge NCP 750 Kg at 25-30 °C in hydrogenator. Also charge 900 Lit Methanol
under vacuum.
Charge 15 kg of Ranny nickel catalyst at 25-30°C. Remove nitrogen with vacuum
and cool to 10-15°C.
Charge 900 L Ammonical nitrogen at 15-20°C. Pass hydrogen gas until the
pressure 0.8 to 1 Kg/Cm2 at 20-25°C.
Maintain H2 pressure 0.8 to 1.0 Kg at 25-30 °C for 12 hrs or up to H2 gas
consumption should be nil.
Send the sample for G.C. & T.L.C. If it is ok than release the H2 by passing N2 gas.
Filter the batch & collect used catalyst. Collect mother liquor in distillation reactor.
Start distillation up to 110-115°C. Also apply vacuum for 1-2 hrs at 110-115°C.
Cool it up to 25-30 °C and collect in drum.
Final product of 750 Kg D-4, 4 – Amino – N – Carbethoxy Piperidine (NCP) will be
obtained.
Mass Balance Table:
Input Kg per batch Output Kg per batch
NCP 750 4-Amino NCP 750
Ammonical
Methanol 15% 900 Spent Nickle 15
R. Nickle 15
Ammonical
Methanol 15% 850
Residue 50
TOTAL 1665 1665
PROCESS FLOW DIAGRAM OF D-4 – 4 – AMINO NCP
HYDROGENATOR 750 Kg NCP
900 Lit Ammonical
Methanol 16%
15 Kg R. Nickle catalyst
H2 Gas
Distillation
250 Lit 7.0 pH water
effluent
850 Liters
Ammonical Methanol
16% for reuse
50 Kg Residue
Spent Nickle catalyst 15
Kg for resale
750 Kg 4- AMINO NCP
Step -3 D-5, DINITRO (4-(2-NITRO – 5- CHLORO ANILINE) NCP)
Charge 375 Kg 4-Amino-NCP at 25-30 °C
Charge 450 Kg 2.5 DCNB, 150 Kg Soda Ash and 150 Kg Potassium Iodide with
stirring at 25 – 30 °C.
Slowly raise temperature up to 100-105 °C in 1 hr and maintain it for 1 hr.
Now again slowly raise temperature up to 135-140°C in 1 hr and maintain it for
10 hrs.
Check sample for T.L.C., if ok then cool it to 70°C.
Charge 1200 Lit D. M. Water. Stir for 1 hr and cool to 40°C.
Centrifuge the mass and collect the effluent.
Pack the product of nitro compound of 675 kgs in bags.
Mass Balance Table:
Input Kg per batch Output Kg per batch
4-Amino NCP 375 D5 DINITRO 675
2.5 DCNB 450 Effluent 1650
Soda Ash 150
Potassium Iodide 150
D.M. Water 1200
TOTAL 2325 2325
PROCESS FLOW DIAGRAM OF D-5 DINITRO
`
Water 1200 Lit
S. S. Reactor 375 Kg 4-Amino NCP
450 Kg 2.5 DCNB
150 Kg Soda Ash
150 Kg Potassium Iodide
Wash with D. M. Water
Centrifuge Filtrate
1200 Lit pH 8.0 water
effluent
(1650 KGs)
675 Kg 4- AMINO NCP
Stage – 4- D-6 – DIAMINE (4-(2-AMINO-5- CHLOROANILINE)-N- CARBETHOXY
PIPERIDINE)
Take 810 Lit Methanol and 810 Lit Toluene in Hydrogenator at 25-30°C. Also
charge 675 Kg D-5, DINITRO compounds.
Charge 15 Kg Ranny Nickel catalyst at 25-30°C. Close main hole of hydrogenator
and passing N2 gas for removal of O2 gas.
Passed H2 gas for removal of oxygen and Nitrogen.
Passing H2 gas upto 6 kg pressure, 105 °C temperature.
Maintain H2 Pressure 6 kg up to consumption NIL. Approximately 190 M3 H2 gas
will be consumed.
Check T.L.C., if ok than filter the batch and collect catalyst and mother liquor.
Collect mother liquor in distillation reactor.
Distil out solvent up to 100-110°C for reuse. Cool the batch up to R.T.
Filter in vacuum nutch and centrifuge the mass.
500 Kg of Diamine product is ready for pack.
Mass Balance Table:
Input Kg per batch Output Kg per batch
Methanol 810 D6 Diamine 500
Toluene 810 Spent Nickle 15
D5 Di Nitro W/C 675 Mix Solvent 1570
R. Nickle 15 Effluent 225
TOTAL 2310 2310
PROCESS FLOW DIAGRAM OF D-6 –DIAMINE (4-(2-AMINO-5 CHLOROANILINE)-NCP)
HYDROGENATOR
810 Lit Methanol
810 Lit Toluene
675 Kg D5
15 Kg R. Nickle catalyst
190 m3 H2 Gas
N2 Gas
Distillation/ Chilling 10 Kg Residue
1500 L mix Solvent
Spent Nickle catalyst 20
kgs for resale
N2 & O2 gas
500 Kg DIAMINE
Solvent Recovery 70 L mix Solvent
200 L (225 Kg) Effluent
Stage – 5 – D-7 (5-CHLORO -1 (4-PIPERIDYL)-2-BENZ-IMIDAZOLONONE)
Charge 500 Kg of D6-DIAMINE in reactor with 250 Kg Urea at 25-30 °C.
Slowly raise the temperature up to 180-185°C for 2 hrs and maintain same
temperature for 6 hrs.
Check sample for T.L.C., if O.K than cool the material at 100-110°C.
Now charge 1000 Lit D.M. Water and 60 Kg Caustic lye at below 110°C.
Transfer the batch into other reactor and charge 2000 Lit D.M. Water & 1000 Kg
48% caustic lye at below 80-85°C.
Raise the temperature up to 99-101°C and maintain for 10 hrs.
Check the sample for T.L.C, if ok than cool the material up to 80-85°C and charge
15 Kg Carbon. Stir it for 1 hr and filter the batch. Collect mother liquor in other
reactor and cool to 25-30°C.
Now charge Ammonium Chloride (400 kg in 1000 Lit Water) solution at 25-30°C.
Centrifuge the materials & spin dry for 45 min.
Unload the cake
In glass line reactor, charge 2500 Lit D.M. Water and charge material cake at R.T.
Adjust pH 2.0 by adding 200 Lit HCl at 20-25 °C.
Cool to 10°C and stir for 1 hr. Centrifuge the material. Unload the material cake.
Charge 2500 Lit D. M. Water and 1000 Lit 25% Ammonia Solution in reactor.
Charge materials cake at R.T. Slowly apply heat up to 50-55°C and maintain for 6
hrs.
Centrifuge the materials at same temperature. Unload the material and dry at 80-
90°C till moisture content below 1.0 %.
Pack the 450 Kg quantity of D-7 (5-CHLORO -1 (4-PIPERIDYL)-2-BENZ-
IMIDAZOLONONE)
Collected Effluent quantity is also 10000 Lit.
Mass Balance Table:
Input Kg per batch Output Kg per batch
D6 diamine 500 D-7 500
Urea 250 Spent carbon 15
Caustic lye 1060 Effluent 11525
D.M. water 8000
carbon 15
Ammonium
Chloride 1000
HCL 200
Ammonia
Solution 1000
TOTAL 12025 12025
PROCESS FLOW DIAGRAM OF D-7 (5-CHLORO -1 (4-PIPERIDYL)-2-BENZ-
IMIDAZOLONONE)
S. S. Reactor /
Hydrolysis
500 kg Diamine
250 Kg Urea
60 Kg Caustic Lye
1000 Lit D. M. Water
S. S. reactor
Reactor
500 Kg D-7
1000 Kg Caustic Lye
2000 Lit D. M. Water
15 Kg Carbon
Ammonium Chloride
Solution 25 % (1000kg)
Centrifuge and Spin
Dry
4000 Lit 10-12 pH
alkaline effluent
(4500 KG)
Glass line Reactor 2500 Lit D. M. Water
200 Lit HCl
After filtration
2500 Lit 2-3 pH acidic
effluent (2700 KG)
S. S. Reactor 2500 Lit D. M. Water
1000 Lit 25% NH3
Solution
After filtration
3500 Lit alkaline effluent
(4310 KG)
15 Kg Carbon
4. D-2 [1 – (3- CHLOROPROPYL)-1- DIHYDRO-2-H-BENZIMIDA-
ZOLONE ]
Stage – 1 – D-1 Charge 2000 Lit of O – Xylene in reactor at 25-30° C.
Raise the temperature up to 140 °C and reflux for removal of moisture for 2 hrs at
140°C.
Now charge weight wise 300 Kg Ortho Phynylene Diamine (OPD) and 360 Kg
Methyl Aceto Acetate (MAA) at 140°C every two hrs and collect water.
Maintain 140C° temperature for 10 hrs and check the sample for T.L.C. If T.L.C. is
ok then distil out 2000 lit O-Xylene for reused.
Cool to R. T. than chill up to 10°C. Centrifuge the materials and wash with 1:3
volume as O-xylene : Hexane (30 Lit + 90 Lit).
Spin dry the cake for 45 min and unload the materials. Dry the materials at 60-
70°C. So we get 360 kg material cake.
Charge 2000 Lit water and 360 Kg dry mass cake in S.S. reactor.
Stir for 15 min and raise temperature up to 45°C.
Adjust pH 12-13 by addition of 300 kg caustic lye at 45°C up to dissolution.
Stir for 1 hr at 45-50°C till solution should be clear. Charge 5 Kg carbon and stir
for 1 hr.
Clarify the materials. Collect filtrate in other reactor. Adjust pH 4.0 by adding 240
Kg HCL at 30-35°C.
Centrifuge the materials and wash with 160 Lit D. M. Water. Spin dry for 45 min.
Unload the mass and dry at 60-70°C. We get 360 Kg D-1.
About 2160 Lit water effluent will be generated.
Mass Balance Table:
Input per batch Output per batch
O-Xylene 2030 D-1 360
OPD 300 carbon 5
MAA 360 O-Xylene 2000
DM water 2376 Effluent 3221
Hexane 90 Residue 15
Caustic Lye 200
carbon 5
HCL 240
TOTAL 5601 5601
PROCESS FLOW DIAGRAM OF D-1
S. S. Reactor 2000 Lit O-Xylene
300 Kg OPD
360 Kg MAA
216 Lit Distil Water
Reflux 140oC
Centrifuge / Spin Dry
Centrifuge and Spin
Dry
S.S. Reactor 2000 Lit D. M. Water
300 Kg Caustic Lye
5 Kg Carbon
Reactor 240 Kg HCL
160 Lit D. M. Water
360 Kg Finish product
D-1
5 Kg Spent Carbon
15 kg residue
2160 Lit effluent
(3221 KG)
2000 Lit O-Xylene distilled & reuse 30 L O-Xylene
90 L Hexane
Stage -2 – D-2
Charge 2150 Lit Acetone at 25-30°C in reactor. Also charge 720 Kg D-1 material at
25-30°C.
Stir for 1 hr till solution should be clear. Add 360 Kg caustic lye to reaction mass at
25-30°C in 3-4 hrs than add 5 Kg TEBAC as catalyst.
Maintain temperature up to 15-20°C for 2 hrs.
Add 840 Kg (1-Bromo -3 Chloro-Propane) BCP at 30-35 °C for 3-4 hrs.
Maintain temperature up to 25-30°C for 10 hrs.
Check T.L.C. of sample if ok then settle the batch for 1 hr. separate the aqueous
layer in clean container.
Now collect oily aqueous layer in glass line reactor. Charge dilutes 1500 Lit HCl at
25-30 °C and raises the temp up to 55-60°C for 4 hrs.
Cool the mass to 30-35°C and observe the material formation. Maintain the same
temp for 1 hr.
Centrifuge the mass. Spin dry for 45 min and unload the dry materials at 55-60 °C.
We get 800 Kg D-2.
Mass Balance Table:
Input per batch Output per batch
Acetone 2150 D-2 800
D-1 720 Acetone 2150
TEBAC 5 Effluent 2610
BCP 840 Residue 10
Caustic Lye 360 Catalyst 5
HCL 1500
TOTAL 5575 5575
PROCESS FLOW DIAGRAM OF D-2
S. S. Reactor 2150 Lit Acetone
720 Kg D-1 mass
5 Kg TEBAC
840 Kg BCP
360 Kg Caustic Lye
Centrifuge / Spin Dry
Glass Line Reactor
1500 Lit HCL
2150 Lit recover Acetone for distil &
reuse
800 Kg Finish product
D-2
10 kg Organic Residue
5 kg catalyst
1750 Lit 7.0 pH water
effluent (2610 KG)
Glass Line Reactor
5. DOMPIRIDONE
5- CHLORO-1-(1-L3-L2-OXO-1-BENXIMIDAZOLINYL) PROPYL) -4-
PIPERIDYL)-2-BENZIMIDAZ
Process
Charge 200 kg M.I.B.K at 25-30 °C in reactor. Now charge 176 Kg D-2, 200 Kg D-7
and 2 Kg Potassium Iodide at 25-30°C in same reactor.
Raise the temperature to 88-90 °C. Add the 144 Kg weight wise Soda ash for every
45 min and record the temperature.
Maintain temperature 88-90 °C for 9 to 10 hrs. Cool the mass to 30 - 35 °C and stir
for 30 - 35 °C for 1 hr.
Centrifuge the materials and unload the wet cake.
Now charge 1500 Lit D. M. Water into another reactor. And add wet cake at R. T.
Raise temperature to 65-70°C.
Charge Ammonium Chloride solution (200 Kg in 1000 Lit) at 60-65°C. Raise the
temp to 65-72°C and maintain for the same for 2 hrs.
Cool to R.T. and maintain for 1 hr.
Centrifuge the materials.
Spin dry for 45 min.
Dry the product and get 320 Kg DOMPIRIDONE AT 80-90 °C
Collect 1800 Lit effluent.
Mass Balance Table:
Input per batch Output per batch
M.I.B.K 200 Dompiridone 320
D-2 176 M.I.B.K 202
D-7 200 Effluent 2950
potassium Iodide 2
Soda ash 144
D.M Water 1750
Ammonium
Chloride solution 1000
TOTAL 3472 3472
PROCESS FLOW DIAGRAM OF DOMPIRIDONE
S. S. Reactor 200 Lit M.I.B.K.
176 Kg D-2
200 Kg D-7
2 Kg Potassium Iodide
144 KG Soda Ash
Centrifuge / Spin Dry
S. S. Reactor 1500 Lit D. M. Water
1000 Lit 20 % soln. of
Ammonium Chloride
200 lit. M.I.B.K. solvent for distil and
reuse (202 KG)
320 Kg Finish product
DOMPIRIDONE
1800 Lit 7.0 pH water
effluent (2950 KG) 250 Lit D. M. Water Wash
Centrifuge
6. 4-CAP (4-CHLORO 2 –AMINO PHENOL)
Process
Take 5500 Lit water in Autoclave.
Charge 600 Kg Caustic flakes or 1250 Kg Caustic lye under stirring. Also charge 1000
Kg 2.5 DCNB slowly with stirring. Close the main hole.
Start heating up to 145-148°C and maintain same temperature for 6 hrs. Take sample
and check melting point and T.L.C.
Cool to 100 °C and release pressure.
Transfer the materials in other M.S. open reactor.
Cool to 20-25°C by adding cooling water.
Filter the batch in nutch filter and centrifuge the materials.
Check the purity and moisture.
Collect the effluent 3000 Lit.
Hydrogenation
Take 3000 Lit water in hydrogenator and charge nitro wet cake in hydrogenator.
Adjust pH 12.5 to 13 by adding caustic lye.
Now charge Platinum/ Carbon catalyst.
Close the main hole and start purge of N2 gas for removal of O2 gas up to Nil.
Start purging of H2 gas two times for removal of N2 & O2 gas. Take pressure 5 Kg of H2
gas.
Start stirring and maintain 5 kg pressure up to reduction completed.
Check T.L.C., if it is ok then filter the batch and collect catalyst for recycle and reuse.
Collect mother liquor in HDPE reactor. Adjust pH up to 4-4.5 by adding HCl.
Filter the mass by nutch filter , centrifuge it ,dry and pack it.
Collect the effluent 2500 Lit.
Mass Balance Table:
Input per batch Output per batch
Water 8500 4 CAP 600
2.5 DCNB 1000 catalyst 8.5
Caustic Flakes 600 Effluent 9800
Platinum Catalyst 8.5
HCL 300
TOTAL 10408.5 10408.5
PROCESS FLOW DIAGRAM OF 4- CHLORO – 2 – AMINO PHENOL
M. S. Autoclave 5500 Lit water
1000 Kg 2.5 DCNB
600 Kg Caustic Flakes
HDPE Reactor
Hydrogenator
3000 Lit water
8.5 Kg Platinum catalyst
H2 gas
(365 m3 H2 gas)
5500 Lit Alkaline effluent with salt
(6100 KG)
600 Kg Finish product 4
CAP
3000 Lit water effluent
(3700 KG)
Filter 8.5 KG Recovered catalyst for reuse
Filter / Centrifuge
HCL 300 KG
Filter
7. CHLOROXAZONE (5-CHLORO-3-H BENZOOXA-ZOLONONE) OR
5-CHLORO-2-BENZOXAZOLIONE
Process
Take 1250 Kg HCL in glass line reactor. Charge 800 Kg real 4 –CAP wet cake in
glass line reactor with stirring. Stir for half hour.
Now add 1065 Kg Urea in glass line reactor with stirring. Close the main hole of
reactor.
Start heating slowly up to 100-101°C for reflux. Reflux for 5-6 hrs up to T.L.C. of
sample shows ok.
Check the pH, it should be 6.0-6.5.
Cool the mass to R. T.
Filter the batch and centrifuge it.
Collect effluent water quantity of 2000 Lit.
Purification
Take 1000 Lit Methanol and charge crude wet cake with stirring.
Heat up to 65-70°C for reflux. Add 10 Kg carbon and reflux for 2 hrs.
Filter the batch and collect mother liquor in other reactor.
Cool the mass to 0-5°C.
Now filter the mass & centrifuge for drying.
Dry the materials and pack.
Mass Balance Table:
Input per batch Output per batch
Real 4 CAP wet
cake 800 CHLOROXAZONE 800
Urea 1065 Effluent 2315
HCL 1250 Carbon 10
Methanol 1000 Methanol 1000
Carbon 10
TOTAL 4125 4125
PROCESS FLOW DIAGRAM OF CHLORZOXAZONE
Glass Line Reactor 800 Kg Real 4-CAP wet
cake
1065 Kg Urea
1250 Kg HCl
Centrifuge / Chilling
S. S. Reactor 1000 Lit Methanol
10 Kg Carbon
2000 Lit 6.5 to 7.0 pH water effluent
(2315 kg)
800 Kg Finish product
CHLOROXAZONE
1000 Lit Methanol
recovered for reuse
Centrifuge
800 kg
Reflux & Filter
Solid waste 10 Kg carbon
8. Peraphenylene Diamine (PPD)
Process :
Take 2500 Lit. Ethyl Acetate in hydrogenation. Charge pera nitro aniline 1600 kg at R. T. Add 11 kgs Ranny Nickle catalyst Purge N2 gas for removing oxygen. Take hydrogen pressure 5 kg. & start stirring. Maintain H2 gas passing upto consumption of H2 Nil Maintain temperature 65 – 70 ºC. H2 gas consumption nil. Then check T.L.C. if ok than filter the batch to collect M.L. in other distillation Reactor & collect spent catalyst for resell Start vaccum distillation for final product packing.
Mass Balance Table:
Input per batch Output per batch
PNA 1600 PPD 1225
Ethyl Acetate 2500 Catalyst 11
R. Nickle 11 Ethyl Acetate 2500
H2 Gas 50 Distilled water 400
waste residue 25
TOTAL 4161 4161
PROCESS FLOW DIAGRAM OF PERAPHENYLENE DIAMINE (PPD)
Reactor 1600 Kg. PNA
2500 Kg Ethyl Acetate
11 Kg Ranny Nickle
catalyst
480 m3 H2 Gas
Distillation
11 Kg Spent catalyst for resale
Vaccum Distillation
PPD 1225 Kg
Final Product
2500 Kg Ethyl Acetate Reused
400 Liter Distilled Water reused
Filter
25 Kg Waste Residue.
9. 2-5 Dichloro Pera Phenylene Diamine Process
Take 0.5 times 1500 Lit mix solvent in Hydrogenator.
Charge 300 Kg 2.5 DCPNA & stirring at R. T.
Charge palladium / carbon catalyst 2.1 kg.
Close the main hole & start N2 gas purge for removing Oxygen.
Purge H2 gas upto 5 kg Pressure
Start hydrogenation
Heat upto 80 – 82 ºC.
Hydrogenation continuous upto H2 gas consumption nil
Take sample & check T.L.C.
If T.L.C. ok than filter the batch
Collect filtrate in other reactor
Chill upto 5 – 10 ºC.
Nutch to C/F the materials. Solvent for distillation & reuse.
Dry the materials 250 kg. & packed
Mass Balance Table:
Input per batch Output per batch
Mix solvent 1500 2.5 DCPPD 250
2.5 DCPNA 300 catalyst 2.75
Pd/Co catalyst 2.1 Mix Solvent 1500
Residue 50
TOTAL 1802.1 1802.1
PROCESS FLOW DIAGRAM OF 2-5 DICHLORO PERA PHENYLENE DIAMINE
Reactor 1500 lit mix solvent
300 kg 2.5 DCPNA
2.1 kg Pd/C catalyst
90 m3 H2 gas
Chilling/ Nutch Filter 10 Kg Residue
1500 Lit Mix Solvent For reuse
2.1 Kg. catalyst recycled or reuse
2.5 DCPPD
250 Kg
Filter / Centrifuge
ANNEXURE – 4
List of Raw Materials
No. Product Raw Materials Qty
Per Month
1 N-METHYL – 4- PIPERIDONE
Methyl Acryalate 17500 Kgs
Mono Methyl Amine
(30% Solution in Methanol)
4900 Kgs
Sodium Methoxide Powder 5600 Kgs
Chloroform 12000 Kgs
D. M. Water 40000 Lit
2 N-METHYL – 4- CHLORO –
PIPERIDINE
(NMCP)
N-Methyl – 4 – Piperdone 2200 Kgs
Nickle Catalyst 80 Kgs
D. M. Water 4700 Lits
Hydrogen Gas 125 m3
Thionyl Chloride 3200 Kgs
Toluene 3000 Kgs
Caustic Lye 800 Kgs
Soda Ash 600 Kgs
Chloroform 2500 Kgs
3
D-7
5-CHLORO-1-(4-PIPERIDYL)- 2 –
BENZIMIDAZOLONONE
N-Methyl – 4- Piperidone 5000 Kgs
Ethyl Chloro Formate 5760 Kgs
Toluene 7000 Kgs
D. M. Water 140000 Lits
Ammonical Methanol
(15 To 17 % Solution)
3000 Kgs
Ranny Nickle Catalyst 300 Kgs
Hydrogen Gas 3000 m3
2,5,Dichloro Nitro Benzene 6000 Kgs
Soda Ash 2000 Kg
Urea 3600 Kg
Methanol 2000 Kgs
Caustic Lye 12000 Kgs
Ammonium Chloride 5000 Kgs
HCl 2000 Kg
NH3 Liq. 25 % Soln 12000 Kg
Carbon 300 Kg
Nitrogen Gas 300 m3
4
D-2
1 – (3- CHLOROPROPYL)-1-
DIHYDRO-2-1-1-
BENZIMIDA-ZOLONE
Ortho Phenylene Diamine (OPD) 3200 Kg
O-Xylene 4500 Kg
Methyl Aceto Acetate (MAA) 3600 Kg
Caustic Lye 3500 Kg
HCl 10500 Kg
N-Hexane 1000 Kg
Caustic Flakes 1500 Kg
1-Brumo-3-Chloro Propane (BCP) 4000 Kg
Tebac (Catalyst) 350 Kg
Acetone 2500 Kg
Benzene 2500 Kg
D. M. Water 35000 Lit
5
DOMPIRIDONE
5- CHLORO -1-(1-L3-L2-OXO-1-
BENXIMIDAZOLINYL)
PROPYL) -4-PIPERIDYL)-2-
BENZIMIDAZ
D-2 4000 Kg
D-9 4500 Kg
M.I.B.K. (Methyl Iso Butyl Ketone) 5000 Kg
Soda Ash 3200 Kg
Ammonium Chloride 4500 Kg
D. M. Water 50000 Lit
Methanol 7000 Kg
6
CHLORZOXAZONE
(5-CHLORO-3-H BENZOOXA-
ZOLONONE)
OR 5-CHLORO-2-
BENZOXAZOLIONE
4-CAP 10000 Kg
HCl 15500 Kg
Urea 13500 Kg
D. M. Water 30000 Lit
Methanol 5000 Kg
Carbon 300 Kg
Acetic Acid 3500 Kg
7 4-CAP
(4-CHLORO 2 –AMINO PHENOL)
2,5 Dichloro Nitro Benzene (2,5 DCNB) 40000 Kg
Caustic Flakes 22500 Kg
D. M. Water 325000 Lit
Platinum / Carbon Catalyst 200 Kg
Hydrogen Gas 9360 m3
Nitrogen Gas 500 m3
8 PARAPHENYLENE DIAMINE
Para Nitro Aniline 65500 Kg
Ethyl Acetate 2500 Kg
Ranny Nickle Catalyst 450 Kg
Hydrogen Gas 2850 m3
9 2.5DICHLORO
PARAPHENYLENE DIAMINE
Mix Solvent 1250 Kg
2.5 Dichloroparanitroaniline 11500 Kg
Pd/Co catalyst 85 Kg
Hydrogen Gas 300 m3
1. Resource optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
Our main raw materials are easily available from developmental city like Baroda, Surat,
etc.
2. Availability of water its source, Energy/ power requirement and source should
be given.
Water source: Bore well
Energy/power requirement: 105 HP from UGVCL
3. Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/disposal.
Solid waste generation and disposal
Sr.
no.
Description Category Total Quantity
per Month
Mode of Disposal
1 Used oil/Spent
Oil
5.1 0.1 MT Collection, storage and Use
within premises as a
lubricant/ sell to registered
recycler
2 Discarded
Plastic Bags/
Drums
33.3 0.8 MT Collection, storage and reuse
within premises / sell to
approved scrap vendor.
3 Waste Residue 28.1 4.5 MT Collection, storage and
incinerated at authorized
CHWIF site.
4 Spent Carbon 28.2 0.3 MT Collection, storage and
incinerated at authorized
CHWIF site.
5 Spent Catalyst 28.2 0.3 MT Collected, Stored and sold to
registered Recycler.
6 ETP Sludge 34.3 22.5 MT Collection, storage and
disposal at authorized TSDF
site.
Waste water generation and Disposal facility
21500 liters waste water will be generated from the Industrial activity.
Effluent treatment plant:
(1) 2 KL/day : Boiler Blow down
(2) 4 KL/day : Washing
(3) 0.5 KL/day : Cooling tower blow down
(4) 15 KL/day : Process Wastewater
Description of ETP Process
The Waste water from the process will be divided into three streams:
1) High COD stream 2) Stream with high Ammonical Nitrogen 3) Other Effluents
The stream with high COD will be treated in Multi Effect Evaporator.
The Stream with high Ammonical Nitrogen will be passed through Ammonia stripper. Then it will be added with the other effluent stream.
The other effluent Stream will be given complete treatment as follows: First of all, the effluent is given Primary treatment. The effluent will be collected in a collection tank. Then it will be passed through Oil & Grease removal Tank from where Oil will
be collected in Drums. Then the effluent will be given Lime- Alum treatment in Neutralization cum
Equalization Tank which will be followed by Primary Settling Tank for chemical sludge removal.
After this, Biological treatment will be given by means of Aeration Tank where microbes will consume the COD.
This will be followed by secondary settling tank where biological sludge will be removed.
Now this treated effluent will be collected in Treated effluent sump from it will be given tertiary treatment.
The treated effluent will be passed through Pressure Sand Filter and Activated Carbon Filter and collected in Treated Water Sump.
From there, the water will be given pretreatment for Reverse Osmosis in form of Ultra filtration.
Finally this water will be treated by and reused in Gardening, Boiler and Cooling Tower.
The Reject from Ultra filtration & Reverse Osmosis will be sent to Multi Effect Evaporator.
4. Schematic representations of the feasibility drawing which give
information of EIA purpose.
The acceptability of the S.O.1533 for the expansion project was explored by
considering different possibilities & provision made in the said notification.
Considering the products & project’s location of the proposed Expansion project,
It is notified that the proposed project falls under Category 5(f)”B” of the
schedule of EIA notification and its amendments.
As per the provisions of the notification, it is necessary to get Environmental
Clearance by applying to MoEF or SPCB, along with the Environmental Impact
Assessment report for the expansion project prior to commissioning of the
expansion activities. Therefore the EIA is required to conduct.
4. Site Analysis
(i) Connectivity.
Nearest Railway
station Jagudan 0.68 Km
Nearest National
highway NH 8 43 Km
Nearest Airport Ahmedabad 53.5 Km
Nearest State highway SH 41 0.75 Km
(iv) Existing land use pattern.
Existing land use pattern shown in fig no: 1
(v) Existing Infrastructure.
(1) Nearest railway station: Jagudan Railway station is 0.68 Km in NW direction
from the project site
(2) Nearest Highway: state highway 41 is 0.75 km in W direction from the
project site.
(3) Nearest Airport: Ahmedabad is 53.5 km in SSE direction from the project site.
(4) Power: 105 HP from Uttar Gujarat Vij Company limited.
(5) Water : Source of the water is Ground water
(6) Basic amenities:
Educational facility: - Gujarat Polytechnic is 0.42 km in west direction from the project site.
Hotel: The Holiday Inn is 4.0 km away in South direction from the project site.
Post Office: - Post office, Sayla is 1.2 km away from the project site.
Hospital: - Sayla is 1.5 km away from the project site.
(vi) Soil classification of district Mahesana
Dominantly the Soils are very deep, well drained and fine and medium textured. They
are slightly alkaline, slight to strong saline. Soil depth in Uttar Gujarat is well distributed
in two parts. The Soils in western side are dominantly very deep followed by
moderately deep and in eastern part soils are dominantly shallow followed by
moderately shallow. The Soils in Mehsana District is dominantly distributed to very
deep soil depth class followed by shallow depth moderately deep soil are also observed,
Soil salinity in Uttar Gujarat varies from slight to strong salinity class. In Mehsana
District soil salinity belongs to slight to moderate.
(vii) Climatic data from secondary sources.
Month
Air Temperature, °C Humidity, % Mean Wind
Speed,
Km/hr.
Predominating
Wind
Direction Max. Min. Max. Min.
July 2013 37 22.2 98 48 7 SW
August 2013 34.2 23.5 98 56 8 SW
September 2013 38.4 23.3 100 40 7 NW
October 2013 36 17.4 98 26 4 N
November 2013 35.8 12.8 91 24 5 NE
December 2013 32 8.3 97 23 5 N
January 2014 30.7 7 96 20 7 NE
February 2014 33.6 7.8 91 17 5 NE/NW
March 2014 38.7 12.4 87 14 5 WNW
April 2014 43.2 19.4 83 16 5 WNW
May 2014 44.5 24.4 82 12 7 SW
June 2014 45 27.5 81 22 11 SW
5. Planning Brief
(i) Planning Concept (type of industries, facilities transportation etc) Town
and Country Planning/Development authority Classification.
Total available area is 6779 sq. meter out of it 2873 sq. meter area will be
provided as a greenbelt area.
(ii) Population Projection
In 2011, Mahesana had population of 2,035,064 of which male and female
were 1,056,520 and 978,544 respectively. In 2001 census, Mahesana had a
population of 1,837,892 of which males were 953,842 and remaining
884,050 were females. SThere was change of 10.73 percent in the population
compared to population as per 2001. Average literacy rate of Mahesana in
2011 were 83.61 compared to 75.22 of 2001. If things are looked out at
gender wise, male and female literacy were 91.39 and 75.32 respectively.
With regards to Sex Ratio in Mahesana, it stood at 926 per 1000 male
compared to 2001 census figure of 927.
(iii) Land use planning (breakup along with green belt etc).
1 Built Up Area 1960 Sq. mt
2 Green belt area 2873 Sq. mt
3 Open/ Road area 1946 Sq. mt
Total Area 6779 Sq. mt
(iv) Assessment of Infrastructure Demand (Physical & Social).
Super Specialty and modern health facilities and medical stores are needed
around.
(v) Amenities/Facilities.
Industry will provide 2.5 % of total profit for CSR activity.
6. Proposed Infrastructure
(i) Industrial Area
Industry will provide 1960 square meters built up area for industrial process
activity. Which provide all needed facility including proper ventilation, safe
handling system, etc.
(ii) Residential Area
Industry will not provide labor quarter for their labors but will provide all
basic facilities to them.
(iii) Green Belt.
2873 sq. meter area will be proposed for greenbelt development. Approx
1430 sq. mt area will be proposed for tree cover area (approx 216 trees).
(iv) Social Infrastructure.
The PP proposes the following social infrastructure facilities within 10.0 km periphery of the proposed project.
Education Facilities:-Many Facilities for village schools like game kits, drawing kits, table-chairs; school construction (classroom/toilet/school boundary), ceiling fans/ coolers or books for school library are proposed.
Health Facilities:-The PP proposes to provide assistance to existing
health facilities in Nearest Hospital, for improvement in health facilities or services.
(v) Connectivity
The nearest Town is Mehsana in N-direction. Approaching road state highway
no 41 is 0.75 km away from the project site.
(vi) Drinking Water Management
Out of 22 KL/day water approx 0.5 KL water will be consume for domestic
purpose; 5 KL/day (Reused: 5 KL/day) water will be consume for green belt
development and 21.5 KL/ day fresh water will be used for industrial purpose.
(vii) Sewerage System.
Domestic waste water 0.4 KL/day will be treated disposed in soak pit via septic
Tank.
(viii) Industrial Waste Management.
21.5 KL/day waste water will be generated from the process activity. It will
be treated in effluent treatment plant and evaporate after treatment.
(ix) Solid Waste Management
Used oil, ETP waste, discarded bags are the main solid hazardous waste
generated from the proposed unit. Used oil will be send to register recycler,
ETP sludge will collected from sludge drying bed, stored into solid waste
storage area and disposed to authorized TSDF site. Discarded bags will be
sold to approved vendor. Spent carbon and Waste residue will be sent to
authorized CHWIF for Incineration.
(x) Power Requirement & Supply / source
105 HP from UGVCL.
7. Project Schedule & Cost Estimates
(i) Likely date of start of construction and likely date of completion
Start construction work: 1st week of December, 2015
Completion of construction work: March, 2016
(ii) Estimated project cost along with analysis in terms of economic viability of the
project.
Total project cost of Project is around 9 crores.