1
FORM-I
For
PROPOSED PESTICIDE INTERMEDIATES, SPECIALTY
CHEMICALS, PHARMACEUTICAL INTERMEDIATES AND
PERFUMERY CHEMICAL UNIT
of
M/s. V INDIA CHEMICAL INDUSTRIES PVT. LTD.
Plot No. CH-11/A, Dahej-I, Dahej Industrial Estate,
Tal: Vagra, Dist: Bharuch, Gujarat
2
APPENDIX I
FORM 1 (I) Basic Information
Sr.
No.
Item Details
1. Name of the Project/s V India Chemical Industries Pvt. Ltd.
2. S.No. in the Schedule 5 (f)
3. Proposed capacity/area/length/tonnage
to be handled/command area/lease
area/number of wells to be drilled
Proposed Chemicals: 725 MT/Month (Please refer
annexure-2)
No bore well to be drilled within the premises.
4. New/Expansion/Modernization New
5. Existing capacity/area etc. N.A.
6. Category of project i.e. ‘A’ or ‘B’ ‘A’
7. Does it attract the general condition? If
yes, please specify.
N.A.
8. Does it attract the specific condition? If
yes, please specify.
N.A.
9. Location Dahej Industrial Area, Dahej, Tal: Vagra, Dist: Bharuch,
Gujarat
Plot/Survey/Khasra No. Plot. No. CH-11/A
Village GIDC, Dahej - I
Tehsil Vagra
District Bharuch
State Gujarat
10. Nearest railway station/airport along with
distance in kms.
Nearest Railway Station: Bharuch: 40 km
Nearest Airport: Baroda: 92 km
11. Nearest Town, city, District Headquarters
along with distance in kms.
Nearest town: Bharuch: 40 km, Nearest District Head
quarter: Bharuch: 40 km
12. Village Panchayats, zilla parishad,
Municipal corporation, Local body
(Complete postal addresses with
telephone nos. to be given)
Village: Dahej, Tal: Vagra, Dist: Bharuch, Gujarat.
13. Name of the applicant V India Chemical Industries Pvt. Ltd.
14. Registered address Plot No. CH-11/A, Dahej–I, Dahej Industrial Estate, Tal:
Vagra, Dist: Bharuch, Gujarat.
15. Address for correspondence: V India Chemical Industries Pvt. Ltd.
D/G-12, Sardar Patel Complex,
Station-GIDC Road, Nr. State Bank of India,
GIDC, Ankleshwar-393002,
Dist: Bharuch (Guj.)
Name Mr. Ankit Shah
3
Designation (Owner/Partner/CEO) Director
Address Plot No. CH-11/A, Dahej–I, Dahej Industrial Estate, Tal:
Vagra, Dist: Bharuch, Gujarat.
Pin Code 392130
E-Mail [email protected]
Telephone No. +919879104761
Fax No. --
16. Details of Alternative Sites examined, if
any location of these sites should be
shown on a topo sheet.
No
17. Interlinked Projects No
18. Whether separate application of
interlinked project has been submitted?
Not applicable
19. If Yes, date of submission Not applicable
20. If no., reason Not applicable
21. Whether the proposal involves
approval/clearance under: If yes, details
of the same and their status to be given.
(a) The Forest (Conservation) Act,
1980?
(b) The Wildlife (Protection) Act,
1972?
(c) The C.R.Z Notification, 1991?
Not applicable, as the project is located in industrial
estate.
22. Whether there is any Government
order/policy relevant/relating to the site?
No
23. Forest land involved (hectares) No
24. Whether there is any litigation pending
against the project and/or land in which
the project is propose to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if
any and its relevance with the proposed
project.
No
4
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will
cause physical changes in the locality (topography, land use, changes in water bodies,
etc.)
Sr.
No.
Information/Checklist confirmation Yes
/No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
1.1 Permanent or temporary change in land
use, land cover or topography including
increase in intensity of land use (with
respect to local land use plan)
No Proposed Project is within GIDC Estate,
Dahej
1.2 Clearance of existing land, vegetation
and buildings?
Yes Minor site clearance activities shall be
carried out to clear shrubs and weed.
1.3 Creation of new land uses? No --
1.4 Pre-construction investigations e.g. bore
houses, soil testing?
No --
1.5 Construction works? Yes Approved plan for construction is
attached as Annexure: 1.
1.6 Demolition works? No --
1.7
Temporary sites used for construction
workers or housing of construction
workers?
No --
1.8 Above ground buildings, structures or
Earthworks including linear structures,
cut and fill or excavations
Yes Approved plan for construction is
attached as Annexure: 1.
1.9
Underground works including mining or
tunneling?
No --
1.10 Reclamation works? No --
1.11 Dredging? No --
1.12 Offshore structures? No --
1.13 Production and manufacturing Yes Manufacturing process, chemical
reaction and mass balance is attached
as Annexure: 3.
1.14 Facilities for storage of goods or
materials?
Yes Dedicated storage area for storage of
Raw Materials and finished products,
solvents, etc. shall be provided.
1.15
Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes Effluent Treatment Plant, MEE and SBT
will be installed to treat effluent so as to
achieve the GPCB norms.
5
Option-1: Treated effluent will be
disposed into CETP as soon as soon as
CETP starts working.
Option-2: Treated effluent after will be
recycled back in plant premises for
various purpose.
Details of water consumption & effluent
generation with segregation of effluent
streams are attached as Annexure: 4.
Details of proposed Effluent Treatment
scheme are attached as Annexure: 5.
Details of Solid Hazardous waste
generation and disposal is attached as
Annexure: 6.
1.16
Facilities for long term housing of
operational workers?
Yes Local operational staff of about 40
people shall be employed.
1.17 New road, rail or sea traffic during
construction or operation?
No --
1.18 New road, rail, air waterborne or other
airports etc?
No --
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No --
1.20 New or diverted transmission lines or
pipelines?
No --
1.21
Impoundment, damming, converting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No --
1.22 Stream crossings? No --
1.23
Abstraction or transfers or the water
form ground or surface waters?
Yes No ground water shall be used. The
requirement of raw water shall be met
through GIDC Water Supply.
1.24
Changes in water bodies or the land
surface affecting drainage or run-off?
No --
1.25
Transport of personnel or materials for
construction, operation or
decommissioning?
No --
1.26 Long-term dismantling or
decommissioning or restoration works?
No There is no dismantling of any sort. Not
applicable.
1.27 Ongoing activity during No No Impact on the Environment
6
decommissioning which could have an
impact on the environment?
1.28
Influx of people to an area in either
temporarily or permanently?
No This is a well developed Industrial Area
and due to project, @ 40 people shall be
employed for operation.
1.29 Introduction of alien species? No
1.30 Loss of native species of genetic
diversity?
No
1.31 Any other actions? No
2. Use of Natural resources for construction or operation of the Project (such as land, water,
materials or energy, especially any resources which are non-renewable or in short supply):
Sr.
No
Information/checklist confirmation Yes/
No?
Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
2.1 Land especially undeveloped or
agriculture land (ha)
No
2.2 Water (expected source & competing
users) unit: KLD
Yes Water requirement will meet through the
GIDC Water Supply. For detailed water
balance refer Annexure – 4.
2.3 Minerals (MT) No Not applicable
2.4
Construction material -stone,
aggregates, sand / soil (expected
source MT)
Yes Company shall use Sand, stone, Cement
and Structural Steel for Construction as
required.
2.5 Forests and timber (source - MT) No No wood shall be used as construction
material or as a fuel.
2.6
Energy including electricity and fuels
source, competing users Unit: fuel
(MT), energy (MW)
Yes Power required from GEB is 250 KVA .
D.G. Set = 100 KVA x 2 (For Emergency
only)
Fuel
Fuel for proposed boilers:
Natural Gas = 1,40,000 SCM/Month or
Agro Waste = 10 MT/Day
HSD = 50 Liter/Hr.
2.7 Any other natural resources (use
appropriates standard units)
No --
7
3. Use, storage, transport, handling or production of substances or materials, which could be
harmful to human health or the environment or raise concerns about actual or perceived risks
to human health.
Sr.
No.
Information / Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates wherever possible)
with source of information data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
Yes
Please refer Annexure : 8.
3.2 Changes in occurrence of disease or
affect disease vectors (e.g. insect or
water borne diseases)
No Not applicable as site is located in Dahej
Industrial Area, Dahej.
3.3 Affect the welfare of people e.g. by
changing living conditions?
No Not applicable as site is located in Dahej
Industrial Area, Dahej.
3.4
Vulnerable groups of people who could
be affected by the project e.g. hospital
patients, children, the elderly etc.,
No Not applicable as site is located in Dahej
Industrial Area, Dahej.
3.5 Any other causes No
4. Production of solid wastes during construction or operation or decommissioning MT/month)
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
4.1 Spoil, overburden or mine wastes No --
4.2
Municipal waste (domestic and or
commercial wastes) No --
4.3
Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Please refer Annexure: 6
4.4 Other industrial process wastes Yes Please refer Annexure: 6
4.5 Surplus product Yes Please refer Annexure: 3
4.6
Sewage sludge or other sludge from
effluent treatment
Yes Please refer Annexure: 6
4.7 Construction or demolition wastes No Construction waste shall be utilized for
leveling, land filling in the premises.
4.8 Redundant machinery or equipment No --
4.9 Contaminated soils or other materials No --
4.10 Agricultural wastes No --
4.11 Other solid wastes No Please refer Annexure: 6
8
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities/rates, wherever possible)
with source of information data
5.1 Emissions from combustion of fossil
fuels From stationary or mobile sources
Yes Details of flue & process gas emission
are attached as Annexure: 7
5.2 Emissions from production processes No Reactors shall be connected to
common scrubber system.
Details of emission levels from process
are attached as Annexure: 7.
Details of Air Pollution Control
measures are attached as Annexure:
7.
5.3 Emissions from materials handling
including storage or transport
Yes All liquid raw materials shall be
procured in bulk tankers and shall be
transferred through a closed circuit
pipe lines by pumps.
Solid raw material shall be handled in
closed charging rooms with proper
ventilation and charged through close
pipeline into reactors.
5.4 Emissions from construction activities
including plant and equipment
No Utmost care will be taken during
construction activity and water
sprinklers shall be utilized whenever
necessary.
5.5
Dust or odours from handling of
materials including construction
materials, sewage and waste
No All the waste shall be stored in
designated places and shall be
transported to TSDF or Cement
Industries/Incineration Site in their
own approved closed vehicles.
5.6 Emissions from incineration of waste No Not applicable as the Incinerable waste
shall be sent to Cement
Industries/common incineration
system.
5.7 Emissions from burning of waste in
open air (e.g. slash materials,
construction debris)
No No open burning of waste will be
carried out.
5.8 Emissions from any other sources No
9
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details there of (with approximate
Quantities /rates, wherever possible)
With source of source of information data
6.1
From operation of equipment e.g.
engines, ventilation plant, crushers
Yes There are few activities due to which noise
would be generated. The equipments
resulting in noise generation are machinery
of plant and Diesel generator. Adequate
noise control measures will be provided
whenever required.
Proper and timely oiling, lubrication and
preventive maintenance will be carried out
for the machineries & equipments to
reduce noise generation.
Use of PPE like ear plugs and ear muffs will
be made compulsory near the high noise
generating machines.
Noise monitoring shall be done regularly in
plant area.
The D.G. Set will be installed in a closed
room and provided with acoustic
enclosure.
The unit will increase the plantation
species in the proposed greenbelt within
the premises which will prevent the noise
pollution in surrounding area.
6.2 From industrial or similar processes Yes All machinery / equipment shall be well
maintained, shall have proper foundation
with anti vibrating pads wherever
applicable and noise levels within
permissible limits.
Acoustic enclosures shall be provided for
DG set.
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational
traffic No
6.6 From lighting or cooling systems No
6.7 From any other sources No Acoustic enclosures shall be provided for
DG set.
10
7. Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
7.1
From handling, storage, use or spillage
of hazardous materials
Yes All the raw material shall be stored
separately in designated storage area
and safely. Bund walls shall be provided
around raw materials storage tanks for
containing any liquid spillage.
Other materials shall be stored in bags /
drums on pallets with concrete flooring
and no spillage is likely to occur. Please
refer Annexure : 8.
7.2
From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
No Sewage effluent shall be treated in
Septic Tank/Soak Pit.
The treated effluent shall be sent to
CETP for further treatment or reused in
plant premises.
7.3
By deposition of pollutants emitted to
air into the land or into water
No The factory is located in Dahej
Industrial Area, Dahej. The treated
effluent shall be sent to CETP or reused
in plant premises.
7.4 From any other sources No Not applicable
7.5 Is there a risk of long term build up of
pollution in the environment from
these sources?
No
Full- fledged Environmental
Management System (EMS) will be
installed. i.e. ETP, Air Pollution Control
systems, Solid Hazardous Waste
Handling and Management as per
norms, etc. which will eliminate the
possibility of building up of pollution.
11
8. Risks of accident during construction or operation of the Project, which could affect
human health or the environment:
Sr.
No
Information/Checklist confirmation
Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
8.1 From explosions, spillages, fires etc
from storage, handling, use or
production of hazardous substances
Yes The risk assessment will be carried out
and all mitigative measures shall be
taken to avoid accidents.
8.2 From any other causes No Not applicable
8.3 Could the project be affected by natural
disasters causing environmental
damage (e.g. floods, earthquakes,
landslides, cloudburst etc)?
No --
9. Factors which should be considered (such as consequential development) which could lead
to environmental effects or the potential for cumulative impacts with other existing or
planned activities in the locality
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible)
with source of information data
9.1 Lead to development of supporting.
laities, ancillary development or
development stimulated by the project
which could have impact on the
environment e.g.:
* Supporting infrastructure (roads,
power supply, waste or waste water
treatment, etc.)
• housing development
• extractive industries
• supply industries
• other
Yes Site is located in Dahej Industrial Area,
Dahej, having all required infrastructure.
This industrial zone is having existing road
infrastructure, power supply are to be
utilized.
Local people will be employed and no
housing is required.
Please refer Annexure – 9.
9.2
Lead to after-use of the site, which
could have an impact on the
environment
No
--
9.3 Set a precedent for later developments No Not applicable
9.4 Have cumulative effects due to
proximity to Other existing or planned
projects with similar effects
No
12
(III) Environmental Sensitivity
Sr.
No
Information/Checklist confirmation Name /
Identity
Aerial distance (within 25 km).
Proposed Project Location Boundary.
1 Areas protected under international
conventions national or local legislation for
their ecological, landscape, cultural or other
related value
Yes Site is located in Dahej Industrial Area,
Dahej, Tal. Vagra, Dist. Bharuch, Gujarat.
2 Areas which are important or sensitive for
Ecological reasons - Wetlands, watercourses or
other water bodies, coastal zone, biospheres,
mountains, forests
Yes Site is located in Dahej Industrial Area,
Dahej, Dist. Bharuch, Gujarat.
.
3 Areas used by protected, important or
sensitive species of flora or fauna for breeding,
nesting, foraging, resting, over wintering,
migration
Yes Site is located in Dahej Industrial Area,
Dahej, Tal: Vagra, Dist. Bharuch, Gujarat.
4 Inland, coastal, marine or underground waters Yes Arabian Sea- 27 Km
River Narmada- 6 Km
5 State, National boundaries Yes --
6 Routes or facilities used by the public for to
recreation or other tourist, pilgrim areas.
No Not applicable
7 Defense installations No NIL
8 Densely populated or built-up area Yes Bharuch city: 5 lakh population
9 Areas occupied by sensitive man-made land
community facilities)
No
10 Areas containing important, high quality or
scarce resources (ground water resources,
surface resources, forestry, agriculture,
fisheries, tourism, tourism, minerals)
Yes
The project being in notified industrial
area does not affect agricultural land.
11 Areas already subjected to pollution or
environmental damage. (those where existing
legal environmental standards are exceeded)
Yes Site is located in Dahej Industrial Area,
Dahej, Tal: Vagra, Dist. Bharuch, Gujarat.
12 Are as susceptible to natural hazard which
could cause the project to present
environmental problems (earthquake s,
subsidence ,landslides, flooding erosion, or
extreme or adverse climatic conditions)
- N.A.
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – 10.
14
ANNEXURES
1 PLANT LAYOUT
2 LIST OF PRODUCTS WITH PRODUCTION CAPACITY AND RAW MATERIALS
3 BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE
WITH FLOW DIAGRAM
4 WATER CONSUMPTION AND EFFLUENT GENERATION WITH SEGREGATION OF
EFFLUENT STREAMS
5 DETAILS OF PROPOSED EFFLUENT TREATMENT PLANT
6 DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL
7 DETAILS OF AIR POLLUTION CONTROL MEASURES
8 DETAILS HAZARDOUS CHEMICAL STORAGE FACILITY
9 SOCIO - ECONOMIC IMPACTS
10 PROPOSED TERMS OF REFERENCES
15
ANNEXURE: 1
PLANT LAYOUT
134 m
94.85 m
N
Plant –III (Specialty
Chemical) – 25 m x
30 m
Plant –I (Pharma
Intermediates) – 25 m
x 30 m
Plant –II
(Pesticide
Intermediates) –
25 m x 20 m
RM &
Product
Godown -
10 m x 20
m
Plant –IV
(Perfumery
Chemical) – 25
m x 20 m
Utility Area –
20 m x 15 m
Storage
Tank Farm
Area
10 m x 25
m
ETP + RO + MEE + SBT
59.52 m
Assembly Point
Assembly
Point
Total Area: 5101.23 m2
Green belt Area: 1340m2
1. 5 m x 60 m = 300 m2
2. 8 m x 70 m = 560 m2
3. 10m x 22m = 220 m2
4. 5m x22 m = 110 m2
5. Other = 150 m2
Admn.
Buildin
g
15m x
20 m
RM &
Product
Godown -
10 m x 25
m
S.C
.
Parking
16
ANNEXURE: 2
LIST OF PRODUCTS WITH PRODUCTION CAPACITY
Sr.
No. NAME OF PRODCUTS
Proposed
Quantity
(MT/M)
1.0 PHARMACEUTICAL INTERMEDIATES
1.1 2, Diazo 1- Napthol, 5- Sulphonic Acid Sodium Salt ( NAS)
150
1.2 2,7 Di Chloro 4- ( 2- Dibutyl Amine) Ethane Fluorine
1.3 1,2 Di Methoxy Benzene
1.4 Ortho Phenoxy Aniline
1.5 3- Quinoline Carboxyllic Acid 7- Chloro -1- Cyclopropyl -1,4 – dihydro 8-
Methyl 4-Oxo – Ethyl Ester
1.6 L-2- Chloropropionic Acid Isobutyl ester
1.7 2- Phenyl Benzimidazol -5- Sulphonic Acid
1.8 Neodecanoyl Chloride
1.9 2- Ethyl Hexanoyl Chloride
1.10 2,3 Dichloro Benzoyl Chloride
1.11 3-(4-Amino-3, 5-Di Methyl Phenyl) Prop-2-ene Nitrile
1.12 4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-
yl)Amino]Benzonitrile
1.13 1-(6-Amino-9H-Purin-9-Yl)Propan-2-Ol
1.14 4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile
1.15 4-[(5- Hydroxy Pyrimidin-2-yl )Amino] Benzonitrile
1.16 4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile
1.17 4-({6-Amino-5-Bromo-2-[(4-Cyanophenyl) Amino ]Pyrimidin-4-
yl}Oxy)-3,5-Dimethyl Benzonitrile
2.0 AGROCHEMICAL INTERMEDIATES
2.1 CCMP / 2- Chloro 5- Chloromethyl Pyridine
150
2.2 CCMT / 2- Chloro 5- Chloromethyl Thiazole
2.3 Na- TCP / 3,5,6 Tri Chloro Pyridinol Sodium Salt
2.4 TCAC / Tri Chloro Acetyl Chloride
2.5 3-Methyl 4- Nitro Imino Per hydro1,3,5 Oxidiazine
2.6 1,2,4 Triazole
2.7 TFP Acid Chloride / Lambda Acid Chloride
17
2.8 Meta Phenoxy Benzyl Alcohol
2.9 4,4’ Thio Diphenol
2.10 Transfluthrin Acid Chloride
2.11 D- Allethrollone
2.12 4- HPA / ( R HPPA - ( R (+) -2- [ 4- (5- Chloro -3- Fluoro pyridine -2- yloxy
Phenoxy ) ] Propionic Acid
2.13 N- NII – N- Nitro Imino Imidazolidine
3.0 SPECIALTY CHEMICALS
3.1 EBASA – Ethyl Benzyl Aniline Sulphonic Acid
125
3.2 5- Cyano Phthalide
3.3 5- Bromo Phthalide
3.4 2- Chloro 6- Nitro Benzotrifluoride
3.5 2,4 Di Chloro 3,5 Dinitro Benzotrifluoride
3.6 Diphenyl Sulfide
4.0 PERFUMARY CHEMICALS
Group -1
4.1 Allyl Caproate
50
4.2 Allyl Haptanoate
4.3 Isobutyl Caproate
4.4 Amyl Caproate / Iso Amyl Caproate
4.5 Hexyl Caproate
4.6 Allyl Phenoxy Acetate
4.7 Octyl Acetate
4.8 Decycle Acetate
4.9 Hexyl Iso Butyrate
4.10 Phenoxy Ethyl Iso butyrate
4.11 Citronellyl Acetate
4.12 Geranyl Tiglate
4.13 Phenyl Ethyl Tiglate
4.14 Cinnamyl Cinnamate
4.15 Ethyl Butyrate
Group -2
4.16 Sandalite
4.17 Purasandal
4.18 Megasandal
18
4.19 DIPAL 50
4.20 PRINILE
4.21 Isogasmine P
Group -3
4.22 Citralite
4.23 Praistone
4.24 Applitone
4.25 Herboxane
Group -4
4.26 SAFRANAL
50 4.27 CDEA
Grand Total MT / Month 725 MT/
Month
By-Products:
S. No. Name of By-Products Proposed Quantity
MT/Month
1. Sodium Sulphate Salt 95
2. HCl (32%) (Recycle in plant Premises) 810
3. Sodium Sulphite (20%) 1237
4. AlCl2 (25%) 776
5. Potassium Chloride 620
6. Caustic Lye 40% (Recycle in plant Premises) 74
7. Formic Acid(Recycle in plant Premises) 150
8. Phosphoric Acid 278
19
LIST OF RAW MATERIALS
Product Raw-material Quantity (MT/MT)
1) Pharmaceutical Intermediates
2- Diazo 1- Napthol, 5-
Sulphonic Acid
Sodium Salt
Sulfo Tobias Acid 1.089
Sodium Nitrate 0.190
30 % HCl Solution 0.600
Sodium Carbonate Solution 1.415
10 % Sodium Hypo Chlorite Solution 1.879
Caustic Soda Lye 0.137
Sodium Chloride Salt 0.287
2,7 Di Chloro 4- ( 2-
Dibutyl Amino) Ethane
Fluorene
DMF 0.200
Chlorine Gas 1.393
Methanol 0.090
EDC 0.250
Aluminum Chloride 1.293
Chloro Acetyl Chloride 0.945
Sodium Borohydrate 0.100
Di Butyl Amine 0.500
1,2 Dimethoxy
Benzene
1,2 Di Hydroxy Benzene 0.810
Caustic Lye 48 % 0.650
Di Methyl Sulphate 2.050
Ortho Phenoxy Aniline Phenol 0.592
2-Nitro Chlorobenzene 0.992
Sodium Hydroxide 0.257
Solvent : 1,2-Dichlorobenzene/DCT 0.030
Iron (Fe) Powder 0.962
Acetic Acid 0.020
Soda Ash 0.015
3- Quinoline
Carboxyllic Acid 7-
Chloro 1-
Cyaclopropyl-1.4
Dihydro 8- Methyl 4-
Oxo Ethyl Ester
3- Quinoline Carboxyllic Acid 7- Chloro
1- Cyaclopropyl-1.4 Dihydro 8- Methyl
4- Oxo 0.752
Cyclopropyl Chloride 0.252
Catalyst – PTSA 0.012
Ethyl Chloride 0.213
20
Solvent – Toluene 0.050
2 % Soda Ash Soln 0.198
L -2- Chloro Propionic
Acid Isobutyl Ester
DL - Propionic Acid 0.451
Chlorine Gas 0.431
Solvent – EDC 0.050
Iso Butyl Acid 0.441
2 % Soda Ash Solution 0.196
2- Phenyl
Benzimidazol -5-
Sulphonic Acid
2- Phenyl Benzimidazol 0.712
Solvent – Xylene 0.049
Chloro Sulphonic Acid 0.428
2 % Soda Ash Solution 0.198
Neodecanoyl Chloride Neodecanoyl Acid 0.921
Solvent – n- Hexane 0.040
DMF – Catalyst 0.010
Thionyl Chloride 0.728
Dilute Caustic Solution 1.568
2 % Soda Ash Solution 0.500
2- Ethyl Hexanoyl
Chloride
2- Ethyl Hexanoyl Acid 0.895
Solvent – n- Hexane 0.040
Thionyl Chloride 0.812
Dilute Caustic Solution 4.000
2 % Soda Ash Soln 0.198
2,3 Dichloro Benzoyl
Chloride
2,3 Dichoro Benzoic Acid 0.920
Solvent – n- Hexane 0.040
Thionyl Chloride 0.578
Dilute Caustic Solution 2.850
2 % Soda Ash Soln 0.198
3-(4-Amino-3, 5-Di
Methyl Phenyl) Prop-
2-Ene Nitrile
4- Chloro 2,6 Dimethyl Aniline 0.911
2- Propene nitrile 0.304
Solvent – DMF 0.040
Potassium Carbonate 0.872
5 %Soda Ash Solution 0.490
21
4-[(4-{[4-(2-Cyano
Ethenyl)-2,6-1) Di
Methyl Phenyl ]
Amino} Pyrimidin-2-
yl)Amino]Benzonitrile
3-(4- Chloro - 3,5 - Dimethylphenyl)
Prop - 2- enenitrile
0.475
4- [ (4- Chloro Pyrimidine yl) amino ]
Benzonitrile 0.627
Solvent – DMF 0.040
Potassium Carbonate 0.420
5 %Soda Ash Solution 0.490
1-(6-AMINO-9H-
PURIN-9-YL)PROPAN-
2-OL
6- Amino 9-H Purin 0.712
4- Methyl 1,3 Dioxolan 2- one 0.524
Solvent – Toluene 0.040
Catalyst 0.015
5 %Soda Ash Solution 0.247
4-[(4-Hydroxy
Pyrimidin-2-yl) Amino]
Benzonitrile
2- Chloro Pyrimidine 4- ol 0.630
4- Amino Benzonitrile 0.552
Solvent – DMF 0.040
Catalyst 0.012
Potassium Carbonate 0.640
5 %Soda Ash Solution 0.492
4-[(5- Hydroxy
Pyrimidin-2-yl )Amino]
Benzonitrile
4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-
yl)amino] Benzonitrile 1.020
Phosphorus Oxychloride 0.514
Solvent – Xylene 0.060
Catalyst 0.010
Caustic Lye 48 % 0.392
5 %Soda Ash Solution 0.245
4-[(5-Oxo-4,5-Dihydro
Pyrimidin-2-yl) Amino]
Benzonitrile
1-(4-Cyano phenyl) Guanidine 0.764
Methyl (2Z) -3- Methoxy 2- Propionate 0.544
Solvent – Methanol 0.050
Catalyst 0.010
Caustic flakes 0.220
5 %Soda Ash Solution 0.245
4-({6-Amino-5-Bromo-
2-[(4-Cyanophenyl)
6- Amino 2- Chloro Pyrimidine 4- ol 0.362
4- Amino Benzonitrile 0.279
22
Amino ]Pyrimidin-4-
yl}Oxy)-3,5-Dimethyl
Benzonitrile
Solvent – DMF 0.070
Catalyst -1 0.012
Potassium Carbonate 0.333
4- Chloro 3,5 - Dimethyl Benzonitrile 0.495
Bromine Liquid 0.183
Catalyst -2 0.014
50 % Hydrogen Peroxide Solution 0.080
5 %Soda Ash Solution 0.245
Pesticide Intermediates
1,2,4 –Triazole Formic Acid 1.937
Ammonia 0.872
Hydrazine Hydrate 0.968
3- Methyl 1,2,4 –
Triazole
Hydrazine Carboxaldehyde 0.733
1-Imino Ethanamine HCl 1.150
Sodium Methoxide 0.660
Ethanol 0.040
3- Methyl 4- Nitro
Imino Per hydro1,3,5
Oxidiazine
Formic Acid 2.880
N- Methyl Nitro Guanidine 0.778
Metane Sulphonic Acid 0.044
Caustic Lye 48 % 0.390
Catalyst 0.012
Solvent -DMF 0.090
( R (+) -2 – [ 4 ( 4- ( 5-
Chloro -3- Fluoro
Pyridine -2- Yloxy
Phenoxy ) ] Propionic
Acid / 4- HPPA / R –
HPPA
Hydro Quinone 0.930
2-Chloro Propionic Acid 0.864
Caustic Lye 48% 0.243
30% HCl 0.374
MIBK 0.060
4 – 4’ Thio Diphenol Phenol 1.900
Sulphur Dichloride 0.945
Toluene 0.030
Soda Ash 0.320
D+ dl Allethrollone &
DL – Isomeres
2- Methyl Furan 1.109
EDC 0.080
DMF 0.060
23
POCl3 1.524
Allyl Chloride 0.661
Toluene 0.050
THF 0.060
Mg Metal 0.205
Sodium Acetate 0.170
Acetic Acid 0.534
2-Chloro 5-
Chloromethyl Pyridine
(CCMP)
Benzyl Amine 0.912
Propanaldehyde 0.494
Toluene 0.075
Acetic Anhydride 0.802
DMF 0.050
Tri ethyl amine 0.048
EDC 0.130
Acetonitrile 0.100
Phosphorus Oxy Chloride 2.125
Chlorine 0.330
Caustic Lye 47% 1.000
2 – Chloro 5-
Chloromethyl Thiazol
Allyl Chloride 1.123
30 % HCl Solution 1.440
Chlorine 0.875
Caustic Lye 0.569
Potassium Thio Cyanate 1.190
Sulfuryl Chloride 1.028
Solvent MDC 0.080
Chloro Butoxy Ethyl
Acetate
Butyl Cellosole 0.015
Mono Chloro Acetic Acid 0.630
Soda Ash 0.020
Lambda Acid Chloride Tri Chloro Tri Fluoro Ethane 1.350
Methyl Pentanoate 1.110
Catalyst -1 0.011
Catalyst -2 0.015
30 % HCl Solution 1.500
Tertiary Butyl Alcohol - TBA 1.248
Na- Metal 0.210
24
Solvent n- Hexane 0.100
Di Methyl Formamide 0.221
Sulfuric Acid 98 % 0.044
Caustic Lye 46 – 48 % 3.233
Solvent Methanol 0.100
Thionyl Chloride 0.570
Meta Phenoxy Benzyl
Alcohol
MPBAD 1.100
Hydrogen 0.300
Catalyst 0.015
Iso Propyl Alcohol 0.060
5 % Soda Ash Solution 0.250
N-Nitro Imino
Iminozoladine
Sulfuric Acid 1.930
Guanidine Nitrate 1.175
EDA 0.710
Caustic Lye 3.090
Sodium Tri Chloro
pyridinol [Na TCP]
TCAC 0.850
Acrylonitrile 0.350
EDC 0.040
Caustic Lye 48% 1.100
Tri Chloro Acetyl
Chloride
Acetic Acid 0.345
Chlorine 1.840
Sulfur Mono Chloride 0.200
Caustic Soda Lye 48% 0.492
Transfluthrin Acid
Chloride
Trans Cypermethrin Acid 3.000
EDC 0.050
Caustic Lye 48% 3.742
HCl 30% 3.663
n-Hexane 0.040
DMF 0.006
Thionyl Chloride 0.610
Specialty Chemical
Ethyl Benzyl Aniline
Sulphonic Acid
Ethyl Benzyl Aniline 0.686
Sulphuric Acid 0.678
Oleum 65 % 0.669
5- Cyano Phthalide Terephthallic Acid 1.138
25
23 % Oleum 0.371
DMF 0.009
Thionyl Chloride 1.750
Solvent - Toluene 0.050
Ammonia Gas 0.122
2-Chloro 6- Nitro
Benzonitrile
2:3 DCNB 1.099
DMF 0.222
NaCN 0.222
CuCN 0.148
5 % Ammonia 1.000
Sodium Hypochlorite soln 1.100
MCB 0.050
2,4 Di Chloro 3,5 Di
Nitro Benzotrifluoride 2,4 Di Chloro Benzotrifluoride 1.000
Nitric Acid 0.780
Sulphuric Acid / Spent Sulphuric Acid 3.400
Oleum 28 % 3.000
10 % Soda Ash Solution 0.200
33% Hydrochloric Acid 0.110
Caustic Lye 48 % 0.105
Di Methyl Formamide 1.500
Di Phenyl Sulphide Benzene 2.941
Ferric Chloride 0.015
Catalyst -1 0.010
Sulfuryl Chloride 0.750
2 % Soda Ash Solution 0.490
Perfumery Chemical
Group A
Allyl Caproate Allyl Alcohol 0.375
Caproic Acid 0.752
P-toluene sulphonic acid 0.015
Soda Ash 0.005
AllYL HEPTANOATE Allyl Alcohol 0.346
Heptanoic acid 0.769
P-toluene sulphonic acid 0.015
Soda Ash 0.005
26
Isobutyl caproate Isobutyl alcohol 0.430
Caproic acid 0.682
P-toluene sulphonic acid 0.014
Soda Ash 0.004
Amyl caproate or
Isoamyl caproate
Amyl alcohol 0.470
Caproic acid 0.632
P-toluene sulphonic acid 0.012
Soda Ash 0.004
Hexyl caproate Hexyl alcohol 0.505
Caproic acid 0.588
P-toluene sulphonic acid 0.011
Soda Ash 0.004
AllYL Phenoxyacetate Allyl Alcohol 0.306
Phenoxy acetic acid 0.796
P-toluene sulphonic acid 0.016
Soda Ash 0.005
Octyl Acetate Octanol 0.760
Acetic Acid 0.570
P-toluene sulphonic acid 0.015
Soda Ash 0.005
Decyl Acetate Decyl alcohol 0.800
Acetic Acid 0.360
P-toluene sulphonic acid 0.016
Soda Ash 0.005
Hexyl isobutyrate Hexyl alcohol 0.598
Isobutyric acid 0.517
P-toluene sulphonic acid 0.020
Soda Ash 0.004
Phenoxyethylisobutyr
ate
Phenoxyethanol 0.667
Isobutyric acid 0.425
P-toluene sulphonic acid 0.013
Soda Ash 0.004
Citronellyl Acetate Citronellol 0.800
Acetic Anhydride 0.528
Geranyl tiglate Geranyl alcohol 0.655
27
Tiglic acid 0.430
P-toluene sulphonic acid 0.013
Soda ash 0.005
Phenyl ethyl tiglate Phenylethyl alcohol 0.602
Tiglic acid 0.496
P-toluene sulphonic acid 0.012
Soda ash 0.004
Cinnamyl cinnamate Cinnamyl chloride 0.578
Sodium cinnamate 0.646
Triethylamine 0.144
Ethyl butyrate Ethyl alcohol 0.400
butyric acid 0.765
P-toluene sulphonic acid 0.008
Soda Ash 0.003
Group -B
SANDALITE Campholenic Aldehyde 0.740
Butyraldehyde 0.355
Methanol 0.030
Sulphuric Acid (30%) 0.103
Sodium Methoxide 0.015
Caustic Lye (50%) 0.015
Methanol 0.103
Sodium Borohydride 0.066
Acetic Acid 0.100
PURASANDAL Campholenic Aldehyde 0.793
Propionaldehyde 0.309
Methanol 0.032
Sulphuric Acid (30%) 0.064
Sodium Methoxide 0.016
Caustic Lye (50%) 0.016
Sodium Borohydride 0.063
Acetic Acid 0.099
Megasandol Campholenic Aldehyde 0.750
MEK 0.022
Methanol 0.022
28
Caustic Potash 0.044
Acetic acid 0.187
Sodium Hydroxide 0.100
DIPAL Propionaldehyde 1.250
Sodium Hydroxide 0.031
Acetic acid 0.043
PRINILE
ISOJASMONE P
Benzyl Cyanide 0.608
Cyclohexanone 0.507
Cyclohexane 0.260
Methanol 0.015
Sodium Methoxide 0.061
Acetic Acid 0.070
Cyclopentanone 0.581
Valeraldehyde 0.598
Methanol 0.023
Sulphuric Acid (30%) 0.045
Sodium Methoxide 0.011
HCl 0.290
Sodium Hydroxide 0.232
Group - C
Citralite D,Limonene / orange terpenes 1.333
Methanol 0.020
P-toluene sulphonic acid 0.04
Diethanolamine 0.033
PRAISTONE Ethyl acetoacetate 0.700
Propylene glycol 0.410
Toluene 0.028
APPLITONE Ethyl acetoacetate 0.752
Ethylene glycol 0.358
Toluene 0.030
HERBOXANE Valeraldehyde 0.465
Hexylene glycol 0.639
P-toluene sulphonic acid 0.023
Toluene 0.037
Soda ash 0.011
29
Group-D
SAFRANAL Citral 1.052
Aniline 0.684
Cyclohexane 0.105
Sulphuric Acid (92%) 4.000
Sodium bicarbonate 0.021
Dimethyl formamide 0.063
Cyclohexane 0.063
Bromine 1.105
Lithium Carbonate 0.610
CDEA Citral 0.680
Ethyl alcohol 0.411
PTSA 0.006
Triethylorthoformate 0.003
Soda ash 0.006
30
SO3H
SO3H
NH2
+
Sulfo Tobias Acid
NaNO2
Sodium Nitrate
+ HCl
Hydrochloric Acid
N=N.Cl
SO3H
SO3H
Diazonium Salt of Sulfo Tobias Acid
+ NaOCl
Sodium Hypochlorite
NaOH
SO3Na
ONa
N2
2- Diazo 1- Napthol, 5- Sulphonic Acid Sodium Salt
ANNEXURE: 3
BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH FLOW
DIAGRAM
Brief Manufacturing Process :
1) 2- Diazo 1- Napthol, 5- Sulphonic Acid Sodium Salt
Stage – 1
Sulfo Tobias Acid undergoes diazotization reaction by Sodium Nitrate in presence of strong Acid
gives Diazonium Salt of Sulfo Tobias Acid.
Stage -2
Diazonium Salt of Sulfo Tobias Acid undergoes oxidation reaction by means of Sodium
Hypochlorite in presence of Caustic Solution to give the final product as 2- Diazo 1- Napthol, 5-
Sulphonic Acid Sodium Salt.
Chemical Reactions:
31
Mass Balance for 1.0 MT
Sr.
No. In Put Quantities Out Put Quantities
Items/ Raw Materials Quantity in Kgs Products / Bi Products Quantity
in Kgs
1 Sulfo Tobias Acid 1100 2- Diazo 1- Napthol, 5-
Sulphonic Acid Sodium Salt 1010
2 Sodium Nitrate 192 Sodium Chloride Solution 3540
3 30 % HCl Solution 605 Aqueous Layer to ETP 1830
4 Water for reaction &
washings 5622 Sodium Chloride Solution 4895
5 Sodium Carbonate
Solution 1430
6 10 % Sodium Hypo
Chlorite Solution 1898
7 Caustic Soda Lye 138
8 Sodium Chloride Salt 290
Total 11275.0 11275.0
32
2. 2,7 Di Chloro 4- ( 2-Dibutyl Amino) Ethane Fluorene
Stage -1 :
Fluorene is reacted with chlorine in presence of Catalyst & Solvent DMF to give Dichloro
Fluorene.
Stage -2 :
2,7 Di Chloro Fluorene undergoes Friedel Craft reaction with Chloro Acetyl Chloride in presence
of anhydrous Aluminum Chloride to give the Acetyl derivative of Dichloro Fluorence.
Stage – 3 :
The above product is further reacted with Sodium Borohydrate to give the intermediate product
as 2,7 Di Chloro 4- Oxy Carbonyl Fluorene
Stage-4 :
2,7 Di Chloro 4- Oxy Carbonyl Fluorene finally reacted with N- Di Butyl Amine to give the final
Product as 2,7 Di Chloro 4- ( 2-Dibutyl Amino) Ethane Fluorene
Chemical Reactions:
Stage-1
Stage-2
2,7 Di Chloro Fluorene M.W. 235.0
Cl
Cl
2HCl
+ DMF
Cl2
+
Fluorene M.W. 166.0
COCH2Cl
Cl
Cl
2,7 Di Chloro Fluorene M.W. 235.0
Cl
Cl
2,7 Di Chloro 4- Chloro Methyl Carbonyl Fluorene
M.W. 235.0
+ ClCH2COCl
EDC
Chloro Acetyl Chloride M.W. 113.0.0
+
HCl
33
Stage-3 O
Stage- 4
CH
CH 2
Cl
Cl
2,7 Di Chloro Fluorene M.W. 311.5
Cl
Cl
2,7 Di Chloro 4- Oxy Carbonyl Fluorene M.W.
277.0
+ NaBH4
Methanol
Sod. Boro Hydride M.W. 37.80
+
COCH2Cl
Cl
Cl
+
CH CH2
CH2CH2CH2CH3 HN CH2CH2CH2CH3
CH2CH2CH2CH3 N CH2CH2CH2CH3
Cl
CH
OH
Cl
2,7 Di Chloro Fluorene M.W. 311.5
2,7 Di Chloro 4- ( 2-Dibutyl
Amino) Ethane Fluorene
O
34
Material Balance / Mass Balance
Sr.
No. In Put Quantities Out Put Quantities
Items/ Raw Materials Quantity in Kgs Products / Bi
Products
Quantity in
Kgs
1 SR-1 1400 Product 1005
2 DMF 7000 Recovered DMF 6800
3 Catalyst -1 140 DMF Loss 200
4 Chlorine Gas 1400 30 % Hydrochloride
Acid 2050
5 Methanol 4000 Recovered Methanol 3910
6 EDC 11350 Methanol Loss 90
7 Aluminum Chloride 1300 Recovered EDC 11100
8 Chloro Acetyl Chloride 950 EDC Loss 250
9 Sodium Borohydrate 100 25 % Aluminum
Chloride Solution 5200
10 Di Butyl Amine 500 Solid Waste 15.0
11 Water 3730 Aq. Layer 1250
Total 31780.0 31870.0
35
3) 1,2 Dimethoxy Benzene: ( Veratrole)
Pyrocatechol ( 2- Hydroxy Phenol) on reaction with caustic converts to Di sodium salt which then
undergoes methylation by Dimethyl Sulphate in presence of catalyst to give the final product as
1,2 Di Methoxy Phenol known as Veratrol.
Chemical Reactions :
3)
Material Balance / Mass Balance
Sr.
No. In Put Quantities Out Put Quantities
Items/ Raw Materials Quantity
in Kgs
Products /
Bi Products
Quantity
in Kgs
1 1,2 Di Hydroxy Benzene
810.0
Veratrole
1000.0
2 Caustic Lye 48 % 650.0 Aq. Layer to ETP 3520.0
3 Di Methyl Sulphate 2050.0
4 Water 1000.0
Total 4520.0 4520.0
OCH3 2 NaOH
+
+
OH OH
2 (CH3)2 SO4
2 H2O
+
2 Na(CH3)SO4
+
OCH3
1,2 – Di Methoxy Benzene
( Veratrole )
1,2 Di Hydroxy Benzene
( Catechol)
36
4) Ortho Phenoxy Aniline:
Brief Manufacturing Process:
Step: 1
Phenol is reacted with 2-Nitro Chlorobenzene in Presence of Sodium Hydroxide to get
intermediate as 2-Nitro- Diphenyl Ether
After the reaction solvent 1, 2 Dichlorobenzene is charged for the extraction for the product and
Sodium Chloride salt which is formed during the reaction it is isolated by filtration
Organic mass along with intermediate is forwarded to next step.
Step: 2
2-Nitro- Diphenyl Ether is undergoes reduction reaction by Iron Powder as well as Acetic Acid to
produce the root product as 2-Amino- Diphenyl Ether
Iron Hydroxide which is formed during the reduction reaction is isolated from the mass by
filtration.
And organic mass is taken for further step
Step: 3
Organic mass is subjected to distillation to strip of the solvent to get the crude product 2-Amino-
Diphenyl Ether which is finally distilled out to get the pure product as 2-Amino- Diphenyl Ether
Chemical Reaction:
STEP-1 OH
Cl
NO2
NO2
+O
+ +
Phenol2- NitroChlorobenzene
2-NitroDiphenyl Ether
NaCl H2O
Sodium Chloride Water
NaOH
M.Wt. = 94.0 M.Wt. = 215 M.Wt. = 58.5 M.Wt. = 157.5 M.Wt. = 18 STEP-2
NO2
NH2
+ + +Fe CH3COOH Fe(OH)3
Iron Powder
Acetic Acid
Iron Hydroxide
Na2CO3
+ H2O
Water
2O
2-NitroDiphenyl Ether
O
2-AminoDiphenyl Ether
M.Wt. = 18 M.Wt. = 107 M.Wt. = 185 M.Wt. = 60 M.Wt. = 56 M.Wt. = 215
37
Mass Balance/Material Balance (All quantities are in Kg)
2- Amino Diphenyl Ether
Input Output
Sr.No Raw Materials / Items Kg/Batch Sr.No Product/By Products Qty/Batch
1 Phenol 592 1 2- Amino Diphenyl
Ether 1000
2 2-Nitro Chlorobenzene 992 2 Recovered Solvent 1170
3 Sodium Hydroxide 257 3 Solvent Loss 30
4 Solvent : 1,2-
Dichlorobenzene/DCT 1200 4 Water Distillalte 288
5 Iron (Fe) Powder 962 5 Sodium Chloride 376
6 Acetic Acid 20 6 Iron Sludge 1960
7 Soda Ash 15 7 Distillate Residue 14
8 Water 800 - -
Total 4838 Total 4838
38
5) 3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4- Oxo Ethyl
Ester.
Brief Manufacturing Process:
Step: 1
3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyclopropyl 1,4 Dihydro 8- Methyl 4- Oxo is reacted
with Cyclopropyl Chloride in Presence of Catalyst and Solvent to get intermediate as –
3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4- Oxo .
Step: 2
3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4 - Oxo .
Finally reacted with Ethyl Chloride in presence of Catalyst and Solvent to give the final product as
3- Quinoline Carboxyllic Acid 7- Chloro 1- Cyaclopropyl-1.4 Dihydro 8- Methyl 4- Oxo Ethyl Ester.
Chemical Reactions:
ClCH3
NH
O
C
O
OH
3-Quinoline Carboxylic Acid 7- Chloro
1- Cyaclopropyl -1.4 Dihydro
8- Methyl
+ Cl
Cyclo propyl Chloride
HCl
OH
O
C
O
N
CH3Cl
8- Methyl 4-Oxo
1- Cyaclopropyl -1.4 Dihydro
3-Quinoline Carboxylic Acid 7- Chloro
+ CH3CH2Cl
Ethyl Chloride Product
ClCH3
N
O
C
O
OC2O5
39
Mass Balance/Material Balance (All quantities are in Kg)
In- put Out – Put
Sr.
No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch
1
3- Quinoline Carboxyllic Acid 7-
Chloro 1- Cyaclopropyl-1.4
Dihydro 8- Methyl 4- Oxo
760
3- Quinoline Carboxyllic Acid 7-
Chloro 1- Cyaclopropyl-1.4
Dihydro 8- Methyl 4- Oxo Ethyl
Ester
1010
2 Cyclopropyl Chloride 255 Recovered Solvent 1950
3 Water for 30 % HCl Soln 292 Solvent Loss 50
4 Catalyst – PTSA 12 30 % HCl Solution 418
5 Ethyl Chloride 215 Aqueous Layer to ETP 306
6 Solvent – Toluene 2000
7 2 % Soda Ash Soln 200
Total 3734 Total 3734
40
6) L -2- Chloro Propionic Acid Isobutyl Ester.
Brief Manufacturing Process:
Stage – 1:
DL – Propionic Acid undergoes chlorination reaction by Chlorine Gas in Presence of catalyst as
well as Solvent to give an Intermediate as DL -2- Chloro Propionic Acid
Stage – 2:
DL – 2- Chloro Propionic Acid further undergoes epimerization reaction in Presence of catalyst as
well as Solvent to give an Intermediate as L -2- Chloro Propionic Acid as well as DL -2- Chloro
Propionic Acid .
L- 2- Chloro Propionic Acid is isolated as pure form for further reaction.
Stage -3 :
L- 2- Chloro Propionic Acid finally undergoes Esterification reaction by Iso Butyl Acid in presence
of Catalyst as well as Solvent to give the final Product as L -2- Chloro Propionic Acid Isobutyl
Ester.
Chemical Reaction:
Cl
CH3CH2-COOH + CL2 ���� CH3-CH-COOH + HCL
DL-Propionic Acid Chlorine L-2 – Chloro Propionic Acid
Cl OH
CH3-CH-COOH + C6H12O6 ���� CH2- CH-CH2.CH3
Iso Butyl Acid L -2- Chloro Propionic Acid Isobutyl Ester
41
Mass Balance/Material Balance (All quantities are in Kg)
In- put Out – Put
Sr.No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch
1 DL - Propionic Acid 460 L -2- Chloro Propionic Acid 1020
2 Chlorine Gas 440 Recovered Solvent 1950
3 Solvent – EDC 2000 Solvent Loss 50
4 Iso Butyl Acid 450 30 % HCl Solution 760
5 Catalyst -1 8.0 Aqueous Layer to ETP 294
6 2 % Soda Ash Solution 200 Distillation Residue 12
7 Water for 30 % HCl
Formation 528
Total 4086 Total 4086
42
N
N
H H
N
N
S
O O
O
H
Cl.SO3H
2- Phenyl Benzimidazole 2-Phenyl Benzimidazole 5- Sulphonic Acid
7) 2- Phenyl Benzimidazol -5- Sulphonic Acid.
Brief Manufacturing Process:
2- Phenyl Benzimidazol when undergoes Sulphonation reaction by Chlorosulphonic Acid in
presence of Solvent Xylene followed by Soda Ash wash gives the final Product as
2- Phenyl Benzimidazol -5- Sulphonic Acid.
Chemical Reactions :
Mass Balance/Material Balance (All quantities are in Kg)
In- put Out – Put
Sr.
No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch
1 2- Phenyl Benzimidazol 720 2- Phenyl Benzimidazol -5-
Sulphonic Acid 1010
2 Solvent – Xylene 2400 Recovered Solvent 2350
3 Chloro Sulphonic Acid 432 Solvent Loss 50
4 Water for 30 % HCl
Solution 320 30 % HCl Solution 455
5 2 % Soda Ash Soln 200 Aqueous Layer to ETP 207
Total 4072 Total 4072
43
CH3 C
CH3
CH3
CH2.CH2.CH2.CH2.CH2 C OH
O
Neodecanoyl Acid
+ SOCL2
Thinoyl Chloride
CH3 C
CH3
CH3
CH2.CH2.CH2.CH2.CH2 C CL
O
+ SO2 + HCl
Neodecanoyl Chloride
8) Neodecanoyl Chloride
Brief Manufacturing Process:
Neodecanoyl Acid undergoes chlorination reaction by Thionyl Chloride in Presence of Catalyst as
well as Solvent to give an Product as Neodecanoyl Acid Chloride.
During the reaction Hydrochloric Acid as well as Sulphur Dioxide Gases are evolved which are
scrubbed to Water as well as Dilute Caustic Solution to get the byproduct as 30 % HCl Solution
and 20 % Sodium Sulphite Solution.
Chemical Reactions:
Mass Balance/Material Balance (All quantities are in Kg)
In- put Out – Put
Sr.
No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch
1 Neodecanoyl Acid 930 Neodecanoyl Chloride 1010
2 Solvent – n- Hexane 2000 Recovered Solvent 1960
3 DMF – Catalyst 10 Solvent Loss 40
4 Thionyl Chloride 736 30 % HCl Solution 660
5 Water for 30 % HCl 460 20 % Sodium Sulphite Solution 1980
6 Dilute Caustic Solution 1584 Aqueous Layer to ETP 555
7 2 % Soda Ash Soln 500 Distillation Residue 15
Total 6220 Total 6220
44
CH3-CH-CH2.CH2.CH2-C-Cl
C2H5 O
+ SOCl2
OC2H5
CH3-CH-CH2.CH2.CH2-C-OH + HCL + SO2
2-Ethyl Hexanoyl Acid Thionyl Chloride 2- Ethyl Hexanoyl Chloride
9) 2- Ethyl Hexanoyl Chloride
Brief Manufacturing Process:
2- Ethyl Hexanoyl Acid undergoes chlorination reaction by Thionyl Chloride in Presence of
Catalyst as well as Solvent to give an Product as 2- Ethyl Hexanoyl Acid Chloride.
During the reaction Hydrochloric Acid as well as Sulphur Dioxide Gases are evolved which are
scrubbed to Water as well as Dilute Caustic Solution to get the byproduct as 30 % HCl Solution
and 20 % Sodium Sulphite Solution.
Chemical Reactions:
Mass Balance/Material Balance (All quantities are in Kg)
In- put Out – Put
Sr.
No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch
1 2- Ethyl Hexanoyl Acid 904 2- Ethyl Hexanoyl Chloride 1010
2 Solvent – n- Hexane 2000 Recovered Solvent 1960
3 DMF – Catalyst 9 Solvent Loss 40
4 Thionyl Chloride 820 30 % HCl Solution 840
5 Water for 30 % HCl Solution 587 20 % Sodium Sulphite Solution 4460
6 Dilute Caustic Solution 4040 Aqueous Layer to ETP 235
7 2 % Soda Ash Soln 200 Distillation Residue 15
Total 8560 Total 8560
45
COOH
Cl
Cl
+ SOCl2
Cl
Cl
C
O
Cl
+ HCl + SO2
2,3 Dichloro Benzoic Acid Thionyl Chloride 2,3 Dichloro Benzoyl Chloride
10 ) 2,3 Dichloro Benzoyl Chloride
Brief Manufacturing Process:
2,3 Dichloro Benzoyl Acid undergoes chlorination reaction by Thionyl Chloride in Presence of
Catalyst as well as Solvent to give an Product as 2,3 Dichloro Benzoyl Acid Chloride.
During the reaction Hydrochloric Acid as well as Sulphur Dioxide Gases are evolved which are
scrubbed to Water as well as Dilute Caustic Solution to get the byproduct as 30 % HCl Solution
and 20 % Sodium Sulphite Solution.
Chemical Reactions:
Mass Balance/Material Balance (All quantities are in Kg)
In- put Out – Put
Sr.
No Raw Materials / Items Kg/Batch Product/By Products Qty/Batch
1 2,3 Dichoro Benzoic Acid 930 2,3 Dichloro Benzoic Chloride 1010
2 Solvent – n- Hexane 2000 Recovered Solvent 1960
3 DMF – Catalyst 10 Solvent Loss 40
4 Thionyl Chloride 584 30 % HCl Solution 600
5 Water for 30 % HCl 423 20 % Sodium Sulphite Solution 3190
6 Dilute Caustic Solution 2878 Aqueous Layer to ETP 213
7 2 % Soda Ash Solution 200 Distillation Residue 12
Total 7025 Total 7025
46
11) 3-(4-Amino-3, 5-Di Methyl Phenyl) Prop-2-Ene Nitrile
Brief Manufacturing Process:
4- Chloro 2,6 Dimethyl Aniline when reacted with 2- Propene nitrile in presence of catalyst &
solvent it gives the final product as 3- ( 4- Chloro – 3,5 – Dimethylphenyl ) Propene nitrile .
Potassium Carbonate is used as acid scavenger which eats up the Hydrochloric acid which is
formed during the reaction and gives our Potassium Chloride as byproduct along with water
molecule. Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.
Reaction Chemistry:
CH3
NH2
CH3Cl
Formula Weight: 155.6247
Molecular Formula: C8H10ClN
4-chloro-2,6-dimethylaniline
+ CH2 CN
Formula Weight: 53.06262
Molecular Formula: C3H3N
prop-2-enenitrile
K2CO3
TBAB
CH3
NH2
CH3NC
Formula Weight: 172.22638
Molecular Formula: C11H12N2
3-(4-amino-3,5-dimethylphenyl)prop-2-enenitrile
47
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
3-(4- Chloro - 3,5 - Dimethylphenyl) Propene Nitrile
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 4- Chloro 2,6 Dimethyl Aniline 930
3-(4- Chloro - 3,5 – Dimethyl
Phenyl) Propene Nitrile 1020
2 2- Propene nitrile 310
Recovered Solvent – DMF 1960
3 Solvent – DMF 2000
Solvent Loss – DMF 40
4 Catalyst 15
Potassium Chloride mix Salt 1110
5 Potassium Carbonate 890 Aqueous Layer to ETP 1015
6 5 %Soda Ash Solution 500
7 Water for Reaction & Washing 500
Total 5145 Total 5145
48
12) 4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-
yl)Amino]Benzonitrile
Brief Manufacturing Process:
3- ( 4- Chloro - 3,5 - Dimethylphenyl ) Prop -2- enenitrile is reacted with 4- [ (4- Chloropyrimidine
2-yl) amino ] Benzonitrile in presence of catalyst & solvent it gives the final product as 4-[(4-{[4-
(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-yl)Amino]Benzonitrile
Potassium Carbonate is used as acid scavenger which eats up the Hydrochloric acid which is
formed during the reaction and gives our Potassium Chloride & Potassium Bi Carbonate as
byproducts along with water molecule.
Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.
Reaction Chemistry:
CH3
NH2
CH3NC
Formula Weight: 172.22638
Molecular Formula: C11H12N2
3-(4-amino-3,5-dimethylphenyl)prop-2-enenitrile
+N
NCl NH
CN
Formula Weight: 230.65308
Molecular Formula: C11H7ClN4
4-[(4-chloropyrimidin-2-yl)amino]benzonitrile
K2CO3, TBAB
CH3
NH
CH3NC
N
N NH
CN
Formula Weight: 366.41852
Molecular Formula: C22H18N6
4-[(4-{[4-(2-cyanoethenyl)-2,6-dimethylphenyl]amino}pyrimidin-2-yl)amino]benzonitrile
49
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1) Di Methyl Phenyl ] Amino} Pyrimidin-2-
yl)Amino]Benzonitrile
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product
Qty/Ba
tch
1
3-(4- Chloro - 3,5 -
Dimethylphenyl) Prop -
2- enenitrile 485
4-[(4-{[4-(2-Cyano Ethenyl)-2,6-1)
Di Methyl Phenyl ] Amino}
Pyrimidin-2-yl)Amino]Benzonitrile 1020
2 4- [ (4- Chloro Pyrimidine yl)
amino ] Benzonitrile 640
Recovered Solvent – DMF 1960
3 Solvent – DMF 2000
Solvent Loss – DMF 40
4 Catalyst 15
Potassium Chloride + Potassium
Bi Carbonate mix Salt 550
5 Potassium Carbonate 410 Aqueous Layer to ETP 980
6 5 %Soda Ash Solution 500
7 Water for Reaction & Washing 500
Total 4550 Total 4550
50
13) 1-(6-AMINO-9H-PURIN-9-YL)PROPAN-2-OL
Brief Manufacturing Process:
6- Amino 9-H Purin when reacted with 4- Methyl 1,3 Dioxolan 2- one in presence of catalyst &
solvent- Toluene it gives the final product as 1-(6-Amino-9H-Purin-9-yi )Propane -2-Ol
Carbon Dioxide gas is formed during the reaction which is stripped off the reaction mass. Solvent
Toluene is used which is recovered after the reaction & recycled to fresh batches.
Reaction Chemistry:
N
N
NH2
N
NH
Formula Weight: 135.1267
Molecular Formula: C5H5N5
9H-purin-6-amine
O O
O
CH3
Formula Weight: 102.08864
Molecular Formula: C4H6O3
4-methyl-1,3-dioxolan-2-one
+
Toluene
-CO2
N
N
NH2
N
NOH
CH3
Formula Weight: 193.20584
Molecular Formula: C8H11N5O
1-(6-amino-9H-purin-9-yl)propan-2-ol
51
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
1-(6-AMINO-9H-PURIN-9-YL)PROPAN-2-OL
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 6- Amino 9-H Purin 720
1-(6-Amino-9H-Purin-9-yi )
Propane -2-ol 1010
2 4- Methyl 1,3 Dioxolan 2- one 530
Recovered Solvent – Toluene 1960
3 Solvent – Toluene 2000
Solvent Loss – Toluene 40
4 Catalyst 15
Aqueous Layer to ETP 755
5 5 %Soda Ash Solution 250
6 Water for Reaction & Washing 250
Total 3765 Total 3765
52
14) 4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile
Brief Manufacturing Process:
2- Chloro Pyrimidine 4- ol is when reacted with 4- Amino Benzonitrile in presence of catalyst &
solvent it gives the final product as 4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile.
Potassium Carbonate is used as acid scavenger which eats up the Hydrochloric acid which is
formed during the reaction and gives our Potassium Chloride as byproduct along with water
molecule. Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.
Reaction Chemistry:
N
N ClOH
Formula Weight: 130.53242
Molecular Formula: C4H3ClN2O
2-chloropyrimidin-4-ol
+
NH2
CN
Formula Weight: 118.13594
Molecular Formula: C7H6N2
4-aminobenzonitrile
K2CO3, TBAB
N
NOH NH
CN
Formula Weight: 212.20742
Molecular Formula: C11H8N4O
4-[(4-hydroxypyrimidin-2-yl)amino]benzonitrile
53
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
4-[(4-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 2- Chloro Pyrimidine 4- ol 640
4-[(4-Hydroxy Pyrimidin-2-yl)
Amino] Benzonitrile 1015
2 4- Amino Benzonitrile 560
Recovered Solvent – DMF 1960
3 Solvent – DMF 2000
Solvent Loss – DMF 40
4 Catalyst 12
Potassium Chloride + Potassium
Bi Carbonate mix Salt 960
5 Potassium Carbonate 650 Aqueous Layer to ETP 887
6 5 %Soda Ash Solution 500
7 Water for Reaction & Washing 500
Total 4862 Total 4862
54
15) 4-[(5- Hydroxy Pyrimidin-2-yl )Amino] Benzonitrile
Brief Manufacturing Process:
4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile when undergoes de oxy Chlorination
process with in presence of Phosphorus Oxychloride catalyst & Solvent – Xylene to give the final
product as 4-[(5-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile.
Potassium Carbonate is used as acid scavenger which eats up the Hydrochloric acid which is
formed during the reaction and gives our Potassium Chloride as byproduct along with water
molecule. Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.
Reaction Chemistry:
Step -1
N
N NH
CN
OH
N
N NH
CN
O
N
N NH
CN
ClChlorination, POCl 3
Formula Weight: 212.20742
Molecular Formula: C11H8N4O
4-[(5-oxo-4,5-dihydropyrimidin-2-yl)amino]benzonitrile
Formula Weight: 230.65308
Molecular Formula: C11H7ClN4
4-[(5-chloropyrimidin-2-yl)amino]benzonitrile
Formula Weight: 212.20742
Molecular Formula: C11H8N4O
4-[(5-hydroxypyrimidin-2-yl)amino]benzonitrile
OR
55
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
4-[(5-Hydroxy Pyrimidin-2-yl) Amino] Benzonitrile
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 4-[(5-Oxo-4,5-Dihydro Pyrimidin-
2-yl)amino] Benzonitrile 1040
4-[(5-Hydroxy Pyrimidin-
2-yl) Amino] Benzonitrile 1020
2 Phosphorus Oxychloride 525
Recovered Solvent –
DMF 2940
3 Solvent – Xylene 3000
Solvent Loss – DMF 60
4 Catalyst 10
Sodium Chloride mix
Salt 310
5 Caustic Lye 48 % 400 Phosphoric Acid 460
6 5 %Soda Ash Solution 250
Aqueous Layer to ETP 685
7 Water for Reaction & Washing 250
Total 5475 Total 5475
56
16) 4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile
Brief Manufacturing Process:
1-(4- Cyano phenyl ) Guanidine is when reacted with Methyl (2Z) -3- Methoxy 2- Propionate in
presence of catalyst & Solvent it gives the final product as 4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl)
Amino] Benzonitrile.
Methanol is used as Solvent and caustic soda flakes used as catalyst for cyclization reaction.
Solvent is used which is recovered after the reaction & recycled to fresh batches.
Reaction Chemistry:
NH
CN
NH2
NH
N
N NH
CN
O
Formula Weight: 160.17592
Molecular Formula: C8H8N4
1-(4-cyanophenyl)guanidine
+
COOCH3
OCH3
CH3OH
CH3ONa
Formula Weight: 116.11522
Molecular Formula: C5H8O3
methyl (2Z)-3-methoxyprop-2-enoate
Formula Weight: 212.20742
Molecular Formula: C11H8N4O
4-[(5-oxo-4,5-dihydropyrimidin-2-yl)amino]benzonitrile
57
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-yl) Amino] Benzonitrile
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 1-(4-Cyano phenyl) Guanidine 780
4-[(5-Oxo-4,5-Dihydro Pyrimidin-2-
yl) Amino] Benzonitrile 1020
2 Methyl (2Z) -3- Methoxy 2-
Propionate 555
Recovered Solvent – Methanol 2950
3 Solvent – Methanol 3000
Solvent Loss – Methanol 50
4 Catalyst 10
Sodium Methoxide mix Salt 270
5 Caustic flakes 225 Aqueous Layer to ETP 780
6 5 %Soda Ash Solution 250
7 Water for Reaction & Washing 250
Total 5070 Total 5070
58
17) 4-({6-Amino-5-Bromo-2-[(4-Cyanophenyl) Amino ]Pyrimidin-4-yl}Oxy)-3,5-Dimethyl
Benzonitrile
Brief Manufacturing Process:
Step -1:
6- Amino 2- Chloro Pyrimidine 4- ol is reacted with 4- Amino Benzonitrile in presence of Solvent-
DMF & Catalyst to give the Intermediate Product as 4 – [ 4- Amino -6- Hydroxypyrimidine 2- yl)
amino ] Benzonitrile (I ).
Potassium Carbonate is used as acid scavenger which eats up the Hydrochloric acid which is
formed during the reaction and gives our Potassium Chloride & Potassium Bi Carbonate as
byproducts along with water molecule. Solvent DMF is used which is recovered after the reaction
& recycled to fresh batches.
Step -2
4 – [ 4- Amino -6- Hydroxypyrimidine 2- yl) amino ] Benzonitrile (I ) is further reacted with
4- Chloro 3,5 - Dimethyl Benzonitrile in presence of catalyst & Solvent it gives the Intermediate
(II) as 4- ({ 6- Amino -2- [( 4- Cyanophenyl) amino ] Pyrimidine -4 –yl} oxy ) -3,5- Dimethyl
Benzonitrile (II).
Hydrochloric acid which is formed during the reaction which is scrubbed to water for formation
of 30 % Hydrochloride Solution.
Solvent DMF is used which is recovered after the reaction & recycled to fresh batches.
Step -3:
4- ({ 6- Amino -2- [( 4- Cyanophenyl) Pyrimidine -4 –yl} oxy ) -3,5- Dimethyl Benzonitrile (II).
is finally undergoes bromination reaction by liquid Bromine in presence of catalyst & Solvent-
EDC to give the final product as 4- ({ 6- Amino -5- Bromo -2- [( 4- Cyanophenyl)amino]
Pyrimidine -4 –yl} oxy ) -3,5- Dimethyl Benzonitrile
Hydrogen Peroxide 50 % Solution is used for hydrobromination whereby resulting Hydrobromic
acid is further reacted with Hydrogen Peroxide & gives away second radical of Bromine.
Solvent EDC is used which is recovered after the reaction & recycled to fresh batches.
59
Reaction Chemistry:
N
N NH
CN
NH2
OH
+K2CO3
N
N ClOH
NH2
CN
NH2
N
N NH
CN
NH2
O
CN
CH3CH3
CN
Cl
CH3CH3
+
N
N NH
CN
NH2
O
CN
Br
CH3CH3Bromination
Formula Weight: 145.54706
Molecular Formula: C4H4ClN3O
6-amino-2-chloropyrimidin-4-ol
Formula Weight: 118.13594
Molecular Formula: C7H6N2
4-aminobenzonitrile
DMF
Formula Weight: 227.22206
Molecular Formula: C11H9N5O
4-[(4-amino-6-hydroxypyrimidin-2-yl)amino]benzonitrile
Formula Weight: 165.61952
Molecular Formula: C9H8ClN
4-chloro-3,5-dimethylbenzonitrile
Formula Weight: 356.38064
Molecular Formula: C20H16N6O
4-({6-amino-2-[(4-cyanophenyl)amino]pyrimidin-4-yl}oxy)-3,5-dimethylbenzonitrile
Formula Weight: 435.2767
Molecular Formula: C20H15BrN6O
4-({6-amino-5-bromo-2-[(4-cyanophenyl)amino]pyrimidin-4-yl}oxy)-3,5-dimethylbenzonitrile
60
Mass Balance / Material Balance
Material Balance / Mass Balance (All Quantities are in Kg)
4-({6-Amino-5-Bromo-2-[(4-Cyanophenyl) Amino ]Pyrimidin-4-yl}Oxy)-3,5-Dimethyl
Benzonitrile
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 6- Amino 2- Chloro
Pyrimidine 4- ol
370
4-({6-Amino-5-Bromo-2-[(4-
Cyanophenyl) Amino ]Pyrimidin-
4-yl}Oxy)-3,5-Dimethyl
Benzonitrile 1020
2 4- Amino Benzonitrile 285
Recovered Solvent – DMF 2430
3 Solvent – DMF 2500
Solvent Loss – DMF 70
4 Catalyst -1 12
Potassium Chloride mix Salt 440
5 Potassium Carbonate 340 30 % HCl Solution 300
6 4- Chloro 3,5 - Dimethyl
Benzonitrile 505
10 % HBr Solution 110
7 Water for HCl Solution
Formation 210
Aqueous Layer to ETP 734
8 Bromine Liquid 187
9 Catalyst -2 15
10 50 % Hydrogen Peroxide
Solution 80
11 Water for HBr Solution
Formation 100
12 5 %Soda Ash Solution 250
13 Water for Reaction &
Washing 250
Total 5104 Total 5104
61
Pesticide Intermediates:
1) 1,2,4 –Triazole
A) Brief Manufacturing Process
Formic Acid is reacted with dry ammonia to form Formamide which on reaction with hydrazine
hydrate gives out the final Product 1:2:4 Triazole. During the reaction ammonia & water
molecules are formed in stechiometric quantities.
B) Chemical Reactions
2HCOOH + 2NH3
Formic Acid Ammonia - 4 x H2O
(MW 46) (MW 17)
O
2H – C – NH2 + H2N - NH2 . H2O
Formamide Hydrazine Hydrate
(MW 45) (MW 50)
N
N + 3H2O + NH3
N
H
1,2,4 Triazole Water Ammonia
(MW 69) (MW18) (MW 17)
62
Mass Balance:
1:2:4 Triazole Material / Mass Balance for 1.0 MT
In Put /Ton Out Put /Ton
No. Name of Item Qty. No. Name of Items Qty.
1 Formic Acid 2000.0 1 1,2,4 Triazole 1032.0
2 Ammonia 900.0 2 22% NH3 Sol. 2968.0
3 Hydrazine Hydrate 1000.0 3 Aq. Layer to ETP 1740.0
4 Water 2315.0 4 Recovered Formic Acid 400.0
5 Recovered Hydrazine Hydrate 75.0
Total 6215.0 Total 6215.0
63
C 3
N
2) 3- Methyl 1,2,4 –Triazole
Process Description: Hydrazine Carboxaldehyde is reacted with 1- Imino Ethanamine Hydrochloride in presence of Sodium Methoxide as well as Solvent – Ethanol form 3- Methyl 1,2,4 Triazole.
Chemical Reaction
STEP-1
H2N H
N C +
H O
HN
NH2
HCl + NaOCH
Ethyl Alcohol
CH3
N
+ N
H
CH3OH
+ NaOH +
NH4Cl
CH3
Hydrazine Carboxaldehyde
1- Imino ethenamine
hydrochloride
Sodium Metoxide
3-Methyl-1,2,4-Triazole
Methanol Sodium Hydroxide Amonium
Chloride
M.W t = 60.00
M.Wt = 94.5
M.W t = 54.00
M.Wt = 83.00
M.Wt = 32.00
M.Wt = 40.00 M.Wt = 53.50
Mass Balance:
65
3) 3- Methyl 4- Nitro Imino Per hydro1,3,5 Oxidiazine :
BRIEF MANUFACTURING PROCESS: -
Step:-I
N-Methyl N-Nitro Guanidine (NMG) undergoes cyclization by the reaction of Para
Formaldehyde (PFA) in presence of solvent (Formic Acid) and catalyst to form Oxidiazine
derivatives as an intermediate.
Further organic mass containing Formic Acid is taken for distillation to recover Formic Acid.
After it is diluted with water, neutralized with Caustic Soda Lye, cool it to form crystal & filtered
it to get Oxidiazine Compound
CHEMICAL REACTIONS :
N-Methyl Nitro Guanidine Para formaldehyde Oxidiazine
NH NH
NH
CH3
N+
O-
O
+ O
H
H
2 N
O
NH
N
CH3
N+
O-
O + OH2
66
Mass Balance 1,3,5 Oxidiazine I MT
Sr
No In Put /Ton
Out Put
/Ton
Name of Item Qty. No. Name of Items Qty.
1 Formic Acid 2880 1 1,3,5 Oxidiazine 1000
2 N- Methyl Nitro Guanidine 778 2 Recovered Formic Acid 2795
3 Metane Sulphonic Acid 44 3 Formic Acid Loss 155
4 Caustic Lye 48 % 390 4 Recovered Solvent DMF 2910
5 Catalyst 12 5 Solvent Loss 90
6 Solvent -DMF 3000 6 Mother Liqour 654
7 Water for Crysrallazation 1000 7 Aqeous Layer 500
Total 8104 Total 8104
67
OH
OH
+ CH3-CH-COOH
ClO
OH
CH COOH
CH3
Hydro Quinone 2-Chloro Propionic Acid 2-(4 Hydroxy Phenyl) Propionic Acid
COOHCH
OH
O
CH3
2-(4 Hydroxy Phenyl) Propionic Acid
+ CH3OH
CH3
O CH COOCH3
OH
+ H2O
+ NaOH + HCl
OH
COOCH3CHO
CH3 CH3
O CH COOH
OH
Product
4). ( R (+) -2 – [ 4 ( 4- ( 5- Chloro -3- Fluoro Pyridine -2- Yloxy Phenoxy ) ] Propionic Acid / 4-
HPPA / R – HPPA
BRIEF MANUFACTURING PROCESS: -
Step:- I
Hydroquinone when reacted with 2- Chloro Propionic Acid in presence of Solvent and catalyst to form
2- ( 4- Hydroxy phenyl) Propionic Acid derivatives as an intermediate.
Step:- 2
2- ( 4- Hydroxy phenyl) Propionic Acid Hydroquinone when reacted with Methanol in presence of
Solvent and catalyst to form 2- ( 4- Hydroxy phenyl) Propionic Acid Methyl Ester.
Step:- 3
2- ( 4- Hydroxy phenyl) Propionic Acid Methyl Ester when undergoes hydrolysis reaction by caustic Soda
Lye gives the final Product as ( R (+) -2 – [ 4 ( 4- ( 5- Chloro -3- Fluoro Pyridine -2- Yloxy Phenoxy ) ]
Propionic Acid.
CHEMICAL REACTIONS :
69
5). 4 – 4’ Thio Diphenol 50 MT / Month
A. Brief Manufacturing Process :-
Phenol and Sulphur Dichloride is reacted in presence of toluene which is needed as solvent, to
form crude 4 – 4’ Thio Di phenol (TDP).
Thio crude Thio di phenol is then purified by treatment of Soda – Ash solution in water to give
pure product.
B. Chemical Reaction :-
Toluene
HO + SCl2 + OH
Solvent
Phenol Sulphur Dichloride Phenol
(94) (103) (94)
HO O S OH + 2HCl
4 – 4’ Thio Di Phenol Hydrochloric Acid
218.0 (2 x 36.5)
Mass Balance:
70
O CH3
+ POCL3
CHO O
+ H3PO4
2 Methyl Furan Phosphorus Oxychloride Aldehyde of 2 Methyl Furan
O CHO
+ CH2=CH-Cl O C
O
CH5CH2
CH5CH2
O
C O
+ CH3COOH
O
CH3
OH
+ CH3COONa
Carbonyl of 2 Methyl Furan
Product
6) D+ dl Allethrollone & DL – Isomeres
BRIEF MANUFACTURING PROCESS: -
Step:- I
2- Methyl Furan is reacted with Phosphorus Oxychloride in presence of catalyst and Solvent to
form Aldehyde of 2- Methyl Furan.
Step:- 2
Aldehyde derivative of 2- Methyl Furan 2- when undergoes Grignard reaction with Allyl Chloride
in presence of Solvent such as Toluene and THF as well as catalyst as Mg- Metal to form
Carbonyl compound of 2- Methyl Furan.
Step:- 3
Carbonyl derivative of 2- Methyl Furan finally undergoes epimerization reaction by Sodium
Acetate in presence of Acetic Acid to gives the final Product d + dl Allethrollone.
Racemic compound of Allethrollone is recovered in statiomatric qty and recycle to fresh batch.
CHEMICAL REACTIONS :
74
8. 2 – Chloro 5- Chloromethyl Thiazol
Step:- 1
Alloyl Chloride reacts with Chlorine to give tri Chloro Propane which on further reaction with
Caustic soda lye gives Dichloro Propane.( DCP)
Step -2
Dichloro Propane reacts with Potassium thiocyanate to give Chloro Iso thiocyanate
intermediate. This on reaction with Sulfuryl Chloride gives the intermediate 2-Chloro 5-
Chloromethyl Thiazol
CHEMICAL REACTIONS :
Step – I CH2=CH–CH2Cl + Cl2 CH2Cl–CHCl–CH2Cl Allyl chloride Tri Chloro Propane M.W. = 76.5 M.W. = 147.5 CH2Cl–CHCl–CH2Cl + NaOH CH2Cl–CCl=CH2 + NaCl + H2O Di Chloro Propane M.W. = 111 CH2Cl–CCl=CH2 + KSCN CH2Cl–CSCN=CH2 + KCl CITC CH2Cl–CSCN=CH2 + SO2Cl2 S + HCl Cl N Cl
Chlorinatio
n
75
2 - Chloro 5 - Chloromethyl Thiazol
CCMT
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 Allyi Chloride 1180
CCMT 1050
2 30 % HCl Solution 1440
Recovered Solvent – MDC 3920
3 Catalyst -1 14
Solvent Loss - MDC 80
4 Catalyst -2 14
30 % HCl Solution 2050
5 Chlorine 875 KCL Solution 3200
6 Caustic Soda Flakes 598
20 % Sodium Sulphite
Solution 5350
7 Potassium Thio Cyanate 1250
Aqueous Layer to ETP 2196
8 Sulfuryl Chloride 1080
Distillation Residue 15
9 Solvent MDC 4000
11 Water for Reaction &
Washings 1250
12 Water for 30 % HCl
Solution 1738
13 Dilute Caustic for 20 %
Solution 4330
Total 17769 Total 17861
76
9) Chloro Butoxy Ethyl Acetate
A) Brief Manufacturing Process :-
The process of manufacturing Chloro Butoxy Ethyl Acetate is described as below.
Butyl cellosolve is reacted with Mono Chloro Acetic Acid (MCA) in presence of Catalyst
(H2SO4). This reaction gives out water molecule in stechiomatric Quality.
B) Chemical Reactions :-
Cl-CH2-COOH + HO-CH2- CH2 - OC4 H9
Mono Chloro Acetic Acid Butyl Cellosolve
(MW 94.5) (MW 118)
O
Catalyst
Cl- CH2 - C – O – CH2-CH2- O C4H9 + H2O
H2SO4
Chloro Butoxy Ethyl Acetate Water
(MW 194.5) (MW 18)
Mass Balance:
77
10) Lambda Acid Chloride
Brief Manufacturing Process
Lambda Cyhalothric Acid Chloride (LCHACl) Manufacturing Process Details
Methyl Pentanoate (MP) reacted with tri chloro tri fluoro ethane (TCTFE) in presence of tertiary butyl
alcohol solvent (TBA) to from Methyl Ester of Di Methyl Trichloro Tri Fluoro Heptonate (Haptanoate)
Haptanoate is further reacted with Sodium / Potassium Salt of Tertiary Butyl alcohol to give me ester of
Dichloro Trifluoro Propynyl Dimethyl Cyclopropane Carboxylate (Sat Methyl Ester) This on reaction with
Caustic Soda gives Methyl Ester & then Na Salt of Chloro Difluoro Propenyl Dimethyl Cylopropyne
Carboxyllic Acid (TFP Acid) which on Hydrochloric Acid treatment gives Chloro Difluoro Propynyl
Dimethyl Cyclo Propane Carboxyllic Acid.
This acid on chlorination by Thionyl Chloride gives Chloro Trifluoro Propynyl, Dimethyl Cyclopropane
Carboxylic Acid Chloride as the final product.
Lambda Cyhalothrin Acid Chloride
Chemical Reaction
79
Mass Balance:
Material Balance / Mass Balance (All Quantities are in Kg)
Lambda Acid Chloride
INPUT OUTPUT
Sr
No Raw Materials / Items Kg/Batch Product / Bi Product Qty/Batch
1 Tri Chloro Tri Fluoro Ethane 1350
Lambda Acid Chloride 1000
2 Methyl Pentanoate 1110
Recovered Solvent – TBA 11738
3 Catalyst -1 11
Solvent Loss - TBA 150
4 Catalyst -2 15
Recovered n- Hexane 4900
5 30 % HCl Solution 1500
n- Hexane loss 100
6 Tertiary Butyl Alcohol - TBA 12478 Recovered Methanol 1300
7 Na- Metal 210
Methanol- Loss 100
8 Solvent n- Hexane 5000
30 % HCl Solution 990
9 Di Methyl Formamide 221
20 % Sodium Sulphite Soln 3984
10 Sulfuric Acid 98 % 44
Recovered Methyl Pentanoate 20
11 Caustic Lye 46 – 48 % 3233
Aqueous Layer to ETP 3944
12 Solvent Methanol 1400 Distillation Residue 16
13 Thionyl Chloride 570
14 Water for Reaction & Washing 1100
Total 28242 Total 28242
80
11) Meta Phenoxy Benzyl Alcohol
A Brief Manufacturing Process
Meta Phenoxy Benzaldelyde is reacted with Hydrogen Gas under pressure in presence of
hydrogenation Catalyst to give Meta Phenoxy Benzyl Alcohol (MPBAL) in stechiometric
proportion.
B) Chemical Reaction
O H
C
CH2 OH
H2
O
Catalyst
O
Meta Phanoxy Benzaldehyde
MPBAD MPBAL
M.W. = 198.0 M.W. = 200.0
Mass Balance:
Meta Phenoxy Benzyl Alcohol
In Put /Ton Out Put /Ton
No. Name of Item Qty. No. Name of Items Qty.
1 MPBAD 1100.0 1 MPBAL 1000.0
2 Hydrogen 300.0 2 Recovered IPA 2940.0
3 Catalyst 15.0 3 IPA Loss 60.0
4 Iso Propyl Alcohol 3000.0 4 MPBAD 100.0
5 5 % Soda Ash Solution 250.0 5 Hydrogen Loss 290.0
6 6 Aq Layer to ETP 275.0
Total 4665.0 Total 4665.0
81
12) N-Nitro Imino Iminozoladine
Brief Manufacturing Process:
Preparation of Nitro Imino Imidazolidine
Step -1 :
Guanidine Nitrite is added slowly to concentrated Sulfuric Acid in presence of Catalyst and
Water to yield Nitro Guanidine.
Step - 2 :
Nitro Guanidine is further hydrolyzed with Caustic in presence of Ethylene Diamine & finally
undergoes cyclization reaction to give the final Product as Nitro Imino Imidazolidine
Reaction Chemical:
83
13) Sodium Tri Chloro pyridinol [Na TCP]
Brief Manufacturing Process
In a glass lined reactor, Trichloro acetyl chloride , Acrylonitrile react in presence of catalyst and
solvent to get crude Trichloro pyridinol. Which is dumped in to another reactor containing
sodium hydroxide in water, here sodium Trichloro pyridinol is formed. The slurry formed is
filtered out in filter press and wash cake with water. The cake is then dry in FBD and sell out.
Chemical Reaction:
Cl Cl
solvent
Cl3COCl + CH2=CHCN
Catalyst Cl N OH
water NaOH Lye
Cl Cl
ONa
Cl N
85
14) Tri Chloro Acetyl Chloride
Brief Manufacturing Process:
In a glass lined reactor, charge Acetic acid and catalyst, purge chlorine gas to get r Trichloro
acetic Acid [ TCA ]. During TCA preparation Hydrochloric Acid gas generates is absorb in water
by scrubbing system. This Hydrochloric Acid can be sold out to local industry. Excess chlorine
gas is absorbed in another glass-lined reactor which contain Acetic acid and catalyst, So, no
excess chlorine is escape out to atmosphere. This Trichloroacetic acid is transfer to another
reactor for Trichloro acetyl chloride [ TCAC ] production with chlorine gas and Sulphur mono
chloride. During this reaction also Hydrochloric acid gas generate is absorb in water and Sulfur
dioxide is absorb in caustic soda lye solution. Both the solution will be use in house or sell in to
local market.
Chemical Reactions :
1) Tri chloro acetic acid (TCA)
CH3COOH + 3Cl2 Cl3CCOOH + 3HCl
Acetic acid Chlorine gas Trichloro acetic acid Hydrochloric acid
M.W.: 60 M.W.: 71x3=213 M.W.: 163.5 M.W.: 36.5x3=109.5
2) Tri chloro acetyl chloride (TCAC)
2Cl3CCOOH + ½ SCl + ¾ Cl2 Cl3CCOCl + 2HCl + ½ SO2
TCA Sulfur Mono Chlorine Gas TCAC Hydro Sulfur
M.W.: 163.5 chloride gas chloric acid dioxide
M.W.: 67.5 M.W.: 71.0 M.W.: 182.0 M.W.: 36.5 M.W.:64
87
15) Transfluthrin Acid Chloride
BRIEF MANUFACTURING PROCESS: -
Step:- I
Hgh trans CMA when undergoes epimerization reaction in presence of Catalyst as well as
Solvent and to form R – Trans CMA isomer as an intermediate, which is isolated by acidification.
RS Trans CMA which is mixture of R & S Isomers is recovered in statiomatric quantity.
Catalyst is also recovered up to 98% and recycled to fresh Batch.
Step:- 2
R – Trans CMA isomer when undergoes chlorination reacted by Thionyl Chloride in presence of
Solvent- Hexane and Catalyst to form R – Trans CMAC.
Chemical Reaction:
Epimerization Epimerization
CH3 CH3
Cl2C=CH –CH – CH – COOH
CH3 CH3
Cl2C=CH –CH – CH – COOH + NaCl
R – Trans Cypermethric Acid
M.W. 209.0
CH3 CH3
Cl2C=CH –CH – CH – COOH + SOCl2
Cypermethric Acid
M.W. 209.0
CH3 CH3
Cl2C=CH –CH – CH – COCl + SO2 +
HCL
Cypermethric Acid Chloride
M.W. 227.5
89
Specialty Chemical
1. EBASA -- Ethyl Benzyl Aniline Sulphonic Acid :
Ethyl Benzyl Aniline ( EBA ) undergoes sulphonation reaction by Oleum 65 % in presence of
sulfuric acid to give EBASA. The resulting mass is Drowned to Ice – water Mixture for quenching.
The resulting mixture is centrifuged and the solid product is packed in Bags/ drums.
20 % Sulphuric Acid is generated as bi product which is being sold out to the actual user.
Chemical Reactions :
1)
Material Balance / Mass Balance
Sr.
No. In Put Quantities Out Put Quantities Remarks
Items/ Raw
Materials
Quantity in
Kgs
Products / Bi
Products
Quantity
in Kgs
1 Ethyl Benzyl Aniline 800 Ethyl Benzyl Aniline
Sulphonic Acid 86 % 1165.0
Product is in the
form of Wet cake.
2 Sulphuric Acid 790 Spent Sulphuric Acid 4555.0 Sold as Bi Product
3 Oleum 65 % 780
4 Water 3350
Total 5720 5720
N – CH2C6H5
+
H2S2O7
+
Ethyl Benzyl Aniline
EBA )
Ethyl Benzyl Aniline Sulphonic Acid
( EBA )
H2SO4
+
H2SO4
C2H5
N – CH2C6H5
C2H5
SO3H
90
COOH
COOH
+ HO(CH2O)n H
C
O
O
OH
Terephthalic Acid Paraformaldehyde 5-Carboxy Phthalide
+ H2O
Step-1
Step-2
O
O
OH
O
O
C
+ SOCl2 DMF/Toluene
C
O
O
Cl
O
+ SO2 + HCl
5-Chloro Carboxy Phthalide
O
Cl
O
O
C
+ NH3
5-Chloro Carboxy Phthalide
+ HCl
O
CNH2
O
5- Carbonyl Phthalide
2) 5- Cyano Phthalide
Brief Manufacturing Process:
Step I
Terephthallic Acid undergoes cyclization reaction in Presence of 23 % Oleum to give an
intermediate as 5-Carboxy Phthalide.
Step II
5-Carboxy Phthalide on further chlorination reaction by Thionyl Chloride in presence of Solvent
& Catalyst gives the Intermediate as 5- Chlorocarbonyl Phthalide.
Step III
5- Chloro carbonyl Phthalide on further reaction of ammonolysis by Ammonia Gas in presence
of Solvent & Catalyst gives the Intermediate as 5- Carbonyl Phthalide.
Step IV
5-Carbonyl Phthalide finally on de- hydration reaction by Thionyl Chloride in presence of
Solvent & Catalyst gives the final Product as 5- Cyano l Phthalide.
Chemical Reactions: -
91
Material Balance
Sr.
No. Input – Raw materials
Quantity
in Kg
Output- Product / Bi
Product
Quantity
in Kg
1 Terephthallic Acid 1150.0 5- Cyano
Phthalide 1010.0
2 23 % Oleum 375.0 Spent Acid to Sale 555.0
3 DMF 9.0 30 % Hydrochloric Acid
Solution 2520.0
4 Thionyl Chloride 1750.0 20 % Sodium Sulphate
Solution 9221.0
5 Solvent - Toluene 2400.0 Recovered Toluene 2350.0
6 Ammonia Gas 122.0. Toluene Loss 50.0
7 Water for 30 % HCl solution
Formation 1764.0 Aqueous Layer to ETP 1272.0
8 Dilute Caustic for 20 % Sodium
Sulphite Solution Preparation 8920.0 Distillation Residue 12.0
9 2 % Soda Ash Solution 500.0
TOTAL 16990.0 16990.0
92
3). 2-Chloro 6- Nitro Benzonitrile
Brief Manufacturing Process:
2:3 Dichloro Nitro Benzene (2:3 DCNB) on Cyanation by Sodium cyanide and cuprous cyanide
gives the nitrile product as 2 - Chloro 6- Nitro Benzonitrile
The excess Sodium cyanide and cuprous cyanide is treated by 10 % Sodium Hydrochloride to 0.2
ppm level and then drained to ETP.
Chemical Reactions:
Material Balance
Sr.
No.
Input – Raw
materials
Quantity
in Kg
Output- Product /
Bi Product
Quantity
in Kg
Remarks
1. 2:3 DCNB 1110.0 2 - CNBN 1010.0 Final Product
2. DMF 225.0 Recovered DMF 215.0 Recycle
3. NaCN 225.0.0 DMF Loss 10.0
4. CuCN 150.0 MNCB 70.0 Bi- Product
5. Water 2000.0 DCNB 40.0 Bi- Product
6. 5 % Ammonia 1000.0 MCB recovered 2950 Recycle
7. Sodium Hypochlorite
soln 1100.0 MCB Loss 50.0
8. MCB 3000.0 Detoxified Aq. layer 4465.0 Sent to ETP
TOTAL 8810.0 TOTAL 8810.0
+
NaCl
NO2
2:3 Di Chloro Nitro
Benzene (2:3 DCNB)
MW.- 192.0
Cl
NaCN
+
2- Chloro 6-Nitro
Benzonitrile (CNBN)
MW. - 182.5
+
CuCN
Cl
NO2
Cl
CN
+
CuCl
Sodium
Chloride
MW-58.5
Cuprous
Chloride M.
W. - 99.0
93
4) 2,4 Di Chloro 3,5 Di Nitro Benzotrifluoride
Brief Manufacturing Process:
Step I
2,4 Di Chloro Benzo Tri Fluoride undergoes Nitration reaction by Nitric Acid in Presence of Sulphuric Acid
to give 2,4 Di Chloro 3- Nitro Benzo Tri Fluoride
Step II
2,4 Di Chloro 30 Nitro Benzo Tri Fluoride on further Nitration by Nitric Acid in Presence of Oleum 28 %
gives the Intermediate as 2,4 Di Chloro 3,5 Di Nitro Benzo Tri Fluoride
Chemical Reactions: -
Material Balance
Sr.
No. Input – Raw materials
Quantity
in Kg
Output- Product / Bi
Product
Quantity
in Kg
1 2,4 Di Chloro Benzotrifluoride 1000.0 2,4 Di Chloro 3,5 Di Nitro
Benzotrifluoride 1000.0
2 Nitric Acid 780.0 Spent Acid to Sale 3340.0
3 Sulphuric Acid / Spent Sulphuric
Acid 3400.0 Spent Acid to Recycle 3400.0
4 Oleum 28 % 3000.0 Recovered DMF 1460.0
5 10 % Soda Ash Solution 200.0 DMF Loss 40.0
6 Water 200.0. Aqueous Layer to ETP 1055.0
7 33% Hydrochloric Acid 110.0
8 Caustic Lye 48 % 105.0
9 Di Methyl Formamide 1500.0
TOTAL 10295.0 TOTAL 10295.0
CF3
+
HNO3
H2SO4
H2SO4 +
+
HNO3
H2SO4
H2S2SO7
+
Cl
CF3 Cl
NO2 Cl
Cl 2,4 Di Chloro Benzo
Tri Fluoride MW-
215.0
Nitric Acid
MW- 63.0.0 2,4 Di Chloro 3- Nitro
Benzo Tri Fluoride
MW- 260.0
CF3 Cl
NO2 Cl
O2N
CF3 Cl
NO2 Cl
2,4 Di Chloro 3,5 Di Nitro Benzo
Tri Fluoride—MW- 305.0
+
HNO3
Sulphuric Acid
MW- 98.0
2,4 Di Chloro 3- Nitro Benzo
Tri Fluoride MW- 260.0
NO2
94
+ SOCl2 + S + 2 HCl
Benzene Thionyl Chloride Di Phenyl Sulphide
5) Di Phenyl Sulphide
Brief Manufacturing Process:
When Benzene Acid undergoes reaction by Sulfuryl Chloride in presence of Catalyst Ferric
Chloride gives the Product Di Phenyl Sulphide.
Chemical Reactions: -
Material Balance for 1.0 MT
Sr.
No. Input – Raw materials
Quantity
in Kg
Output- Product / Bi
Product
Quantity in
Kg
1 Benzene 3000.0 Di Phenyl Sulphide 1020.0
2 Ferric Chloride 15.0 Recovered Benzene 2120.0
3 Catalyst -1 10.0 Benzene Loss 80/0
4 Sulfuryl Chloride 765.0 30 % Hydrochloric Acid
Solution 700.0
5 Water for 30 % HCl solution
Formation 490.0 Aqueous Layer to ETP 848.0
6 2 % Soda Ash Solution 500.0 Distillation Residue 12
TOTAL 4780.0 4780.0
95
Perfumery Chemical:
MANUFACTURING PROCESS DETAILS – Group A
01. Product Name – Allyl Caproate
Brief process:
Allyl Caproate can be prepared by refluxing mixture of Allyl Alcohol and Caproic acid in
presence of acid catalyst. After the completion of reaction,the reaction mass will be washed
with soda ash wash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
CH3OOHCH3 + CH2
CH2OH
CH3O
O
CH2 + H2O
Caproic Acid Allyl Alcohol Allyl Caproate Water
M.Wt – 119 M.Wt- 58 M.Wt- 159 M.Wt - 18
Material Balance:
Step: 1
Input Quantity
in Kgs
Out Put Quantity in Kgs
Allyl Alcohol 500 Allyl Caproate 1330
Caproic Acid 1000 Water generated during
reaction
151
96
247
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1577 Total 1577
96
02. Product Name – AllYL HEPTANOATE
Brief process:
Allyl heptanoate can be prepared by refluxing mixture of Allyl Alcohol and Heptanoic acid in
presence of acid catalyst. After the completion of reaction, the reaction mass will be washed
with soda ash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
CH3OOHCH3 + CH2
CH2OH
O
O
CH3
CH2
+H2O
Heptanoic acid Allyl Alcohol Allyl Heptanoate Water
M.Wt-133 M.Wt – 58 M.Wt – 173 M.Wt-18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Allyl Alcohol 450 Allyl Heptanoate 1300
Heptanoic acid 1000 Water generated during
reaction
135
92
227
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1527 Total 1527
97
03. Product Name – Isobutyl caproate
Brief process:
Isobutyl caproate can be prepared by refluxing mixture of Isobutyl Alcohol and Caproic acid in
presence of acid catalyst. After the completion of reaction, the reaction mass will be washed
with soda ash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
CH3OOHCH3 +
O
O
CH3CH3
CH3
+H2OOH
Caproic acid Isobutyl Alcohol Isobutyl caproate Water
M.Wt-119 M.Wt – 74 M.Wt – 175 M.Wt-18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Isobutyl alcohol 630 Isobutyl caproate 1465
Caproic acid 1000 Water generated during
reaction
151 242
P-toluene sulphonic
acid
20 Aqueous layer to ETP 91
Soda Ash 7
Water 50
Total 1707 Total 1707
98
04.Product Name – Amyl caproate or Isoamyl caproate
Brief process:
Amyl caproate can be prepared by refluxing mixture of Amyl Alcohol and Caproic acid in
presence of acid catalyst. After the completion of reaction, the reaction mass will be washed
with soda ash solution, and aqueous layer will be sent to ETP.
Chemical
Reaction:
CH3OOHCH3 +
O
O
CH3
CH3
+ H2OOH
Caproic acid Amyl Alcohol Amyl caproate Water
M.Wt-119 M.Wt – 88 M.Wt – 189 M.Wt-18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Amyl alcohol 743 Amyl Caproate 1580
Caproic acid 1000 Water generated during
reaction
151
89
240
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1820 Total 1820
99
05 Product Name – Hexyl caproate
Brief process:
Hexyl caproate can be prepared by refluxing mixture of Hexyl Alcohol and Caproic acid in
presence of acid catalyst. After the completion of reaction, the reaction mass will be washed
with soda ash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
CH3OOHCH3 +
O
O
CH3
CH3
+ H2OOH
CH3
Caproic acid Hexyl Alcohol Hexyl caproate Water
M.Wt-119 M.Wt – 102 M.Wt –203 M.Wt-18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Hexyl alcohol 860 Hexyl Caproate 1700
Caproic acid 1000 Water generated during
reaction
151
86
237
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1937 Total 1937
100
06 Product Name – AllYL Phenoxyacetate
Brief process:
Allyl Phenoxyacetate can be prepared by refluxing mixture of Allyl Alcohol and Phenoxyacetic
acid in presence of acid catalyst. After the completion of reaction, the reaction mass will be
washed with soda ash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
+ CH2
CH2OH + H2O
O
O OO
OH
O
Phenoxyacetic acid Allyl Alcohol Allyl Phenoxyacetate Water
M.Wt-152 M.Wt – 58 M.Wt –192 M.Wt-18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Allyl Alcohol 385 Allyl Phenoxyacetate 1255
Phenoxy acetic acid 1000 Water generated during
reaction
118
89
207
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1462 Total 1462
101
07 Product Name – Octyl Acetate
Brief process:
Octyl Acetate can be prepared by refluxing mixture of Octanol and Acetic acid in presence of
acid catalyst. After the completion of reaction, the excess of Acetic acid is recovered & this is
salable.
Then reaction mass will be washed with soda ash wash solution, and aqueous layer will be sent
to ETP.
Chemical Reaction:
CH3 CH2OH + CH3COOH CH3O CH3
O
+ H2O
Octyl alcohol Acetic acid Octyl acetate Water
M.Wt – 130 M.Wt – 60 M.Wt -172 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Octanol 1000 Recovered Acetic Acid with
water (spent acid for sale)
426 (288+138)
Acetic Acid 750 Octyl Acetate 1315
P-toluene sulphonic
acid
20 Aqueous layer to ETP 86
Soda Ash 7
Water 50
Total 1827 Total 1827
102
08 Product Name – Decyl Acetate
Brief process:
Decyl Acetate can be prepared by refluxing mixture of Decyl alcohol and Acetic acid in presence
of acid catalyst. After the completion of reaction, the excess of Acetic acid is recovered & this is
salable.
Then reaction mass will be washed with soda ash wash solution, and aqueous layer will be sent
to ETP.
Chemical Reaction:
+ CH3COOH + H2OOHOCH3
O
Decyl alcohol Acetic acid Decyl acetate Water
M.Wt – 158 M.Wt – 60 M.Wt -200 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Decyl alcohol 1000 Recovered Acetic Acid with
water (spent acid for sale)
184 (70+114)
Acetic Acid 450 Decyl Acetate 1250
P-toluene sulphonic
acid
20 Aqueous layer to ETP 93
Soda Ash 7
Water 50
Total 1527 Total 1527
103
09 Product Name – Hexyl isobutyrate
Brief process:
Hexyl Isobutyrate can be prepared by refluxing mixture of Hexyl alcohol and Isobutyric acid in
presence of acid catalyst. After the completion of reaction, then reaction mass will be washed
with soda ash wash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
+ + H2OOH
O
OHO
O
CH3
CH3 Hexyl alcohol Isobutyric acid Hexylisobutyrate Water
M.Wt – 102 M.Wt – 88 M.Wt -172 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Hexyl alcohol 1000 Hexyl isobutyrate 1670
Isobutyric acid 864 Water generated during
reaction
176
95
271
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1941 Total 1941
104
10 Product Name – Phenoxyethylisobutyrate
Brief process:
Phenoxyethyl Isobutyrate can be prepared by refluxing mixture of Hexyl alcohol and Isobutyric
acid in presence of acid catalyst. After the completion of reaction, then reaction mass will be
washed with soda ash wash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
+ + H2O
O
OH
OOH
O
O
O
Phenoxyethanol Isobutyric acid Phenoxyethylisobutyrate Water
M.Wt – 138 M.Wt – 88 M.Wt -208 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Phenoxyethanol 1000 Phenoxyethylisobutyrate 1500
Isobutyric acid 638 Water generated during
reaction
130
85
215
P-toluene sulphonic acid 20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 1715 Total 1715
105
11 Product Name – Citronellyl Acetate
Brief process:
Citronellyl Acetate can be prepared by esterification of Citronellol with Acetic anhydride in
presence of catalyst. After the completion of reaction, then reaction mass will be washed with
water . after settling spent acetic acid will be separated and stored in drums as salable by
products & organic layer neutralize d with soda ash wash solution, and aqueous layer will be
sent to ETP.
Chemical
Reaction:
+ + H2OOH OO
O
O
O
Citronellol Acetic Anhydride Citronellyl acetate Acetic Acid
M.Wt – 158 M.Wt – 102 M.Wt -200 M.Wt - 60
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Citronellol 1000 Spent Acetic Acid by product 610
Acetic Anhydride 660 Citronellyl Acetate 1250
Water 200
Total 1860 Total 1860
CH3COOH
106
12 Product Name – Geranyl tiglate
Brief process:
Geranyl tiglate can be prepared by esterification of geranyl alcohol with tiglic acid in presence
of resin catalyst. After the completion of reaction, Resin catalyst filtered and then washed with
soda ash wash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
OH
+
O
OH
O
O
CH3
CH3
+H2O
Geranylalcohol Tiglic acid Geranyl tiglate Water
M.Wt – 154 M.Wt – 100 M.Wt -236 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Geranyl alcohol 1000 Geranyl tiglate 1525
Tiglic acid 656 Water generated during
reaction
117
91
208
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda ash 7
Water 50
Total 1733 Total 1733
107
13 Product Name – Phenyl ethyl tiglate
Brief process:
Phenyl ethyl tiglate can be prepared by esterification of Phenyl ethyl alcohol with tiglic acid in
presence of acid catalyst. After the completion of reaction, Resin catalyst filtered and then
washed with soda ash wash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
+
O
OH+ H2O
OH O
O CH3
Phenylethyl alcohol Tiglic acid Phenylethyl tiglate Water
M.Wt – 122 M.Wt – 100 M.Wt -204 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Phenylethyl alcohol 1000 Phenylethyl tiglate 1660
Tiglic acid 825 Water generated during
reaction
147
95
242
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda ash 7
Water 50
Total 1902 Total 1902
108
14 Product Name – Cinnamyl cinnamate
Brief process:
Cinnamyl cinnamate can be prepared by esterification of cinnamyl chloride with sodium
cinnamate in presence of amine. After the completion of reaction, the mass washed with water
(sodium chloride solution) & organic mass neutralized with acetic acid.
Chemical Reaction:
Cl+
Na+
O
O-
O
O + NaCl
Cinnamyl chloride Sodium cinnamate Cinnamyl cinnamate Sodium chloride
M.Wt – 152 M.Wt – 170 M.Wt -264 M.Wt - 58
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Cinnamyl chloride 1000 Sodium chloride solution as
byproduct
665
Sodium cinnamate 1119 Cinnamyl cinnamate 1730
Triethylamine 25
Acetic acid 1
Water 250
Total 2395 Total 2395
109
15 Product Name –Ethyl butyrate
Brief process:
Ethyl butyrate can be prepared by refluxing mixture of Ethyl alcohol and butyric acid in
presence of acid catalyst. After the completion of reaction, then reaction mass will be washed
with soda ash wash solution, and aqueous layer will be sent to ETP.
Chemical Reaction:
CH3
OH
+ CH3
OOH
CH3
OO
CH3
+ H2O
Ethyl alcohol butyric acid Ethyl butyrate Water
M.Wt – 46 M.Wt – 88 M.Wt -116 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Ethyl alcohol 1000 Ethyl butyrate 2500
butyric acid 1913 Water generated during
reaction
391
99
490
P-toluene sulphonic
acid
20 Aqueous layer to ETP
Soda Ash 7
Water 50
Total 2990 Total 2990
110
Group B
1 Product Name – SANDALITE
Brief process:
Step -1
SANDALITE can be prepared by adding mixture of Campholenic aldehyde and Butyraldehyde
under reflux of alkaline methanol. After the completion of reaction, the reaction mass is
neutralized with Sulphuric acid, then recover the excess of methanol; wash the mass with water
and taken for reduction.
Chemical Reaction:
CH3CH3
CH3 O+
O
CH3
CH3CH3
CH3
O
CH3
+H2O
Campholenic Aldehyde Butyraldehyde Cabal
water
M.Wt – 152 M.Wt – 72 M.Wt -206 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Campholenic
Aldehyde
1000 Cabal 1350
Butyraldehyde 480 Recovered Methanol &
Recycled
1960
Methanol 2000 Aqueous layer to ETP 790
Sulphuric Acid (30%) 140 Vapour loss 40
Sodium Methoxide 20
Water 500
Total 4140 Total 4140
111
Step -2
Above mentioned purified Cabal material is treated with alkaline sodium borohydride solution
in methanol media, after completion of process neutralized with acetic acid and recover the
excess of methanol; wash the mass with water and unload the crude.
Chemical Reaction:
CH3CH3
CH3
O
CH3
CH3CH3
CH3
OH
CH3
+ NaBH4+
Cabal Sodiumborohydride Sandalite
M.Wt – 206 M.Wt – 38 M.Wt -208
Material Balance:
Step-2:
Input Quantity in Kgs Out Put Quantity in Kgs
Purified Cabal 1350 Sandalite 1360
Caustic Lye (50%) 20 Recovered Methanol 1960
Methanol 2000 Aqueous layer to ETP 735
Sodium Borohydride 90 Vapour loss 40
Acetic Acid 135
Water 500
Total 4095 Total 4095
112
02. Product Name – PURASANDAL
Brief process:
Step -1
PURASANDAL can be prepared by adding mixture of Campholenic aldehyde and
propionaldehyde under reflux of alkaline methanol. After the completion of reaction, the
reaction mass is neutralized with Sulphuric acid, then recover the excess of methanol; wash the
mass with water and crude taken for reduction.
Chemical Reaction:
CH3CH3
CH3 O+ CH3
O CH3CH3
CH3
CH3
O
+ H2O
Campholenic Aldehyde Proionaldehyde Palca
water
M.Wt – 152 M.Wt – 58 M.Wt - 192 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Campholenic
Aldehyde
1000 Palca 1255
Propionaldehyde 390 Recovered Methanol &
recycled
1960
Methanol 2000 Aqueous layer to ETP 735
Sulphuric Acid (30%) 80 Vapour loss 40
Sodium Methoxide 20
Water 500
Total 3990 Total 3990
113
Step -2
Above mentioned purified Palca material is treated with alkaline sodium borohydride solution
in methanol media, after completion of process neutralized with acetic acid and recover the
excess of methanol; wash the mass with water and unload the crude.
Chemical Reaction:
CH3CH3
CH3
CH3
O
CH3CH3
CH3
CH3
OH
+ NaBH4
Palca Sodiumborohydride Purasandal
M.Wt – 192 M.Wt – 38 M.Wt -194
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Palca 1255 Purasandal 1260
Caustic Lye (50%) 20 Recovered Methanol &
Recycled
1860
Methanol 1900 Aqueous layer to ETP 720
Sodium Borohydride 80 Vapour loss 40
Acetic Acid 125
Water 500
Total 3880 Total 3880
114
03 Product Name – Megasandol
Brief process:
Step -1
CAMAC can be prepared by adding mixture of Campholenic aldehyde and Methyl ethyl ketone
into mixture of methanol, Caustic potash and water under cold condition. After the completion
of reaction, the reaction mass is neutralized with Acetic acid, then recover the excess of
methanol and MEK (recycled for 3 times), Separate aqueous layer (recycled in next reaction)
and unload organic layer.
Chemical Reaction:
CHO+
O
O
+ H2O
Campholenic Aldehyde MEK CAMAC water
M.Wt – 152 M.Wt – 72 M.Wt – 206 M.Wt – 18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in
Kgs
Campholenic
Aldehyde
300 CAMAC 400
MEK 750 Recovered Methanol & MEK
Recycled
1340
Methanol 750 Aqueous layer to ETP 153
WATER 80 Vapour loss 18
Caustic Potash 16
Acetic acid 15
Total 1911 Total 1911
115
Brief process:
Step -2 : SUPER CAMEK
Super Camek can be prepared by adding purified camek into the mixture of methanol and
sodium hydroxide under cold condition. After the completion of reaction, the whole mass is
neutralized with acetic acid, wash the organic layer with water, all aqueous layer is sent to ETP,
recover the excess of methanol and collect the crude.
Chemical Reaction:
OO
+ NaOH
CAMAC Sodium Hydroxide Super CAMEK
M.Wt – 206 M.Wt – 38 M.Wt -206
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
CAMAC 400 Super CAMEK 400
Methanol 400 Recovered Methanol 390
Sodium Hydroxide 40 Aqueous layer to ETP 300
Water 200 Vapour loss 10
Acetic Acid 60
Total 1100 Total 1100
116
Step -2 : METHYL CAMEK
Methyl Camek can be prepared by adding purified super camek into the mixture of dimethyl
formamide, toluene and sodium tertiary butoxide under cold condition. After the completion of
reaction, then add methyl bromide into the reaction mass under cold condition. After the
completion of reaction, the whole mass is quenched in chilled water after that mass is
neutralized with acetic acid, wash the organic layer with water, all aqueous layer is sent to ETP,
recover the excess of toluene and collect the crude.
Chemical Reaction:
CH3 CH3
CH3
CH3
O
CH3 +CH3Br
CH3 CH3
CH3
CH3
O
CH3
CH3
+ NaBr
Super CAMEK Methyl bromide Methyl CAMEK Sodium bromide
M.Wt –206 M.Wt –95 M.Wt -220 M.Wt -103
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Dimethyl formamide 800 Methyl CAMEK 422
Toluene 800 Recovered Toluene 784
Sodium Tert.
Butoxide
40 Aqueous layer to ETP 828
Methyl Bromide 190 Vapour loss 32
Super CAMEK 400 Dimethyl formamide 784
Water+Ice 600
Acetic Acid 20
Total 2850 Total 2850
117
Step -3: Megasantol
Above mentioned purified Methyl Camek material is treated with alkaline sodium borohydride
solution in methanol media, after completion of process neutralized with acetic acid and
recover the excess of methanol; wash the mass with water and unload the crude.
Chemical Reaction:
CH3 CH3
CH3
CH3
O
CH3
CH3
+ NaBH4
CH3 CH3
CH3
CH3
OH
CH3
CH3
+
Super camac Sodium borohydride Megasandol
M.Wt –220 M.Wt –95 M.Wt -222
Material Balance:
Step-2:
Input Quantity in Kgs Out Put Quantity in Kgs
Methyl Camek 422 Megasandol 420
Caustic Lye (50%) 6 Recovered Methanol 590
Methanol 600 Aqueous layer to ETP 288
Sodium Borohydride 40 Vapou loss 10
Acetic Acid 40
Water 200
Total 1308 Total 1308
Flow Chart:
Purified Methyl Camek
Caustic Lye
Methanol
Acetic Acid
Sodium Borohydride
Water
Stainless Steel
reactor Recovered Methanol &
recycled
Megasandol Aqueous layer to ETP
for Treatment
118
04 Product Name – DIPAL
Brief process:
DIPAL can be prepared by adding propionaldehyde into alkaline water. After the completion of
reaction, the reaction mass is neutralized with Acetic acid, then separate aqueous layer &
organic mass.
Chemical Reaction:
CH3 CHO2 + NaOH CH3
CH3
CHO
+ H2O
Propionaldehyde Sodium hydroxide Dipal Water
M.Wt –58x2 =116 M.Wt –40 M.Wt -98 M.Wt -18
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Propionaldehyde 200 Dipal 160
Water 100
Sodium Hydroxide 5 Aqueous layer to ETP 152
Acetic acid 7
Total 312 312
Note: Water after neutralization the aqueous layer recycled for one more time, and then send
it for ETP for treatment.
119
05 Product Name – PRINILE
Brief process:
Step -1 : Prenile
Prinile can be prepared by adding mixture of benzyl cyanide and cyclohexanone under refluxing
alkaline methanol. After the completion of reaction, the reaction mass is neutralized with acetic
acid & recover the excess of methanol, then extract the mass with cyclohexane and wash the
material with water, aqueous layer sent to ETP, recover the excess of cyclohexane and collect
the crude.
Chemical Reaction:
N
+
O
N
+ H2O
Benzyl cyanide Cyclohexanone Prenile Water
M.Wt –117 M.Wt –98 M.Wt -197 M.Wt -18
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Benzyl Cyanide 210 Prinile 345
Cyclohexanone 175 Recovered
Cyclohexane
88
Cyclohexane 90 Recovered Methanol 225
Methanol 230 Aqueous layer to ETP 102
Sodium Methoxide 21 Vapour Loss 40
Water 50
Acetic Acid 24
Total 800 Total 800
120
06. Product Name – ISOJASMONE P
Brief process:
Step -1
ISOJASMONE P can be prepared by adding mixture of cyclopentanone and valeraldehyde under
reflux of alkaline methanol. After the completion of reaction, the reaction mass is neutralized
with Sulphuric acid, then recover the excess of methanol; wash the mass with water and crude
taken for reduction.
Chemical Reaction:
O
+ CH3
CHO
O
CH3
+H2O
Cyclopentanone Valeraldehyde PCP water
M.Wt – 84 M.Wt – 86 Wt – 152 M.Wt – 18
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Cyclopentanone 100 PCP 175
valeraldehyde 103 Recovered Methanol &
recycled
196
Methanol 200 Aqueous layer to ETP 88
Sulphuric Acid (30%) 8 Vapour loss 4
Sodium Methoxide 2
Water 50
Total 463 Total 463
121
Step -2
Above mentioned purified PCP material is treated with HCl solution media, after completion of
process neutralized with Sodium hydroxide and wash the mass with water and unload the
crude.
Chemical Reaction:
OCH3
+ HCl
OCH3
PCP Hydrochloric acid Isojasmone P
M.Wt – 152 M.Wt – 36.5 M.Wt -152
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
PCP 175 Isojasmone P 172
HCl 50
Sodium Hydroxide 40 Aqueous layer to ETP 163
Water 70
Total 335 Total 335
122
GROUP C
01 Product Name – Citralite
Brief process:
Citralite can be prepared by refluxing mixture of methanol and d-limonene/ orange terpenes in
presence of acid catalyst. After the completion of reaction, the organic mass neutralized and
excess of methanol is recovered & is to be recycled.
The reaction mass will be washed by water and aqueous layer will be sent to ETP.
Chemical Reaction:
+ CH 3OH Terpinyl methyl ether isomers
Citralite
Limonene Methanol M.Wt- 168
M.Wt –136 M.Wt –32
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
D,Limonene / orange
terpenes
1000 Recovered Methanol
recycled
750
Methanol 1000 Citralite 1230
P-toluene sulphonic acid 30 Aqueous layer to ETP 110
Diethanolamine 25 Vapour Loss 15
Water 50
Total 2105 Total 2105
123
02. Product Name – PRAISTONE
Brief process:
Praistone can be prepared by refluxing mixture of Propylene glycol and ethyl acetoacetate and
Toluene in presence of acid catalyst remove water continuously through ageotropic . After the
completion of reaction, recover Toluene. After solvent recovery unload the crude mass.
Chemical Reaction:
OO
O+ OH
OH O
OO
O + H2O
Ethylacetoacetate Propyleneglycol Praistone Water
M.Wt –130 M.Wt –76 M.Wt- 188 M.Wt –18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Ethyl acetoacetate 1000 Aq. Layer of effluent 157
Propylene glycol 586 Recovered Toluene
recycled
1960
P-toluene sulphonic
acid
1 Praistone 1430
Toluene 2000 Vapour loss 40
Total 3587 Total 3587
124
03.Product Name – APPLITONE
Brief process:
Applitone can be prepared by refluxing mixture of ethylene glycol and ethyl acetoacetate and
Toluene in presence of acid catalyst remove water continuously through ageotropic . After
completion of reaction, recover Toluene. After solvent recovery unload the crude mass.
Chemical Reaction:
OO
O
+OH
OHO
OO
O + H2O
Ethylacetoacetate Ethyleneglycol Applitone Water
M.Wt –130 M.Wt –62 M.Wt- 174 M.Wt –18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put
Quantity in Kgs
Ethyl acetoacetate 1000 Aq. Layer of effluent 148
Ethylene glycol 477 Recovered Toluene recycled 1960
P-toluene sulphonic
acid
1 Applitone 1330
Toluene 2000 Vapour loss 40
Total 3478 Total 3478
125
04 Product Name – HERBOXANE
Brief process:
Herboxane can be prepared by refluxing mixture of valeraldehyde and Hexylene glycol and
Toluene in presence of acid catalyst remove water continuously through ageotropic . After the
completion of reaction, neutralize with soda ash water & recover Toluene. After solvent
recovery unload the crude mass.
Chemical Reaction:
CHO +
OH
OH
O
O + H2O
Valeraldehyde Hexylene glycol Herboxane Water
M.Wt –86 M.Wt –118 M.Wt- 186 M.Wt –18
Material Balance:
Step: 1
Input Quantity in
Kgs
Out Put Quantity in Kgs
Valeraldehyde 500 Water collected during
reaction
104
Hexylene glycol 687 Recovered Toluene
recycled
980
P-toluene sulphonic
acid
25 Herboxane 1075
Toluene 1000 Aqueous layer to ETP 145
Soda ash 12 Vapour loss 20
Water 100
Total 2324 Total 2324
126
Group –D
01 Product Name – SAFRANAL
Brief process:
Step -1 : TMCC
TMCC can be prepared by adding Anitral (Mixture of Citral, Aniline & Cyclohexane) into mixture
of Cyclohexane and 92% of Sulphuric Acid under cold condition. After the completion of
reaction, the reaction mass is quenched into chilled water, then separate spent acid , remain
organic layer is neutralized with sodium bicarbonate solution, then recover the excess of
cyclohexane and collect the crude.
Chemical Reaction:
CH3 CH3
CH3
CHO
+
NH2 CH3 CH3
CH3
CHO
Citral Aniline TMCC
M.Wt –152 M.Wt –93 M.Wt- 152
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Citral 100 TMCC 99
Aniline 65 Recovered
Cyclohexane
490
Cyclohexane 500 Spent Acid (by
product)
588
Sulphuric Acid (92%) 380 Vapour Loss 10
Sodium bicarbonate 2.0 Aniline recover 60
Water 200
Total 1247 Total 1247
127
Step -2 : Safranal
Safranal can be prepared by adding liquid Bromine into mixture of Dimethyl formamide &
purified TMCC under cold condition. After bromine addition, add lithium Carbonate into the
reaction mass and heat for some time, after completion of reaction, extract the mass with
cyclohexane, wash the organic mass with water(Lithium bromide solution as byproduct), and
also neutralized organic layer with sodium bicarbonate solution, then recover the excess of
cyclohexane and collect the crude.
Chemical Reaction:
CH3 CH3
CH3
CHO
+ Br2 + LiCO3
CH3 CH3
CH3
CHO
+LiBr
TMCC Bromine Lithium carbonates Safranal Lithium bromide
M.Wt –152 M.Wt –159.8 M.Wt- 66.9 M.Wt- 150 M.Wt- 86.8
Material Balance:
Step: 2
Input Quantity in Kgs Out Put Quantity in Kgs
TMCC 99 Safranal 95
Dimethyl formamide 470 Recovered
Cyclohexane
314
Cyclohexane 320 Lithium bromide
solution as byproduct
1037
Bromine 105 Vapour Loss 6
Lithium Carbonate 58
Water 400
Total 1452 Total 14512
128
02 Product Name – CDEA
Brief process:
Step -1 :
CDEA can be prepared by refluxing mixture of ethyl alcol and Citral and Triethylorthoformate in
presence of acid catalyst . After completion of reaction, neutralize with soda ash solution and
unload the crude mass.
Chemical Reaction:
CH3 CH3
CH3
CHO
+ CH3
OH
CH3 CH3
CH3
O
O
CH3
CH3
+ H2O
Citral Ethyl alcohol CDEA Water
M.Wt –152 M.Wt –46x2=92 M.Wt- 226 M.Wt - 18
Material Balance:
Step: 1
Input Quantity in Kgs Out Put Quantity in Kgs
Citral 1000 CDEA 1470
Ethyl alcohol 605
PTSA 10 Effluent to ETP 210
Triethylorthoformate 5
Soda ash 10
Water 50
Total 1680 Total 1680
129
ANNEXURE: 4
WATER CONSUMPTION AND EFFLUENT GENERATION
Proposed
Sr.
No.
Category Proposed Scenario (m3/day)
Water Consumption Waste Water
Generation
1. Industrial
Process 57 50
Boiler 20 1
Cooling 20 1
Washing 4 4
Scrubber 4 4
2. Gardening 5 -
3. Domestic 10 8
Total (Industrial) 105 60
Total 120 68
130
WATER BALANCE DIAGRAM
Raw Water – 120 KL/Day from GIDC
Domestic –
10 KL/Day
Process -
57 KL/Day
Boiler – 20
KL/Day
Cooling
Tower – 20
KL/Day
Gardening
– 5 KL/Day
Soak Pit/ Septic
Tank – 8 KL/Day
50 KL/Day 1 KL/Day 1 KL/Day
Effluent 60 KL/Day
Washing
– 4 KL/Day Scrubber
– 4 KL/Day
4 KL/Day 4 KL/Day
MEE –20 KL/Day
MEE Salt (1
MT/Day) �
TSDF
MEE Condensate (19 KL/Day)
Option-1: 60 KL/Day effluent
(Primary ETP) Option-2 : 60 KL/Day effluent
(Primary ETP)
Option-1: 59 KL/Day treated
effluent � CETP for further
treatment
Effluent (40 KL/Day) + 19
KL/Day MEE Condensate to
ETP = 59 KL/Day
Solvent Stripper –60 KL/Day
High COD Stream –
2 KL/Day � Common
Incinerator MEE –58 KL/Day
MEE Salt (4
MT/Day) �
TSDF
MEE Condensate (54 KL/Day)
SBT
RO RO Permeate -40 KL/Day
RO Reject – 14 KL/Day
131
ANNEXURE: 5
ETP DETAILS
Option-1
Process Description of Effluent Treatment Plant
M/s. V-India Chemical Industries pvt. Ltd. shall have an Effluent treatment plant consisting of
primary, secondary and advance treatment units. The effluent confirming to inlet standards of
CETP shall be sent to CETP (under execution). The details of proposed ETP are as follows.
For low COD and TDS Stream: I (40 KLD)
First all non-toxic and biodegradable streams of wastewater shall pass through Screen Chamber
(SC) where floating material shall be removed with help of Screen (S-01). Then effluent shall be
collected in Equalization cum Neutralization Tank-1 (ENT-1). Here, caustic is added from Caustic
Dosing Tank by gravity to maintain neutral pH of wastewater. Mixer is provided in ENT-1 to
keep all suspended solids in suspension and to provide proper mixing.
Then after, neutralized wastewater shall go to Flash Mixer-1 (FM-1) by gravity. Alum and
Polyelectrolyte shall be dosed from Alum Dosing Tank (ADT) and Polyelectrolyte Dosing Tank
(PEDT) respectively by gravity into FM to carry out coagulation by using a Flash Mixer.
Then after, coagulated wastewater shall be settled in Primary Tube Settler (PTS). Clear
supernatant from PTS shall be passed in Aeration Tank (AT). Here, condensate from MEE shall
be mixed with effluent. In AT biodegradation of organic matter of the wastewater shall be
carried out by bacteria (suspended growth) in the AT and for that oxygen shall be supplied by 2
nos. of air blowers (B-01) through diffusers. Air blowers also keep MLSS in suspension.
Nutrients will be added from NDTs to Aeration Tank for growth of Bacteria.
Then after, waste water shall go to Secondary Settling Tank (SST) from AT. Here, the suspended
solids shall be settled. Sludge shall be removed from bottom of SST and pumped to AT to
maintain MLSS and excess activated sludge shall be sent to Sludge Sump (SS). Clear supernatant
from SST shall be collected in Treated Effluent Sump before sending to CETP.
Sludge settled in PTS and excess sludge from SST shall be collected in Sludge Sump then sludge
shall be pumped to Filter Press where, dewatering shall be carried out before storage in HWSA
and ultimate disposal to TSDF. Leachate from FP shall be sent back to ENT-1 for further
treatment.
132
For High COD and high TDS Stream: II (20 KLD)
All High COD & TDS streams of wastewater shall be collected in Equalisation cum Neutralisation
Tank-2 (ENT-2) where caustic shall be added from Caustic Dosing tank to maintain neutral pH of
waste water. Then after, Neutralised wastewater shall be pumped to Flash Mixer-2 (FM-2)
where Alum and poly shall be added from Alum Dosing Tank and Poly Dosing Tank respectively.
Then after, coagulated wastewater shall be settled in Primary Settling Tank (PST). Sludge settles
in PST shall be sent to Sludge sump (SS) and then pumped to Filter Press (FP) for dewatering.
Clear effluent from PST shall be collected in Holding Tank (HT) before pumped to strippers.
Effluent from stripper shall be then collected in MEE Feed Tank before pumped to Multiple
Effect Evaporator. Condensate from MEE shall be sent back to Aeration Tank (AT) for further
treatment and solids from Dryer (ATFT) shall be collected and stored in HWSA for disposal in
TSDF.
133
SIZE OF TANKS
S.N. Name of unit Size (m x m x m) No. MOC/ Remark
Steam I -Low COD and TDS Stream (40 KLD )
1 Screen Chamber (SC) 2.0 x 0.5 (0.05 LD+0.5 FB) 1 RCC M25+A/A
Bk. Lining
2 Equalization cum Neutra-
lization Tank-1 (ENT-1)
3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A
Bk. Lining
4 Flash Mixer-1 (FM-1) 1.0 x 1.0 x (2.0 LD +0.5 FB) 1 RCC M25
5 Primary Tube Settler (PTS) 2.0 x 2.0 x (2.0 LD + 0.75 HB+
0.5 FB)
1 RCC M25
6 Aeration Tank (AT) 9.0 x 6.0x (4.5 LD +0.5FB) 1 RCC M25
7 Secondary Settling Tank(SST) 3.0 x 2.0 x(2.5 LD + 0.75 HB+0.5
FB)
1 RCC M25
10 Sludge Sump (SS) 2.5 x 2.5 x (2.5 LD + 0.5) 1 RCC M25
11 Filter Press (FP) 20 M3 / day 1 PP
12 Treated Effluent Sump(TES) 4.8 x2.5 x (2.5 LD+0.5 FB) 1 RCC M25
Stream II High COD and TDS Stream (20 KLD)
1 Equalisation cum Neutr-
alization Tank-2(ENT2)
3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A
Bk. Lining
2 Flash Mixer-2(FM-2) 1.0 x 1.0 x (1.5LD+0.5 FB) 1 RCC M25
3 Primary Settling Tank (PST) 2.0 x 1.2 x (2.0LD+0.5 FB) 1 RCC M25
4 Holding Tank (HT) 3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25
5 Strippers 20 m3/day 1 SS
6 MEE Feed Tank (MFT) 3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25
7 Four Stages Multiple Effect
Evaporators with ATFT (MEE
,ATFT)
20 m3/day 1 SS
RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)
PCC = PLAIN CEMENT CONCREAT
SS = STAINLESS STEEL
PP = POPYPROPELINE
135
Option-2:
Process Description of Effluent Treatment Plant
M/s. V-India Chemical Industries Pvt. Ltd. shall have an Effluent treatment plant consisting of
primary, SBT and advance treatment units. The details of ETP are as follows.
Low COD and TDS Stream: I (40 KLD)
First all non-toxic and biodegradable low Cod and TDS streams of wastewater shall pass
through Screen Chamber (SC) where floating material shall be removed with help of Screen (S-
01). Then effluent shall be collected in Equalization cum neutralization tank-1 (ENT-1). Mixer
will be provided in ENT-1 to keep all suspended solids in suspension. There continuous addition
and stirring of Caustic solution will be done to maintain neutral pH of wastewater from Caustic
Dosing Tanks (CDT) as per requirement by gravity.
Then after, neutralized wastewater shall go to Flash Mixer-1 (FM-1) by pumping. Alum and
Polyelectrolyte shall be dosed from Flocculants Dosing Tank (FLDT) and Polyelectrolyte Dosing
Tank (PEDT) respectively by gravity into FM to carry out coagulation by using a Flash Mixer.
Then after, coagulated wastewater shall be settled in Primary Tube Settler (PTS). Clear
supernatant from PTS shall be collected in Holding Tank-1 (HT-1). Here, MEE condensate water
shall be mixed with the effluent. From HT-1, effluent shall be pumped to Catalytic Advance
Treatment System (CAOS) as pre treatment, and then effluent will be collected in Holding Tank-
2 (HT-2).
Then after effluent will be pumped to Bio-Reactor-1 (BR-1). The process will be batch process
in which wastewater will be pumped and applied onto the top surface of the Bioreactor. The
design has suitable provision for manual removal of suspended solids from the bio-filter
surface. Distribution of wastewater over the media will be achieved via pumping, piping and
distribution arrangements. Separate distribution lines s h a l l b e provided for raw
wastewater as well as recycle water. There will be two modes of suspended solids handing. In
one types, suspended solids can be applied on the surface directly and can be scrapped out
manually may be once in a month. The top 2 inch layer can be replaced with the additive
material which is easily available in the local open market. The suspended solids will be
filtered out which includes additives that combine with organic of waste to produce manure.
In the second mode, solids can be retained in the settling tank and then can be removed
mechanically. Water first percolates through the bioreactor media which in houses cultured
media in 40-60 min and gets collected into the collection tank-1. It can then be pumped on to
the media again (recycling) in order to achieve maximum solid liquid contact.
Then after, it will be pumped to Bio-Reactor-2 and collected in Collection Tank-2 as Dissolved
organic and inorganic are oxidized and the water is purified further. Then effluent will be
pumped to Bio Reactor-3 and filtered effluent will be collected in RO Feed Tank. The
recirculation mode wi l l be provided in ROFT for further polishing of the effluent, if
136
required. Treated Effluent will then sent to RO Unit for further treatment. RO permeate shall be
reused in process and RO reject water shall be sent to MEE feed Tank for further treatment.
High COD and TDS Stream: II (20 KLD)
All High COD & TDS streams of wastewater shall be collected in Equalisation cum Neutralisation
Tank-2 (ENT-2), where caustic shall be added from Caustic Dosing tank to maintain neutral pH
of waste water. Then after, Neutralised wastewater shall be pumped to Flash Mixer-2 (FM-2)
where Alum and poly shall be added from Alum Dosing Tank and Poly Dosing Tank respectively.
Then after, coagulated wastewater shall be settled in Primary Settling Tank (PST). Sludge settles
in PST shall be sent to Sludge sump (SS) and then pumped to Filter Press (FP) for dewatering.
Clear effluent from PST shall be collected in Holding Tank-3 (HT-3) before pumped to strippers.
Effluent from stripper shall be then collected in MEE Feed Tank before pumped to Multiple
Effect Evaporator. Condensate from MEE shall be sent back to Holding Tank-1 (HT-1) for further
treatment and solids from Dryer (ATFT) shall be collected and stored in HWSA for disposal in
TSDF.
137
SIZE OF TANKS
Low COD and low TDS Stream: I (40 KLD)
S.N Name of unit Size (m x m x m) No. MOC/ Remark
1 Screen Chamber (SC) 2.0 x 0.5 (0.05 LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
2 Equalization cum
Neutralization Tank-1
(ENT-1)
3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
3 Flash Mixer-1 (FM-1) 1.0 x 1.0 x (2.0 LD +0.5 FB) 1 RCC M25
4 Primary Tube
Settler(PTS)
2.0 x 2.0 x (2.0 LD + 0.75 HB+
0.5 FB)
1 RCC M25
5 Holding Tank-1 (HT-1) 7.0 x 3.5 x (3.0 LD +0.5 FB) 1 RCC M25
6 Catalytic Advance
Oxidation System
(CAOS)
As per requirement 1 SS
7 Holding Tank-2 (HT-2) 6.0 x 3.0 x (3.0 LD +0.5 FB) 1 RCC M25
8 Bio Reactor-1 (BR-1) 25.0 x 7.0 x 3.3 1 RCC M25
9 Collection Tank-1 (CT-
1)
3.0 x 3.0 x (2.5 LD +0.5 FB) 1 RCC M25
10 Bio Reactor-2 (BR-2) 9.0 x 7.0 x 3.3 1 RCC M25
11 Collection Tank-2 (CT-
2)
3.0 x 3.0 x (2.5 LD +0.5FB) 1 RCC M25
12 Bio Reactor-3 (BR-3) 6.0 x 8.0 x 3.3 1 RCC M25
13 RO Feed Tank (ROFT) 4.5 x3.0 x (3.0 LD+0.5 FB) 1 RCC M25
14 RO Unit (RO) 80 m3/d 1 SS
15 Sludge Sump (SS) 3.0 m x 3.0 m x (2.5 m + 0.5) 1 RCC M25
16 Filter Press (FP)
20 M3 / d
1 PP
138
High COD and high TDS Stream: II (20 KLD)
S.N Name of unit Size (m x m x m) No. MOC/ Remark
1 Equalisation cum
Neutr- alization Tank-
2(ENT2)
3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25+A/A Bk.
Lining
2 Flash Mixer-2(FM-2) 1.0 x 1.0 x (1.5LD+0.5 FB) 1 RCC M25
3 Primary Settling Tank
(PST)
2.0 x 1.2 x (2.0LD+0.5 FB) 1 RCC M25
4 Holding Tank-3 (HT-3) 3.0 x 3.0 x (2.5LD+0.5 FB) 1 RCC M25
5 Strippers 20 m3/day 1 SS
6 MEE Feed Tank (MFT) 4.0 x 4.0 x (2.5LD+0.5 FB) 1 RCC M25
7 Four Stages Multiple
Effect Evaporators with
ATFT (MEE ,ATFT)
40 m3/day 1 SS
RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)
PP = POLYPROPELENE
MSEP = MILD STEEL EPOXY PAINTED
SS = STAINLESS STEEL
140
ANNEXURE: 6
DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL
Type of
Waste
Schedule
Category
Source Quantity Disposal Method
ETP waste
34.3
ETP 15 MT/ Month Collection, Storage,
Transportation & Disposal to
TSDF site
Used Oil
5.1 Plant &
Machinery
0.2 KL/ Month Collection, Storage,
Transportation & recycle to
GPCB authorized recycler
Discarded
Containers/
Bags/
Carboys
33.3 Process Bags – 2000
NoS./ Month,
Drums – 500
Nos./ Month
Decontamination, Storage &
sent to GPCB registered vendor
Distillation
Residue
20.3 Process 15 MT/ Month Collection, Storage,
Transportation & Disposal to
Incinerator site or sent to
cement industries for co-
processing
MEE Salt -- MEE 120 MT/Month Collection, Storage,
Transportation & Disposal to
TSDF site Process
Waste (Iron
Sludge &
other sludge)
26.1 Process 70 MT/Month
Inorganic
Waste
-- Process 300 MT/Month
141
ANNEXURE: 7
DETAILS OF FLUE & PROCESS GAS EMISSION
Flue Gas Emission
1. Details of Flue Gas Stack; Stack Attached To Thermopack Boiler
SOURCES OF GASESOUS EMISSIONS STACK
Capacity 100 U
Fuel Used Natural Gas = 60,000 SM3/month or
Agro Waste = 4 MT/Day
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 25 m
Stack Diameter at the Top 600 mm
2. Details of Flue Gas Stack; Stack Attached To Steam Boiler
SOURCES OF GASESOUS EMISSIONS STACK
Capacity 2 TPH
Fuel Used Natural Gas = 80,000 SM3/month
Agro Waste = 6 MT/Day
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 25 meters
Stack Diameter at the Top 600
3. Details of Flue Gas Stack; Stack Attached To D.G.Set
SOURCES OF GASESOUS EMISSIONS STACK
Capacity 100 KVA x 2
Fuel Used HSD = 50 Liter/Hr
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 11 meters
142
4. Details of Process Vent ; Vent Attached To Process
Sr. No. Stack attached to Stack Height Air Pollution
Control System
Parameter Permissible Limit
Proposed
1 Process Vent-1 11 m Two Stage
Scrubber
NH3
175 mg/Nm3
2 Process Vent-2 11 m HCl
20 mg/Nm3
3 Process Vent-3 11 m HCl
SO2
20 mg/Nm3
40 mg/Nm3
143
ANNEXURE: 8
DETAILS HAZARDOUS CHEMICAL STORAGE FACILITY
Sr.
No.
Name of the
Hazardous
Substance
Maximum
Storage
Mode of
Storage
Actual
Storage
State &
Operating
pressure &
temperature
Possible type of
Hazards
1 Methanol 10 MT Tank 10 MT x 1 NTP Flammable/
Toxic
2 HCl 20 MT Tank 10 MT x 2 NTP Corrosive
3 EDC 10 MT Tank 10 MT x 1 NTP Flammable/
Toxic
4 DMF 10 MT Tank 10 MT x 1 NTP Flammable/
Toxic
5 Chlorine 4 MT Cylinder 900 Kg 7 Kg/cm2
pressure and
room temp.
Toxic
6 Toluene 15 MT Tank 15 MT x 1 NTP Flammable
7 Ammonia 5 MT Tank 5 MT x 1 NTP Toxic
8 Sulphuric Acid 10 MT Tank 10 MT x 1 NTP Corrosive
9 Thionyl Chloride 10 MT Tank 10 MT x 1 NTP Corrosive
10 Xylene 5 MT Tank 5 MT x 1 NTP Flammable
144
ANNEXURE 9
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
The manpower requirement for the proposed project is expected to generate some permanent
jobs and secondary jobs for the operation and maintenance of plant. This will increase direct /
indirect employment opportunities and ancillary business development to some extent for the
local population. This phase is expected to create a beneficial impact on the local socio-economic
environment.
2) INDUSTRIES
Required raw materials and skilled and unskilled laborers will be utilized maximum from the local
area. The increasing industrial activity will boost the commercial and economical status of the
locality, to some extent.
3) PUBLIC HEALTH
The company regularly examines, inspects and tests its emission from sources to make sure that
the emission is below the permissible limit. Hence, there will not be any significant change in the
status of sanitation and the community health of the area, as sufficient measures have been
taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION
Since the existing factory is having proper linkage for the transport and communication, the
development of this project will not cause any additional impact.
In brief, as a result of the proposed project there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be taken
under the EMP. The proposed project is not expected to make any significant change in the
existing status of the socio - economic environment of this region.
145
ANNEXURE – 10
PROPOSED DRAFT TERMS OF REFERENCE
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various industries,
surface water bodies, forests etc.
• Project cost
• Project location and Plant layout.
• Water source and utilization including proposed water balance.
• Product spectrum (proposed products along with production capacity) and process
• List of hazardous chemicals.
• Mass balance of each product
• Storage and Transportation of raw materials and products.
2. Description of the Environment and Baseline Data Collection
• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5 km
area.
• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project site.
For SPM, RSPM, SO2, NOx.
• Ground water quality at 5 locations within 5 km.
• Complete water balance
3. Socio Economic Data
• Existing socio-economic status, land use pattern and infrastructure facilities available in the study
area were surveyed.
4. Impacts Identification And Mitigatory Measures
• Identification of impacting activities from the proposed project during construction and
operational phase.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
146
6. Risk Assessment
• Objectives and methodology of risk assessment
• Details on storage facilities
• Process safety, transportation, fire fighting systems, safety features and emergency capabilities to
be adopted.
• Identification of hazards
• Consequence analysis through occurrence & evaluation of incidents
• Disaster Management Plan.
7. Information for Control of Fugitive Emissions
8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Information on Rain Water Harvesting
10. Green Belt Development plan
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