Pre-Feasibility Report. Neogen Chemicals Ltd

Transcription

1 Pre-Feasibility Report of Neogen Chemicals Ltd Plot Z/109, SEZ Dahej, Tehsil: Vagra, Dist.: Bharuch Proposed Project for Manufacturing of Fine Chemicals and Agro Intermediates (1555 TPM) Project Activity: 5(f) & 5(b), Category: A PFR of Neogen Chemicals Ltd 0

2 1. INTRODUCTION Neogen Chemicals Ltd proposes Manufacturing of Fine Chemicals and Intermediates (1555 TPM) at Plot Z/109, SEZ Dahej, Tehsil: Vagra, Dist.: Bharuch The area of the site is 50,012 m 2. Location of the proposed project in industrial estate and 10 km radius around the location are shown below. The estimated cost of the project is estimated around Rs. 55 crores. 2. LOCATION OF PROJECT PFR of Neogen Chemicals Ltd 1

3 Plot allotment letter PFR of Neogen Chemicals Ltd 2

4 3. PRODUCTION CAPACITY Production capacity is prescribe below: 1 Bromination and Chlorination of Alcohols such as; 1.1. Ethyl Bromide; 1.2. n-propyl Bromide; 1.3. Iso Propyl Bromide; 1.4. n-butyl Bromide; 1.5. Iso Butyl Bromide; 1.6. Sec-Butyl Bromide; 1.7. n-hexyl Bromide; 1.8. n-heptyl Bromide; 1.9. n-octyl Bromide; n-decyl Bromide; Lauryl Bromide; Cetyl Bromide; Myristyl Bromide; Stearyl Bromide; ,2 Dibromo Ethane; ,3 Dibromo Propane; ,4 Dibromo Butane; ,5 Dibromo pentane; ,6 Dibromo Hexane; Chloro 2 Ethyl Hexane; Chloro 1 Hexanol; Chloro Propanol; ,6 Dichloro Hexane; Name of Products End use Quantity Fine chemicals and agro intermediates (MT/Year) (MT/month) PFR of Neogen Chemicals Ltd 3

5 Name of Products End use Quantity (MT/Year) (MT/month) Cyclo Propyl Methyl Bromide; Cyclo Pentyl Bromide; Cyclo Pentyl Chloride; bromohexanol; bromooctanol; bromodecanol; 2 Bromination of Organic Acids and Esterification thereof such as; Bromo propionic Acid; Bromo Propionyl Bromide; Bromo Valeric Acid; Bromo Hexanoic Acid; 2.5 Sodium 2 Bromo Propionate; 2.6 Ethyl 3 Bromo Propionate; 2.7 Methyl 2 Bromo Butyrate; 2.8 Ethyl 2 Bromo Butyrate; 2.9 Ethyl 4 Bromo Butyrate; 2.10 Methyl 2 Bromo Iso Butyrate; 2.11 Ethyl 2 Bromo Iso Butyrate; 2.12 Iso Propyl 2 Bromo Iso Butyrate; 2.13 Ethyl 2 Bromo Valerate; 2.14 Methyl 2 Bromo valerate 2.15 Ethyl 5 Bromo Valerate; 2.16 Tert-Butyl 2 Bromo Iso Butyrate; 2.17 Methyl 2 Bromo Caproate; 3 Grignards Formation from Organic Halides such as; 3.1 Methyl Magnesium Chloride 3M in THF; Fine chemicals Fine chemicals PFR of Neogen Chemicals Ltd 4

6 Name of Products End use Quantity (MT/Year) (MT/month) 3.2 Methyl Magnesium Bromide 1.5M in THF; 3.3 Ethyl Magnesium Chloride 2M in THF; 3.4 Ethyl Magnesium Bromide 2M in THF; 3.5 Vinyl Magnesium Bromide in 1M in THF; 3.6 Isopropyl Magnesium Chloride 1M in THF; 3.7 Phenyl Magnesium Bromide 2M in THF; 3.8 n-butyl Magnesium Chloride 1M in THF; 3.9 Iso Propyl Magnesium Chloride Li Cl Complex 1.3M in THF; 3.10 Iso Propyl Magnesium Bromide 1M in THF; 4 Halogen Exchange Reactions such as; Bromo 2 Chloro Ethane; Bromo 4 Chloro Butane; Bromo 5 Chloro Pentane; Bromo 6 Chloro Hexane; 4.5 Bromo Fluoro Methane; 4.6 Methylene Dibromide; 4.7 Bromo Chloro Methane; Iodo Valeric Acid Ethyl Ester; Bromo Hepta Fluoro Propane; Methyl Allyl Bromide; 5 Addition of Halogen and Halogen Acids across Double Bonds such as; 5.1 Ethylene Dibromide; 5.2 Phenyl Ethyl Bromide; 5.3 1Bromo 3 Chloro Propane; Fine chemicals and agro intermediates Fine chemicals and agro intermediates PFR of Neogen Chemicals Ltd 5

7 Name of Products End use Quantity 5.4 n-hexyl Bromide; 5.5 n-octyl Bromide; 5.6 n-decyl Bromide; 5.7 Cyclo Pentyl Bromide; 5.8 Cyclo Pentyl Chloride; 5.9 1,2 Dibromo 3 Chloro Propane; ,2 Dibrmo hexa fluoro Propane; ,4 dibromo 2 butene; ,1 Dibromo 3 chloro Propane; 6 Bromination or Chlorination of Cyclic and Aromatic Compounds with or Without Functional Groups such as; 6.1 Bromo Benzene; 6.2 Di Bromo Benzene; 6.3 Ethyl 4 Bromo Methyl Benzoate; Bromo 4 Chloro Benzene; 6.5 p- Bromo Toluene; Bromo O Xylene; Chloro 1,4 Naphthaquinone; Bromo 4 Fluoro Benzene; Bromo Methyl 2 Cyano Biphenyl (Bromo OTBN); Bromo 3,4 Dichloro Benzene; 6.11 Deca-DPE; 6.12 Tribromophenol; Bromo 2 4 difluorobenzene; bromo benzyl bromide; bromo 4 fluoro aniline; nitrobenzyl bromide; Fine chemicals and agro intermediates (MT/Year) (MT/month) PFR of Neogen Chemicals Ltd 6

8 Name of Products End use Quantity (MT/Year) (MT/month) 6.17 Deca bromodiphenyl oxide; bromo phenol; bromo anisole; 6.20 TBBE DGE; 6.21 Tetra bromo phthalic anhydride; 7 Dehydrohalogenation of Organic Halides with or without functional Group Such as; 7.1 Vinyl Bromide; 7.2 Vinyl Bromide in 25% THF; 7.3 Vinyl Chloride ; Bromo 1 Butene ; Bromo 1 Hexene; Bromo 1 Heptene; Bromo 1 Octene; Bromo 1 Pentene; 8 Advance Intermediates from Category 1 to 7 Such as; Methoxy 2 Naphthaldehyde; Fluoro 5 Bromo Benzonitrile; 8.3 Ethyl 4- (dimethyl amino) Butyrate; 8.4 Bromo Acetal; Bromo Hexyl Trimethyl Ammonium bromide; Bromo 3 Phenoxy Propane; Chloro 2 Hexanone; 8.8 n-octyl Amine; 8.9 Bifenthrin Alcohol; 8.10 Ethyl 7 Chloro 2 Oxo Heptanoate; Fine chemicals Fine chemicals and agro intermediates PFR of Neogen Chemicals Ltd 7

9 Name of Products End use Quantity (MT/Year) (MT/month) Bromo 6 Methyl Heptane; 8.12 Methyl 3 Oxo Pentanoate; 8.13 TBC; ,4 DFBA; 8.15 Homophthal; 8.16 L-valine OTBN; 8.17 Tetrazole; 8.18 DEMBB; 8.19 Tetralone; Chloro hexanol tetra hydro pyran derivative; bromo propyl trimethyl ammonium bromide; bromohexanol tetra hydro pyran derivative; bromohexanol tetrahydropyran derivative; bromo tetrahydro pyran derivative; amino-3,4 -difluorobiphenyl 9 2-Cyclopropyl 6-Methyl Phenol Fine chemicals 60 5 and agro intermediates 10 R&D Total PFR of Neogen Chemicals Ltd 8

10 4. MANPOWER REQUIREMENTS Total manpower requirement at all level of plant will be ENERGY & FUEL REQUIREMENTS Energy requirement for the proposed project will be 2000 kva, and will be sourced from Dakshin Gujarat Vij Company (DGVCL). PNG SCM/day, FO-380 kg/hr for boilers. Diesel requirement will be 60 Liter per hour (for 3 D.G. set of 250 kva each) 6. MANUFACTURING PROCESS Detailed manufacturing process is given in Annexure-II of Form-I. 7. WATER REQUIREMENTS AND WASTEWATER GENERATION The total fresh water requirement will be 522 KL/day, which will fulfill by GIDC water supply. The breakup of water consumption and wastewater generation is given below. Source Water Consumptio n (KLD) Wastewate r Generation (KLD) 1. Domestic 45 40* 2. Green Belt 12+40* Industrial A Process B Scrubber 34 5 C Boiler D Cooling Tower E Washing Total Industrial TOTAL ( ) Reuse water 40* - Freshwater requirements PFR of Neogen Chemicals Ltd 9

11 Water Balance Diagram Total water consumption = 562 KLD (Fresh water 522 KLD + Reuse water 40 KLD) Domestic 45 Process 121 Scrubber 34 Washing 30 Utilities 280 Greenbelt * STP 40* HBr 17 (45-48%) Liquor of HBr 26 (16 to 30%) HBr 14 Used captively SBS 6 To greenbelt HCl* 24 Spent H 2 SO 4 5 HCl* 8 Used captively NaOCl 1 Boiler 80 Cooling 200 Salt solution to recovery 55 Blow down 10 Bleed off 50 Process 78 5 ETP = KLD to GIDC Drainage PFR of Neogen Chemicals Ltd 10

12 8. SOURCES OF POLLUTION AND MITIGATION MEASURES A. Air Pollution Adequate stack height will be provided to control & disperse the air pollutants within the satisfactory levels. Furthermore, facility for sampling such as ladder and sampling point will be provided as per the GPCB guidelines. The details of stacks with their APC measures & height are given in below. Stack attached to Flue gas stacks Stack Height in m Fuel Used Fuel Consumption Rate APC measure Pollutant 1 Boiler (3 nos.) (2 TPH each) 2 D G set (250 KVA x 3) Process vent 30 (common stack) PNG SCM/day -- SPM<150 mg/nm 3 FO* 380 Kg/hr 21 HSD 60 Lit/hrs. each -- SO 2 <100 ppm NO X <50 ppm 3 Halogen Specific Reaction Plant (4 nos) 16 m each - - Water & Alkali Scrubber HBr<20 mg/nm 3 HCl<20 mg/nm 3 Br 2 <2 mg/nm 3 Cl 2 <9 mg/nm 3 4 Common Reaction & Multi-purpose Plant (4 nos) 16 m each - - Water & Alkali Scrubber SO 2 <40 mg/nm 3 HBr<20 mg/nm 3 HCl<20 mg/nm 3 Br 2 <2 mg/nm 3 Cl 2 <9 mg/nm 3 5 Common stack attached to suction of work place area (2 nos) 16 m each - - Alkali Scrubber HBr<20 mg/nm 3 HCl<20 mg/nm 3 Br 2 <2 mg/nm 3 6 Bromine scrubber 16 m - - Two stage Alkali Scrubber * in case of unavaibility of natural gas HBr<20 mg/nm 3 Br 2 <2 mg/nm 3 PFR of Neogen Chemicals Ltd 11

13 B. Water Pollution Industrial effluent will be treated in ETP having primary-secondarytertiary treatment units. After achieving GIDC/GPCB norms, effluent will be discharged into GIDC drainage for final disposal. Domestic wastewater will be treated in STP and will be used for greenbelt development. C. Hazardous Wastes Entire quantity of hazardous waste will be handled & disposed as per Hazardous & Other waste (Management & Transboundary Movement) Rules, The unit will provided isolated area with impervious flooring & roof cover for the storage of hazardous waste. Details of hazardous waste and disposal are given below. Type of Waste Quantity Method of Disposal 1. ETP waste 50 MT/month Collection, storage & disposal at TSDF site approved by GPCB. 2. Process/distillation residue 3. Discarded containers/ barrels/ liners 1100 MT/month Barrels-5000 nos./month Liner-500 kg/month Collection, storage & disposal at CHWIF or co-processing. Collection, storage, decontamination and disposal by selling to registered recyclers. 4. Used Lubricating Oil 1.0 Kl/year Collection, storage & use within premises as lubricant/sell to registered recycler. 5. Liquor of HBr (<30%) 6. Sodium hypochlorite 676 MT/month 26 MT/month 7. Spent H 2 SO MT/month 8. Acetic acid 25 MT/month 9. Inorganic salts like (Sodium Bromide, Magnesium Bromide, Potassium Bromide, Calcium Bromide, Sodium Sulphate, Sodium Bisulfite, Ammonium Bisulphite, Potassium Bicarbonate) 445 MT/month Collection, storage, transportation and sold to actual end users under Haz Waste Rules 9. Collection, storage, transportation and sold to actual end users under Haz Waste Rules 9. Collection, storage, transportation and sold to actual end users under Haz Waste Rules 9. Collection, storage, transportation and sold to actual end users under Haz Waste Rules 9. Collection, storage, and send to own inorganic plant for product recovery (within premises) having GPCB consent no (non-ec activity). PFR of Neogen Chemicals Ltd 12

14 9. GREEN BELT DEVELOPMENT The unit proposes to earmarked space for development of green belt along the plan periphery to arrest noise pollution and fugitive emissions as well as to improve aesthetics. 10. FUNDS FOR POLLUTION CONTROL MEASURES The management is quite conscious of its responsibility for maintaining clear environment. Thus, around Rs. 5.5 crores will be provided for the pollution control measures as a part of overall project financing. 11. MONITORING FACILITIES Company is ready to carry out monitoring proposed by pollution control board from time to time through outside agency. 12. CONCLUSION On the basis of information presented here on pollution control measures and its implementation, there will be no emission from the plant beyond the norms specified by the Board as per the provisions of Water (Prevention and Control of Pollution) Act, 1974 and Air (Prevention and Control of Pollution) Act, PFR of Neogen Chemicals Ltd 13