DEEPAK NITRITE LTD. QUALITY CONTROL

Transcription

1 DEEPAK NITRITE LTD. PFR for Environmental Clearance (EC) of proposed expansion project of manufacturing of Speciality Chemicals & intermediates at Plot No.: 1-7 & 26-31, Dhatav MIDC, Roha, Raigad , Maharashtra. Goldfinch Environmental Engineering Systems Private Limited ( Goldfinch ), November 2016 This report is released for the use of the M/s Deepak Nitrite Ltd. (DNL). Regulators and relevant stakeholders solely as part of the subject EC of Proposed modernization project of Manufacturing of Synthetic organic chemicals and allied products at existing manufacturing facility located at plot No-1-7 & 26-31, Dhatav MIDC, Roha, Raigad , Maharashtra. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Goldfinch/DNL. QUALITY CONTROL Name of Publication Deepak Nitrite Ltd Proposed modernization project of Manufacturing Synthetic organic chemicals and allied products at Plot No-1-7 & 26-31, Dhatav MIDC, Roha, Raigad , Maharashtra Project Number Report No. 1 Version 1 Released December, 2016 Prepared By Reviewed By Released By Dr. Nivedita Kulkarni & Mr. Umesh Parab Mr. K. N. Sharma Mr. Anand Apte DISCLAIMER Goldfinch has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Goldfinch also believes that the facts presented in the report are based on information submitted by DNL and based on the technical expertise of Goldfinch as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Goldfinch therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 1

2 Index EXECUTIVE SUMMARY INTRODUCTION OF THE PROJECT Introduction of the Project Introduction of the Project Proponent Need for the project and its importance to the country and or region Demands-Supply Gap Imports vs. Indigenous Production Domestic /Export Markets Employment Generation due to the project PROJECT DESCRIPTION Type of Project Project Location Details of alternate sites considered and the basis of selecting the proposed site Size or Magnitude of Operation Size/Magnitude of Proposed By-Production Capacity PROCESS DESCRIPTION Raw material required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product Raw Materials: Source for Raw Material Procurement: Mode of Transport of Raw Materials: Storage at the site: Raw Materials are stored in storage yard at the project site. Location of storage yard is demarcated in Layout Plan Table 2-2: Details of Raw material Quantity Resource optimization/recycling and reuse envisaged in the project Availability of water its source, energy/power requirement and source Water Requirement and Source Recycled water from STP will be near about 30 CMD which will be used for gardening, floor washing flushing, spraying on coal etc PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 2

3 2.8.2 Power Requirement Emergency power Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal Gaseous Emissions Effluent Existing treatment Scheme for Trade Effluent Details of Hazardous wastes Schematic representations of the feasibility drawing which give information of EIA purpose SITE ANALYSIS Connectivity Land Form, Land use and Land ownership Topography Figure 3.1: Toposheet Showing Project site and 10Km of area Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ Soil classification Climatic data from secondary sources Social Infrastructure Availability Planning In Brief Planning Concept Land Use Planning Assessment of Infrastructure Demand (Physical & Social) Amenities/Facilities Population Projection Existing infrastructure Industrial area PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 3

4 5.2 Residential Area Green Belt Social Infrastructure Connectivity Connectivity Drinking Water Management Sewage System Industrial Water Management Solid Waste Management Power Requirement & Supply / source Rehabilitation and Resettlement (R & R) Plan Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless PROJECT SCHEDULE & COST ESTIMATES Likely date of start of construction and likely date of completion The modernization/product mix activity is likely to start after getting Environmental Clearance and NOC/CTE from the authorized committee Estimated project cost along with analysis in terms of economic viability of the project Economic Viability ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 4

5 EXECUTIVE SUMMARY Deepak Nitrite is a leading supplier of organic, inorganic and fine chemicals to global chemical majors. The Deepak Nitrite Ltd.(DNL)is a multi-division and multi-product company with manufacturing facilities at Nandesari and Dahej in Gujarat, Roha and Taloja in Maharashtra, and at Hyderabad in Andhra Pradesh. Deepak Nitrite aggressively works towards adopting the principles of responsible chemistry and stands among 18 Indian companies to be accredited with Responsible Care certification - towards global environment, safety and health management. The proposed products covered under application shall save $ 5 million foreign exchange for the country since they are import substitutes and besides which some of them will generate $10 million of exchange for our country through their export. Needless to say that these initiatives shall be our contribution to Make in India movement and shall generate additional profits for the company and revenue for the states. DNL proposed modernization project of manufacturing of synthetic organic chemicals and allied products at existing manufacturing unit at Plot No. 1-7 & 26-31, Dhatav MIDC, Roha, Raigad , Maharashtra. The proposed project falls under classification 5(f) of schedules listed in EIA notification SO1533 dated 14/09/2006. Its appraisal category is B-1. Project Synopsis: Sr. No Parameters Description 1. Category as per EIA Notification 5 (f ) B 2. Longitude N 3. Latitude E 4. Production Capacity after product mix 740MT/M, and By-products 371 MT/M 5. Total Plot Area /Built up area sq. m./ sq. m 6. Green Belt Area 2581 sq. m. 7. Fresh Water Requirement 519 CMD 8. Effluent Quantity (Trade + Domestic) 243 CMD + 31 CMD = 274 CMD Trade Effluent Treatment Domestic Waste water Treatment 243 CMD effluents are presently treated in ETP of capacity 400 CMD. It is consists of primary, secondary and tertiary treatment. Treated water will be discharged to CETP Mahad for final disposal into sea. 31 CMD treatment in Sewage treatment plan having capacity 35 CMD. Treated domestic waste will be recycle and reuse for cooling tower and gardening Fuel requirement at full load Boiler: 8 TPH X 1 no : TPD (Type Fuel: Indonesian Coal) 6 TPH X 1 no : TPD (Type Fuel: Indonesian Coal and 9 TPD(Type Fuel: Farnese Oil) Thermopack 6 lac Kcal/hr X 1no = 1 TPD (Coal)/ 0.5 TPD (FO) PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 5

6 Sr. No Parameters Description D G set = 750 KVA X 2 no 500 KVA X 1 no Fuel Required = 6 TPD (Type Fuel: HSDl) 12. Power Requirement 2100 KW Dispersion of emission for Boiler and Stack Height: 34 m stack for boiler and common stack for 13. Thermopac boiler (6TPH) and thermo Pac 24.5m. 14. Dispersion of emission DG Sets, Stack Height : 4.5m above enclosure 15. Work Force 220no. 16. Total Capital Cost the project (Cr) Rs Cr. 1.0 INTRODUCTION OF THE PROJECT 1.1 Introduction of the Project Deepak Nitrite Ltd. (Hereafter being referred as DNL for brevity in this text) intends to modernize/product mix of existing projects in the category of synthetic organic chemicals and allied products. The existing manufacturing unit is in MIDC Dhatav; which is approved chemical manufacturing zone of MIDC. DNL is located at plot no- 1-7 & Existing manufacturing capacity of the unit is 822 MT/M along with byprodtcs 371 MT/M. With this change in product mix the total quantities of products and by-products will becomes 740 MT/M and 371 MT/M respectively. As per the EIA Notification S.O dated 14th September 2006, proposed activity is covered under Synthetic Organic Chemical Industry 5 (f) and needs prior environmental clearance. Further, as the proposed industry is under category B. Since it is located in a notified industrial area the project will not need public approval and is under category B. 1.2 Introduction of the Project Proponent List of Directors and their designations S.No. Name Designation 1 Mr. C.K. Mehta, Chairman-Emeritus 2 Mr. Deepak C. Mehta Chairman & Managing Director 3 Mr. Ajay C. Mehta Managing Director 4 Mr. Umesh Asaikar CEO & Executive Director 5 Mr. Maulik Mehta Whole-Time Director PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 6

7 1.3 Brief description of nature of the project Existing manufacturing capacity of the unit is 822 MT/M along with byprodtcs 371 MT/M. With this change in product mix the total quantities of products and by-products will becomes 740 MT/M and 371 MT/M respectively. DNL have included all these products in four groups like Nitration/Hydrogenation based products, Amine based products, Speciality products and Synthetic organic chemicals. However, we have added new by-product 2NBTF(2 Nitro BTF) /2ABTF(2 Amino BTF)/4ABTF(4 Amino BTF) (Qty.-41 MT/M which is generated from the existing product 3 Amino BTF ) and OHBTF/OABTF (Qty.-20 MT/M) generated from TFMAP and increased the quantity of existing by- product OT by 5 MT/M and decreased the quantity of existing by-product PPO(Poly Phenylene Oxide) by 66 MT/M, The quantity of Byproducts Ortho Nitro Cumene (Qty.-150 MT/M) remains same as per existing consent. 1.4 Need for the project and its importance to the country and or region A global supplier of choice DNL build enduring relationships with leading chemical majors offering a spectrum of ingredients used for multiple applications and in multiple geographies.capabilities include manufacturing of high-value synthetic organic chemicals and allied products either based on our own end products or developed especially for users. The proposed products covered under application shall save $ 5 million foreign exchange for the country since they are import substitutes and besides which some of them will generate $10 million of exchange for our country through their export. Needless to say that these initiatives shall be our contribution to Make in India movement and shall generate additional profits for the company and revenue for the states. Trusted supplier for leading global companies across more than 20 countries. DNL is a global supplier of varieties of chemical Intermediates which are used in Agrochemicals, Pharmaceuticals and other chemical industries. These products will serve to cut the supply of imports from foreign countries thus saving currency and at the same time will earn valuable foreign currency by export of the proposed products 1.5 Demands-Supply Gap Competition in the Indian Chemical market swelled in recent years, with increasing generic penetration. This had many companies opting out of low-margin segments, as competition resulted in lower prices. This created a gap between demand and supply. Such unusual price hikes take place when there is withdrawal of some of the key competitors, which leads to demand override and as a consequence prices start soaring in a freepricing market. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 7

8 1.6 Imports vs. Indigenous Production The proposed products including production of speciality chemicals having high in demand in the export market. Also their demand is increasing in the domestic market. Production of these products are domestically reduces the need to import these in future along with significant scope for export in these products. 1.7 Domestic /Export Markets The finished goods will be sold in domestic market and would be largely exported to the Regulated International Market as per demand all over the world. 1.8 Employment Generation due to the project Existing emplyopes are 220 no and are sufficient. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 8

9 2.0 PROJECT DESCRIPTION 2.1 Type of Project Proposed project is a modernization/product mix of existing products in the category of synthetic organic chemicals and allied projects in existing manufacturing facility located at MIDC Dhatav, Roha. It is included in category 5(f) B of EIA notification Project Location Existing manufacturing unit is located at Plot No. 1-7 & 26-31, Dhatav MIDC, Roha, Raigad , State- Maharashtra. Major factories adjacent to the manufacturing unit are Valentine Agro located on west side and Kores on south side, Sudarshan Chemicals Ltd is located on east side there is. The site is well connected by road to Mumbai by Mumbai Goa (NH-66) National Highway at 9 Km. It connects Panvel (south of Mumbai city) to Kanyakumari, passing through the states of Maharashtra, Goa, Karnataka, Kerala and Tamil Nadu. Maharashtra State Road Transport Corporation has a Bus Depot at Roha for public transport. Nearest railway station is at Roha which is 7 Km away from site. The nearest airport is at Mumbai 117 km and Pune at 125 km. Corner Latitude Longitude A B C D E F center Figure 2-1 : Google Image of the Site PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 9

10 Figure 2-2 : DNL Plot on Dhatav MIDC plan Tank Farm for Nitration Plant Green Belt Area PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 10

11 ETP with Clalifier DEMAP Plant Fig.2-3 : Photographs of Site Location PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 11

12 The project site is situated in MIDC Dhatav. It is a notified industrial area where the land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity.the detail plant lay out is attched as Annexure-I Land Ownership: Land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company for 99 years. 2.3 Details of alternate sites considered and the basis of selecting the proposed site The proposal is for modernization/product mix of existing products in the same manufacturing unit using existing infrastructure only hence consideration of alternate site is not required. 2.4 Size or Magnitude of Operation The products manufactured and their capacities proposed are shown in below Table 2.1. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 12

13 Sr. NO. Name of Existing Product Existing Capacity Name of Proposed Product Mix Proposed Capacity 1. Para Cumidine(PC) or 2 Ethyl Hexy Nitrite 200 Para Cumidine(PC) or 3 Amino Benzotri Flouride (3ABTF) Ortho Anisidine(OA) OR Tri Methyl Hydro Quinine(TMHQ) 2,4 Xylidine and 2,6 Xylidine or nitrobenzene or 2,3 Xylidine and 3,4 Xylidine Meta Cholro Aniline Diphenyl Amine Derivatives Crystal Diethyl Meta Amino Phenol(Cryst. DEMAP) or Dibutyl Para Phenylene Di amine (DBPPDA ) Ortho Anisidine(OA) OR Tri Methyl Hydro Quinine(TMHQ) 2,4 Xylidine and 2,6 Xylidine or2,3 Xylidine and 3,4 Xylidine or2,5 Xylidine and 2,3 xylenol2,4 and 2,5 Xylenol Diphenyl Amine Derivatives Crystal Diethyl Meta Amino Phenol(Cryst. DEMAP) or Dibutyl Para Phenylene Di amine (DBPPDA or 3 NAP (3 Nitro Aceto Phenone)/ or 3AAP(3Amino Aceto Phenone) or 3 HAP (3 Hydroxy Aceto Phenone) TFMAP(3- (trifloromethyl)acetophenon MePPDA Sulphate (2 Methyl P- phenylene Diamine Sulphate) or 1,3 CHD(1,3 Cyclohexane dione) or 4-NAX (Benenamine,N-(1- ethyloropy)-3-4-dimethyl) Pilot Plant Products 1,3 CHD(1,3 Cyclohexane dione) and SMIA(syn Methoximino(2 furanyl)acetic acid TFMAP(3- (trifloromethyl)acetophenon 2 MePPDA Sulphate (2 Methyl P- phenylene Diamine Sulphate) or 1,3 CHD(1,3 Cyclohexane dione) Pilot Plant Products ( synthetic Organic Chemicals) Total PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 13

14 Size/Magnitude of Proposed By-Production Capacity Sr. NO. Name of Existing by Product Existing Capacity Name of Proposed by Product Mix Proposed Capacity 1. Ortho Nitro Cumene(from p- cumidiene) 150 Ortho Nitro Cumene(from p- cumidiene) PPO (Poly phenylene Oxide) from product tri methyle hydro quinine NBTF(2 Nitro BTF)/2 ABTF(2 Amino BTF)/ 4 ABTF (4 Amino BTF) from 3 Amino BTF Ortho Toludine(OT) 20 PPO (Poly phenylene Oxide) 135 OHBTF/OA BTF from TFMAP 20 Ortho Toludine(OT) 25 Total 371 Total 371 PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 14

15 2.5 PROCESS DESCRIPTION 1. 3-Amino acetophenone (3-AAP) Chemical Reaction:- O CH 3 O CH Fe + 4 H 2 O 4 NO 2 3-NAP AAP 540 NH Fe 3 O Process Description:- In this step, we simultaneously take the required qty. of water, 10% Sulphuric acid, Iron powder & Ammonium chloride into the reactor. Then we added the lot wise Iron powder & AAP slowly into same mass by maintaining the reaction temperature. After completion of reaction, we filtered out the reaction mass & removed the Iron powder, which recycled to the next batch. Then we added the sod. Dithionate & chilled the reaction mass, after that we filtered out the AAP by using Centrifuge. Wet AAP then dried into the dryer & we got finished AAP as a product. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 15

16 Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 16

17 2. 3-Hydroxy Acetophenone (3-HAP) Chemical Reaction:- O CH 3 3-AAP NH 2 + Diazotization 1/2 H 2 SO 4 + NaNO 2 Hydrolysis O CH 3 OH 3-HAP /2 Na 2 SO 4 + N 2 + H 2 O Process Description:- STEP-1 Diazotization & Hydrolysis In this step, we simultaneously take the required qty. of water, 98% Sulphuric acid, 3-Aminoacetophenone & toluene into the reactor. Then we added the NaNO2 Solution slowly into same mass by maintaining the reaction temperature. After completion of reaction, the reaction mass cooled down up to 5 C & filtered out through Centrifuge. Wet 3-HAP then dried into the dryer & we got crude 3-HAP. STEP-2 Purification In this step, we simultaneously take the required qty of water, Methanol, wet cake (3HAP) & charcoal into the reactor. Then heated the mass up to C & maintained it for 1 hrs. Then filtered out the reaction mass through sparkler filter. The clarity of the reaction mass is checked & the clear solution is taken into another reactor. Then filtered out the slurry mass through centrifuge. The wet cake (3HAP) is being filled into the bags & Filtered ML transferred to storage tank for recycling to next batch. Wet 3-HAP then dried into the dryer & we got finished 3-HAP as a product. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 17

18 Block Diagram: Nitro Acetophenone (3-NAP) PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 18

19 Chemical Reaction:- O CH 3 O CH 3 + HNO 3 H 2 SO 4 + H 2 O Acetophenone Nitric acid 63 3-NAP NO 2 18 Process Description:- In this step, we simultaneously take the required qty. of Acetophenone, 98% Sulphuric acid into the reactor at certain temperature. Then we added the Pre-cooled Mixed Acid (H2SO4 + HNO3) slowly into same mass by maintaining the reaction temperature. After completion of reaction, we quenched out the reaction mass by adding crushed ice. Then we filtered out the NAP by using Centrifuge. Wet NAP then dried into the dryer under certain vacuum & we got finished NAP as a product. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 19

20 Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 20

21 4. 3-Nitrobenzotrifluoride (3-Nitro BTF) Chemical Reaction:- Stage: 1 Preparation of 3-Nitrobenzotrifluoride (3-Nitro BTF) CF 3 CF 3 + HNO 3 Nitration H 2 SO 4 NO 2 BTF 3-NBTF H 2 O Stage: 2 Preparation of 3-Aminobenzotrifluoride (3-Amino BTF) CF 3 3-NBTF NO % Pd/C CF H H 2 O Methanol NH 2 3-ABTF Process Description:- 1 The 3ABTF manufacturing is a four stage process Nitration, Nitromass Separation, Hydrogenation & Hydromass Separation. 2 The BTF nitration is done to convert NBTF (Nitromass) 3 The Nitromass separation in to 2NBTF & 3NBTF. 4 The 3NBTF Hydrogenation to form ABTF Hydromass. 5 The 3ABTF Hydromass separation to 3ABTF & 4ABTF. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 21

22 Block Diagram:- Stage-I PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 22

23 Stage-II 5. Cyclohexadione (1, 3 CHD) Chemical Reaction:- Step-I PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 23

24 Step-II Process Description:- STEP 1 - Hydrogenation. In this Step, Hydrogenation is carried out in the presence of caustic lye. The Resorcinol is charged into hydrogenation reactor. Hydrogenation addition is started at specified Temperature & pressure. The temperature & pressure are maintained within specified limits during reaction. After completion of reaction, Sodium salt of 1 3 cyclohexanedione formed & which is used for further acidification process. STEP 2 Acidification In this step, the required quantity of Sodium salt of 1 3 Cyclohexanedione is taken into the reactor & then added the required quantity of 30 % HCL into the same. After complete addition, 1 3 Cyclohexanedione formed which is filtered & dried in the dryer. Block Diagram:- Hydrogenation PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 24

25 ISOLATION 1, 3, CHD CRYSTALLISATION PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 25

26 6. 2, 3 Xylenol Chemical Reaction:- Na NH2 CH3 + 1/2 W ate MIBK Process Description:- STEP 1 Diazotization & Hydrolysis Reaction In this step, we simultaneously take the required qty. of water, 98% Sulphuric acid, 2,3 Xylidine & MIBK into the reactor. Then we added the NaNO2 Solution slowly into same mass by maintaining the reaction temperature. After completion of reaction, aqueous layer separated out & organic mass then washed with 5 % soda soln. Then we transfer organics mass for further distillation Process. STEP 2 Distillation In this step we recovered MIBK, which is recycled back to Next diazotization Process & Pure 2,3 Xylenol as a finished product. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 26

27 Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 27

28 7. 2, 4 Xylidine & 2,6 Xylidine Chemical Reaction:- Stage 1: Nitration of Meta-Xylene to 2, 6-Nitro Xylene and 2,4-Nitro Xylene Stage -2: Separation/Distillation of Nitro-Xylene to 2,6-Nitro Xylene and 2,4-Nitro Xylene Stage-3 : Reduction of 2, 6-Nitro Xylene / 2,4-Nitro Xylene to 2,6-Xylidine / 2,4-Xyledine Process Description :- Nitration of Meta-Xylene to 2,6-Nitro Xylene and 2,4-Nitro Xylene 1. Nitration is carried out using spent acid, sulfuric acid & Nitric acid. Along with these compounds, the compound to be nitrated is continuously charged in to the reactors. 2. Reaction is conducted under controlled conditions as mentioned. 3. After completion of Nitration, Spent acid is seperated. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 28

29 4. After Separation Nitro mass is washed in washer to remove acidity. 5. The washed Nitro mass is then send for further Distillation. Reduction of 2, 6-Nitro Xylene / 2,4-Nitro Xylene to 2,6-Xylidine/2,4-Xyledine 1 Hydrogenation is carried out in presence of a catalyst. The compound to be hydrogenated is charged into a Hydrogenation reactor. 2. Hydrogen addition is started at specified temperature. The reaction is conducted under controlled conditions. The temperature and pressure are maintained within specified limits. 3 After complete reaction, catalyst filtered. And transferred it for Distillation. 4 The Process of hydrogenation of p- Nitrosamine, 2, 4 Nitro xylene, 2,6 Nitroxylene and o-nitro Anisole are same. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 29

30 Block Diagram:- Stage I PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 30

31 Stage II Product 2,4 Xylidine PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 31

32 Product 2,6 Xylidine 8. 2, 5 Xylenol Chemical Reaction:- NH 2 CH 3 1) NaNO2 + H2SO4 2 ) MIBK OH CH 3 H 3 C 3) o c H 3 C Process Description:- STEP 1 Diazotization & Hydrolysis Reaction In this step, we simultaneously take the required qty. of water, 98% Sulphuric acid, 2,5 Xylidine & MIBK into the reactor. Then we added the NaNO2 Solution slowly into same mass by maintaining the reaction temperature. After completion of reaction, aqueous layer separated out then we transfer organics mass for further distillation Process. STEP 2 Distillation PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 32

33 In this step we recovered MIBK, which is recycled back to Next diazotization Process & Pure 2,5 Xylenol as a finished product. Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 33

34 9. 2, 5 Xylidine Stage I: Nitration of Para Xylene to Para Nitro Xylene Stage II: Separation/Distillation of Para Nitro Xylene Stage III: Reduction of Para Nitro Xylene. Process Description:- Nitration of P-Xylene to Para Nitro Xylene 1. Nitration is carried out using a mixed acid. This mixed acid, which a mixture of nitric and Sulphuric acid is to be prepared separately. 2. Add sulfuric Acid in the Reactor. Start addition of nitric acid so that the temperature remains within specified limits. 3. Charge the compound to be Nitrated in the Reactor. Then add mixed acid gradually under controlled conditions in the compound to be nitrated. The temperature of the reaction is maintained within specified limits. A sample is drawn at the end of the addition of a defined quantity to verify that the reaction is complete. 4. From the nitrated mixture, organic layer is separated and washed with water till free of acid. The final Nitromass is to be transferred for Distillation. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 34

35 Distillation 1. In the Distillation 2,5 Nitro Xylene is Separated as pure Product. Hydrogenation Process:- 1 Hydrogenation is carried out in presence of a catalyst. The compound to be hydrogenated is charged into a Hydrogenation reactor. 2 Hydrogen addition is started at specified temperature. The reaction is conducted under controlled conditions. The temperature and pressure are maintained within specified limits. 3 After complete reaction, catalyst filtered. And transferred it for Distillation. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 35

36 Block diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 36

37 10. Para Cumidine Chemical Reaction:- Stage I: Nitration of Cumene to Para Nitro Cumene and Ortho Nitro Cumene Stage II: Separation/Distillation of Cumene to Para Nitro Cumene and Ortho Nitro Cumene Stage III: Reduction of Para Nitro Cumene. Process Description:- Nitration of Cumene to Para Nitro Cumene and Ortho Nitro Cumene 1. Nitration is carried out using a mixed acid. This mixed acid, which a mixture of nitric and Sulphuric acid is to be prepared separately. 2. Add sulfuric Acid in the Reactor. Start addition of nitric acid so that the temperature remains within specified limits. 3. Charge the compound to be nitrated in the Reactor. Then add mixed acid gradually under controlled conditions in the compound to be nitrated. The temperature of the reaction is maintained within specified limits. A sample is drawn at the end of the addition of a defined quantity to verify that the reaction is complete. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 37

38 4. From the nitrated mixture, organic layer is separated and washed with water till free of acid. The final Nitromass is to be transferred for Distillation. Hydrogenation Process:- 1 Hydrogenation is carried out in presence of a catalyst. The compound to be hydrogenated is charged into a Hydrogenation reactor. 2 Hydrogen addition is started at specified temperature. The reaction is conducted under controlled conditions. The temperature and pressure are maintained within specified limits. 3 After complete reaction, catalyst filtered. And transferred it for Distillation. Block Diagram:- Nitration PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 38

39 Distillation Reduction 11. Meta Chloro Aniline (MCA) PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 39

40 Stage I: Chlorination of Nitro-Benzene to Nitro- ChloroBenzene Stage II: Distillation of Nitro Chloro Benzene to Meta Nitro Chloro Benzene Stage III: Reduction of Meta Nitro Chloro Benzene to Meta Chloro Aniline Process Description:- 1. Nitro Benzene Reacted with Chlorine in presence of Ferrous Chloride to Form Crude Chloro Nitro Benzene 2. Meta Nitro Chloro Benzene is Separated from Crude Chloro Nitro Benzene in Distillation. 3. Meta Nitro Chloro Benzene is then reacted with Caustic Lye and Sulfur to form Meta Chloro Aniline. Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 40

41 PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 41

42 12. 2 Methyl P- Phenylene Diamine Sulphate ( 2 MePPDA Sulfate ) Chemical Reaction:- Step I - 2-Methyl-p-Phenelene diamine Step II - 2-Methyl-p-Phenelene diamine sulfate CH 3 NH 2 H 2 SO 4 NH 2 H 3 C H 2 SO 4 H 2 N NH 2 Process Description:- Step-I 1. 2-Methyl-p-Phenelene diamine is prepared by Hydrogenation in the presence of methanol + Rec. OT as a solvent. Stage-II 2. 2-Methyl-p-Phenelene diamine Sulphate is prepared by reacting with sulfuric acid. 3. In filtration the solid 2-Methyl-p-Phenelene diamine sulphate is separated from mother liquor. Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 42

43 13. 4-Methoxy 2-Methyl Diphenyl Amine (MMDPA) Chemical Reaction:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 43

44 Methylation Bromination PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 44

45 Condensation Hydrolysis PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 45

46 Process Description:- 1. MMDPA is produced by carrying out reaction stages called Methylation, Bromination, Condensation & Hydrolysis followed by purification stages. 2. Charge a measured quantity of water in to the methylation reactor. Then charge caustic lye with specified strength from metering tank. Charge M-Cresol into the reactor. 3. Add DMS gradually. 4. Charge water in to reaction mass and then charge Sulphuric acid Separate aq. and organic Layer. 5. Separate organic from the previous aq. layer, Collect the both organic layer. 6. Charge HBr of specified strength then charge measured quantity of 3-Me-Anisole in to the reactor gradually. Start addition of Nitric Acid. Neutralize the mass and then allow the mass to settle. Drain out the aqueous layer and collect the organic layer. 7. Charge measured quantity of 4-Br-3-Me Anisole into the reactor. Subsequently charge measured quantity of Soda Ash, acetanilide, cuprous chloride & iodine. Heat gradually to the temperatures and maintain subsequently. 8. Charge measured quantity of potassium hydroxide, Caustic & water into condensation mass. Hydrolyzed the mass till specified temperature approaches. 9. Filter the mass & Separate the aqueous and organic layer. 10. Charge Crude MMDPA and Distill out. 11. Charge methanol followed by a measured quantity of semi pure MMDPA into the crystallizer. 12. Separated out the Solid MMDPA & Mother liquor from centrifuge. 13. Wet MMDPA dried out in RCVD. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 46

47 Block Diagram:- Methylation Bromination Condensation PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 47

48 Distillation Crystallization Drying MeOH Distillation PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 48

49 14. Ortho Anicidine (OA) Chemical Reaction:- Stage I: Nitration of Anisole to Ortho Nitro Aniline Stage II: Reduction of Ortho Nitro Anisole to Orhto Anicidine Process Description:- Nitration of Anisole to Ortho Nitro Aniline 1. Mix Acid is prepared by Nitric and Sulfuric Acid. 2. Mix Acid is added to Anisole gradually. 3. Then Spent Acid is separated from ONA. 4. After washing ONA is send for reduction. Reduction of Ortho Nitro Anisole to Orhto Anicidine PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 49

50 1. Ortho Nitro Anisole is reduced to Ortho Anicidine by hydrogen. 2. Then the crude OA is Distilled to have pure Ortho Anicidine Block Diagram:- Nitration PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 50

51 Reduction of ONA 15. 2,3-Xylidene and 3,4-Xylidene Chemical Reaction:- Stage I: Nitration of Ortho-Xylene to 2,3-Nitro Xylene and 3,4-Nitro Xylene Stage II: Separation/Distillation of Nitro-Xylene to 2,3-Nitro Xylene and 3,4-Nitro Xylene Stage III: Reduction of 2, 3-Nitro Xylene and 3,4-Nitro Xylene to 2,3-Xyledine and 3,4-Xyledine PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 51

52 Process Description:- Nitration of Ortho-Xylene to 2, 3-Nitro Xylene and 3,4-Nitro Xylene 1. Nitration is carried out using spent acid, sulfuric acid & Nitric acid. Along with these compounds, the compound to be nitrated is continuously charged in to the reactors. 2. Reaction is conducted under controlled conditions as mentioned. 3. After completion of Nitration, Spent acid is separated. 4. After Separation Nitro mass is washed in washer to remove acidity. 5. The washed Nitro mass is then sending for further Distillation. 6. In the Distillation 2,3-Nitro Xylene and 3,4-Nitro Xylene is Separated as pure Product. Reduction of 2,3-Nitro Xylene and 3,4-Nitro Xylene to 2,3-Xyledine and 3,4-Xyledine 1. 2, 3-Nitro Xylene is then reduced by Hydrogene to Produce 2,3-Xylidene. 2. 3, 4-Nitro Xylene is then reduced by Hydrogene and Catalyst to Produce 3,4-Xylidene. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 52

53 Block Diagram:- Nitration PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 53

54 Distillation PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 54

55 Reduction 2, 3-Xylidene Reduction 3,4-Xylidene PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 55

56 16. 3'-(Trifluoromethyl) acetophenone (TFMAP) Chemical Reaction:- Stage :- I Diazotization Stage: - II Hydrolysis Process Description:- Stage-I 1. 3'-(Trifluoromethyl)- acetophenone oxime is prepared by 3-amino-benzotrifluoride diazotization and with acetaldoxime. Stage-II 2. 3'-(Trifluoromethyl) - acetophenone is prepared by hydrolysis of 3- (Trifluoromethyl) - acetophenoneoxime. 3. In Distillation 3'-(Trifluoromethyle)-Acetophenone is separated as finished product. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 56

57 Block Diagram:- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 57

58 17. TMHQ Chemical Reaction:- O 2- C + N /2 2- NH 2 Process Description:- STEP 1 Oxidation of TMP to TMBQ In this step, TMBQ is prepared by oxidation of TMP with Hydrogen peroxide with catalyst in presence of Methanol. The resultant reaction mass is filtered for recovery of catalyst which is recycle back. STEP 2 Hydrogenation of TMBQ to TMHQ In this step TMBQ prepared in the earlier step is hydrogenated using catalyst. The hydromass is then separated from catalyst which is recycled back into system.the filtered mass is then sent for solvent recovery STEP 3 Solvent recovery Methanol is recovered in this step & methanol free reaction mass is sent for purification. STEP 4 Purification The reaction mass free from methanol is purified, using Toluene, precipitated, filtered t get crude TMHQ. The crude is treated with charcoal & then again purified with solvent & reprecipitated. The final mass is again filtered through centrifuge to get wet cake & the solvent is recovered & recycled back STEP 5 Drying The wet cake obtained from previous step is then dried in suitable dryer to get finished product. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 58

59 Block Diagram;- PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 59

60 2.6 Raw material required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product. Raw Materials: The detailed raw material list for product mixed products as per selected capacity is detailed below for all reactants, solvents and support chemicals. Source for Raw Material Procurement: Raw Materials are easily available in the local market, from Mumbai and Gujarat. Part of the raw materials are generated In-house and used internally and some raw material will be imported Viz. Mode of Transport of Raw Materials: Raw Materials will be transported through Trucks/ Tankers from suppliers factories or traders go-downs. Those which are in house will be transported through internal pipelines as per the requirements. Storage at the site: Raw Materials are stored in storage yard at the project site. Location of storage yard is demarcated in Layout Plan. Table 2-2: Details of Raw material Quantity PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 60

61 2.7 Resource optimization/recycling and reuse envisaged in the project To conserve the water, various recycle/ reuse schemes will be implemented. Most energy efficient technology is selected. 2.8 Availability of water its source, energy/power requirement and source Water Requirement and Source Fresh water requirement of the project for domestic and industrial activity during operation phase will be same as existing, which is 524 CMD. The existing source of water supply is from MIDC. The details of water requirement are given below Table 2-3: Details of Raw water consumption S. No. Units Raw Water Qty.(KLD) A Process 328 B Utilities Cooling water make up 2 Boiler make up C Domestic 35 Total 519 D Gardening 15 ( Recycled from STP) Recycled water from STP will be near about 30 CMD which will be used for gardening, floor washing flushing, spraying on coal etc Power Requirement Existing power requirement is 2100 KW and is sufficient for product mix. No extra power is required. Source is State Electricity Board. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 61

62 Emergency power Existing 3 no of D. G. set having capacities 750 KVA (2 no) and 500 KVA (1 no.) are sufficient to meet emergency power requirement Utility Existing Sr No Item Quantity Capacity Type Rating 1 Boiler TPH Imported /Indian Coal Kg/cm2 fired Boiler TPH FO based Kg/cm2 2 Thermopack 2 6 Lac Kcal 4 Lacs Kcal Coal/ FO 0 C 3 D G Set 3 750(2 nos.) 500 (1 no.) HSD -- Fuel Requirement Sr No Item Fuel Quantity required at full load 1 Boiler Imported Coal/FO TPD (Indian Coal) TPD (Imported Coal) - 9 TPD FO 2 Thermopack FO 1 TPD/ 0.5 TPD 3 D G set HSD 6MTD 2.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 62

63 2.9.1 Gaseous Emissions Details of gaseous emissions from Process and Flue gas are given in Table 2-4 Table 2-4: Details of emissions from process and flue gas Sr. No. Pollutant Source of Emission Concentration in flue gas 1. SO 2 Boiler (Coal) Boiler(FO) Thermopack (FO) 2. NO X CO < Kg/D < 810 Kg/D < 45 Kg/D 4. Others PM10 Boiler <1 18 mg/nm 3 PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 63

64 Details of stack are given in Table 2-5. Table 2-5: Details stacks along with their mitigation methods Attached to Boiler TPH Thermopack DG KVA Existing Proposed Existing Proposed Existing Proposed Capacity 08 (1 nos.) 06 (1 nos.) -- 6 Lac Kcal 4 Lacs Kcal (2 nos.) 500 (1 no.) -- Fuel type Coal FO -- Coal/ FO -- HSD -- Fuel quantity TPD (Indian Coal) TPD (Imported Coal) - 9 TPD FO -- 1 TPD/ 0.5 TPD -- 6 TPD -- MOC MS --- MS -- MS -- Shape Round -- Round Round -- Height m (above ground level) Mitigation Measures - 34 M M Common for Thermopack & Boiler -cyclone with Dust Collector -Chimney & Membrane dust collector M Common for Thermopack & Boiler Chimney & Membrane dust collector 4.5 each -- Stack, Acoustic enclosure Stack, Acoustic enclosure PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 64

65 2.9.2 Effluent The quantity of effluent generated proposed project is given in Table 2.6 Table 2-6: Details of Effluent Generation Effluent generation S. No. Units (KLD) A Process 234 B Utilities 9 1 Cooling water make up 2 Boiler water make up Trade effluent Total 243 Domestic 31 Maximum effluent generation from the proposed product mix will be 247 LKD and will be treated in existing ETP of capacity 400 KLD. Domestic effluent will be treated separately in proposed STP. Treated domestic waste water will be reused for gardening, floor washing flushing, spraying on coal etc. Existing treatment Scheme for Trade Effluent Primary Treatment The system is designed to treat 400 KLD of waste water. Wastewaters from different streams of process along with wastewater from cooling tower, boiler blow down etc. will be collected in the Equalization Tank and air stripped. This effluent will be then be pumped to the Flash Mixer where it is dosed with alum for coagulation. Flash Mixer is followed by a flocculator where poly will be dosed for bigger flock formation. This effluent is overflowed into the settling tank where the solids will be settled down and removed. Secondary (Aerobic) Treatment: The system will be designed to treat 400 KLD waste water. The neutralized effluent will enter the 16.5 m3 / hr. In the bio reactor, dissolved organic material is degraded by the micro organisms present in the bio reactor. Oxygen required for the oxidation of organic matter will be provided by means of proposed diffuser aeration system which will mix the contents of the bioreactor also. The mixed liquor will overflow into Secondary Settling Tank (SST). In the secondary settling tank, solid-liquid separation takes place and solids i.e. biomass will settle at the bottom of the tank. Settled biomass will be recycled to the bio reactor for maintaining the MLVSS concentration by using proposed sludge recycle pumps and excess biomass will be wasted periodically to the sludge sump. Two stage treatments are proposed where the overflow from the 1 st stage clarifier will enter the 2 nd stage bioreactor where PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 65

66 the non-degraded organics from the 1 st stage bioreactor will be treated. The clear overflow from the 2 nd stage Secondary Settling Tank will be Collection in the intermediate sump. Tertiary Treatment: The system will be designed to treat 400 KLD of waste water. The clear effluent from the intermediate sump will be pumped by tertiary Feed pumps through the pressure sand filter (PSF) & activated carbon filters. The final treated effluent will be Collection in the final Collection tank from where it will be discharge to proposed upgraded CETP. Sludge Handling: Primary sludge, excess biomass from the secondary treatment and backwash water from PSF will be collected in the sludge sump. From the sludge sump the sludge will be pumped to the decanter for dewatering. The solid cake from the decanter will be sent for disposal to Hazardous waste disposal site. The filtrate from the Filter press will be drained to the collection tank. Table 2-6: Design details and Performance Projection of ETP. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 66

67 Table 2-6 Design Parameters for ETP S. No. Parameters Unit Inlet Effluent Characteristics Outlet Effluent Characteristics Effluent discharge standards (MPCB) 1 Design Quantity M 3 /day ph BOD C mg/l <100 4 COD mg/l <250 5 TSS mg/l <100 6 TDS mg/l < Oil & Grease mg/l <10 Treatment Scheme for Domestic Wastewater The sewage generated due to domestic activities will be treated separately in proposed sewage treatment plant Details of Hazardous wastes The types of Hazardous wastes generated from the project, method of disposal is shown in below table below Table 2-7: Details of Proposed Hazardous Solid waste along with the Category and disposal method S. No. Waste Name Category Hazardous Waste 1 2 Used Spent oil (Kg) Spent Chemical / Acid ( T/M) Existing Quantity MTPA Propose d Total Form (Sludge/d ry/ slurry) Liq solid 3 Spent Chemicals solid 4 5 Discarded containers/barrel s/liner Chemical sludge from waste water treatment Liq/solid Disposal Method Sale to Authorized re processor Sale to Authorized re processor Sale to Authorized re processor To CHWTSDF,Taloja/ Sale to Authorized party Solid To CHWTSDF,Taloja 6 Spent catalyst Solid Send back to Authorized party PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 67

68 S. No. Waste Name Category 7 Distillation residue from contaminated organic solvents Existing Quantity MTPA Propose d Total Form (Sludge/d ry/ slurry) Disposal Method Solid/Liq To CHWTSDF,Taloja Non- Hazardous Waste 1 Ash from boiler 2.50 T/day T/day 2 Insulating Material 2 T/A -- 2 T/A 3 4 Glass ware / Broken Discarded Glass Non- hazardous industrial waste 1 T/A -- 1 T/A 2 T/A -- 2 T/A Sale to brick manufacturer. To CHWTSDF,Taloja / Sale To CHWTSDF,Taloja / Sale To CHWTSDF,Taloja / Sale PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 68

69 2.10 Schematic representations of the feasibility drawing which give information of EIA purpose. Project Identification What environmental impacts are normally associated with such type of projects being proposed? Pre-feasibility Analysis Is the Project feasible from an environment point of view? Project Design (a) What negative environmental impacts could arise if the proposed project is implemented with proposed design? (b) Is there alternative design with less environmental impacts? Project Appraisal Have all the environmental concerns associated with the project been eliminated? Project Implementation What environmental concerns might arise at the implementation phase of the project? Preparation of an Environment Monitoring and Evaluation Plan (a) What environment monitoring indicators are required to ensure that the implementation of components of the project will be executed within environmentally sound limits? (b) What is required to ensure that the recommended environmental control measures will be implemented and enforced? Post EIA Monitoring and Environment Audit (a) Is the implementation of components of the project being executed in an environmentally sound manner? (b) Are all the recommended environmental control measures being implemented and enforced? (d) Are there any environmental impacts that were earlier not anticipated when EIA was done? ( Identify gaps and corrective action ) PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 69

70 3.0 SITE ANALYSIS 3.1 Connectivity Proposed unit is planned at Plot No. 105, Dhatav MIDC, Roha, Raigad , Maharashtra. The nearest city from the site is Roha at a distance of 5.0 Km The nearest railway station is Roha at a distance of 7 Km from the site on Mumbai Goa Manglore Kokan railway. The nearest airport is at Mumbai 117 km and Pune at 125 km. National Highway NH 66 (previously known as NH 17) passes through Kolad (9 km) It connects Panvel (south of Mumbai city) to Kanyakumari, passing through the states of Maharashtra, Goa, Karnataka, Kerala and Tamil Nadu. Maharashtra State Road Transport Corporation has a Bus Depot at Roha for public transport.\ 3.2 Land Form, Land use and Land ownership The proposed land is situated in approved chemical zone of MIDC where land use is industrial. Land is owned by MIDC and is leased for 99 years. 3.3 Topography The proposed industry is located at Latitude N and Longitude Elevation above mean sea level is: 12 m. Toposheet of the site is shown below. The study area (10 km radius) around the project site exhibits flat terrain in the east and relatively elevated terrain in the west side. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 70

71 Figure 3.1: Toposheet Showing Project site and 10Km of area 3.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. Proposed site falls under the Industrial MIDC. The land is reserved for Industrial use. River Kundalika is sufficiently away from project site. 3.5 Soil classification There is sandy loam to clay in texture, yellowish in colour and under laid with murum derived from the basic rock basalt. 3.6 Climatic data from secondary sources The climate, if proposed area is characterized by hot summer and general dryness throughout the year except the south west monsoon season. The year may be divided into three seasons. The winter or cold season is from December to February, summer or hot season from March to May. The south west monsoon season is from June to September, while October and November constitute the post monsoon season. The annual average rainfall of the area is mm, month of May is the generally the hottest month of the year with average temperature in between 32 to 370 C. In cold season the area is sometimes affected by the cold waves over north India and the minimum temperature may drop to 14 to 170 C. The air is generally dry except during the south west monsoon season, when the relative humidity is high. 3.7 Social Infrastructure Availability Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of Maharashtra Industrial Estate. 4.0 Planning In Brief 4.1 Planning Concept MIDC Industrial area, Dhatav provides many basic facilities like uninterrupted water supply, power and road network & solids disposal facility if feasible. When various sites were seen, this site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is inside the campus of the MIDC and means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 71

72 4.2 Land Use Planning Existing land is converted for industrial purpose. The land is located in a designated industrial area. No change in land use Table 4-1: Land Use Break Up Sr.no Particular Area in Sq.m 1 Plant Area Raw material storage area+ Finished goods 3 ETP Parking Internal road Open Space Green Belt Total Assessment of Infrastructure Demand (Physical & Social) Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of Maharashtra Industrial Estate. 4.4 Amenities/Facilities In proposed site many basic facilities like uninterrupted water supply, Power and Road Network & solids disposal facility if feasible are available. This site is inside the campus of the MIDC and means safe transportation, less need of utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal facility), MWML, Taloja in vicinity established with support of MIDC and MPCB. All nearby villages are provided with drinking water from wells or Government Water Supply Schemes RWS. Hence we do not encroach upon their supply Population Projection Roha city has a population of 34,345 as per census It has more than 7,563 households of Maratha, Muslim, Buddhist, and also includes SC, ST, OBC and open categories community. The village has basically an agrarian economy and industrial workers and farming is the main occupation of the villagers. The local self- Government vests with a Grampanchayat having an elected body of headed by a Sarpanch. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 72

73 Population growth is being increased at alarming rate with their basic requirements. Amongst, Medicine is one of the basic need, which is very essential for everyone to live happy life. So to fulfil their future basic need of Medicine for social community there is a necessity to promote R & D Centre in each industrial sector. There will be in ratio of population increase in similar way their need also increases so to fulfil their needs we are going to set up a proposed unit which again generates employment. 5.0 Existing infrastructure 5.1 Industrial area Industrial Area (Processing area) Utilities Cooling towers HSD unloading/storage area Boilers DM water plant Cooling towers Hydrogen trolley area Non- Processing Area Weighbridge Administrative Buildings Security cabins Workers restroom Vehicle Shed Water reservoirs Temporary storage sites Works block etc. For proposed product mix existing infrastructure will be utilized and is sufficient for the proposed activity 5.2 Residential Area There is no any residential area has been proposed. 5.3 Green Belt The project is built on an MIDC plot with plot area of sq. m. and green belt area sq. m. Green belt will be developed at proposed project site and details will be provided in EIA report. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 73

74 5.4 Social Infrastructure The basic amenities within the study area include primary schools, dispensaries, water supply, electric supply, public telephones, hotels, banks, post offices, petrol pumps, bus services, technical training institute and entertainment etc. 5.5 Connectivity Connectivity Proposed unit is planned at Plot No. 105, Dhatav MIDC, Roha, Raigad , Maharashtra. The nearest city from the site is Roha at a distance of 5.0 Km The nearest railway station is Roha at a distance of 7 Km from the site on Mumbai Goa Manglore Kokan railway. The nearest airport is at Mumbai 117 km and Pune at 125 km. National Highway NH 66 (previously known as NH 17) passes through Kolad (9 km) It connects Panvel (south of Mumbai city) to Kanyakumari, passing through the states of Maharashtra, Goa, Karnataka, Kerala and Tamil Nadu. Maharashtra State Road Transport Corporation has a Bus Depot at Roha for public transport 5.6 Drinking Water Management The source of water supply is from MIDC Dhatav. 5.7 Sewage System The domestic effluent will be treated in proposed sewage treatment plant. 5.8 Industrial Water Management Trade effluent will be treat in existing ETP and treated effluent after meeting the MPCB norms for discharge will be sent to CETP for final disposal. 5.9 Solid Waste Management Hazardous solid waste generated from the process will be collected, stored, transported and send to MWML, Taloja CHWTSDF as per Hazardous waste (Management, Handling and Transboundry Movement) Rules Power Requirement & Supply / source The Total Power required for the proposed project is 2100 KW. 6.0 Rehabilitation and Resettlement (R & R) Plan 6.1 Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless. Proposed activity will be at existing manufacturing unit located at MIDC area. Hence, there is no any kind of activity of Rehabilitation and resettlement carried out over it. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 74

75 7.0 PROJECT SCHEDULE & COST ESTIMATES 7.1 Likely date of start of construction and likely date of completion The modernization/product mix activity is likely to start after getting Environmental Clearance and NOC/CTE from the authorized committee. 7.2 Estimated project cost along with analysis in terms of economic viability of the project The total investment envisaged is Rs Crore. Economic Viability The project has been conceived assuming that there will be a growth in demand for the proposed products, leading to a reasonable rate of return in the medium term. The project is considered bankable. 8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) Proposed product mix activity will provide benefits to the local people in terms of financial and social welfare. Company will contribute in improving education and health facilities in nearby area. The proposed products covered under application shall save $ 5 million foreign exchange for the country since they are import substitutes and besides which some of them will generate $10 million of exchange for our country through their export. Needless to say that these initiatives shall be our contribution to make in India movement and shall generate additional profits for the company and revenue for the states. PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 75

76 Annexure I Plant Lay out PFR for M/s. Deepak Nitrite.Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd. Page 76