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Sadekar Enviro Engineers Pvt. Ltd. Page 1
PPrree -- FFeeaassiibbiilliittyy RReeppoorrttFFoorr
Astec Lifesciences Ltd.
PPlloott nnoo –– BB--1166,,1177,, 1188,, && BB--2211,, MMIIDDCC MMaahhaadd ,, MMaahhaadd,, RRaaiiggaadd,,MMaahhaarraasshhttrraa.. 440022330099
EIA Consultant
M/s. SADEKAR ENVIRO ENGINEERS PVT. LTD.
QCI – NABET accredited EIA consultancy for schedule 5(b) Cat.-‘A’Certificate No – NABET/EIA/1518/SA 021
NABL Accredited Laboratory, Valid up to 29.06.2018Lab. Recognized by MoEF& CC, GOI, Valid up to 2.01.2019
Certified by ISO 9001:2008 & BS OHSAS 18001:2007
310, Dempo Towers, EDC Patto, Panaji, Goa state, India. PIN: 403001Email :[email protected] / [email protected]
Web site:-www.sadekarenviro.com Telephone :0832-2437048/2437164
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Table of Content
Sr. Title Page
1 Executive summary 3
2 Introduction of the project 5
3 Description of Project 8
4 Site Analysis 19
5 Planning 22
6 Proposed infrastructure 23
7 Rehabilitation and resettlement 27
8 Project schedule and cost estimation 27
9 Analysis of proposal 27
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1. Executive summary
Salient Features of ProjectName & Address ofCompany
M/s Astec Lifescience Ltd.
Plot no B-16,17, 18, & B-21, MIDC Mahad , Mahad, Raigad, Maharashtra.402309.
Schedule of project asper EIA Notification,2006
5 (b)
Category of Project ‘A’
Area statementExisting, sq. m. Proposed, sq. m. Total, sq. m.
Plot area
B-16,17,18 12150 -- 13950
B-21 1800
Built up area 8544 -- 8544Green belt 3500 1100 4600
Production detailsExisting
(MT/month)
Proposed (MT/month) Total
(MT/month)
Pesticide products 219
(Vide consent no.
Format 1.0/ AS(T)/EIC
No. RD-3108-
15/Amend/CC-3030 dt.
25/07/2016)
562 781
Pesticide Formulation 700
(Vide consent no.
MPCB/ROR/15/11840
dt. 08/09/2015)
-- 700
byproducts -- 1773 1773
Total production 919 2335 3254
Water Requirement Existing, CMD Proposed, CMD Total, CMD
Vide pesticide productionCTO
205.67 94.33 447
Vide pesticide formulationCTO
147
Total 352.67 94.33 447Effluent generation 35.43 164.57 200
136.43 164.57 200
Effluent treatment Existing 36.43 CMD effluent & 15 CMD sewage is treated in 55 CMD ETP.
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The treated effluent is discharged to CETP. Additional 164.5 CMD will betreated by two psychrometric evaporators of 500 TR capacity each. Total 52.5CMD effluent will be recycled to process.
Sewage generation 11 -- 15415 -- 15
Sewage Treatment Sewage is mixed with effluent and treated in aeration tank of ETP.
Utility requirementExisting Proposed Total
Boiler 06 TPHStack : 30m
10 TPHStack : 39 m
1 unit of 6 TPH1 unit of 10 TPH
2.5 TonStack Height :25m
Will be discontinued
850 Kg/hrStack Height :24 m
Will be discontinued
Thermic fluid heater -- 6 lakh kcal/hrStack Height: As perCPCB norms
6 lakh kcal/hrStack Height: As perCPCB norms
-- 2 lakh kcal/hrStack Height: As perCPCB norms
2 lakh kcal/hrStack Height: As perCPCB norms
Electrical powerConnected load 1600 KVA -- 1600 KVA
900 KVA -- 900 KVADG set 250 KVA
Stack height: 3.5 m
500 KVA
Stack height: 4.5 m
1. 250 KVA
Stack height: 3.5 m
2. 500 KVA
Stack height: 4.5 m
125 KVA*2 units
Stack height: 3.5 m
(Will be
discontinued)
FuelCoal for boiler 22 MTPD 35 MTPD 57 MTPD
FO for TFH 125 L/day 6450 L/day 6575 L/day
HSD 110 L/day 2700 L/day 2810 L/dayStack height
Boiler 30 m 39 m 1 stack of 30 m1 stack of 39 m
Thermic fluid heater - As CPCB guidelines 2 stacks as per CPCBguidelines
DG , 125 KVA 3.5 m above roof 125 KVA DG Will be discontinued250 KVA 3.5 m above roof -- 3.5 m above roof500 KVA -- 4.5 above roof 4.5 above roofProcess scrubber 5 m above roof -- 5 m above roof
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Hazardous wasteType Category Existing After expansion Disposal
Used/ spent oil 5.1 50 1000 L/month Sale to Authorised recycler /CHWTSDF
Residues and waste 29.1 204 411MT/m CHWTSDF
Chemical sludge residuefrom herbicides
29.2 2.7 0 CHWTSDF
Discarded containers 33.1 78 1250 nos/M Sale to Authorised recycler /CHWTSDF
Chemical sludge from ETP 35.3 1.12 69 MT/m CHWTSDF
Filter & filter materialhaving organic liquid
36.2 32 500 kg/m CHWTSDF
Spent carbon 36.2 10 200 kg/m CHWTSDF
Asbestos gaskets 15.2 - 100 kg/m CHWTSDF
Spent solvents 29.4 28 MT/m 140 MT/m Sale to Authorised recycler /CHWTSDF
Non hazardous wasteExisting After expansion Disposal
Paper waste (paper boxesand bags)
150 kg/m 5600 kg/m
Sale to registered brickmanufacturer
Plastic waste 50 kg/m 5600 kg/mMetal scrap 100 5000 kg/mWooden pellets 25 1000 nos/mCoal ash 2700 8550 kg/d
Existing Proposed TotalMan power 160 - 160EMP cost, 60 Lakh rupees capital cost. 7.2 lakh rupees operating costProject Cost, 5 Cr. rupees
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2. Introduction of the project
2.1 Identification of Project Proponent:
The objective of this pre-feasibility study is to provide information for the Pesticides and
Chemical Intermediates manufacturing unit of Astec Lifesciences Ltd. at Plot No. B-16, 17,
18 and B-21, MIDC Mahad, District Raigad, Maharashtra.
As per the EIA Notification No S. O. 1533 promulgated on 14th September 2006, proposed
expansion project has covered Pesticides Industry and pesticide specific intermediates as 5 (b) and
need prior environmental clearance. It is stated that 5(b) industries located in a notified
industrial area are classified in category A and would be appraised by Centre Level Expert appraisal
committee. Based on the OM dated 16th May 2014 by Director MoEF, Public Hearing is
exempted for the Industrial Estates / Parks which have taken Environmental Clearance.
Introduction of the Project Proponent
Mr. Ashok Hiremath, Managing Director, Astec LifeSciences, is a Masters of Arts from
University of Oxford and Post Graduate Diploma holder in Chemical Engineering from University
College, University of London. He started his career as Project Engineer in 1978 with GEA Air
exchangers Ltd., London. He returned to India in 1980 and joined Hiremath Chemicals Ltd., a
company promoted by his brother as Technical Manager where he was responsible for
manufacturing and business development. After leaving this company in 1994 from the post of
Technical Manager, he established Astec Lifesciences Ltd. as one of the promoters and since
then he has been actively involved and played a key role in the growth of the Company with his
inputs in strategic planning and business development.
2.2 Nature of project:
The expansion project will be done at Plot No B-16, 17, 18 and B-21 at MIDC Industrial area
Mahad with land admeasuring 13950 Sq Meters. The land is already in demarcated as “Industrial”
in a notified industrial area and is not a prime agricultural land. Thus there is no change in the land
use status.
2.3 Need for the project and its importance to the country and or region:
India's Chemical industry is the third largest in the world in terms of volume. Its rank is 14 in terms
of value. India is also one of the top five active Chemical ingredients producers (with a share of
about 6.5%). The ever-increasing demand for Pesticides and Intermediated in India and abroad as
well as changing market conditions requisite Indian Chemical industries to grow further.
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The company aims to expand its product portfolio further in order to cater to Domestic &
International markets by expanding its production capacities. 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.
Astec Lifesciences Limited is a global supplier of Pesticides and chemical intermediate to the other
chemical companies worldwide. Astec Lifesciences Limited aims to expand its product portfolio
further in order to cater to domestic & international markets by expanding its production capacities.
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.
2.4 Demand 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 free-pricing market.
2.5 Import Vs. Indigenous production
The proposed products including production of pesticides and chemical intermediate have huge
demand in the domestic as well as export market. Production of these pesticides and chemical
intermediate are domestically reduces the need to import products along with significant scope for
export in these products.
2.6 Export & economic feasibility
The Indian crop protection industry is of USD 4.25 billion in FY14 and is expected to grow at a
CAGR of 12% to reach USD 7.5 billion by FY19. Exports currently constitute almost 50% of
Indian crop protection industry and are expected to grow at a CAGR of 16% to reach USD 4.2
billion by FY19, resulting in 60% share in Indian crop protection industry. Domestic market on the
other hand would grow at 8% CAGR, as it is predominantly monsoon dependent, to reach USD 3.3
billion by FY19. Globally, India is fourth largest producer of crop protection chemicals, after
United States, Japan and China. The crop protection companies in India can be categorized into
three types –Multi-National, Indian including public sector companies and small sector units.
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Source: Industry Analysis by Tata Strategic
2.7 Domestic/ export markets
The finished goods will be sold in domestic market primarily and it would be exported to the
Regulated International Market as per demand.
2.8 Employment generation:
The activities will be done by industry would produce improvement in the socioeconomic
status of people in the study area in terms of local labor employment and contract basis jobs.
The expansion activity provide employment opportunities services like transportation activity.
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3. Description of Project
3.1 Project type:
Proposed expansion project is to manufacture Pesticides and Chemical Intermediates. Production
capacity of the manufacturing of pesticide and chemical intermediate will be of 781 MT/M and
1773 MT/month of byproducts and 700 MT/m of formulation products.
3.2 Location
Astec Lifesciences Ltd. proposes expansion of existing manufacturing unit located at Plot No B-
16, 17, 18 and B-21, MIDC Mahad, District Raigad, Maharashtra. A total of about 13950 SQMs of
land is acquired for the expansion project. Satellite image of the expansion project is shown
below.
Figure 1: Location of M/s Astec Lifescience Ltd
The project site is well connected by Mumbai- Goa highway (NH 66). The national highway is
approximately 9 km away and can be reached by state road network. The nearest railway station
is Veer which is approximately 18 km away from site. The MIDC map is given in figure 2
showing location of plot in MIDC.
Nearby Industries
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Sr. Direction Industry
1 North Odessy organics Pvt. Ltd.
2 South Tritech catalyst and
intermediates Pvt. Ltd.
3 East Caprolactum chemicals Pvt.
Ltd.
4 West Vinati Organics Pvt. Ltd.
Figure 2: MIDC Mahad map
The plot layout of expansion unit of M/s Astec Lifescience Ltd. is given in figure 3. Total plot
area is 13950 sq. m. the location of plant building, utility building, ware house, internal roads,
parking area is shown in the layout.
M/s. Astec Lifesciences Ltd.Plot no. B-16,17,18 & B-21
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Figure 3 : Plot layout of Astec Lifesciences Ltd.
Area statement of M/s Astec Lifescience Ltd
Sr. Particulars Existing Area (sq. m.) Proposed Area (sq.
m.)
Total Area (sq. m.)
1 Total plot
area
13950 13950 13950
2 Built up area 8544 -- 8544
3 Green belt
area
3500 1100 4600
3.3 Details of alternate sites considered:
This is an expansion project for existing products and new products along with byproducts will be
manufactured on existing plot. There is sufficient area available for expansion and current site is in
approved chemical zone of MIDC and is well connected to get raw material by road / railway and
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carry on the manufacturing activities. the MIDC have all adequate facilities viz. good road and rail
network, 24 hour electricity, water supply, MIDC roads, CETP etc.
3.4 Size of operation
The production capacity with byproducts is given in following table.
Sr. No.Product
ExistingQty
(MT/M)
Total Quantity(MT/M)
1 Propiconazole 15.00 1652 Hexaconazole 14.00 1003 Tebuconazole 60.00 1504
Dextrinol6.00
2
5 3,4-Chlorostyrene 30.00 256 Metalaxyl 5.00 10
74-Hydroxy 3-Methyl-2-(Propinyl)-2-Cyclopentene-1-Lon
12.00 12
8 Dichloro Benzyl Cyanide/4-Chlorophenyl Ethyl Chloride
5.00 5
9 Bromuconazole 30.00 4010 Cyproconazole 25.00 2511 Prallethrine 12.00 1212 Difenoconazole 5.00 3013 Tricyclazole - 30
14 2-Ethyl 2-Methyl ButanoicAcid
- 10
15 Metconazole - 20
165-Methyl-Α-(2-Propinyl) -5-Furfuryl Alcohol
- 10
17 Myclobutynil - 2518 Dimethoxy Benzoic Acid - 2019 Boscalid - 2020 Prothiconazole - 20
21 Ipconazole - 20
22 4-Trifluromethyl BenzylAlcohol
- 20
23 Fenpyroximate - 10
Total219
781
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List of byproducts
Sr No Name of Byproduct Qty Unit Remarks1 Aliphatic Hydrocarbon 114
2MT/month Sale / Job work
2 Biphenyl3 Dil HCL 49 MT/month Sale / Job Work4 H3PO3 2 MT/month Sale /Job Work5 K2CO3
,K2SO4,KTMI,KBr,KOH,KCL, 805MT/month Sale /Job Work
6 LiOH H2O 3 MT/month Sale /Job Work7 MGCl2, MgBr2,MgSO4 242 MT/month Sale /Job Work8 Na2SO4,Nacl,NaBr,NaOH 536 MT/month Sale /Job Work9 ZnCl2,Zn,Zn(CH3CO)2 21 MT/month Sale /Job Work
Total 1773 MT/month
List of formulation products
S.No.Product Existing
Qty.(MT/M)
ProposedQty.
(MT/M)
Total Quantity(MT/M)
1 Wettable Powder(WP/SP) 150 0 100( 50 MT will bereduced)
2 Granular Products(CG/G) 150 0 1503 Liquid Product EC 200 0 2004 Liquid Product (SC/SL) 200 50 250
Total 700 50 700
3.5 Project description with process detail.
The process details and material balance for Propiconazole Technical is given in following table.
Manufacturing process of other products is given in annexure-1.
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3.6 Raw material details
Raw Materials:
The basic raw material for this key product capacity are submitted herein below and for the
details are
given for all reactants, solvents and work up support chemicals.
Source for Raw Material Procurement: Raw Material is easily available in the local market;
some of the raw materials will be procured from the International Market.
Mode of Transport of Raw Materials: Few of the raw materials will be transported locally
and few will be imported from the International Market.
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Storage at the site: Raw Materials will be stored in storage yard at the project site. Location of
storage yard is demarcated in Layout Plan. Raw Material list is given in following table.
Table 4: Raw Material List
Sr.No. Product Name of RM1
Hexaconazole
Valeryl ketone2 Dimethyl Sulphide3 Dimethyl Sulphate4 Pottasium Hydroxide5 Valeryl Oxirane6 Dimethyl Acetamide7 Triazole8 Sodium Hydroxide9 Sodium bisulphide10 Sodium thiomethoxide11 Methanol12
Tebuconazole
Pentanone13 Potassium Hydroxide14 Dimeyhyl Sulphide15 Dimethyl Sulphate16 Oxirane17 Dimethyl Formamide18 Triazole19 Potassium Hydroxide20
Metalyxal
2,6 Xylidine21 Methyl chloro propionate22 Sodium Bromide23 Dimethyl formamide24 Cyclohexane25 Sodiumbi carbonate
26T-Butyl AmmoniumBromide
27 Methoxy acetyl chloride28 Ammonia soln29
Benzenepropanenitrile4-chloro-a-phenyl
p-Dichloro Benzene30 Mg31 THF32 Toluene33 Thionyl Chloride
Benzyl nitrileLiNH2
34 Ethylene Oxide35
Dextronil
Crotonic acid36 Butydine37 Isobutidine38 Xylene
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39 Hydrochloric acid40 Potassium Hydroxide41
Propiconazole
Dichloroacetophenone42 1,2 propanediol43 Sulphuric Acid44 Cyclohexane45 Bromine46 Caustic lye47 Dimethyl acetamide48 Triazole49 Sodium Hydroxide50
Cyproconazole
Ketone51 Dimethyl Sulphide52 Dimethyl Sulphate53 Sodium Hydroxide54 SPT Oxirane55 Dimethyl Acetamide56 Triazole57 Sodium Hydoxide58
Difenoconazole
CCP-ll59 Propylene glycole60 Sulphuric acid61 Cyclohexane62 Bromine63 Caustic lye64 CCP-lV65 Dimethyl Acetamide66 Triazole67 Sodium Hydroxide68
Bromoconazole
Trichloro acetophenone69 Magnessium70 Tetrahydrofuron71 Allyl Chloride72 Hydrochloric acid73 Potassium Carbonate74 Dimethylformamide75 Methanol76 Hydrobromic acid77 Dichloromethane78 Sodium Thiosulphate79 Triazole80 Bromine81 Pottasium Hydroxide82
TRICYCLAZOLEHMBT
83 Formic acid84 Pallethrin 2-Methylfuron
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85 Dimethylformamide86 Phosgene87 2,3-Dichloropropane88 Zink89 Acetic acid solution90 Toluene91 DMCC92 Potassium Hydroxide93 Celite94 Triacetonalkamine95
4-HYDROXY-3-METHYL-2-(2-PROPINYL) -2-CYCLOPENTENE-1-ON
2-Methylfurfural96 Tetrahydrofuron97 Magnessium98 Allyl chloride99 HCl100 Acetic acid101
3,4-Chlorostyrene
Chlorobenzaldehyde102 THF103 Methyl chloride104 Magnesium105 HCl 32%106 Sulphuric acid107
Metconazole
Dimethyl Adipate108 Sodium methoxide 28%109 Toluene110 Dimethyl Formamide111 Methyl Bromide112 Sodium methoxide 28%113 Dimethyl Formamide114 P-chloro benzyl chloride115 Toluene116 Ketone M117 Sodium hydride118 Toluene119 Dioxane120 NaOH solution 48%121 Ketone-K122 Dimethyl Sulphide123 Dimethyl Sulphate124 Pottasium Hydroxide125 Oxirane126 Dimethyl Acetamide127 Triazole128 Sodium Hydroxide129
MyclobutynilIntermediate
130 Dimethyl Acetamide
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131 Triazole132 Sodium Hydroxide133
2-Methyl 2-EthylButanoic acid
Methyl Chloride134 Magnesium135 Tetrahydrofuron136 Diethyl Ketone137 HCL (32%)138 DK-2139 Thionyl chloride140 DK-3141 Magnesium142 Tetrahydrofuron143 Toluene144 CO2 gas145 HCL (32%)146
5-METHYL-α-(2-PROPINYL) -5-FURFURYLALCOHOL
Propygil Chloride147 Magnesium148 THF149 Toluene150 Zink chloride151 Methyl Furfuryldehyde152 Biphenyl153 HCL (32%)154
Dimethoxy BenzoicAcid
Dichloro Benzyl nitrile155 Sodium Methoxide156 NaOH Sol. 20%157 Dimethyl sulphoxide158 HCl159
Boscalid
1,4 Dichlorobenzene160 Magnesium161 Toluene162 THF163 Trimethyl Borate164 HCl165 1-chloro-2-nitrobenzene166 Toluene167 Catalyst168 Methanol169 Pd-C170 Acetonitrile171 PCl3172 Sodium Hydroxide173 Cat.174 Cyclohexane175
ProthioconazolePTC-l
176 N-butyl lithium
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177 Hexane178 Sulphur179
Epconazole
Dimethyl adipate180 Sodium methoxide181 2-Bromopropane182 Toluene183 Cat-R184 4-Chlorobenzyl chloride185 Sodium hydrxide
186
Fenpyroximate
Dimethyl 4-chloropyrazole formaldehyde
187 Pottasium Hydroxide188 Phenol189 Toluene190 Distilled DMPF
191Hydroxylaminehydrochloride
192 Methanol193 NaOH194 p-Toluic chloride195 Butanol196 BE197 Bromine198 Chloroform199 5 % NaOH200 BTBE201 DMPO
202
4-trifluoromethylbenzyl alcohol
4-trifluro methyl benzylchloride
203 Bromoethane204 Magnessium205 THF206 Formaldehyde207 HCl
3.7 Resource optimization ( recycle/ reuse):
1. The effluent generated from process and scrubber will be sold as byproduct.
2. The treated domestic sewage will be reused for gardening which will reduce daily fresh water
need for gardening.
3. The company have rooftop rain water harvesting system and the harvested rain water is stored
in dedicated underground water tank. In rainy season the fresh water need will be reduced.
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4. The high TDS effluent will be treated in MEE and thermo-siphon reboiler system and recycled
back to plant.
3.8 Availability of water, energy fuel:
The water will be supplied by MIDC Mahad. Daily fresh water need for domestic and process
water requirement will be 447 CMD.
A 2.5 MVA capacity transformer is installed to meet the daily power demand of company.
One DG set of capacity 250 KVA and Two DG Sets of 125 KVA will be replaced by 500 KVA to
meet emergency power requirement of the plant.
3.7.3 Fuel Requirement
FuelCoal for boiler 22 MTPD 35 MTPD 57 MTPD
FO for TFH 125 L/day 6450 L/day 6575 L/day
HSD 110 L/day 2700 L/day 2810 L/day
3.9 Quantity of waste to be generated
Trade effluent generated from the expansion project will be 200 CMD. High TDS will be treat in
MEE and thermo siphon reboiler and Low TDS will be treat in 55 CMD ETP plant consisting
primary, secondary and tertiary treatment The sewage generated due to domestic activities will be
treated in aeration tank of ETP and treated water will be reused for gardening.
Parameter Requirement, CMD Losses , CMD Effluent, CMDDomestic Process
Domestic 17 3.4 13.6
Process 34.5 6.4 28.1
Cooling Tower152 144 8
BoilerGardening -- -- -- --Total 203.5 153.8 13.6 49.7
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Proposed water budget after expansion
ParameterRequirement, CMD
Losses ,CMD Effluent, CMD
Domestic ProcessDomestic 20 5 15
Process 32.3 0 -- 36.3Cooling Tower 394 230 164BoilerGardening -- -- --
Total447 235
15+36.3=51.3 CMD is treated in ETP. 46 CMDtreated effluent is discharged to CETP as per
valid CTO.164 CMD blow down will be treated by
psychrometric evaporator. 55 CMD water willbe recycled to plant. 109 CMD losses
3.8.2 Solid waste generation and Disposal
The types of Hazardous wastes generated from the project with method of disposalis shown in below table 3.6.
Table 3.6 : Details of Hazardous Waste Generation
Hazardous wasteType Category Existing After expansion Disposal
Used/ spent oil 5.1 50 1000 L/month Sale to Authorised recycler /CHWTSDF
Residues and waste 29.1 204 411MT/m CHWTSDF
Chemical sludge residuefrom herbicides
29.2 2.7 0 CHWTSDF
Discarded containers 33.1 78 1250 nos/M Sale to Authorised recycler /CHWTSDF
Chemical sludge from ETP 35.3 1.12 69 MT/m CHWTSDF
Filter & filter materialhaving organic liquid
36.2 32 500 kg/m CHWTSDF
Spent carbon 36.2 10 200 kg/m CHWTSDF
Asbestos gaskets 15.2 - 100 kg/m CHWTSDF
Spent solvents 29.4 28 MT/m 140 MT/m Sale to Authorised recycler /CHWTSDF
The non hazardous waste generation after expansion is presented in the table below,
Non hazardous wasteExisting After expansion Disposal
Paper waste (paper boxes 150 kg/m 5600 kg/m Sale to registered brick
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and bags) manufacturerPlastic waste 50 kg/m 5600 kg/mMetal scrap 100 5000 kg/mWooden pellets 25 1000 nos/mCoal ash 2700 8550 kg/d
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3.10 schematic representation of feasibility drawing for EIA purpose
PRODUCTION ACTIVITY
RESOURCE CONSUMPTION(WATER)
POWER CONSUMPTION
WASTEGENERATION
FINISHED PRODUCTS
MARKET
ECONOMY
EMPLOYMENT
RAW MATERIAL
POLLUTIONABATEMENT
CLEANENVIRONMENT
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4. Site Analysis
4.1 Connectivity:
M/s Astec Lifescience Ltd. is located at lot No. B-16, 17, 18 and B-21, MIDC Mahad,
District Raigad, Maharashtra. The nearest city from the site is Mahad at a distance of 8.0 Km.
The nearest railway station is Veer at a distance of 11 Km from the site. National Highway 17 is
near from site which is connected to Mumbai and Goa.
4.2 Land Form, Land use and Land Ownership
The Pesticides and Chemical intermediate manufacturing unit is located in Notified Industrial
Estate –Mahad MIDC having plot area 13950 SQM. The plot no B-16,17,18 & B-21 is owned by
M/s Astec Lifescience Ltd. The land use type is industrial for the manufacturing unit.
4.3 Topography:
The Geographical location of this industry is Latitude: 180 06’03.20” N Longitude: 730 29’ 24.56”
E. with an elevation of 59 ft (18m) above mean sea level MSL.
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Environmentally sensitive features within 15 km radius of the plant
The environmentally sensitive features exist around 15 km radial distance from the plant is,
1. Reserve Forest near Khaire Village at an approximate aerial distance of 0.4 km towards NE
from the project site.
2. Reserve Forest near Boargaon Village at an approximate aerial distance of 1.8 km towards S
from the project site.
3. Reserve Forest near Kharvali Village at an approximate aerial distance of 2.4 km towards SE
from the project site.
4. Reserve Forest near Kondivae Village at an approximate aerial distance of 3.5 km towards SW
from the project site..
5 Kal River is 750 m away and Savitri River is 2.1 km away from the project site.
6 Meeting point of Kal and Savitri river is 2.52 km away from plant aerially
7 A Bajire dam backwater is 14.8 km away from project site.
8 No national or state boundary is within 15 km.
9 Raigadh fort and Shivathar ghal are approximately 14.8 km away at aerial distance.
10 No defense installations are within 15 km area.
11 Nearest densely populated area -Mahad town is 8 km away.
12 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship,
community facilities) are Present in and around 15 km distance from project site.
13 The expansion project is in Mahad, MIDC area which is not declared as critically polluted area
by CPCB O.M. J-11013/5/2010-IA.II(I) dated 17/09/2013.
4.4 Existing land use pattern
The expansion project is located in the notified industrial area which has been developed for
industrial development. The existing land use pattern in the 10 km radial distance of the project site
comprises of Industrial, human habitations/settlements, small agricultural/ crop lands, quarrying
land use classes.
4.5 Existing infrastructure:
The land is in a recognized MIDC industrial area.
All infrastructures are available.
Air travel is readily available from Mumbai airport.
Water is available from MIDC.
Electricity is available from MSEDCL.
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4.6 Soil classification:
The soils in the area are formed from the Deccan Trap which is predominating rock formation with
small out crops of Laterite at a few places in the Poladpur taluka. The soils are medium black and
black soil which can be further grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium
and Laterite as per the location and topographical situation.
Climatic data from secondary sources
The climate in area is characterized by hot summer and general dryness throughout the
year except the south west monsoon season.
Climate Classification: Project site features a semi arid climate. In rainy season the climate is very
humid.
Temperature: annual average max. Temperature is 32°C and min. temperature is 17 °C
Rainfall: The analysis of long term rainfall data indicates that normal annual rainfall over the
district ranges from 2200 mm to more than 3000 mm in the plains and it is above 5000 mm in the
hills. The average rainfall around Mahad area is 3360 mm in rainy season.
4.7 Social infrastructure available:
Social infrastructure like schools, road, hospitals, is available near MIDC Mahad.
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5. Planning Brief
5.1 Planning concept:
The expansion activity will start after acquiring environmental clearance
The MIDC Mahad have road network and water will be provided by MIDC, therefore company
will not be relied on ground water in the MIDC area.
Electricity will be provided by MSEDCL and transformer and substation will be constructed.
The construction material is available locally and it will be transported through road network.
5.2 Population projection:
As per the 2011 census data, the Mahad region have 1,80,191, of which 88,734 are males and
91,457 are females. Total population equal to 19,044 is lied in 0-6 year age group. Area according
to census data total literates are 1,31,981.
The data published by census India 2011, shows that density of Raigad district for 2011 is 368
people per sq. km. It is assumed that due to expansion project minor migration of skilled labour in
the region is expected after commissioning of the project.
5.3 Land use planning:
The expansion of manufacturing unit will be done at existing project site at plot B-16,17, 18 & 21,
MIDC Mahad . The land is acquired by MIDC and the land use will be industrial type. No
cultivated land or forest land will be utilized for the expansion unit.
5.4 Assessment of Infrastructure demand
The major physical infrastructure like road, water supply is provided by MIDC Mahad . The
electricity will be supplied by MSEDCL by means of continuous feeder substation.
The industrial infrastructure will be constructed after grant of EC. The need of social infrastructure
is not presently envisaged.
5.5 Amenities:
Basic amenities like road, electricity, process water will be available at site. The drinking water will
be provided by further purification of process water by RO purification unit. In the plant personal
hygiene facilities will be provided to workers as per the rule.
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6. Proposed infrastructure:
6.1 Industrial area
Astec Lifescience Ltd proposed an expansion of manufacturing capacity project from 919 MT/M
to 1099.94 MT/M manufacturing of Pesticides and Chemical intermediate and 116.36 MT/month
at the existing project located at plot No. B-16, 17, 18 and B-21 at MIDC Industrial Area Mahad,
Dist: Raigad, State: Maharashtra..
6.2 Residential area
The unit is pesticide manufacturing unit and situated at notified MIDC Mahad therefore there
will be no need of residential infrastructure.
6.3 Green belt
The project is available in MIDC area. Total plot area of project 13950 sq. m. and existing green
belt area is 3500 sq. m. additional 1100 sq. m. greenbelt will be developed in the premise totaling
4600 sq. m. which will be 33% of total plot area. 200 Trees along with some garden variety
shrubs are already available at the site and more 400 no. of new trees and shrubs will be planted at
site to fulfill MoEF norms.
6.4 Social infrastructure:
The project site is approximately 8 km from Mahad city. All basic social infrastructure facilities
are available in the study area.
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.
6.5 Connectivity
The site can be accessed by national highway and connecting state highway from Mahad to
Solamkund village. The MIDC Mahad have excellent internal and connecting road network
therefore no additional connectivity infrastructure will be constructed.
6.6 Sewerage system
MIDC Mahad have provided sewerage and storm water drainage network. The effluent generated
is treated in the ETP and transferred to CETP,Mahad by MIDC provided drainage network.
6.7 Industrial waste management
Existing 36.43 CMD effluent & 15 CMD sewage is treated in 55 CMD ETP. The treated effluent
is discharged to CETP. Additional 164.5 CMD will be treated by two psychrometric evaporators
of 500 TR capacity each. Total 52.5 CMD effluent will be recycled to process.
6.8 Solid waste management
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Sadekar Enviro Engineers Pvt. Ltd. Page 31
The hazardous waste will be segregated as per category in schedule I of “Hazardous and Other
Wastes (Management and Trans-boundary Movement) Rules, 2016” and it will be stored in
demarcated area. The hazardous waste will be treated at CHWTSD facility or it will be sold to
MPCB authorized re-processor. The fly ash will be sold to brick manufacturers or authorized
vendours.
6.9 Power requirement/ supply/ source
A 2.5 MVA capacity transformer will be installed in the company for connected load of equal
amount. The power demand will remain same for expansion unit. Electrical power will be supplied
by MSEDCL.
Total 57 T/day foreign grade coal will be required for running boiler. 6575 L/day fuel oil will be
used to run FO run boiler and thermic fluid heater.
Total 2800 L/day HSD will be used for running D.G. sets in case of power failure.
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Sadekar Enviro Engineers Pvt. Ltd. Page 32
7. Rehabilitation and resettlement:
The expansion will be done at existing production unit situated at notified industrial area of
MIDC Mahad. No rehabilitation and resettlement will be incorporated.
8. Project schedule and cost estimation
It is proposed that the project will be commissioned after 24 months from grant of EC.
9. Analysis of proposal
The expansion activity will provide employment to the local residents, resulting financial and
social benefits of the nearby people.
Indirect employment will be generated by the unit like canteen, transportation facilities to
workers.
The export will result in generation of foreign exchange to the country.
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Sadekar Enviro Engineers Pvt. Ltd. Page 33
Annexure A: mass balance
Product Hexaconazole
Reaction
Process Description
Material Balance
Step-I
1 CLS-I 1003.12
R-01Reaction
3480.82 Reaction mass
2 FFB 1705.303 Saturn 4.554 Water 36.475 DMS 731.36
Total 3480.82 3480.82 Total
Reaction mass 3480.82
R-02Quenching
2769.27 Organic Layer
HOT 650.43 2273.77 Aqueous layerWater 911.84
Total 5043.08 5043.05 Total
Organic Layer 2769.27
Recovery
1063.97 CLS-II (Crude)
1637.09 FFB68.21 FFB loss
Total 2769.27 2769.27 Total
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Sadekar Enviro Engineers Pvt. Ltd. Page 34
Aqueous layer 2273.77
Recovery
948.31 Water recover
1008.94 K2SO4185.78 CH3OH104.37 H2O
4.55 Saturn21.93 Residue
Total 2273.77 2273.89 Total
Step-II
1 CLS-II (Crude) 1063.97
R-03 water washand seperation
1040.24 CLS-II pure
2 Water 690.15 713.92 water recover
Total 1754.12 1754.16 Total
Step-III CLS-II pure 1040.24
R-04 Reaction
1426.19 CLS-III crude
DMF 2280.09 2211.69 DMFTMI 299.93 68.40 DMF lossK2CO3 86.02
Total 3706.28 3706.28 Total
Step-IV CLS-III crude 1426.19
R-05 Cystalization
1000.00 CLS-III pureWater 1735.40 877.29 MeOHMethanol 913.84 36.55 MeOH loss
1735.40 Water340.79 Impurity
9.17 K-TMI76.24 K2CO3
Total 4075.43 4075.43 Total
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Sadekar Enviro Engineers Pvt. Ltd. Page 35
Product Tebuconazole
Reaction
Material BalanceStep-l
PCS-II
PCS-II 778
Reaction
Organic Layer 2230.65
Dimethyl sulfide 991 Aqueous layer 1479.95Saturn 3.235Water 25.92DMS 622HOT 553.24Water 323.99
Dimethyl sulfide 413.10Total 3710.6 3710.6
Aqueous layer 1479.95
Water Recovery
Water 349.91
K2SO4 858.17CH3OH 158.02Water 88.78
Loss Water 25.06Total 1480.0 1480.0
Organic Layer 2230.65
Recovery
PCS-lll 816.47
Water 486.0 Dimethyl Sulphide 1334.31Dimethyl Sulphide loss 70.23Water (Aqueous Layer) 486.00Water 9.6
Total 2716.7 2716.7
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Sadekar Enviro Engineers Pvt. Ltd. Page 36
Step-II
PCS-III 816.5
Reaction
CMD 6769.2
CMD 7051.277 CMD 281.5TMI 269.0496 PCS-IV crude 1196.5NaOH 110.4192
Total 8247.2 8247.2
PCS-IV crude 1196.5
Washing
Organic Layer 1918.2
Water 1113.368 Aqueous layer 1248.6XP-100 856.9152
Total 3166.8 3166.8
Organic layer 1918.2
Crystallization
Product 1000.0
MLR 918.2
Total 1918.2 1918.2
MLR 918.2
Solvent recovery
XP-100 822.6
XP-100 34.3Residue 61.2
Total 918.2 918.2
Aqueous Layer 1248.6
recovery
Water 1113.4
Residue 135.2
Total 1248.6 1248.6
August 2017
Sadekar Enviro Engineers Pvt. Ltd. Page 37
Product : Dextrinol
Material Balance
Crotonic acid 425.0
Reaction
BTD 272.0 486.6 aqueous layer 1Catalyst 20.0 2355.2 Orgnic layerEthyl cyclohexane 1499.83
HCl, 30% 625.0
Total 2841.8 2841.8
Org. lyer 2355.2ReactionTer. Butyl alcohol 372.0 184.7 aqueous layer 2
PTSA 15.0 2649.9 Orgnic layer
NaOH, 5% 92.4Total 2834.6 2834.6
Orgnic layer 2649.9Recovery
1467 Ethyl cyclohexane
1000.0 DTX
145.0 Residue38.0 Loss
Total 2650 2650.0
aqueous 1+2 184.7recovery
159.7 Rec water
25.0 NaCl salt
Total 184.7 184.7
August 2017
Sadekar Enviro Engineers Pvt. Ltd. Page 38
Product: Chlorostyrene
Reaction:
Material Balance:
Inputs Qty. kg
Chlorobenzaldehyde 1035
Reaction
Organic Layer 3537.63
Magnessium 176.985 Aqs. Layer 1 2580.255
Tetrahydrofuron 2020.32
Methyl Chloride 367.425
Chlorobenzaldehyde 1035
Tetrahydrofuron 366.39
HCl 32% 828
Water 1324.8Total 6118.92 6117.885
Organic layer 3537.63
Solvent Recovery
CRB-1 1141.605
Rec THF 2267.685
Loss 119.025
Residue 9.2115
Total 3537.63 3537.527
CRB-1 1141.605
Reaction
Product 1000.328
Sulphuric acid 23.4945 Rec. water 131.445
Residue 33.741
1165.1 1165.514
Aqs. Layer 1 2580.255Water recovery
Rec. water 1324.8
MgCl2 692.415
Cl
O
H + CH3 Cl+ MgCl
O-MgCl
CH3 +HCl
Cl
CH3
OH
+ MgCl2
Cl
CH3
OH
+ H2SO4
Cl
CH2 + H2O H2SO4+
August 2017
Sadekar Enviro Engineers Pvt. Ltd. Page 39
HCl 563.04
2580.255 2580.255
Product METALAXYL
Reaction
Material Balance
2,6 Xylidine 783.0
R-02Reaction
MCP 525.0 1138.0 OrganicDMF 20.0 2653.1 AqueousNaHCO3 428.75Water 2034.3
Total 3791.0 3791.0
Distillation
825.0 MXL1Organic 1138.0 286.9 rec. 2,6 Xylidine
26.1 loss
Total 1138.0 1138.0
Aqueous 2653.1 Recovery 2212 Rec water
NH2 +O
Cl
O
NaHCo3,DMFNH
O
O
NH
O
O + OO
ClN
O
OO
O
August 2017
Sadekar Enviro Engineers Pvt. Ltd. Page 40
188.6 CO2252.5 NaCl
Total 2653.1 2653.1
MXL-l 825.0Methoxy acetyl chloride 495.0DMF 161.8
Reaction1000.0 Metalaxyl
Cyclohexane 1648.2 1803.0 AqueousCaustic Lye 48% 208.9 1769.5 Filtration MLWater 1234.0Total 4572.8 4572.5
Aqueous 1803.0recovery
1333.0 Rec water150.0 rec DMF320.0 salt
Total 1803.0 1803.0
recovery1615.3 rec Cyclohexane
Filtration ML 1769.5 82.00 Residue72.3 Loss
Product: LOON
Reaction:
Material Balance
Inputs Qty. kg
Allyl chloride 588.5
Reaction
Organic Layer 1906.74
Allyl chloride 588.5 Aqs. Layer 1 1800.81
Tetrahydrofuron 782.705
Magnessium 311.905
2-Methylfurfural 847.44
HCl 394.295
Water 782.705
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Sadekar Enviro Engineers Pvt. Ltd. Page 41
Total 3707.55 3707.55
Organic layer 1906.74
Solvent Recovery
THF 747.395Intermediate-I 1053.415
Impurity 105.93
Total 1906.74 1906.74
Intermediate-I 1053.415
Reaction
Organic layer 1936.165
Impurity 105.93
Acetic acid 29.425
Total 1159.345 1936.165
Organic layer 1936.165
Solvent Recovery
Organic layerLOON 1000.45
THF 711.4965
Loss 35.31
Impurity 158.895
Acetic acid 29.425
Total 1936.165 1935.577
Aqs. Layer 1 1800.81
Water recovery
Water (HCl) 247.17
MgCl2 729.74
Water 782.705
THF loss 41.195
Total 1800.81 1800.81
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Sadekar Enviro Engineers Pvt. Ltd. Page 42
Product: Dichloro Benzyl Cyanide
Reaction:
Material Balance
Inputs Qty. kg2,4-dichlorobenzylchloride 1167
Reaction
Residue(Product) 999.652,4-dichlorobenzylchloride 1167 Water 537.29Sodium cyanide 298.4019 TBAB/Residue 38.51TBAB 38.511 NaCl 349.28Water 537.2868 Impurity 116.47
Total 2041.2 2041.2
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Sadekar Enviro Engineers Pvt. Ltd. Page 43
Product Bromuconazole
Reaction
Material BalanceStep-l
MDA 958.00
Reaction
Organic layer 7470.83
All 593.96 Aqueous layer 3360.85Mg 172.44 Rec. All 264.1toluene 3458.38THF 2874.00HCl(32%) 1123.73Water 1916.00
Total 11096.51 11095.80
Water Recovery
Water 2680.77
Aqueous layer 3360.85 MgCl2 672.52loss 7.0892
Total 3360.85 3360.38
Step-ll
Organic layer Step-l 7470.83Reaction
Toluene 3284.98
K2CO3 266.32 Toluene 170.52THF 2759.04
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Sadekar Enviro Engineers Pvt. Ltd. Page 43
Product Bromuconazole
Reaction
Material BalanceStep-l
MDA 958.00
Reaction
Organic layer 7470.83
All 593.96 Aqueous layer 3360.85Mg 172.44 Rec. All 264.1toluene 3458.38THF 2874.00HCl(32%) 1123.73Water 1916.00
Total 11096.51 11095.80
Water Recovery
Water 2680.77
Aqueous layer 3360.85 MgCl2 672.52loss 7.0892
Total 3360.85 3360.38
Step-ll
Organic layer Step-l 7470.83Reaction
Toluene 3284.98
K2CO3 266.32 Toluene 170.52THF 2759.04
August 2017
Sadekar Enviro Engineers Pvt. Ltd. Page 43
Product Bromuconazole
Reaction
Material BalanceStep-l
MDA 958.00
Reaction
Organic layer 7470.83
All 593.96 Aqueous layer 3360.85Mg 172.44 Rec. All 264.1toluene 3458.38THF 2874.00HCl(32%) 1123.73Water 1916.00
Total 11096.51 11095.80
Water Recovery
Water 2680.77
Aqueous layer 3360.85 MgCl2 672.52loss 7.0892
Total 3360.85 3360.38
Step-ll
Organic layer Step-l 7470.83Reaction
Toluene 3284.98
K2CO3 266.32 Toluene 170.52THF 2759.04
August 2017
Sadekar Enviro Engineers Pvt. Ltd. Page 44
THF 114.96RM 1287.84Loss 119.75
Total 7737.15 7737.10
RM 1287.84
Filtration
RM 4065.17
DMF 3065.60 KCl 288.26
Total 4353.44 4353.43
Step-lll
RM of Step 2 4065.17
Reaction
Rec DMF 2973.63
TMI 354.46 DMF Loss 91.97KOH 102.79 RM 1456.83
Total 4522.42 4522.43
RM 1456.83Separation
Organic layer 1275.85
Water 2874.00 Aqueous layer 3054.91
Total 4330.83 4330.76
Aqueous layer 3054.91
Water recovery
Water 2874.00
K-TMI 160.45KOH 20.50
Total 3054.91 3054.95
Organic Layer 1275.85
Crystalisation
Water 513.49
MeOH 670.60 MeOH 643.78Water 513.49 MeOH 26.82
Impurity 241.21TAA (Int-3) 1034.64
Total 2459.94 2459.94
Step-lV
TAA (Int-3) 1080.00
Water recovery
Organic layer 6911.97
MDC 5387.79 Aqueous layer 2016.49Br2 546.06 Loss 56.52HBr 1200.37NaOH 284.05Water 517.32Na2S2O3 14.37
Total 9029.96 8984.99
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Aqueous layer 2016.49
Water Recovery
NaBr 732.58
Water loss 127.99Na2S2O3 14.37Water 1141.46
Total 2016.49 2016.40
Step-V
Organic layer 6911.97
Reaction
Organic layer 6659.59
NaOH 198.31 Aqueous layer 1629.85Water 424.09MeOH 754.90
Total 8289.27 8289.44
Aqueous layer 1629.85
Recovery
Water 424.01
NaBr 327.64MeOH 754.90Water loss 56.23
NaOH 67.061629.85 1629.85
Organic layer 6951.56
Recovery
Rec MDC 5173.2
MDC Loss 215.55BRL-lll Crude 1271.27
6951.56 6660.02
BRL-lll Crude 1271.27
Crystalisation
BRL-III 1000.92
MeOH 1080.62 Impurity 271.11Water 586.30 MeOH 1037.5
MeOH 43.2Water 586.3
Total 2938.19 2939.0
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Product Cyproconazole
Reaction
Material Balance
Step-lMethyl Cyclopropylketone 684.90
Reaction
Organic Layer 5273.73Dimethyl sulfide 4109.40 Aqueous layer 5965.48Dimethyl sulfate 1404.05Pottasium Hydroxide 643.81Sodium Hydroxide 424.64Water 3972.42
Total11239.2
1 11239.2
RecoveryCPMK-l 698.60Dimethyl sulfide 4040.91
Organic Layer 5273.73 Dimethyl sulfide 68.49
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lossImpurity/Residue 109.58Methanol 356.15
Total 5273.73 5273.73
Water Recovery
Potassium sulfate 999.95Aqueous layer 5965.48 Sodium sulfate 753.39
Water 3972.42Loss water 239.72
Total 5965.48 5965.48
Step-llCPMK oxirane 698.60
ReactionReaction Mass 2095.79
Tetrahydrofuron 1397.20 Catalyst 84.86Catalyst 84.86
Total 2180.65 2180.65
Step-lll
Magnessium 1006.80
recoveryTetrahydrofuron 2075.25 Grignard mass 3780.65P-Dichloro Benzene 1534.18 Magnessium 835.58
Total 4616.23 4616.23
Grignard mass 3780.65CouplingCPMK-ll Reaction Mass 2095.79 Reaction mass 5876.44
Total 5876.44 5876.44
Reaction Mass 5876.44
Quenching
Aqs. Layer 2883.43HCl (32%) 1095.84 Organic Layer 5458.65Water 1369.80Total 8342.08 8342.08
Organic Layer 5458.65
Recovery/Distillation
Rec. THF 3301.22CPMK-lll 1013.65Residue 972.56Loss 171.23
Total 5458.65 5458.65
Aqs. Layer 2883.43 Water recovery Water 2116.34
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Sadekar Enviro Engineers Pvt. Ltd. Page 48
Magnesiumchloride 664.35
Loss water 102.74Total 2883.43 2883.43
Step-lV
CPMK-lll 1013.65
Reaction
Aqs. Layer11643.3
0Toluene 5794.25 Organic Layer 7821.56Sodium Hypochlorite 7095.56NaBr 77.80Sodium bicarbonate 405.67TEMPO 2.88Water 4061.46Toluene 1013.65
Total19464.9
319464.8
6
Organic Layer 7821.56
Recovery
Rec. Toluene 6739.07Loss 68.49Ketone 984.20Impurity 29.79
Total 7821.56 7821.56
Aqs. Layer11643.3
0
Water recovery
Water11086.1
3Sodium chloride 557.17
Total11643.3
011643.3
0
Step-V
Impurity (Carry Over) 29.79
Reaction
Organic Layer 5606.59Ketone 984.20 Aqs. Layer 5040.18Dimethyl sulfide 3212.18Saturn 3.42Dimethyl sulfate 934.14Pottasium Hydroxide 539.98Sodium Hydroxide 138.14Water 3738.18FFB 1068.44Total 10648.4 10646.7
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8 7
Organic Layer 5606.59
Recovery
Dimethyl sulfide 4216.31Dimethyl sulfideloss 68.49SPT-II 1012.28Impurity 72.19Methanol 237.32
Total 5606.59 5606.59
Aqs. Layer16683.4
8
Water recovery
Water15379.3
6Pottasium sulfate 838.32Sodium sulfate 245.26Loss water 220.54
Total16683.4
816683.4
8
Step-VlSPT-II 1012.28
Reaction
Rec. CMD 2950.89CMD 3034.11 Rec. Toluene 2954.80Triazole 344.09 Aqs. Layer 2220.03Pottasium Carbonate 192.73 SPT-lll Crude 1354.32Water 2027.30 CMD loss 68.49Toluene 3036.16 Toluene loss 68.49Total 9646.7 9617.02
SPT-lll Crude 1354.3
Crystalisation
XP-50 2463.11XP-50 2534.13 XP-50 loss 68.49
SPT-III 1000.43Residue 356.42
Total 3888.45 3888.45
Aqs. Layer 2220.03
Water recovery
Water 2027.30K2CO3 192.73
Total 2220.03 2220.03
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Product: Prallethrin
Reaction:
Material Balance
Inputs Qty. kg
2-Methylfuran 369.3
Reaction
Organic Layer 2474.3
2-Methylfuran 369.3 Aqs. Layer 1 2152.2
Dimethylformamide 406.2
2,3-Dichloropropane 694.3
Phosgene 491.2
zinc 588.2
Acetic acid solution 1080.5
Toluene 997.1Total 4626.7 4626.5
Organic layer 2474.3
Solvent Recovery
Intermediate-I 671.6
Dimethylformamide 388.0Dimethylformamideloss 14.8
Toluene 947.3
Toluene loss 52.1
Impurity 205.3
2,3-Dichloropropane 195.1Total 2474.3 2474.2
Water Recovery
Zn(CH3CO)2 825.3
Aqs. Layer 1 2152.2 Water 540.2
HCl 164.2
ZnCl2 613.0
Water loss 9.5
Total 2152.2 2152.2
Step-ll
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Impurity 205.3
Intermediate-I 671.6
Reaction
Organic layer 2316.6
DCPC 570.8 Aqueous layer 1771.6
KOH 222.1
Toluene 997.1
Water 1421.8
Total 4088.8 4088.3
Organic layer 2316.6
Solvent Recovery
Product 1000.1
Toluene 947.3
Toluene loss 49.9
Impurity 319.0
Total 2316.6 2316.2
Aqs. Layer 1 1771.6
Water recovery
Water 1421.8
KCl 268.3
Water 64.8
Water loss 16.8
Total 1771.6 1771.6
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